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I am about to start the process of rebuilding my 96 TD42 N/A, install TD05 and top mount intercooler, and install into my GU2. As this engine has not done 50,000 kms yet, whats the forum's general concensus on just replacing the pistons with the turbo pistons and rings, and not bother about rebuilding anything else? I know its the cheap way out, and there is an element of risk as far as failure of components not overhauled etc, but with the motor not having many km's, one could assume that the rest would be ok. I will obviously inspect all components, and if all are ok, is it a feasible idea? Money saved here could be used elsewhere?
I am comitted to full overhaul cost, but saving a few dollars to spend on other kit might achievable.
As a general rule, what would be the "must do" replacements or overhauls? Injectors? Glow plugs? Injection pump? Big end bearings?
I would do bearings, both big end and main. Going to turbo pistons depending on what rods you have now you may have to change these, the reason being is there is differences in gudgeon pin diameters. A must do while you have it pulled down would be a minimum of bearings, rings and a good hone.
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