Still leaking oil after 3rd engine drop, Source? Options

[Wew]

Hi all,

I have posted several times on this forum regarding my engine and transmission rebuild.

Thanks to Ian Karr's video on valve train geometry it really helped me visualize what exactly needed to be done in order to get everything lined up and adjusted properly.
Haven't done it yea, but the engine is dropped and ready to tackle this project.

My big concern is my inability to stop this oil leak which is present on both sides on the engine.

I bought the extra thick cork valve cover gaskets from 914 rubber.

Based on the images could anyone deduce the source of the problem and a once and for all remedy?

Same with the push rod tubes. Are there any oil leak proof pushrod tubes and seals that can keep the oil leaks from sneaking back?

The engine rebuild probably has 20 miles on it as due to the oil leaks and a terrible valve train geometry job done by a local volkswagen shop. These things prompted me to drop the motor and redo things.

Oil pressure sensor leak resolved. Oil cooler seals are good and no leaks.

The oil you see in the images, and some drips from the pushrod tubes, which could be from above and also on the heat exchangers streaks of oil coming down them from the engine.

It also have noticed oil in the exhaust to muffler gaskets. Is this normal, if not what would that cause and remedy be?

Thanks a bunch, I know I have a lot of questions but I would really prefer once and for all to address these issues.

Thanks,

Gary

[iankarr]

I agree...odd. Glad the video was helpful. Curious...how did you know the VW shop incorectly set your valve geometry?

As for the pushrod tubes and seals...they're all leak proof (IMG:style_emoticons/default/wink.gif). They just need to be installed properly. The bores need to be hostpital clean, the tubes need to be round, and the seals need to be intact. And there isn't much room for error. Viton seals are generally thought of to be the best. I used some teflon sealant around the seals on the head side and plain old motor oil on the case side. Make sure the seals don't tear on the way in.

You should also check the oil pressure sender area on top of the case, near the distributor. Oil leaking from there can end up in all kinds of places.

Is the "VW" upside down or right side up on your (installed) valve covers. Jake Raby says the VW should be upsdide down and he knows a thing or three.

You'll get this sorted, I'm sure...

[Wew]

I agree...odd. Glad the video was helpful. Curious...how did you know the VW shop incorectly set your valve geometry?
He said he does things by eye on the vw's and that once you get the length for one you got it. I had my suspicions but the shop has been around a long time. Once I started the car for the first time on valve was so loose it was clacking like crazy. I dropped the motor that time and reset to zero lash. Went over them all for good measure and there were some serious gaps. I ordered new pushrods and got the spacers from your guy Ian, so I am going to follow your process. I am wondering if my Valve covers are warped or not perfectly flat.

As for the pushrod tubes and seals...they're all leak proof (IMG:style_emoticons/default/wink.gif). They just need to be installed properly. The bores need to be hospital clean, the tubes need to be round, and the seals need to be intact. And there isn't much room for error. Viton seals are generally thought of to be the best. I used some teflon sealant around the seals on the head side and plain old motor oil on the case side. Make sure the seals don't tear on the way in.
I will definitely be re-sealing them.

You should also check the oil pressure sender area on top of the case, near the distributor. Oil leaking from there can end up in all kinds of places.
I have checked this and had it rethreaded and can confirm there are no leaks from that location. Motor is dry on the top.

Is the "VW" upside down or right side up on your (installed) valve covers. Jake Raby says the VW should be upside down and he knows a thing or three.
I will double check that but I believe yes. Oops one side upside down and the other right side up. Both sides leak.

You'll get this sorted, I'm sure...

Fingers crossed!

Thanks Ian!