[Vwdiesel] Still trying to resurrect 1980 vw rabbit diesel

[LBaird119 at aol.com]

In a message dated 7/16/2006 2:22:23 PM Pacific Standard Time, 
tolbert192 at hotmail.com writes:

> a) intermediate pulley has a 2 1/4" piece broken off on the inside. Going 
> to 
> postpone change out until status of engine is resolved.

  This happens when someone trys to pry it off at some time or 
dropped something in there.  It's getting hard to find one that isn't
chipped anymore and I do believe new replacements have no flange 
at all.  Three choices, run it as is, build it up with JB Weld and sand 
smooth or replace.  I've done both all three but with a used rather than 
new one.

> 
> b) received new style tensioner (uses wrench with holes in hub) Going to 
> have to use old style,
> (with the hex head adjuster) the new style does not line up correctly and 
> will not turn when the nut is tightened. (have to loosen engine mount bolt 
> and jack up engine to remove/install)

  New one should work as a direct replacement.  That's the factory 
original one you're running there!  They usually tend to get noisy at 
about the second belt.  I liked the old hex style but spend $15 to 
$20 at Baum tools (or ebay maybe) and get a proper wrench.  If 
it's not turning when tightened down, something's not kosher so 
find what's going on, they should be identical from the outer flange 
on back.  You can double nut the stud out, I believe so 
as to not need to loosen the mount.  You may have to put a jack 
under the engine and give it a bit of a lift though.

> 
> c) Having the ^%$#@#$% time trying to locate TDC, even with cam loosened. So 
> 
> far, we in north texas are in our "hot weather mode"(100+), last 6-7days, no 
> 
> friends want to come out and help. Going to kidnap someone soon.

  Kidnap me!  I could use a cross half the country trip!  :-)  Send me your 
phone number and I'll talk you through it if you like (I have free weekend 
minutes)  :-)

> 
> d) Drained coolant, able to get about half in aux tank, will try to put 
> remainder in radiator upper
> hose with funnel.

  Usually the process is to fill the upper rad hose (pouring into the 
rad end of the hose) until it's full and THEN fill the reservoir after 
tightening down the hose to the radiator.
     Loren