slightly long reply [Diy_efi] blown engine...

[Ian Molton]

Hi again

Well the engines been rebuilt.

it would seem the small metal fragments I found in the cylinders are the 
remains of the glowplugs. The local diesel specialist says that when 
turbos go and the engine starts burning oil, the oil ignites before TDC, 
and thus a flame is sucked into the combustion chamber, against the 
glowplugs. this burns them away very quickly.  (normally combustion 
gasses exit the combustion chamber before doing too much damage.

This also explains why the combustion chambers (hard metal inserts in 
the aluminium head) had moved - they had simply overheated. they were 
proud enough that a faceplate on the head actually /rocked/ on the 
centre one giving a ~0.5mm gap at the edge!

so, a new set of glowplugs, turbo off ebay, and a head gasket and it is 
all up and running. Total cost ~20ukp, which isnt bad - but who knows 
how long this new turbo is going to run?

Next task will be to tear  apart the old turbo and see if it can be 
salvaged in any way. I've heard some turbos can use ordinary 
ballbearings (garrett models) so perhaps... will have to see.

TTFN!