byrdman454

I have been having issues with the front drivers side intake runner not sealing on this '85 32v engine (first cylinder/fwd/drivers side). The second cylinder (part of the same intake casting as the first cylinder seals fine. I thought it was due to warpage from the PC'ing, but now I see that is not the problem since I had them trued. The issue is that this intake casting is interfering with the oil filler. This engine has one of Greg Brown's oil baffles installed under the oil filler. I am using the pre'84 gaskets to seal this baffle. I assume the gaskets and baffle is raising the oil filler too high and the intake casting portion that goes over the top of it is hitting. I even tried doubling up the intake gasket to see if it will clear the oil filler but it does not. The only thing I can think of it to grind a little bit on the oil filler and the intake casting to try and gain some clearance. Has anyone else had this problem? Any ideas to fix this?

Imo000

As GB for a suggestion.

Mrmerlin

seems like the fill spout may be too tall, did you use the louvered plate ?
did you fit check it to the GB baffle? it should fit flush to the baffle

byrdman454

I believe the preferred method to seal these baffles are to use (2) pre-84 baffle gaskets. These gaskets are pretty thick as well. So you have the block, gasket, baffle, gasket, and then oil filler. This works fine with the S4, but might be part of the problem with the S3. Do you think the paper gaskets can be deleted and just use Dreibond between the block, baffle, and oil filler?

GregBBRD

I have not run into this problem....

However, I don't use any gaskets. I make sure the filler neck is flat and use Dreibond between all the pieces.

byrdman454

Thanks for the info Greg. I appreciate it. I will pull off the oil filler and get rid of the gaskets.

Mrmerlin

NOTE a picture of what your doing would be good.

NOTE fit check the assembly to make sure the bolts your using are long enough,
removing two gaskets will give you about 5 more threads.
.

KenRudd

I did exactly this last week on my S3 rebuild, and clearance is good.

On a related note, the Greg Brown Oil Baffle cannot be installed/removed when the coolant bridge is in place:


So you will need to coordinate your install accordingly.

byrdman454

Thank goodness I have not re-installed the water bridge yet! I knew this was an issue with the '84 Euro I did a while back. Thanks for letting me know the same issue appears on the S3.

ihoe

I had the exact same problem on my S3 using two pre-84 gaskets. It is not safe to use this solution on all cars, I guess it is related to tolerances.