Former VWDieselParts.com Forum

I just changed the passenger side motor mount on my 1.6d. As I was removing the bracket, I inadvertently chipped the shoulder of the IM shaft pulley. I stole one of the newer "shoulderless" pulleys off of another engine I had laying around. I then buttoned everything back up.

Problem now, I noticed now the pulley seems to ride a little closer in to the block. This is causing the belt to ride slightly off center on the IM shaft pulley. The belt overhangs by ~1mm. Everthing else lines up- although on the crankshaft the belt rides more to the outer side of the sprocket- since I put the outer alt belt pulley back on I dont think this is an issue. The camshaft and the IP all ride perfect.

Question- is the belt riding over the IM shaft pulley with a slight overhand an issue? If so, how do I correct this? Is there a shim I can get?

It rides over the edge of the intemediate shaft pully,
without riding off the edge of the injection pump pully?

I've never heard of such a thing,..
no weird wear on the edgeless pully?

Might have to trim the edges off the old pully.

Taking your advice to heart. I took the old pulley and chiped off the rest of the broken shoulder. I filed the edges down and took an emery cloth to it to smooth it out. Looked so good with the one side shoulder/one side flat you couldn't tell it was modified. Anyway, I pulled the shoulderless pulley out and put the old modified one in. No probelm- belt tracks just fine over all pulleys. The only issue I am supper anal about is that the belt rides flush on the end of the crankshaft and not in dead center. All other pulleys the belt rides in the center.

I think as long as the belt's not riding off the end of the crank pully, it's fine. I believe the last time I changed my Tbelt (and had to adjust the IP so the belt would track right) the Tbelt rode at the front edge of the crank pully.