My 1.6 TD build

[quasi]

Ok I am finally putting everything together on my engine.  I will now use this topic for all and any questions i come up with.  I had small previous posts here and their, but will now stay with just this one topic as i do my rebuild.

I had put things together before but ran into issues with the connecting rod bearings I had purchased from Prothe.  So now I got two sets of good bearings.  My block and crank were previously checked at a local speed machine shop and all measurements were about dead center of standard.  While they had it, I had them install the new intermediate shaft bearings, and also they cross hatched the cylinder walls.

So now I am installing different new main bearings cause I now do not trust the main bearings I previously installed (they were also from Prothe), since the connecting rod bearings were not correct.

So with the two sets of main bearings, and new thrust washers I am installing.  My question on bearing #3, do I use the slotted bearings on the top and bottom, or the sloted on the bottom, and the smooth in the cap?   Bearing #4 I have slotted on the bottom, and a slotted in the cap.  Is that also correct?

[quasi]

I used the slotted bearing on the bottom, and the smooth one in the bearing cap.  Torqued it all down per Bentley manual.  Installed the new pistons, threw away the Arco rings I originally had purchased from Prothe and installed the Goetze rings I had ordered in after reading more threads here in the forums.  The main and connecting rod bearings I am using are the brand name Mahle.  The thrust washers I ordered from Mike_W here in the forums.  Perfect fit.

Installed the new seals, new oil pump and the oil pan.  Installed the clutch housing to the engine.  Front side of engine I installed the pulleys and lower shield.  Naturally installed new oil plugs at both ends of the engine and the freeze out plugs. Installed the water pump housing and new water pump and a few new water hoses, along with the new oil cooler.  My oil cooler looked sludgy inside and gritty, and I did not trust it even after i soaked and cleaned it a few times.  

I am not liking how the o-ring is fitting between the block and the water pump housing.  I purchased a o-ring for it when I ordered my bearings and rings...  it didn't look right, so i picked another one up from a local VW shop and it is the same.  But neither match what I took out.  The old one was was a lot thicker and had edges rather than a pure round o-ring

[Alcaid]

The o-ring is supposed to be round, hence the name The old one's shape is due to it being squeezed for a long time together with temperature has "baked" it into it's new form (that will follow the o-ring groove and the sealing surfaces)