200 tdi Tapping noise

steve2286w · Apr 27, 2023

that piston looks really bad, will the bore hone to better surface, any idea what cause the damage
what do you mean by 0.025MM SP

i have the pistons to the engine machinist, I did get a printed sheet of bore sizes, but can’t measure my own now as have no gear,
how did you gap your rings , did you use a special tool

jameslandy · Apr 27, 2023

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

steve2286w · Apr 27, 2023

once you’re sure of measurements then a calm call to machinists hopefully get them to accept some responsibility and a but free machining

steve2286w · Apr 27, 2023

I just picked up new rear leaf springs and the engine bits today, leaf springs look both the same , ore plugs about 3mm too small, starter ring from 2l diesel rather than 2286. I’ll be having a similar call tomorrow

jameslandy · Apr 28, 2023

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 measurements are coming back roughly the same as a block that has covered 150 000 miles. Its very plain to see there has been insufficient cylinder to wall clearance. I remember the original measurements were around 0.025 to 0.03 absolute max and he told me i didnt even need to bother checking the ring gaps which i did and had to adjust. He better not play the old slightly tighter tolerances are better and run in gently because its pretty much proven these days that out of spec tighter tolerances are far worse than looser. Mahle pistons even state a bit of piston slap is safer than a tight bore that will never recover. Anyway the blocks junk now it was a plus 40 rebore and if he cant get that right im not trusting him to put liners in.

lynall · Apr 28, 2023

jameslandy said:
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 measurements are coming back roughly the same as a block that has covered 150 000 miles. Its very plain to see there has been insufficient cylinder to wall clearance. I remember the original measurements were around 0.025 to 0.03 absolute max and he told me i didnt even need to bother checking the ring gaps which i did and had to adjust. He better not play the old slightly tighter tolerances are better and run in gently because its pretty much proven these days that out of spec tighter tolerances are far worse than looser. Mahle pistons even state a bit of piston slap is safer than a tight bore that will never recover. Anyway the blocks junk now it was a plus 40 rebore and if he cant get that right im not trusting him to put liners in.

I dont think the liners are to costly
Easy job for a machine shop

jameslandy · Apr 28, 2023

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 guides as well driving them in the tops were slightly damaged but i lived with it cause it didnt effect the valves or seals and i had to finish the skimming of the cylinder head by hand as that was given back still scored. Anyway ill find out what his reaction is very shortly. I think these machine shops are a law un to themselves they dont expect people to measure there work and too used to having people polishing there balls. Everyone has a **** day but the trouble is in his game it costs other people serious time and money. Anyway ill wind my neck in and get this rebuilt somehow fast need the landy back running for work

steve2286w · Apr 28, 2023

Good luck, was thinking he could use oil pump only low pressure but then bearings would be dry , I would check the liner cost too rather than scrapping block but a cheapie engine cheaper than rebuild
my rebore was £240+ vat + pistons + rebuild bits

jameslandy · Apr 28, 2023

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 its pretty obvious too tight clearences. Its ok i got a few very experienced respected engineers behind me so if it goes legal it goes legal. Im going back to the machine shop monkeys first thing tuesday and if they dont resolve it then will advance with legal proceedings. If they choose to resolve it all there work will be accurately measured. Hope your problems have gone better than mine mate!

200 tdi Tapping noise

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