Please bare with me as long story but Need some serious help, i'm currently locked in battle with my wits end on how and why My 147 2.0 2002 plate is making a tapping/Knocking noise Mid engine/Higher Engine location after rebuild.
Story so far -
Engine Blew Gasket (Water Hose blew - Cooked itself)
Ripped head off, Skimmed the head and replaced gasket (Metal CF3 Gasket) set including renewing Cam due to worn lobes, replaced water pump, cam-belt etc etc - the standard stuff.
Put back together and started...
Now... The timing is good, compression on all cylinders, the oil is flowing through all port holes, firing is good tick-over good and no Warning lights on Dash. The problem is the noise, sounds like something hitting - I cleaned all Hydraulic Damps fresh oil blew holes etc and the noise is louder than the tappets anyway.. changed the variator 3 times with 3 different ones so we know its not that or anything top end.
The next step we did was strip the engine again, took head of and examined for knocking/Slapping/Tapping, it seems the Pistons was just touching the cylinder head (valves closed the pistons don't touch due to some Cylinder head seat thingy and also it was timed right) anyway.. There are indents of the piston ring marks in the cylinder head, now im not a genius but im pretty sure the Pistons are not supposed to be touching the head at all no matter what heat or rev.
My question is
- Will the Big end shells worn cause the pistons to fly up higher on TDC if loose to hit the cylinder head Head and is the CF3 Gasket to thin?? If i replace with a CF2 Gasket will i loose too much compression and power? I have heard story's people use 2 gaskets and also going crazy with sand paper shaving the minute layer of pistons ... its a 2002 model so should be all cf3 gear, however removing the old gasket of the head was composite...