19J Pistons Cracked - Replace or Try to find a 200tdi

Hi
I have a 19j engine which appeared to run fine until i noticed that there was an oil leak at the back of the head gasket. I removed the head to find that all 4 pistons are cracked. My question is, should i replace the pistons - if so is it difficult and any idea of how much it would cost vs try and find a 200tdi to install?

any guidance welcome

if head isnt cracked between the valves the best fix would be 4 over size pistons and a rebore likely around 300 but obviously theres more to it ,would you be doing the rebuild or wanting someone to recon yours

No Cracks between the valves, only on the hot spots - how difficult is the rebuild? never done one before..... or would i be better to try and find someone to do it

The very first engine I rebuilt was one of them, never done one before and it turned out great just followed the Haynes manual.
Had some help off my local indy with the lending of timing tools and the big socket for the crank bolt though.
Twas 16 yrs ago so can't remember much but apart from the seals that go either side of the crank end blocks (fiddly), it was easy.

Remember it's not 2006 anymore, and there simply aren't loads of rusty 200tdi Discos just hanging around with good engines anymore. Those engines that are available will likely be very high mileage by now and could be equally knackered. Even 300tdi engines will all be 20 years old now at least. Far better now to keep an early 90 or 110 standard.

I'd suggest working with what you've got- take it out, take it apart and see what's broken. If it makes sense, fix it.

Pistons are around 50 quid each, was it running fine before the HG let go?

Look at Turner Engineering for the bits.

billythewhizz said:

No Cracks between the valves, only on the hot spots - how difficult is the rebuild? never done one before..... or would i be better to try and find someone to do it

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not difficult but involved youd need a workshop manual, providing you use a good engine shop to bore and hone the block to your new piston set

The quickest and cheapest fix is to fit new pistons, but if you go down the tdi route, don't discount the 300tdi engine, they are not particularly difficult to fit once you have sorted out the engine mounts.

nobber said:

Pistons are around 50 quid each, was it running fine before the HG let go?

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No it was running fine except the oil screwed up the started motor which is how i noticed it

billythewhizz said:

No it was running fine except the oil screwed up the started motor which is how i noticed it

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Any photos of the pistons? Ive seen 19js run just fine with cracked piston crowns.

Pics

nobber said:

Any photos of the pistons? Ive seen 19js run just fine with cracked piston crowns.

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not for long

billythewhizz said:

Pics View attachment 172461 View attachment 172462 View attachment 172462 View attachment 172461

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bore wear is very common ,doesnt stop them running, but you need new pistons at least, get bores checked and rebored and honed if needed or honed and new pistons if not, pistons should be teflon coated its a grey colour on piston crown rather than the std aluminum silver it helps to prevent cracking

My last one ran for over a year, the cracking wasn't bad but bad enough for me to be concerned, eventually killed it by driving it into a pond and bending a rod. Sometimes the cracking isn't all the way through the crown.

looks quite "clean" in there, prolly the cleanest old diesel i've seen..

nobber said:

My last one ran for over a year, the cracking wasn't bad but bad enough for me to be concerned, eventually killed it by driving it into a pond and bending a rod. Sometimes the cracking isn't all the way through the crown.

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that can be true but equally that could be tomorrow when it blows through the piston leaving you stranded

Henry_b said:

looks quite "clean" in there, prolly the cleanest old diesel i've seen..

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they do , its rocker cover and sump that show signs of lack of servicing

jamesmartin said:

they do , its rocker cover and sump that show signs of lack of servicing

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Maybe OP will post Pic's when it's apart..

Then we can see the 1/2 inch of sludge and build up

Mind you..

This was out of a 300tdi





'twas like cleaning out a chimney..

Gave the parts washer a work out..

Very simplistic, as was the car it came out of..

Henry_b said:

Maybe OP will post Pic's when it's apart..

Then we can see the 1/2 inch of sludge and build up

Mind you..

This was out of a 300tdi

'twas like cleaning out a chimney..

Gave the parts washer a work out..

Very simplistic, as was the car it came out of..

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a turbo diesel has higher combustion temps that cracks the pistons ,tdis have intercoolers but lots of carbon is usually an effect of egr