Should I Skim?

Thor1950 · Jan 20, 2014

Turboman said:
Something has caused the piston to crack. Might be a blown injector nozzle, or overheating. It would be good to find out what it was and fix before it breaks another!

He did say bent push rods......... could it have been hydro locked some time in it's life

jamesmartin · Jan 20, 2014

Thor1950 said:
He did say bent push rods......... could it have been hydro locked some time in it's life

its poor burn that cause that on those engines injectors are usual culprit , ive just rebuilt one similar the guy fitted new head gasket ,a weelk later theres a hole burnt straight through the piston,hed never noticed they were cracked

RodneyA · Jan 20, 2014

I suspect that the timing belt has snapped at one point as the piston with the crack has 2 bent con rods also, I just need to find some info on how to change the pistons and other related parts

RodneyA · Jan 20, 2014

I mean push rods

jamesmartin · Jan 20, 2014

RodneyA said:
I suspect that the timing belt has snapped at one point as the piston with the crack has 2 bent con rods also, I just need to find some info on how to change the pistons and other related parts

you need to measure piston first to find what size it is ,then measure bores and new piston ,gap rings in bore before fitting piston and ensure anti rotation tags face cam on con rod , a manual would help plus torque wrench

RodneyA · Jan 20, 2014

I've got a Haynes manual, ain't had a look in it yet, there's info about the pistons in there?

RodneyA · Jan 21, 2014

I had a good look at the pistons this morning and I can clearly see the large crack on that piston, I can also see rather small cracks on the other 3 piston's so it look's like i'm going to have to replace all 4 of them. Defo look's like a timing belt snap for it to affect all 4 of them

What else should I be changing while i'm down there, I know I need to de glaze the bores but not sure of any other components I should change.

Thanks
Chris

RodneyA · Jan 22, 2014

I've decided against just replacing the pistons and I'm in the process of taking the engine out and getting it rebored and a good service, going to replace a lot of parts, well the garage is and this should be the engine fine for a good 150k+ miles

jamesmartin · Jan 22, 2014

RodneyA said:
I've decided against just replacing the pistons and I'm in the process of taking the engine out and getting it rebored and a good service, going to replace a lot of parts, well the garage is and this should be the engine fine for a good 150k+ miles

best option ,unless you fit a 200tdi instead

Turboman · Jan 23, 2014

RodneyA said:
I've decided against just replacing the pistons and I'm in the process of taking the engine out and getting it rebored and a good service, going to replace a lot of parts, well the garage is and this should be the engine fine for a good 150k+ miles

If its nicely rebuilt and you look after it well, you could get a lot more than that, 2.5 naturally aspirated is a very solid and reliable unit.

RodneyA · Jan 24, 2014

Well that's the engine out, was pretty easy except some of the bell housing bolts.

How easy is the clutch to replace, just a bolt in job?

jamesmartin · Jan 24, 2014

yes just 6 bolts but you need to ensure clutch plate is held central whilst cover is secured

RodneyA · Jan 24, 2014

Sweet, the clutch and fork actually look relatively new but im just going to replace anyway, worth changing the flywheel also?

jamesmartin · Jan 24, 2014

check the ball end on the clutch lever pivot

Should I Skim?

Thor1950

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jamesmartin

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RodneyA

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RodneyA

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jamesmartin

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RodneyA

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RodneyA

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RodneyA

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jamesmartin

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Turboman

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RodneyA

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jamesmartin

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RodneyA

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jamesmartin

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