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There trying to tell me that damage is caused by dirt ingress which is an absolute joke. After seeing them a second phone call explaining exactly what is going to happen next has bucked there ideas. I have an independent engineering company willing to report on the block. Ive already been told...

Thing is Lynall the original boring and honing was suppose to be an easy job for the machine shop and yet hes completely ****ed that up which is costing me time and money. Ive got another spare block he can pay for a whole new set of pistons and a rebore and cleaning. They damaged the valve...

Ill be going to the machine shop first thing in the morning. Done some measurements on the pistons and block and to be honest there completely irrelevant as the engine has done 226 miles and every single bore is scored (just checked the mileage not 120 whatever i thought it was) and the...

Insufficient piston to wall clearance. Early stages of engine seizure. Textbook machine shop failing to hone to correct clearences.

Steve check your bores accurately before u do anything do not trust the machine shop

The middle ring is completely compressed to the piston

The ring gaps were too tight in every cylinder before adjustment

All my ring gaps were checked before installed despite being told by the machine shop i wouldn't worry weve never had any come back

The little marks on the bottom of the shell are from the dial bore gauge there not scratches

Ive got into the guts and to be honest im relieved and ****ed off at the same time. Im relieved because i cannot find anything wrong with my work. Theres no contact with valves the oil jet was full of oil and not blocked the bolt was all good everything was tight and rotating as it should...

So if that's the case then the injection pump could not have caused it to overheat with a lean mixture......when it did cut in and out made the engine quite rough wondering if that caused it to knock a top end out or maybe i was just running it too hard in the first 100 miles. Ill keep thinking...

So took the head off today and cylinder 1 has overheated. 2 3 and 4 are as new pretty sure the valve train was ok so either an oil jet has failed or/and top end bush as I reused the old ones they seemed fine. The injector pump was in a state leaking and filthy in the top cap actually cut out on...

Thanks

Pretty sure I did check them but will double check again tomorrow

Will check the underside as well good advice yeah caps are all on and staying on during operation

Tappets are properly adjusted no head gasket leaks everything's in order its a shame rocker no 1 came loose wide open....tap tap tap but **** happens. Full rebuild bores pistons bearings camshaft bearings etc. Ill find out tomorrow when i inspect the valve gear. Its nice to have someone else...

Great im glad you said that im going to check no 1 slide and roller see if there damaged as that rocker arm went wide open. It sounds like when you drop the roller onto a metal table or drop it on the camshaft repeatedly that sort of metallic pinging. The engine was ok for a while low speeds...

Rebuilt 200tdi attached 2 videos 1 of first fire of engine (tappets were a little noisy but were adjusted after) 2nd video with loud tapping after 120 miles running in. Havent dived into the engine yet any ideas? I have checked the usual valve clearences and injectors timing the injection pump...

Sorry bit late to reply just seen this i know a bit about the air heaters maybe this will help. Cant go wrong with Eberspacher or Webasto although im biased towards Eberspachers as my dad designed the controllers for them through the 80s to the present day however hes retired now. The airtronics...

Maybe 0.17mm overall wear takes into account average piston skirt wear.....maybe overall wear means overall bore and piston to bore clearance wear.