Today's problems...
On removing the head I found damage to number 2 piston, and some scoring on the bore. The markings on the bore show that the top ring at least isn't sealing properly.

I will obviously need to replace the piston, but what does the forum think about the bore. Will I get away with using a Machine Mart glaze breaker, or will I need a rebore? I can feel the scratches with my fingernail.

I suppose that a problem with the injector caused a hot spot, or does anyone have any other ideas? I have sent the injectors for cleaning and setting.

I was a bit hasty in removing the vacuum pump, and only read afterwords that I should have kept the original mating in the gears. My question - how important is this?

Cheers folks.

injector fault ,needs rebore ,new pistons ,skew gear wont matter as vac pump isnt timed

Jesus your injector must have been ****ing diesel - did you notice any knocking or engine oil dilution? James Martin's advice is always very well taken but it might just save you a hell of a lot of money to have the bores measured before you shell out for a complete rebore at a machine shop. Do you know anyone or have a local specialists who would be able to come out and measure the cylinders? You need to know that they are within tolerances with no ovality. If they are alright then you would get away with new standard sized pistons and rings (providing it has them in now). I have just rebuilt my 200tdi. The bores were in a similar condition to yours. I simply deglazed and re-ringed. It went from this:



to this:



...and it only took 10 seconds per bore with a deglazer in a slow drill. I am now 900 miles down the line and it is nicely run in with no oil consumption, no blow-by and bags of power / torque. I can not stress enough how important it is to gap your piston rings correctly too.

-Tom

Sorry POS, I didn't mention the engine is one I recently bought (cheaply) from a reportedly crashed Disco. I have never seen it running, but bought it with the intention of doing a rebuild and fitting it in place of my 19J.

As it will be completely stripped down to the block this weekend, I will be able to cart the block to have it checked.

Thanks for the advice.