TD5 Piston change?

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W

Winter Rover

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Hi
TD5 discovery 1999. As previously posted having a nightmare with this engine and am refitting a new cylinder head now due to crack in the original head. I have previously mentioned I have a damaged piston and here it is shown above.
It doesnt look too bad seems to have some kind of burnt deposit on it. Should I change this is my question. Or can i try removing the deposits with wet and dry.
Also if piston needs changing id be very happy to take advice on whether to take engine out or just take the sump off.
Any advice and comments much appreciated. Also any advice about how to get the injectors out of the old head,. Would it be best to buy a tool do do this?
Thanks in advance as not giving up on the old beast just yet.
John
 
Sorry to say bud, but that is knackered.. :-( looks like you've dropped a valve or some other foreign body has been bouncing around inside the cylinder.. the bore looks scored too. I'd be looking for a decent used engine if it was mine.
 
Post some more pics of the bore walls, I think it might be OK.

Piston is goosed though, deffo foreign object been bouncing around in there.
 
Do you think using a honing tool and new piston it will be ok. I have measured everything and all ok and engine runs perfect. Just started with overheating and gasket failure.
 
For the cost of a flexhone I'd be giving that a deglaze and risking it with a used replacement piston & new rings. Just depends on how deep those vertical scores are - does your finger nail catch on them?
 
alps. Im going to take engine out and use honing tool as everything is in tolerance. Just need advice on whether this will do. Or whether to just buy a recon short assembly
 
You can remove the sump and stiffener plate to remove the piston. When I recently removed one on our td5 the piston and bore were knackered. Also the valves on that cylinder had been damaged. By the time you have bought cylinder head bolts, cam carrier sealant and head gasket you will have spent well over £100 and that's without replacement piston.
 
Do you know how the damage occurred and are you sure there is no damage to the crank? If there is no other damage I think I would try to hone the bore before looking for another engine. If it comes up OK then swap the piston and put it back together. I've not done it on a TD5 yet, but I'm not aware of any reason why you should not be able to take off the big end and push it upwards (someone with more experience will be along in a minute). But if the journals on the crank are damaged I would look elsewhere.
As to the injectors, I got one out with a Jbar, but the others would not move and I did not want to force them. I invested in the slide hammer tool and extraction becomes easy. Others with better technique get them out without, just don't damage them trying.
 
Recon short block will be ££££ - probably cheaper to source a complete used engine, but shipping might kill you.

Hone the bore, and see what those vertical scores come up like, tbh I think they will likely not be a big issue. If they are very light then purchase replacement piston & rings - you can get the piston with them already fitted from Turner engineering, or buy rings separate and obtain a good used piston. Be sure to measure the tolerances as per the workshop manual.

Just be super careful to not get hone material on the crank and to wash the bore out thoroughly, ATF on a white lint free rags will show up the hone material coming out.
 
brianconwy said:
You can remove the sump and stiffener plate to remove the piston. When I recently removed one on our td5 the piston and bore were knackered. Also the valves on that cylinder had been damaged. By the time you have bought cylinder head bolts, cam carrier sealant and head gasket you will have spent well over £100 and that's without replacement piston.
Click to expand...
Hi
Ive got all that as have recon head already
 
I used a snap on small pry bar to lever the injectors out. Didn't take much force. Pity you didn't live nearer. I have four good pistons and a toming tool. It was the piston nearest the radiator on mine. Which was it on yours?
 
Bennehboy said:
Recon short block will be ££££ - probably cheaper to source a complete used engine, but shipping might kill you.

Hone the bore, and see what those vertical scores come up like, tbh I think they will likely not be a big issue. If they are very light then purchase replacement piston & rings - you can get the piston with them already fitted from Turner engineering, or buy rings separate and obtain a good used piston. Be sure to measure the tolerances as per the workshop manual.

Just be super careful to not get hone material on the crank and to wash the bore out thoroughly, ATF on a white lint free rags will show up the hone material coming out.
Click to expand...
Yes I'm going to get the engine out as already have the piston. Will try honing all the bores as they are not bad
 
brianconwy said:
I used a snap on small pry bar to lever the injectors out. Didn't take much force. Pity you didn't live nearer. I have four good pistons and a toming tool. It was the piston nearest the radiator on mine. Which was it on yours?
Click to expand...
Middle piston has gone. I will attack the injectors next week once engine is out
 
brianconwy said:
I used a snap on small pry bar to lever the injectors out. Didn't take much force. Pity you didn't live nearer. I have four good pistons and a toming tool. It was the piston nearest the radiator on mine. Which was it on yours?
Click to expand...
If you like to sell pistons and tool let me know
 
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