I am starting a 1.6TD build version 2, hoping for more than 40,000 miles :D

[Gizmoman]

Congratulations Mr!
Only 39,996 miles to go and you'll beat your old record by a mile

[theman53]

Yep, it is off to a rough start.

[CRSMP5]

Congratulations Mr!
Only 39,996 miles to go and you'll beat your old record by a mile

[Dakotakid]

I would use a mirror and light (however it works for you) to carefully examine that plug hole (cast iron). Probably no problems. But..........examine it none the less. I would also be a bit concerned about ALL the others as well.

Make sure you check to see if any oil running out of the trans/engine seam (the small plug).

[Dakotakid]

Additionally:

If you go with the block heater, spend a couple moments looking at how the particular heater bung/heater cord plug orients. Determine what is your best goal as far as electrical cord placement back there behind the turbo and downpipe.

I have installed some and then been irritated with an additional loop of cord in order to exit out the passenger-side of block (due to orienting it 180 degrees wrong).

I know it seems like small stuff, but small stuff matters. And, you can avoid a burned cord (which you only discover in the middle of a cold snap!).

[CRSMP5]

my issue is ive had a properly installed one blow out 1.5 years after install as the o-ring corroded.. had grease on it.. and pushed it out the block.. like they forgot the coating on the potmetal it was made from.. it was not a cheap crappy one.. never did that again on any of mine.. the 2 i have are og original vw ones.. still work and all.. have removable plug.. will not touch/remove or anything.. both 1.6 non hydro bottom ends.. 1 na, 1 td.. 12mm headbolts... so 82.5-86 parts... too bad aftermarket ones junk..

[theman53]

I have checked out the hole with a light and ran my finger around, seems good. The plug I have maybe vw. as it looks like good stuff and I had to pry it out of my aaz block as it would not come out. I am just using it to plug a hole as I already have a block heater installed from the last engine in the far passenger side hole. Both block heaters on the car have the removable cord, so it is a shot that they could be stockers. I don't know what but I remember the middle freeze plug didn't look seated compared to the rest of them. I hoped to be further along than this. I at least wanted to have the first 20 mile filter change. Oh well.

[CRSMP5]

you did not replace after hottank??? all need replaced if hottanked.. weakens them...

[libbydiesel]

They all need replaced if the block is tanked.  The two oil galley plugs and the plug at the end of the intermediate shaft should be as well.  The larger plugs are 36.6mm which is not a 'normal' size.  IIRC the galley plugs are 14mm.

[CRSMP5]

called him just now.. they were.. sadly he also states/is thinking that one did not look to be in like the rest too. . opps... how we learn.. big mistake =  brain winkle..

[theman53]

my machinist did all the freeze plugs, oil plugs, IM bearings, and the oil squirters. I did the assembly of the rest of the block. I don't think I would have done any better as I am not a good freeze/welch plug installer. I will have it going again, hopefully tonight.

[theman53]

https://www.dropbox.com/s/n9su0uexjzme746/VID_20130714_180256_514.mp4


There it is running its return voyage, before the freeze plug incident.

[theman53]

Can you guys see that video?

[Gizmoman]

Yes - sounds ready to rock

[CrazyAndy]

Yaaay living. 

Won't say anymore; might jinx it.