Intermediate Shaft Pulley Problem

[ffgb]

I have a 1984 VW rabbit N/A.  I just received a new intermediate shaft pulley part #068115021D without the lip because my stock one is damaged.  It seems the new pulley's offset isn't the same as the stock one I had on with the lip.  When I install the new one, it doesn't exactly sit inline with the timing belt tensioner and it almost touches the engine mount bracket that bolts to the engine, like only a human hair can pass through the distance between.  I made sure to use the correct side of the pulley because if you use the wrong side, the pulley will definitely hit the engine mount bracket.  The stock one sits further away from the engine.  Am I missing something here?  Is there suppose to be some sort of washer or concentric ring that I am suppose to purchase and place between the pulley and intermediate shaft to line everything up?
Thanks

[dennis]

The part number is right. Did you remove the shaft?

[ffgb]

Yes I removed the shaft because I just rebuilt my engine.  Nothing is wrong with the shaft.  There is a definite difference between the two pulleys.  I put a straight edge on the engine side of both pulley's and there is less of a gap on the stock one compared to the new one.  How close to the engine bracket are your guy's pulley setup with this lipless one.
Thanks

[burn_your_money]

Are the diameters the same?

[burn_your_money]

Sorry Andrew, that question was aimed at ffgb. The 1.9 one has a smaller diameter and I noticed the PNs you posted don't match ffgb's PN so I was just thinking...

[burn_your_money]

  Glad that's straight then

[ffgb]

I ended up using the new pulley.  It is pretty close to the engine bracket but isn't touching.  I finally fired up my new rebuilt motor and it sounds awesome.  I broke it in pretty good for the first 25 miles, there were no water leaks, but a small oil leak around the updated windage tray gasket, had to tighten those bolts up for a third time.  I checked the pulley to see if it would touch with a load on it, and it didn't.  But, now I have a small problem, my timing belt has shift about 1/8"-1/4" toward the injection pump.  I didn't have this problem with the stock style lip pulley, but once I went with the lipless one, the belt has shifted.  I am afraid, because the belt is so close to the engine block when riding the lipless intermediate shaft pulley, that possibly it may shift a little more and start shredding/fraying.  Can anyone suggest a solution?
Thanks

[ffgb]

Thank You, I'll try that.  When you mean the two bolts, do you mean the top two bolts on the injection pump or the two that bolt the engine mount/ip bracket to the engine block?  Are we talking about moving it in either direction about the width of a credit card or less than that?
Thanks

[fatmobile]

The 2 mounting the bracket to the block.
 You'll just have to try it to see how much.
 tighten them, put the pump/belt back on,
 turn by hand.
 I suggest masking taping the sprocket to the belt when you pull the pump.

 Once the timing belt is tracking right,
 remove it one more time,
 remove one of the adjustment bolts and blue locktite it.
Do the same to the other bolt holding the adjustment bracket.

NOW you can proceed to timing the pump.

[ffgb]

So, I guess you have to remove the pump?  Is there any way to do this procedure without removing the pump, because I just got everything timed so perfect.

[Rabbit79]

I think you can get to those with a long extension. Seems like the last time I took those off I used a 10 inch 3/8 drive. If I'm thinking about the right bolts anyway.

[fatmobile]

I couldn't get to them with the pump on,
 it would be worth my time to make a special wrench/socket for it,..
 but that hasn't happened yet.