Hi guys,
Just putting together my second 1.6td engine after my first one ran for 60k burning oil
(built when I was 19 could have been more carefull!)
Background:
Spare block acid stripped and bored 0.5mm over
Used OS Kolbenschmidt pistons originally used in first build
My original rebuild had low 1 notch pistons due to me not machining the deck surface coupled with the OS pistons having allowance for this.
With the new block I had the deck machined 0.006" to bring the pistons up to around a high 1 notch or 2 notch.
After the block work the machine shop I used had a look at the small end bushings in the con rods and checked for play which resulted in them being replaced. (The small end bushings had never been replaced so had at least a good 200k miles of hard driving)
Fast forward, i've now fitted pistons and checked protrusion
Cyl. 1 - 0.97mm
Cyl. 2 - 1.04mm
Cyl. 3 - 0.97mm
Cyl. 4 - 0.98mm
I've got a feeling the new small end bushes have resulted in the pistons being higher up the bore and coupled with the deck machining I now have a piston which falls out of the 1.02mm max height tolerance of a 3 notch gasket by 0.02mm!
Can anyone lend some advice? I don't think i'm happy risking it and would like the piston down to where the rest of them are any thoughts on how this can be achieved?
Before anyone questions this machine shop I learnt my lesson from last time and used a place which is highly regarded in this part of the country and they have been much more reassuring then the last place I used!.
Thanks
Will