Lightening and balancing the intermediate shaft. - page 2 - IDI Engine - VWDiesel.net The IDI, TDI, and mTDI source.

• #15 by subsonic on 20 Mar, 2008 07:16
• I will get a picture up of mine today if possible.  I guess if anyone has a AAZ shaft they can snap a picture of, we can compare them.  
  Does the AAZ engine have the same problems with the IM shaft bearings going bad?
  If it does not, and the shaft does not have the extra lobe on it, that may help support my idea about the failures on the 1.6 models.
• #16 by jimfoo on 20 Mar, 2008 09:32
• Unfortunately if this thread was a few weeks earlier, I could have taken pics.
  BTW, my bearings looked great although they supposedly have less than 50k on them.
• #17 by subsonic on 20 Mar, 2008 12:40
• Here are the photo's:  (still looking for someone to add a AAZ IM shaft photo)
  
  Full shot of the IM shaft.  You may be able to see the taper.  The end that has the gear to drive the vacume pump is the smaller diameter end.  The lobe for the old style fuel injection pump is on the right.
  
  
  The big side and the small side of the lobe. Close up.
  
  
  
  
  These are pictures of scoring on the end of the shaft.  If I run my finger nail over them I can barely feel them.  Any opinions on weather you think this will be ok if it polished off?
  
  
  
• #18 by dillenger1 on 20 Mar, 2008 14:03
• That looks like the area where the seal rides.I dont think thats metal bearing surface right there.strange,dont know why the seal would do that.Unless there was dirt and debris slowly grinding away 8)NEVER MIND im wrong im thinking of something else :oops: ,You could polish and fit a new bearing.
• #19 by subsonic on 20 Mar, 2008 15:14
• It may be a seal there, I will need to check the bentley.
• #20 by jimfoo on 20 Mar, 2008 16:14
• I believe that is where the seal rides. My AAZ shaft sure didn't look like that, so I guess it has no hump.
• #21 by Black Smokin' Diesel on 20 Mar, 2008 17:34
• From what I've read on vwvortex, im shafts badly need to be lightened and balanced.
• #22 by hillfolk'r on 20 Mar, 2008 19:46
• important /critical,huh??
  i  i really dont see where itll make a huge difference still,,being its running 1/2 speed
  but if you are going all out,it cant hurt
  id think there would be more gain by running no dampener pulley
• #23 by subsonic on 20 Mar, 2008 20:18
• I don't think it is critical.  But what the hell.  I have it out and sitting at the machine shop.  No way that thing is very balanced looking like that.  Couldn't get much easier than it is right now to clean it up.  Couple passes on a lathe. BAM!!  Drop a little weight, get rid of some shake. :lol:
  Hell, if I had it out on a N/A I would do it to.  Course there is no way I would be tearing this thing out of an engine just to turn and balance it.
  
  Just one of those things you should do while it's apart I guess.
  
  I post a picture when it's done.
• #24 by rabbid79 on 19 Apr, 2008 21:41
• How did your lightening and balancing go?  Any before and after pics/weights?  Was that Techtonics you contacted about doing this for you?
• #25 by subsonic on 20 Apr, 2008 05:09
• The guy who was turning it probably has it done.  I need to go ask him.  Last time I was there he was way busy.  He builds race engines on the side, and everyone wants to get started in the spring.  I will post a photo of the finished product for comparison with the photo at the top of the post.
• #26 by Mark(The Miser)UK on 20 Apr, 2008 06:40
• Weighing before and after would have been interesting to do some mathematics... :cry:
• #27 by subsonic on 20 Apr, 2008 07:14
• Perhaps there is another member who has one out of the car.
• #28 by hamradio on 20 Apr, 2008 07:50
• Tempting to pull mine and balance it, while I have my engine out.  
  
  Not to threadjack, but from what I understand, the lobe can be completely removed?
• #29 by subsonic on 20 Apr, 2008 08:59
• Yep, That baby comes right off when it is turned.