[Vwdiesel] help with 1.9 rebuild

[greg rich]

Hi Gang
I am in need of desparate help with a Canadian 1.9 idi turbo diesel.
Basically I installed a "rebuilt" motor for my neighbour who supplied the
engine from a local machine shop (bought over the counter with a core). I
have since removed the engine TWICE, first time the crankshaft face was
warped and the pulley had a wobble (real pro job...they modified the old
crank to accept a tdi pulley) and the oil buzzer went once so they replaced
the oil pump, second time was LOW oil pressure (10 psi at idle, max 30 psi
on highway with oil hot-buzzer on constant). I suggested that the
intermediate shaft bearings were never replaced, the block of the engine had
not been dipped just repainted -suggests bearings were never removed. We got
the engine back and I took it apart to have a look. They claim to have
replaced the inter shaft bearings. Would one not have to machine the shaft
aswell to match the bearing races (they clearly didn't) and can the far
bearing be changed without removing the vacuum pump/oil pump and brass plug
behind the clutch? I also removed the #2 main bearing, it has standard
bearings still, they claim everything is "new" inside the motor, we know the
crank is not, would one not expect oversize bearings on a rebuilt motor?
Obviously they did not machine anything in this engine, nor check anything
after bringing it back with low oil pressure. What would low pressure like
that due over the course ofsix months, say 5000 miles? (he did not drive it
that much, and the oil light only came on at the end of the week, but we
have no idea how the pressure was the last 6 months).
What are the torque specs and for rod and main bearing bolts? Clearances for
bearings? I want to plstiguage them.
I am not involved with the dispute but I want to help him as much as  I can,
I really don't have time to keep removing the motor time after time (I am
getting paid but this is rediculous)
If anybody has clear knowledge/advice please let me know
Thanks, Greg









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