Piss, got the head on and motor running...noticed a problem... - IDI Engine - VWDiesel.net The IDI, TDI, and mTDI source.

• Piss, got the head on and motor running...noticed a problem... by vdubspeed on 22 Oct, 2011 16:22
• So I bought an 89 NA Jetta with a snapped t-belt. Slapped it all backed together and tonight it fired up AWESOME. Then I noticed something....the lip on the intermediate shaft that is on the tb cover side is gone. I checked my other diesel engine blocks and sure enough...big fat lips.
  
  So...do I suck it up and replace it or will the t-belt track straight without the lip.
  
  Thanks,
  
  Jason
  
  P.S...if I do replace it...are they a PITA to get off while in car?
• #1 by vdubspeed on 22 Oct, 2011 16:32
• Might have jumped the gun. Seems as if there are two pulley styles. Early ones with lip and later ones without the lip. Hmmmm...I just don't want to f up this awesome running franken diesel engine.
• #2 by R.O.R-2.0 on 22 Oct, 2011 16:37
• Quote from: vdubspeed on 22 Oct, 2011 16:32

  Might have jumped the gun. Seems as if there are two pulley styles. Early ones with lip and later ones without the lip. Hmmmm...I just don't want to f up this awesome running franken diesel engine.
  

  
  yea, the later engines got a smooth IM shaft pulley.
  
  i imagine its so that if the belt isnt tracking perfect, then that lip on the pulley wont chew it up..
  
  because if the belt is walking off the injection pump, then the IM shaft pulley is going to be the next place the belt runs, and if its not entering the pulley straight, then its going to chew up the belt, from running on the lip..
• #3 by vdubspeed on 22 Oct, 2011 16:41
• Thanks for the reassurance friend. That makes me feel good now.
  
  This puppy fired up third crank and I has been a MASSIVE learning experience over the last three weeks. 89 hydro block, 85 turbo diesel mech head, an old rabbit diesel cam, head resurfaced, pc cups peened, block tapped and plugged, head tapped and plugged, etc, etc, etc. Just glad to hear it ROAR to life
• #4 by CRSMP5 on 22 Oct, 2011 20:07
• if the lip is damaged.. stop.. it will cut the belt..
  
  now buy new.. NO F IN WAY...
  
  pull the pully off.. goto a local brake shop.. with case of beer.. ask the guy really nicely.. do you have a adapter for a old say beetle brake drumb.. really thin.. fits right thru the hole of pully..and use brake lathe to remove it... 2-3 min of work you will have late model looking pully.. 
  
  yep done that a few times...
• #5 by vdubspeed on 23 Oct, 2011 05:38
• the lip is not damaged...it's just not there. I'm used to working on mk1 diesels and their intermediate pulley's have lips. I found that starting with the mk2's, VW went to pulley without a lip.
  
  Should have never made a post. Pretty soon I'm sure I'm going to be told to rebuild the motor.
• #6 by CRSMP5 on 23 Oct, 2011 11:43
• actually 89/90 started no lip ones... had tons of screwed up lip ones that got modded after that.. how i know brake lath trick.. took old kept for scrap aluminum and converted them into on shelf for older ones..
• #7 by regcheeseman on 23 Oct, 2011 14:08
• Intermediate shaft with a lip? Never seen one.
  
  Ignore it, I'm more interested in the setup of the elusive 'perfect running' Franken - is it a 16/19?
  
  
• #8 by rabbitman on 23 Oct, 2011 14:40
• With how old this stuff is nothing is factory anymore. My '82 rabbit: no lip......'92 golf: has lip. I think somebody messed with both.
• #9 by R.O.R-2.0 on 23 Oct, 2011 14:49
• ALL of my engines have a lip on the IM shaft pulley.. but ive seen both kinds on both early and late engines..
  
  its kinda funny, gassers got an IM shaft SPROCKET (runs on the cogged side of the belt)
  
  and the diesel got an IM shaft PULLEY.. (runs on the smooth back side of the belt)
  
  ive experienced first hand, as to why they removed the lip.. i had a bad bushing on my first diesel, and the belt walked off the IP about a 1/4", then the IM pulley started eating the belt. i cant believe how long i ran it with a chewed up belt.. thinking back on it, it kinda makes me sick.. atleast i changed the belt before it snapped..
• #10 by rabbitman on 23 Oct, 2011 16:34
• Quote from: R.O.R-2.0 on 23 Oct, 2011 14:49

  its kinda funny, gassers got an IM shaft SPROCKET (runs on the cogged side of the belt)
  
  and the diesel got an IM shaft PULLEY.. (runs on the smooth back side of the belt)

  
  The gasser has to keep the distributor in time while the vac pump on a diesel doesn't matter......
• #11 by RabbitJockey on 23 Oct, 2011 18:33
• even the early ones have a variety of styles, not that its really anything to discus, they all do the same thing
• #12 by vdubspeed on 24 Oct, 2011 18:09
• Quote from: vdubspeed on 23 Oct, 2011 05:38

  the lip is not damaged...it's just not there. I'm used to working on mk1 diesels and their intermediate pulley's have lips. I found that starting with the mk2's, VW went to pulley without a lip.
  
  Should have never made a post. Pretty soon I'm sure I'm going to be told to rebuild the motor.
  

  
  Don't know what you mean by 16/19 but this motor runs like a dream.
• #13 by rabbitman on 24 Oct, 2011 19:33
• Quote from: regcheeseman on 23 Oct, 2011 14:08

  Intermediate shaft with a lip? Never seen one.
  
  Ignore it, I'm more interested in the setup of the elusive 'perfect running' Franken - is it a 16/19?

  
  
  
  He's talkin' about a 1.6 block and a 1.9 head.
• #14 by vdubspeed on 25 Oct, 2011 03:08
• Na...nothing like that. Just a motor built from the pieces of many other motors.