First time diesel rebuild need some help

[mittimj]

So this is my first time rebuilding one of these diesels. I can do a gas engine just about in my sleep know what to look for whats good and bad.

Engine was hard starting for number of reasons so I started here.

 I decided a rebuild was needed when I did a leak down test. The gauge says 8% leak is a healthy engine. 3 of my cylinders had 35 to 40% leak and one about 15%. intake and exhaust valves were not leaking all the air was blowing out past the rings.

so I take engine apart. Head is not cracked in between valves, always a good sign. cylinders look beautiful, (120,000 1.6na) they do look glazed over a bit. is this enough to be getting that much blow by? I honed them up with a ball hone and there a few ever so light scratches, I bet I could get them out but I don't want to take excessive material off with this hone. should I replace the rings? reason im asking is these ones seem to have outstanding tension compared to the vw gas engines i typically deal with.

Im not looking for any super performance engine here, and dont want to break the bank. The engine is getting turboed.  I just want to to be somewhat fresh so it will start good.


so if you say replace the rings, not a big deal, just want it to definitely be worth it.

thanks-tim

[mittimj]

oh and do they sell total seal rings for these diesels. lol if im buying rings im doing it right.

[Vincent Waldon]

should I replace the rings?

IMHO... absolutely.  You're there, rings are relatively inexpensive, and most importantly you want fresh sealing surfaces to break in against your freshly-honed bores.