Pulley alignment and Progress update

[CoolAirVw]

My current motor project, thats been on hold for months, is nearing completion for installation. Here's the status...



Current problem I'm facing is that the pullies dont line up.



You can see the inner waterpump pulley doesn't line up with the AC compresser. I assume its the wrong pulley.

The easiest fix would be to get a couple (one wont do it) PS pump pulley shims like this one....



But I would like to know how it is supposed to be. Is there different "height" waterpumps? I checked ETKA and there are lots of different part numbers for this pulley but I dont know how to tell which is for me.

Anyone have a 85 Jetta with AC & PS that has belts that line up right that can take a picture and get the part number off thier pulley?

Or any suggestion for the long term fix please.

[bottleworks]

Is there different "height" waterpumps?

Yes there are. There are 30 mm and 40 mm hub water pumps and of those, there's a choice of 2 5/8" or 2 7/8" (hub mounting surface to pump sealing surface).

[libbybapa]

There are also quite a few different pulley versions that offset the belt different amounts along with being different diameters.

Andrew

[CoolAirVw]

I checked with the dealer today and he said that on my application the pulley should be part number 068121031L.

My pulley is 068121031 without the "L". Dealer said that that number fits earlier Jetta's/Rabbits ect.

I could have bought 2 of the shims, but they were 27.00 each. The pulley was $77.00 and still available so I ordered it.

Also look at this pic of my pulleys & belts when I removed the motor from the car....


Notice no adjuster in the slot between the Alt and the AC. I assume the previous owner eliminated it with a short belt. I realized it needed one by looking at my parts motor that had one on it.

Previous owners suck.

[CoolAirVw]

Oh, I reinstalled the motor today. Just stuck in the engine/trans and mounts then called it a day.

[CoolAirVw]

ARRRRGGGGHHHH!

Pulley got here and its exactly the same as the one I got! Because the dealer said my Part Number was from a early Jetta/rabbit I was convinced that it was going to solve my problem. Of course he told me up front that if I order it I own it (non-returnable). So 70 bucks down the tubes!

............there's a choice of 2 5/8" or 2 7/8" (hub mounting surface to pump sealing surface).

This is probably the solution to my problem. After I read it I thought it might be but I had allready ordered the pulley and was hoping that it would solve my problem.

[82vdub]

Would a washer or two behind your pully move the pully out far enough to more align the belts up? I had thought of that, but since you said you ordered the pully, I didn't mention it at that time. You will definately want to use longer bolts if you put washers behind the pully and probably loctite them in.

[Fatmobile]

The engine is looking good, glad to see you are so close to a test run.
Hate to see a damn pully slow you down.
Since you own 2 pullys now, maybe you can cut the center out of one to use as a spacer.

[CoolAirVw]

Since you own 2 pullys now, maybe you can cut the center out of one to use as a spacer.

Should I cut the one I just paid 70 bucks for or the one that I have 3 hours work invested into bead blasting and painting?

I was hoping my spare engine had the taller waterpump but I havn't had a chance to measure yet.

[Fatmobile]

Should I cut the one I just paid 70 bucks for or the one that I have 3 hours work invested into bead blasting and painting?

tough decision
I still haven't checked the number on the one for my '86 Jetta parts car.

[CoolAirVw]

Yep, I measured the pump today and its 2 5/8. The one on my parts motor is 2 7/8.

Lessen learned.... Dont try to solve your problem fast.... wait for info for answers and you save 70 bucks. Not to mention now I have the motor installed in the car and it'll be a pain to change the waterpump. Looks like intermediate shaft has to come off so timing belt has to come off.

What a pain.

More progress today though. I bought all new PS hoses (160 bucks!) and installed them and hooked up a few odds and ends.

Just need to get this waterpump installed and the radiator, condenser, grill and core support and I'll be ready to fire it up. Maybe a few other odds and ends too. I'm exited! Its been 5 months!

[CoolAirVw]

Yep, I measured the pump today and its 2 5/8. The one on my parts motor is 2 7/8.

I guess I measured wrong. Must have had the tape measure at an angle or my view was angled or something. When I got the two pumps side by side they were the same, 2 7/8.

I'm gonna make some shims just to get this thing done.

[Vdub-bub]

I might be wrong, but! The way I see it in the photo it looks to me like the AC compressor is out of line more than anything else. Shouldn't your water pump/AC drive belt be lined up and your PS pump and your water pump drive belt lined up?

[CoolAirVw]

I might be wrong, but! The way I see it in the photo it looks to me like the AC compressor is out of line more than anything else. Shouldn't your water pump/AC drive belt be lined up and your PS pump and your water pump drive belt lined up?

I couldn't get the crank pulley in the pic, but it lines up exactly with the power steering pulley and the AC compresser. Simply put the waterpump is too short. I shimmed it out and its fine now. I'll post a pic later.

[CoolAirVw]

Big update! I started the engine today!

Everything went smooth.

1. Primed oil pump
2. Vacuum sucked fuel to filter
3. Vacuum sucked fuel into injection pump
4. Cranked & got oil pressure immediatly
5. Cranked until noticed fuel dripping from injector lines (left them loose to bleed)
6. Tightened injector lines
7. Engine tried to start
8. Another bleed on each injector line while cranking.
9. Engine started with minor missing.
10. One last time cracking loose the injector lines, watch the engine stumble on the cylinders that were working and watch the missing clear up as the last injector lost its last bit of air.
11. Engine purrs like a kitten!

Started break in but a antifreeze leak on the thermostat housing cut me short.