Td5 cracked head and bent rod

**Davetd5** · 30th June 2019, 02:05 PM

Hi Folks
I have a suspected cracked head on a 9/02 D2a Td5 at 319,000km
I've owned this for 10 years since it had 100,000kms
I replaced the head gasket 7 years ago at 180,000kms

I'm losing coolant and the engine is hydraulically locked if left overnight.
I suspect #1 cylinder as that exhaust port looked darker than the other 4 when I had the manifold off recently

I'm planning on ordering a new head from Turners, and TRS told me I probably have a bent rod also.

So I have some questions please for anyone who's done this:

1. How can I tell if a rod is bent? Do I use a dial indicator, or a feeler gauge to check the piston to deck height?

2. At 319,000km can you just put another rod in, or should I replace all the rings and bearings (like I would in a petrol engine at these km's)?

3. Timing chain replacement at this mileage?

Planning to keep this vehicle for about another 3 years and then upgrade to a D4

Thanks Dave

**INter674** · 30th June 2019, 04:32 PM

TRS......mmmmm....no comment😎

**justinc** · 30th June 2019, 05:54 PM

A used long engine, with a new head gasket fitted and oil pump bolt checked is likely the cheapest method. You will find the bore in the cylinder with water ingress will be trashed, a bent rod is a huge labour job and there is also no guarantee the crank isn't compromised, either. Don't forget these have micro toleranced bearings and fracture cap conrods. Totally different deal to just replacing the good old school rods,

J

**discorevy** · 30th June 2019, 07:35 PM

I've also seen the egr cooler on the D2a's let go , causing hydraulic lock ........worth checking.
last one was around three years ago and happily still going strong with no issues

**Davetd5** · 30th June 2019, 08:41 PM

Originally Posted by discorevy

I've also seen the egr cooler on the D2a's let go , causing hydraulic lock ........worth checking.
last one was around three years ago and happily still going strong with no issues

Thanks, I've got the EGR delete so I assume that shouldn't be a problem?
The cooler is still there but there's no EGR valve anymore

**Davetd5** · 30th June 2019, 08:58 PM

Originally Posted by justinc

A used long engine, with a new head gasket fitted and oil pump bolt checked is likely the cheapest method. You will find the bore in the cylinder with water ingress will be trashed, a bent rod is a huge labour job and there is also no guarantee the crank isn't compromised, either. Don't forget these have micro toleranced bearings and fracture cap conrods. Totally different deal to just replacing the good old school rods,

J

Thanks Justin,
I'd be doing all the labour myself (I was a Ford mechanic in a former career), but if the bore is stuffed then that's a worry.
Just curious, do people rebuild/ rebore these engines, or is it not worthwhile cost wise?

**INter674** · 1st July 2019, 05:34 AM

20 thou max rebore...plenty done with rebore and oversize pistons according to eng rebuilder in tassie...mine was done that way....cost @4k for full rebuild inc head reco...german pistons. .....kobleschmitt or suffin😕

**Davetd5** · 1st July 2019, 10:43 AM

Originally Posted by INter674

20 thou max rebore...plenty done with rebore and oversize pistons according to eng rebuilder in tassie...mine was done that way....cost @4k for full rebuild inc head reco...german pistons. .....kobleschmitt or suffin😕

Thanks, I wouldn't mind calling them. Could you please send me their name or details?

**INter674** · 1st July 2019, 04:37 PM

Pm sent

**Davetd5** · 5th July 2019, 12:37 PM

Going to take the head off either today or tomorrow. Decided I'll first try and save this engine

Guy at my usual machine shop says he can sell me a brand new head from China, $1850 with my valves fitted.
Anyone heard of or used these? Its non-branded and he says he's been sourcing these heads from a mob in Melbourne for 10 years with no problems...
I'd rather use an AMC head from Turners, but this is about an $800 saving...

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