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)

 

[Jim San]

Not a lot to report - i've only been picking at it as prioritised other projects.
Turbo manifold scabby studs all drlled out, only screwed up one by going off centre so will replace with over sized bolt in that corner!

Ive been out of my depth for some time now but its pretty much ready to go back in - as I need to get clutch assy back on to do the timing (cant do that on the engine frame).

Getting cam, crank & fuel pump timed is stressing me out - note to self, set engine to TDC before removing fuel pump if im ever stupid enough to try this again.