Car is a March 2003 156 Sportwagon 1.9JTD
(Diesel 8 valve) – Chassis 01322964 ( ePer LINK
: Horrible knock under load (rev related).
: Buggered big ends, slack oil change history (recent oil change to Shell helix Ultra 5-40W).
: pull the big ends, inspect and replace.
The lower shells looked okay
, so I bought Glyco Std size new ones (71-3994/4 pic1). However, when I pulled the upper shells it became apparent that they were really worn (see pic3 &4). Just to make things even more confusing, they’re also a completely different part number to the lower shells (46536494 verus 46430579 - see pic2)!!. And whilst we're on the intrigue train the lower shells (46430579) are marked 0303 which is the build date of the car - so, maybe they're the original shells, in good nick (WTF?!)
In any case, I still have a horrible knock. So, I will pull the sump again (yay) and check for signs of damage to the new shells this weekend.
I did plastigage the clearances when i replaced the shells and both old and new lower measured 0.02” (0.151mm). Searching now suggest this is possibly (x2) too much. So, I shouldn’t have gone std. Although, I don’t really know, now i’m just confused.
Does anybody know what ePer means by SP=1,527-1,531 or TOR when describing the shells. This doesn’t logically = the expect crankshaft OD of 50.8mm or so (...does it?)
Other things pertinent things
1. Car had a recent clutch change (would a failng DMF or dodgy install make a knock?)
2. Car had a recent oil change using Shell Helix Ultra 5-40W – too thin?
3. On the test run after fitting the new shells, the knock returned v’quickly. The spun bearing noise on accl/boost remains AND the car has now entered Limp mode with her first ever MCSF error.
Turbo and big ends - how lucky could i be (mains too)!?
I'm in Aust., in Brisbane where there are no decent (Diesel) Alfa Indies.. the Stealer.. is indifferent as my car in an import (I brought her home).
All thoughts, comments, etc., appreciated
Pics for entertainment