Looking at the soft soot on all the piston tops makes me wonder if that's where your oil is going to, question is is it turbo seals, could be piston oil rings, or the engine breathing into the intake.This is the block side of the gasket. It was stuck to the block in a few places, so there's a few places where bits look missing.
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I emailed pictures of the pistons and cylinders to Turner Engineering and they've replied asking me to call them Monday morning.
The exhaust manifold gasket is at the bottom of this pic and you can see it was blowing.
Yeah, ran it with the breather venting in to a catch can and nothing. The air intake pipe (from air filter to turbo) is not oily.Looking at the soft soot on all the piston tops makes me wonder if that's where your oil is going to, question is is it turbo seals, could be piston oil rings, or the engine breathing into the intake.
Did you ever run it with the rocker box vent diverted away from the air intake?
Any thoughts about the honing being good enough?
Hmmm, hadn't contemplated the bore diameter. Having said that, I did check the gap on the rings and it was spot on, so should be ok.Struth Al203 ! I feel for you - all that work and expense and now this!
They look as I'd expect them to look - more or less fresh from a recently rebored and honed bore that hasn't done many miles....
I can't see any witness marks on the HG - the exhaust gasket marks are quite easy to see - but even when I zoom in to your HG pics - they pixelate before I can see anything which is and in equal measure - with a modicum of - which you'd already mentioned.....
The amount of soot is clearly an issue, though, and......, I'm confused, given the new turbo and every other possible cause which has been given consideration.... it's sort of leading me down the road of the bores being too big for the pistons - which I'm genuinely hoping is close to impossible. ( this assumes that the rings themselves are ok, and not from some sort of "bad batch" etc .... will be interesting to see what turners say on Monday )
In terms of the high oil pressure - have you checked the bypass valve spring - both for length and for any miscellaneous carp "keeping it company", stopping it working as intended....?
Cheers, raywin. Yes, it's a shame it's not just running nice and sweet. On the other hand, who doesn't like taking their engine apartHone marks dont look too bad to me, have you tried running your finger nail accross them? I can only go on the pictures but I honestly dont thing that they are your problem.
I cant see any problem with the head and gasket, if the oil was getting in that way I would only expect one sooty piston, but they all look similar.
So logicaly its going in with the air or up past the rings, if the ring gap was OK then the bores should not be too far out, did you measure the pistons?
If you have had a catch can on the breather then eliminating that leaves turbo oil seal.
By the way I also feel for you it cant be good to have all of your effort rewarded by problems, you deserve better than this, hope you can get it sorted soon.
Yeah, the injectors look awful.Cylinder head gasket looks good, that is the right type also for older engines. Hone looks fine in the pics (as everyone said)
All the injector nozzles apart from no.3 look a bit unhappy to me, not sure if it's just the image though.
The oily wetness on the crowns, but lack of smoke while driving (i.e the intrusive oil is always burnt on compression strokes not constantly leaking in / blowing out) and general "looks good" factor of everything else in the pics does very much point back to the turbo, even though the intercooler should have a few tablespoons of oil pooled at the bottom of it if the oil control rings have failed / were never installed correctly, but I think you checked that already.
Would do as disco1 suggests as well and have a peak at your bypass valve, as nothing answers the high oil pressure question so far either.
More questions no answers! Hope you had a nice spin over to Belfast in the interim if nothing else, mind
The oil appearing in the induction pipework does seem to be blowing through without settling in larger quantities.
I can easily take the bypass valve out, but don't know how to check it It's just a spring.
When I was rebuilding the engine I discussed on my thread changing the valve guides as they had a bit of wear. James Martin said he wouldn't bother because they wouldn't cause much bother. I think because it was a diesel and I was raising a problem associated more with petrol engines. Early on after the rebuild, when I realised it was burning oil, I raised the worn valve guides as a potential culprit with Turner Engineering. Richard Turner also said they wouldn't be an issue and he said something about the aspiration of the engine and I think the turbo. Going back a few years now though. I didn't understand the theory and still don'tWorn guides will always leak, new stem seals of course slow the leak of worn guides - but remember worn guides leak fairly evenly across the whole cycle, blowing oil straight out the exhaust without it burning, whereas a turbo leaking on the compressor side will only pass oil into the intake tract - causing it to only enter the engine on the intake stroke. So you'd see bluey / whitey smoke all the time with bad guides, especially on start up after sitting overnight.
Ahh, ok.Keep your peepers peeled for foreigners in the assembly, beyond that nothing to check for besides damage.
Ha ha, we met the Merkins in the Crown Liquor Saloon. It's very popular with American and Chinese tourists (All tourists really, including us). Bus loads walk in the front door, walk through and go out the side door. Some stop for a drink. There was only three of us, so we kept inviting people in to share our drinking booth. They all turned out to be Americans. They were good companyGlad to hear it, nothing quite like a holiday to see family ending stress free! Pity about the merkins though eh? .
Would do as disco1 suggests as well and have a peak at your bypass valve, as nothing answers the high oil pressure question so far either.
Keep your peepers peeled for foreigners in the assembly, beyond that nothing to check for besides damage.
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I can easily take the bypass valve out, but don't know how to check it It's just a spring.
When I was rebuilding the engine I discussed on my thread changing the valve guides as they had a bit of wear. James Martin said he wouldn't bother because they wouldn't cause much bother. I think because it was a diesel and I was raising a problem associated more with petrol engines. Early on after the rebuild, when I realised it was burning oil, I raised the worn valve guides as a potential culprit with Turner Engineering. Richard Turner also said they wouldn't be an issue and he said something about the aspiration of the engine and I think the turbo. Going back a few years now though. I didn't understand the theory and still don't
Ha ha, we met the Merkins in the Crown Liquor Saloon. It's very popular with American and Chinese tourists (All tourists really, including us). Bus loads walk in the front door, walk through and go out the side door. Some stop for a drink. There was only three of us, so we kept inviting people in to share our drinking booth. They all turned out to be Americans. They were good company
Another worry are these bits I found in the bottom of the sump. The top bit is metal. All the rest is rubber
Yes, there is a pic of the bits in the sump. Thought I'd put it inWas there a pic?
Would've expected some carbon on the piston sides (above the top compression ring) owing to the buildup on the top, none on the skirts though which is good.
What does the turbo look like both sides?
I wasn't very clear there. The oil squirt didn't fall off. When I was rebuilding the engine and putting the oil squirts back in, one of the bolts snapped. I bought a new one and fitted the remaining oil squirt. The oil squirt bolts are hollow, to allow the flow of oil up them. When the original bolt snapped it's possible that a small piece of the bolt wall came away. It could have stuck in the engine somewhere as there was a lot of engine assembly lube about. When I take the remaining pistons out I might be able to see where it came from. If not, the broken oil squirt bolt is my best guess.if the oil squirt had fallen off your oil pressure would be lower surely?