Upon tear down of a recently acquired Ex-Defence 4BD1 I found a bent rod and a chip out of the bottom of the cylinder.

The rod contacted the liner and displaced the chip.

Looking at it I think it will be fine to de-bur and refit a new liner. The actual area would not see any pressure from expansion gases and the skirt of the piston would have minimal to zero side loading as it is at the bottom of the stroke.

The piston base does does travel past the damage...the ears on the skirt would travel about 10mm into the damage.

Do we have any experienced engine builders on the forum who can weigh in on whether to bin it or run it?

I'll take it to the local engine shop in the absence of some expert advice. I have built many engines for my various project cars but I have no experience with this situation.

The reference pictures were taken with the block upside down.





The faint black line shows the limit of downward travel of the piston..the liner is upside down on the bench with a piston stuck in it.



The piston skirt dimensions


Cheers,

Jason