You have bigger fish to fry. The corrosion on the water pump and visible in the other pics indicates that you have acidified coolant. That is caused by acid formed from combustion products in the cooling system. Nothing else will do that. Fix it now before you have more problems down the road.
If you still have the old coolant check is "coolant voltage" with a DVM and a piece of brass. Set the DVM on the lowest DC volt scale and hook one lead to something brass. Put both leads (including the one with the piece of brass) into the coolant. You get a "brass/acid" acid battery that way. The voltage read indicates how much acid is in the coolant.
.050 volts DC an you are golden.
.300 volts and you have trouble.
.450-.700 volts and you are toast.
Thanks Toby... I have had the coolant out for a long time already so not possible to check it. Yes you are right... the PO did not have ANY anti-freeze in the coolant at all! So it was corroding the engine (what an idiot!).
Anyhow I have not updated this thread for ages... since my last post I have done a huge amount of work - mostly with the help of Andrew Libby and some other great guys over on the Samba.
Here are the highlights:
cam out, checking valve lash
![](http://images.thesamba.com/vw/gallery/pix/1432394.jpg)
pulling IP sprocket
![](http://images.thesamba.com/vw/gallery/pix/1463341.jpg)
removing IP
![](http://images.thesamba.com/vw/gallery/pix/1464334.jpg)
removing glow plugs
![](http://images.thesamba.com/vw/gallery/pix/1465543.jpg)
IM shaft sprocket off
![](http://images.thesamba.com/vw/gallery/pix/1464547.jpg)
problems found
![](http://images.thesamba.com/vw/gallery/pix/1468447.jpg)
oily rear seal
![](http://images.thesamba.com/vw/gallery/pix/1468434.jpg)
crank sprocket off
![](http://images.thesamba.com/vw/gallery/pix/1467027.jpg)
ugly mess
![](http://images.thesamba.com/vw/gallery/pix/1467024.jpg)
working conditions
![](http://images.thesamba.com/vw/gallery/pix/1467016.jpg)
troubles removing oil pan
![](http://images.thesamba.com/vw/gallery/pix/1468899.jpg)
injectors out
![](http://images.thesamba.com/vw/gallery/pix/1468878.jpg)
hacked tranny mount
![](http://images.thesamba.com/vw/gallery/pix/1468572.jpg)
damaged muffler
![](http://images.thesamba.com/vw/gallery/pix/1468464.jpg)
turbo welded to exhaust
![](http://images.thesamba.com/vw/gallery/pix/1469376.jpg)
messy turbo
![](http://images.thesamba.com/vw/gallery/pix/1469365.jpg)
bent oil return line out
![](http://images.thesamba.com/vw/gallery/pix/1469255.jpg)
IM shaft out
![](http://images.thesamba.com/vw/gallery/pix/1469220.jpg)
fried bearing
![](http://images.thesamba.com/vw/gallery/pix/1469216.jpg)
crank plate off
![](http://images.thesamba.com/vw/gallery/pix/1469199.jpg)
a look at my turbo inside
![](http://images.thesamba.com/vw/gallery/pix/1469709.jpg)
oil inside turbo to intake hose
![](http://images.thesamba.com/vw/gallery/pix/1469697.jpg)
dip stick stuck into turbo from above shows that oil is not pooling inside turbo.
![](http://images.thesamba.com/vw/gallery/pix/1469649.jpg)
checking oil pump
![](http://images.thesamba.com/vw/gallery/pix/1472653.jpg)
oil pan off
![](http://images.thesamba.com/vw/gallery/pix/1472608.jpg)
making IM shaft front bearing pulling tool
![](http://images.thesamba.com/vw/gallery/pix/1478545.jpg)
new oil rtn pipe comes... too small ID
![](http://images.thesamba.com/vw/gallery/pix/1477630.jpg)
...so I drilled it more wide
![](http://images.thesamba.com/vw/gallery/pix/1477629.jpg)
pulling IM shaft bearing
![](http://images.thesamba.com/vw/gallery/pix/1478844.jpg)
new bearing installed
![](http://images.thesamba.com/vw/gallery/pix/1479177.jpg)
![](http://images.thesamba.com/vw/gallery/pix/1479175.jpg)
im shaft plate ready to install
![](http://images.thesamba.com/vw/gallery/pix/1480481.jpg)
crank plate ready to install
![](http://images.thesamba.com/vw/gallery/pix/1481407.jpg)
new FEBI (in spec), ready to install
![](http://images.thesamba.com/vw/gallery/pix/1481416.jpg)
crank plate installed
![](http://images.thesamba.com/vw/gallery/pix/1481422.jpg)
im shaft, seal, and plate installed
![](http://images.thesamba.com/vw/gallery/pix/1481429.jpg)
oil pump installed
![](http://images.thesamba.com/vw/gallery/pix/1481431.jpg)
oil pan installed
![](http://images.thesamba.com/vw/gallery/pix/1481432.jpg)
![](http://images.thesamba.com/vw/gallery/pix/1481874.jpg)
![](http://images.thesamba.com/vw/gallery/pix/1481876.jpg)
oil return line installed
![](http://images.thesamba.com/vw/gallery/pix/1481881.jpg)
crank bolt installed (ouch!)
![](http://images.thesamba.com/vw/gallery/pix/1481888.jpg)
crank and im sprocket
![](http://images.thesamba.com/vw/gallery/pix/1482175.jpg)
installing new shims
![](http://images.thesamba.com/vw/gallery/pix/1482183.jpg)
cam ready
![](http://images.thesamba.com/vw/gallery/pix/1482181.jpg)
cap #1 ready
![](http://images.thesamba.com/vw/gallery/pix/1482178.jpg)
cam in
![](http://images.thesamba.com/vw/gallery/pix/1482177.jpg)
second hand turbo found, considering rebuilding and installing