Alternator & Generator Pulley, Billet Aluminum, Polished

OVERVIEW

Elevate your engine bay with the ultimate fusion of precision engineering and show-stopping aesthetics. The EMPI Billet Aluminum Polished Alternator and Generator Pulley is designed for the air-cooled enthusiast who demands more than just a functional component. Unlike standard stamped-steel pulleys that are prone to warping, wobbling, and belt slippage under high RPM loads, this unit is CNC-machined from high-grade billet aluminum. This ensures an exceptionally true spin, reducing vibration and extending the life of your alternator or generator bearings. Whether you are building a high-performance street machine or a trophy-winning show car, this pulley provides the structural integrity needed to maintain consistent belt tension while adding a brilliant, mirror-like finish to your Volkswagen''s cooling system.

Precision fitment is the hallmark of this EMPI performance upgrade. Because this pulley is machined from a solid block of aluminum, it offers a much thicker and more stable profile than the flimsy factory counterparts. This extra material helps dissipate heat more effectively and prevents the "flex" that often leads to thrown belts during aggressive driving. It is important to note that because of the unique dimensions of a billet pulley, you cannot reuse your stock stamped-steel shims or nut. To achieve perfect belt alignment and secure fastening, this pulley must be paired with the specialized billet nut and washer set (Part # 16-9708-0) and the dedicated billet shim set (Part # 16-9709-0). When installed correctly, this pulley transforms your Type 1, 2, or 3 engine into a masterpiece of mechanical efficiency and style.

FITMENT

• Volkswagen Type 1 Beetle: 1950 through 1979 (All models equipped with 12V Alternator or Generator)
• Volkswagen Type 1 Karmann Ghia: 1956 through 1974
• Volkswagen Type 2 Bus / Transporter: 1950 through 1971 (Up to 1600cc engines)
• Volkswagen Type 3 Squareback, Fastback, Notchback: 1961 through 1973
• Volkswagen Type 181 Thing: 1973 through 1974
• Custom Applications: Ideal for Dune Buggies, Sand Rails, Trikes, and Kit Cars using VW-based air-cooled engines.

SPECS

• Material: High-Grade 6061-T6 Billet Aluminum
• Finish: High-Luster Mirror Polished
• Component Type: Alternator or Generator Pulley
• Manufacturing Process: Precision CNC Machined
• Weight: Approximately 1.12 lbs
• Compatibility: Standard VW 12-Volt Alternators and Generators
• Required Hardware (Sold Separately): Requires Billet Nut/Washer Set (#16-9708-0)
• Required Shims (Sold Separately): Requires Billet Shim Set (#16-9709-0)
• Engine Application: Type 1, 2, and 3 Air-cooled VW 1300cc-1600cc based engines

PRO TIPS

1. Never Mix Billet and Stamped Components

One of the most common mistakes I see in the shop is trying to use original equipment (OE) stamped steel shims or the factory pulley nut with a billet aluminum pulley. The inner hub thickness of a billet pulley is significantly different from the thin steel versions. Using stock shims will prevent you from achieving the correct belt tension and can lead to the pulley half stripping the woodruff key or the shaft threads. Always ensure you have the EMPI Billet-specific shim kit (16-9709-0) and the matching nut/washer set (16-9708-0) on hand before you begin the installation. This ensures the pulley is seated deeply enough on the shaft to engage the woodruff key fully while allowing for precise belt adjustment.

2. Master the Art of Shimming for Belt Tension

Achieving the perfect belt tension on a VW air-cooled engine is a balancing act. You should have approximately 1/2 inch of deflection in the belt when pressed firmly with your thumb. To tighten the belt, you must remove shims from between the two pulley halves and place them on the outside, under the nut/washer. To loosen the belt, you move shims from the outside to the inside (between the halves). With a billet pulley, this process is even more critical because the aluminum does not "give" like steel. Take your time to rotate the engine by hand as you tighten the nut to ensure the belt isn''t getting pinched, which could lead to a false tension reading or damage to the belt.

3. Protecting the Polished Finish During Install

Since this pulley features a high-luster polished finish, it is very easy to scratch it with a standard pulley holding tool or a large pair of channel locks. To keep your engine bay looking pristine, I recommend using a strap wrench or a dedicated pulley tool with a protective rubber coating when tightening the nut. If you must use a metal tool, wrap the pulley in a thick rag first. Additionally, after the first 50 to 100 miles of driving, re-check the torque on the pulley nut. Aluminum can expand and contract differently than the steel shaft of the alternator, and a quick "snug-check" ensures that everything remains seated perfectly for the long haul.