Well they need replacing! Just seen a nice 200tdi crank on eBay decent price

If the bores are ok and within tolerance of the +20 oversize and pistons not worn or damaged they can be used again but then youlll need to check the end gaps of piston rings in the bores to see if they are in spec if they are use again without...

Yes it’s had a rebore. Hopefully won’t need another

Found this might be useful, and you can re grind the tdi crank according to doc

Yes, 100% sure all clean & tight. Thanks

Some higher res photos would be better a few MB rather that KB ,but the area where the crank seal runs looks better, I cleaned bearing surfaces with some 1000grit wet and dry and some wd40 Need a mic to measure diameters to check, not sure you...

Ah so the clearances were to tight? I had in my mind they would be slack, if that is the case that makes a lot of sense. If that is all it was I would be buying a lottery ticket:banana:

Think I’ve had exhaust noises coming out of air filter when one exhaust valve not set properly as that was only way gas could get out! , glad you sorted it

Can confirm it was the tappets! Just did them (took 2 hours as it was my first big engine job 🤦‍♂️) Have a listen to this and compare!

I would leave pump on for now , if you rotate crank until all the timing marks line up ,then you can insert the locking tool in pump then release the tensioner wheel to remove belt , then you can unbolt pistons and push them out top of block with...

Do you know what the 'click' is ? It's likely that it is the starter solenoid. The contacts wear and don't make proper contact so there is not enough current (power) to turn the starter motor/engine over. Your battery may also be a little flat...