VW 92 Golf with 1.6L diesel

[harchar626]

So i picked up a 1.6L diesel out of a 84 Jetta and i'm putting it in a 92 Golf.  the clutch has been replaced and the timing belt is going in next and i could use some help.



you can see that one of the pulleys has nicks out of it and i would like to replace it.  but where to look, and what to look for?  is it a lift pump pulley?  and where are the timing marks for the crank and cam?  i found the injection pump timing mark very easily, so should i just mark (with a marker) where TDC is? and re-time accordingly?  

[R.O.R-2.0]

So i picked up a 1.6L diesel out of a 84 Jetta and i'm putting it in a 92 Golf.  the clutch has been replaced and the timing belt is going in next and i could use some help.



you can see that one of the pulleys has nicks out of it and i would like to replace it.  but where to look, and what to look for?  is it a lift pump pulley?  and where are the timing marks for the crank and cam?  i found the injection pump timing mark very easily, so should i just mark (with a marker) where TDC is? and re-time accordingly?  

you gotta have a trans bolted up to have the bell housing to find TDC.. or pull a injector and use a chunk of small rod..

[Quantum TD]

you can see that one of the pulleys has nicks out of it and i would like to replace it.

Actually, we can't. Your photo link isn't working. But I did see the pic by responding with quote. That's the intermediate shaft pulley. You can do one of a few things:

1) Replace it
2) File down the sharp edges and forget about it. Or
3) Completely remove the outer edges of that pulley. The 1986-1992 motors did not have the lip on that pulley.

If you want an original just like it, I have several I'd sell. PM me for details.


I should also note two other things:

1) You may want to swap the tensioner bracket. The MK1 has an integrated motor mount. The later MK2 ones don't us it. It may get in the way of your inner fender once installed. Minimally, it may be a PITA to work around. You can always sell the MK1 bracket. They're always in demand.

2) Whoever tensioned the timing belt, tensioned the idler bearing incorrectly. It's supposed to be rotated CLOCKWISE to tension it, not counter-clockwise.

[Quantum TD]

One last thing. That's quite an odd setup you have there. NON-AC, but WITH power steering? I've never seen that before. For posterity (and if it's not too much of a pain), maybe you could document the part numbers on the pulleys.