300 Tdi Rebuild

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Saint.V8 said:
Oil amount is similar from memory, will have another look - but may not be until the weekend before I get the chance....will report back.
Click to expand...
No hurry, mate.
I'm not sure if my 'I/C pipe off' experiment proved anything. It still smoked. JM suspects piston ring to bore seal. :( I'm hoping it's valve guides. I reckon guides will be easier to solve. Either way, dreading it.
 
Right, gents. I was going to wait until Saturday to do the compression tests, probably because I was frightened for the results. :oops:
Anyway, grown a pair tonight and in a gap in the rain decided to give it a go. Here are the results.
I used the heater plug hole.
Here is cylinder No1
P1190417.JPG

440psi
The end of the heater plug was a little sooty in one part and grey over the rest. I rubbed it with my finger - too late to take a picture then!
But, I took pictures of the others! Here's heater plug No2
P1190418.JPG

Here's the compression on cylinder No2
P1190419.JPG

440psi
The heater and compression on No3
P1190420.JPG

P1190421.JPG

432psi (Tester had an extra elbow in it to get in behind air filter)
Finally No4
P1190422.JPG

P1190423.JPG

432psi approx Again with the extra elbow on the tester compared to cylinder 1 and 2.

I thought 300Tdi compression was in the region of 348psi so mine seem to be very high! Is that a problem? Gauge carped?
Do the heater plugs look as though they are getting too hot? I'm a bit nervous about that as the piston crown in cylinder No4 was melting when the engine knacked.

What do you all reckon?
 
jamesmartin said:
its held in hone or boring grooves
if your burning oil its either the bores or oil entering through manifold
Click to expand...
So via manifold you're thinking turbo seals or breather? Hmm............I'll have to clean the air pipe to turbo and then the other I/C pipes and see if oil appears before and after the turbo or just after!

jamesmartin said:
depends on the angle and whether theres not enough honing to remove boring tool grooves
Click to expand...
Are boring tool grooves microscopic, cos I can't remember seeing any. Just honing marks!
 
Al2O3 said:
So via manifold you're thinking turbo seals or breather? Hmm............I'll have to clean the air pipe to turbo and then the other I/C pipes and see if oil appears before and after the turbo or just after!


Are boring tool grooves microscopic, cos I can't remember seeing any. Just honing marks!
Click to expand...
very small too small to see the surface looks smooth but its like a thread on a bolt
 
James, if I was to go down the home honing route. What do you think of the idea of honing the bores with engine still in? I could wrap the crank up to keep metal particles off it and fabricate a catcher to go over the bottom of each bore. I don't fancy taking the crank out again!
 
yes i do often do them with engine in situ you just need to cover crank etc with a rag with journal at lowest point, you need to remove oil squirts though
 
jamesmartin said:
yes i do often do them with engine in situ you just need to cover crank etc with a rag with journal at lowest point, you need to remove oil squirts though
Click to expand...
That's good news :)
I presume you use a honer with the three arms on, like the one you pictured, rather than one of those with all the beads?
 
Al2O3 said:
That's good news :)
I presume you use a honer with the three arms on, like the one you pictured, rather than one of those with all the beads?
Click to expand...
yes with medium stones 280 grit, your putting grooves on at the correct angle 22 degrees to horizontal or 45 degrees to each other,you then use a fine hone 400 grit or whats called a plateau hone for a few strokes 15 or so ,which flattens the peaks which is what running in does as well
 
jamesmartin said:
yes with medium stones 280 grit, your putting grooves on at the correct angle 22 degrees to horizontal or 45 degrees to each other,you then use a fine hone 400 grit or whats called a plateau hone for a few strokes 15 or so ,which flattens the peaks which is what running in does as well
Click to expand...
Ok, sounds good. I'm not ruling the turbo out yet though. Obviously I'm hoping it is the turbo cos it'll be a lot easier. :) I've got a boost gauge to go in at some point. If the seals are iffy, will it show if I temporarily fit the boost gauge up in to the cab?
 
Al2O3 said:
Ok, sounds good. I'm not ruling the turbo out yet though. Obviously I'm hoping it is the turbo cos it'll be a lot easier. :) I've got a boost gauge to go in at some point. If the seals are iffy, will it show if I temporarily fit the boost gauge up in to the cab?
Click to expand...
yes check everything first ,sometimes the oddest thing shows up, no just knowing oil is passing will do that, id isolate any sources of oil too the turbo ie breather hose and run engine with out let hose off and place a catch sheet to see what amount if any oil passes fro turbo
 
jamesmartin said:
yes check everything first ,sometimes the oddest thing shows up, no just knowing oil is passing will do that, id isolate any sources of oil too the turbo ie breather hose and run engine with out let hose off and place a catch sheet to see what amount if any oil passes fro turbo
Click to expand...
I did a brief, similar test, the other night. I looked primarily at the amount of smoke coming from the exhaust. It still smoked, but I was thinking that might be fuel smoke if it wasn't breathing properly.
How long would you do the test you describe for? Which outlet hose do you mean, out of turbo or out of I/C?
 
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