1.5/1.6 intermediate shaft questions

[morgoon]

Hello

I did a quick search but I didn't find what I was looking for

I have a low mile 1.5D that I am going to swap in place of my early 11mm 1.6D in my 81 Rabbit

I noticed that the 1.5D intermediate shaft pulley has a chip out of it, and I was wondering if I could straight swap the whole shaft and pulley from the 1.6 into the 1.5

Or should I have the pulley pressed off of the 1.5 shaft and just swap it for a better one?

[theman53]

You should be able to just unbolt the pulley and swap it. It isn't a press fit, there is a key in it.

[morgoon]

Oh...well there you go

Thanks very much

[fatmobile]

 You should pull the seal carrier and replace the seal and especially the o-ring.
 Gives you a good chance to check the I-shaft thrust surface and a great chance to pul the I-shaft out a little and check the outer I-shaft bearing.

The 1.6 should fit in the 1.5 but the longer stroke of the 1.6 will cause the crank to hit a 1.5 I-shaft gear where it isn't beveled out.
 So keep that 1.6 shaft if it's in good shape.

[morgoon]

Thanks I appreciate the help, this VW diesel stuff is all new to me

I bought a complete engine gasket kit (minus the headgasket), and I am changing the front and rear crank seals etc, and had planned to pull the intermediate shaft on the 1.5 going in to inspect for wear etc, and reseal.

This replacement 1.5 engine has been sitting stored for a very long time. I have been agonizing over pulling the head off, and I put the engine on my engine stand and pulled the pan, everything was pristine inside. The area that I could see of each cylinder looked good and showed no signs of corrosion.

I may yet regret not pulling the head and doing it right, but I just could not justify the ARP cost, vs money saved towards the core (later)1.6 I have that I want to build.

This 1.5 is a 60 000km unit that was pulled and stored a long time ago originally to be marinized by my neighbour for his sailboat. He changed direction and here we are today

I ordered the reseal kit for the injection pump and should be getting to that in the next few weeks... :0

New Timing Belt and tensioner on the way as well

Any thoughts, suggestions are always welcome

[fatmobile]

It's easy to pull the head later, while it's in the car.
 The rest of the stuff you mentioned isn't.