Oil Leaks, I am tired of them Options

[sdoolin]

Rebuilt my 2.0 back in 2016. Full "Raby Spec" 2056. Runs very well. It is out of the car right now as I am dealing with a rusty battery tray (separate thread on that). It appears that I have leaks at most/all of the pushrod tube seals, the valve cover seals, and the rear main seal. This is not a surprise to me, I clean the bottom of the engine regularly, and knew this day was coming

Pretty sure I used the Victor Reinz gasket set that came with my engine "kit" from the Type IV Store. I used the cork valve cover seals from the Victor Reinz set. I did not use any RTV anywhere. Hate the stuff. I know I used a rear main seal from GoWesty as someone back then had suggested it is a better part then what is included with the Victor Reinz set.

I installed new pushrod tubes and used the O-Rings from the Victor Reinz set.

Does anyone really have an oil tight VW Type IV engine? If yes, how does none do that?

[sdoolin]

I (finally) have the engine back in the car. I have the heat exchanges and related ducts and heater bits all installed. When I went to install the muffler (it is a Bursch unit), I noticed that things don't line up. The flanges on the muffler are closer together than the flanges on the heat exchangers. This means that the bolt holes on the muffler do not align with the bolt holes on the heat exchangers, they are off by maybe 1/4". I don't remember having this problem the last time I installed the engine.

I am considering loosening the heat exchangers and related bits to give me some "wiggle room" to line up the flanges and bolt holes. I am worried though that this may impair the ability for the heat exchangers to seat solidly and completely in the heads against the copper gaskets?

Anyone else run into this issue? Maybe I have just found an excuse to purchase a new muffler?

[930cabman]

I (finally) have the engine back in the car. I have the heat exchanges and related ducts and heater bits all installed. When I went to install the muffler (it is a Bursch unit), I noticed that things don't line up. The flanges on the muffler are closer together than the flanges on the heat exchangers. This means that the bolt holes on the muffler do not align with the bolt holes on the heat exchangers, they are off by maybe 1/4". I don't remember having this problem the last time I installed the engine.

I am considering loosening the heat exchangers and related bits to give me some "wiggle room" to line up the flanges and bolt holes. I am worried though that this may impair the ability for the heat exchangers to seat solidly and completely in the heads against the copper gaskets?

Anyone else run into this issue? Maybe I have just found an excuse to purchase a new muffler?

Yes, I have seen this and have not gotten to the bottom of it. Must be mis alignment at the heat exchanger/cylinder head connection or bent heat exchangers.