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Old 22-05-2020, 04:37 PM   #1
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Default T1 crankcase oil gallery core plugs

Am rebuilding my 1500 single port engine (H prefix), and using an airline to blow through the oil passages, I've noticed a 'restriction', (some 'back-pressure', not a complete blockage), in the short oilway between No. 4 bearing seat (the small one closest to the pulley end), and the main oil gallery.
I compared this to another crankcase, (a 1600 AD case), with the same airline, and that crankcase has 'free-flow' at that point.
So, I'm going to remove the oilway core plug to investigate.
My question : is it best to replace the core plugs with the original solid soft aluminium plugs, and do these need to be pressed in ?
Or, is there a benefit in tapping the outer end of the oilway and using a threaded plug/grub screw type. Plain thread with Loctite hydraulic seal, or taper thread ?
Any advice much appreciated.
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Old 22-05-2020, 08:36 PM   #2
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Just tap it and put an allen key headed plug in it
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Old 22-05-2020, 09:07 PM   #3
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Originally Posted by GARRICK.CLARK View Post
Just tap it and put an allen key headed plug in it
Thanks, that sounds the simplest method without specialist tools.
Cheers.
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Old 22-05-2020, 10:41 PM   #4
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Don't remove that restriction

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Old 23-05-2020, 12:10 PM   #5
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Your new screw in plug can be shortened in length , get your local machine shop to do it..
You still need to be sure that passage way isn't partially blocked
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Old 23-05-2020, 12:28 PM   #6
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Don't remove that restriction

Wow ! I never knew that, Thanks very much.
I was just about to start drilling out the core plug, so just in time.
I'm just going to flush the oilways through again, and leave it alone.

It makes perfect sense, having seen a few remanufactured engines with oil leaks from the pulley. I always thought this was just due to excessive clearance between the case and the oil return scroll on an aftermarket pulley, or an oversize case 'nose' bore, requiring an oversize pulley boss. If those engines had the core plugs replaced during the Reconditioning process, and that removed the restriction, they would be getting full pressure to no. 4 bearing, overcoming the oil return scroll capacity.

The Crankcase I was comparing with, was a reconditioned unit. (sadly damaged beyond repair), it seems to have been done twice, there was an ally plate stamped with a remanufacturers serial number rivetted over the original engine number. I removed that plate, and found the original Engine number had been machined off and replaced with a VW factory "Austausch" Exchange engine number. It appears that at some time, the oil gallery core plugs were replaced, but, (probably on the second remanufacturing), the restrictor wasn't.
Thanks again lukej .
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Old 23-05-2020, 12:42 PM   #7
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Quote:
Originally Posted by GARRICK.CLARK View Post
Your new screw in plug can be shortened in length , get your local machine shop to do it..
You still need to be sure that passage way isn't partially blocked
Thanks, I'm sure the oilway to No. 4 isn't blocked, just doesn't flow as fast as the others.
I filled the oilways with solvent and left overnight, the solvent came out with a brown tint, no debris. I'll flush it again, and check the back pressure again.
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Old 23-05-2020, 08:17 PM   #8
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Further investigation and measurement of the depth of the oil drilling on No. 4, reveals that my 1500 case does indeed have the restrictor, and my scrap recond case has had the core plug replaced and does not have the restrictor.
I'm satisfied that the restriction I found is intentional and not a partial blockage, so I'll proceed with the build.
Thanks lukej and GARRICK.CLARK, for your help and advice.
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Old 23-05-2020, 10:21 PM   #9
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All's good. Potential nightmare averted!
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