Basically im saying whats more important piston to wall or bore wear specs because it seems you cant have both in spec? Say your into your engine the cylinders look great no corrosion and you can even see the original hone marks so you mic the bore gauge and check anyway and lets say you get...

I bet he put that engine up for sale around 10 grand as well

I had a cylinder head come back from the machine shop the other day completely out of spec I guess he wasnt banking on me measuring it. Last time i trust a machine shop.......and to be honest theres not many shops i would trust reboring and honing either

I remember reading that post and you mentioning that! Thats why especially these days we gotta do things ourselves

To be honest at the moment im accepting that piston wall to bore clearence is the optimum figures to be concerned with and completely ignore the bore allowance specs they give us in the manual. Another example 200tdi vs 300tdi manual..... 200 states bores must be deglazed before renewing rings...

Yes makes total sense and the issue is not why bores wear the way they do and how to measure its the specs they give us! As u say take the piston to the machine shop and they will bore then hone to what ever the new piston manufactures state. Our manuals state 0.02-0.05mm of piston clearence...

Ok thanks for the reply. But we get taper from the top of bore enlarging through wear? Also why are we concerning ourselves with these measurements they give us in our manuals when surely piston to wall clearance are the important figures to measure such as 0.02-0.05mm or whatever it is i dont...

Just going through the manual specs for the 200tdi and it states Maximum permissible overall wear is 0.177mm but then it states maximum permissible taper is 0.254mm. How is it possible to have a taper of 0.254mm when that would take the bore wear well over 0.177mm?

If the hotspots too hard to weld like you say James i was thinking maybe getting a stick electrode low amps and try and get it stuck in the pin obviously without striking an arc releasing the stinger and seeing if i can gently rock it out kind of like what you would do if u broke a key off in a lock

I tried a carbide drill bit it wouldn't touch the pin

To be honest i think its a stupid design why not just have a ridge on the side of the hotplugs that locate into a recess on the head!

My hotspots are out tried everything couldn't remove any of them they were seized solid. I even thought about fitting the hot spots back in and trying to catch the edge of the pin and fusing it to the hotspot with the tig welder then knocking them through. For such a small pin they are really...

Ah i see no luck for me

I am aware of this however its not the removal of hot plugs thats the issue its removal of the split pins that keeps the plugs in place.

Anybody had success removing the locating pins from the head for the hot plugs? The ones I'm dealing with are damaged and seized solid.

Ok will give that a go. Its gonna be hard to get clear pipe and clip on banjo fitting to seal unless I can find clear hard plastic line heat it up and slide over barbed pipe. I been using flexible pipe 8mm almost like garden hose which cant be heated. Might change the banjo fitting to match the...

Replaced the lift pump with Delphi and clear fuel line from tank to lift pump and clear line from injection pump back to tank. Engine struggles to start when left overnight. The diesel is draining away from lift pump heading back toward tank but engine fires as soon as diesel hits lift pump...

Anyone bored and stroked a 200tdi to 2.8? I know you can buy the kit of ebay for the 300tdi but what about a crank for the 200tdi?

I got a 3 wire sender but 2 wires are plugged in