Engine rebuild - after engine fail in Germay (Jul 2024)

[Jim San]

I've got a set of 'NOS' 1.9tdi pistons if they're of any interest.

Thanks Andy, hope things are good with you.
Thanks for the offer, mine are looking OK thanks.

[Jim San]

Latest update.

I am adding the cost of things as I go along. I know costs can easily run away - but i'm using reputable suppliers and trying to balance quality with affordability 

update as Oct 2024:  Costs: so far = £2000 - current state: Block & head together, ancileries being attached as I find suitable new fixings where needed!

- 4 x Injectors 1.9 - test, refurbished with Italian tips (bosch out of stock everywhere) £315
- Head gasket & bolts est £120
- Head test and overhaul £190
- Barrels honed and block built £1314  (Included clutch kit, belt kit, oil pump, water pump)
- Thermostat +  sundries £60

On the to do list:

change out all the cruddy studs on the exhaust/turbo 

Bolt the rest of the bits on and put the bloody thing back in

[Jim San]

Managed to finally split the exhaust gasket from the turbo (pretty gnarly state).  Still have to get whats let of the studs out.

Ive had 2 turbos and on both I've always had a little turbo whistle.

Right or wrongly I wanted to get the manifolds fitted to head as individual parts without 'stuff' hanging off them.
Haivng spilt the turbo and manifold, ive pulled the spacer out and found what I beleive is evidence its 'leaking' through the faces.
The faces have rough surfaces and there is no gasket.  
Should I get faces on the manifold and turbo skimmed (and replace the spacer - £35 odd quid from SJB)