crankshaft, intermediate shaft timing - SHAFTED- HELP!

["Victor Farren" <vfarren@rrs.cdie.org>]

This isn't on a scirocco, but my brother's A1 Jetta w/ a  8v JH engine
so I guess its kind of appropriate for the list.  Pretty long so
please bear w/ me.

We are having difficulty timing the crankshaft to the intermediate
shaft after removing and replacing the timing belt and we can't get
the car to start.  The following is what I know, according to
Bentley:

align the notch in the crankshaft pulley with the punch mark on the
intermediate shaft sprocket.  Align the punch mark on the inside of
the cam shaft sprocket with the top of the cylinder head (so, a hair
below the valve cover).  This I can do, and have done in the past w/
other JH engines, so I do know how to replace a timing belt and get
the car started on a car with no AC or power steering.

It appears that the Jetta had power steering or something b/c there
are 2 pulleys on the crankshaft.  In act, the inner pulley is made up
of two rings (for lack of a better word) seperated by spacers,
followed by a genuine pulley on the outer edge of the crankshaft.  The
inner pulley has no belts running on it, while the alternator, water
pump belt runs on the outer pulley.  

PROBLEM:  Neither pulley on the crankshaft has a notch in it!!!  The
only mark visible is on the outer pulley, and this has a large punch
mark (more like a circular indentation about 2 cm diameter) on the
actual face of the pulley, about 1-1.5 inches from the lip of the
pulley.  I have never seen a pulley like this, and it makes it a real
b*itch to try and line up w/ the punch mark on the intermediate shaft

WHAT I DID (TAKE #1):  I marked a line on the outer edge of the outer
crankshaft pulley in line w/ the 2cm diamter indentation.  I lined up
this new mark w/ punch mark on the intermediate shaft and proceeded to
put on the timing belt after aligning the camshaft w/ top of cylinder
head (followed Bentley procedures).  I accounted for movement in the
intermediate shaft and camshaft so in the end all the marks lined up. 
Turnd engine to where the timing mark on the flywheel was pointing at
the arrow on the bell housing.  Looked at where the rotor was pointing
and ran spark plug wire from that post on the distributor cap to the
#1 cylinder.  Followed firing order of 1,3,4,2.

Cranked engine and didn't start.  Loosened distributor and moved it
around a little while brother cranked engine.  Nothing, no sound of it
even trying to start.  Didn't seem liek I was getting spark to the
correct cylinder.  

TAKE #2:  Did above procedure, but this time trying to align notch on
intermediate shaft with the 2cm diameter indentation on crankshaft
pulley.  Very hard to do b/c the mark is on the face of the pulley,
and the center puch on the intermediate shaft pulley goes behind the
crankshaft pulley when the marks line up.  Did the same thing w/ the
flywheel, etc, with same results.

WTF!  What am I doing wrong?  I have never seen a pulley set up on
the crankshaft like this one.  This is really starting to get on my
nerves b/c I have been trying to get this thing started for 2 nights
now.

Car has brand new spark plugs, cap and rotor as of last night.

If you have read this far I thank you, and would love any input.

Victor

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