So looking at a friends jdt 1.9. It was sounding like a bag of nails was let loose.

Was locking engine by hand but running on its own when started, yes I know bad idea to run it, but any damage would have already been done.

Took injectors out and cylinder closest to cam pulley, either one or four, not familiar with these so not sure what way round they have it. And it has oil in cylinder. Only one all other bores are clear.

So question, head, valves seals, or is there another reason. Not suspecting turbo as its only one bore.

Still locks when turned by hand with injectors out so I'm guessing its bent a valve, cam belt and all other timing parts are ok. Car was stopped very quickly after noise and was turned over for 2 seconds to hear noise.

I'm guessing the hydro lock isn't that bad as nothing like a belt or cam has been snapped.

I'm also assuming the oil is coming from top as when pressure applied by hand there is no give or slow release of pressure if the rings or bore was damaged.

So does what I'm saying make any sense to anyone? Can anyone help in telling me if this has been known before? Done a search but nothing has turned up.

The strange part is that the oil in bore is clean, not black like the rest of it but new looking oil. I'm going to find out if he has topped up with oil or noticed a drop in oil. But saying this and thinking out loud if the valve seals had gone would topping up the oil let clean oil in cylinder. But I'm sure it would have been pushed out exhaust by now.

It's number 1 new timing belt.
Could the oil in the cylinder be diesel?
Possibly from number 1 injector sticking open slightly, this would also cause the bag of nails sound.

Be very wary of high pressure diesel it can cause amputation or other injuries.

Quite likely to be a leaking injector. But as said above, don't try to test it out of cylinder head, unlessit is in a pot of some sort, that will withstand the pressures. Pot needs a cover and you need eye protection. Very high pressures, will penetrate skin easily, and as advised, the affected part will be amputated, only cure!

Leaking valve seals don't usually allow enough through to lock a cylinder. Valve stem in guide should be very close tolerance, so only a small amount of leakage passes the stem. Some engines used to run without seals.

Clean oil added to engine mixes immediately with the existing, so would look black by the time it is circulated. So unlikely to be engine oil.

ok. what I was thinking.

Sorry should have said more about me I guess. I'm a diesel fitter for H E services and work with excavators and construction every day.

It's 100% not diesel. The oil on the injector did look clean but after getting a good look at what was in cylinder its more black and dirty.

Going to have the engine out today and rip the sump off to check the con rod as I'm starting to think its bent.

Either way the engine has to come out for repair or replace.

Is there a chance oil will get through gasket into cylinder? Or is the water jacket in the way? There is no sign of oil in water or water in oil.

I have a pop tester at work for injectors. But I don't know what the release pressure is on these.

Will post more after I've got the sump off and a good look at rods.

oh my god. The electrical engineer for fiat needs a meeting with a baseball bat....who in there right mind doesn't put a connecter in the loom between engine and bulkhead...why...just spent the best part of 2 hours wrestling with the loom...

Well engine is out and gearbox off. Just need flywheel off as I have got a long enough bit to reach the last two sump bolts.

But after a talk another engine is on the cards anyway, I cant see much point in messing around rebuilding this one. It's just not worth the hassle. Pick up another engine for a few hundred and would spend that on new con rods and grinding before paying for gaskets and anything else.

But still not found the main cause of oil in cylinder. And only being one cyclinder I've ruled out turbo. The engine still locks when turned By hand.

So it would appear to be sump oil then, not fuel. Enough in one cylinder only suggests a big leak. Could be rings broken, but normally pressure above piston would keep that out. Needs a big leak across the gasket ot do this, but if gasket failure is near the oil supply this could happen. A cracked head or block is possible.

As you said, a bent rod is likely, although a result not a cause. I agree, if another engine is available, not worth rebuilding this one.

With injectors, not really important what the release pressure is, as long as they all release at a similar pressure. The pop tester will usefully show if leaking, and the spray pattern. At least you know the safeguards. I'm surprised there's no loom connector. Try not to cry if you find one later, hiding in plain sight, as things do.

Good luck

thanks. I did read on the punto you pull the herness through the bulkhead. But not looked properly and only read that after getting engine out. D'oh.

On another note looking for the engine ID plate.
Owner did say there was a pop and a bang in engine before it started making noises. Dropped oil and it doesn't smell of fuel but it was stopped very quickly after and was only started by me for a few seconds to listen to noise.

Left the engine for tonight as back to working on excavtaors next week. Stopped when I have undone head bolts and the head won't budge. So threw a spanner at it and walked indoors. Lol.

Put two head bolts back in with a lot of clearance, turn engine over a few times. This often unsticks a head, especially on a diesel.

Yes sensible course of action is replacement engine.
Do let us know what failure was though!
You can check for bent rod by turning crank to top dead center , measuring through injector holes to top of pistons and comparing measurements of 1 and 4 cylinders to each other , then 2 and 3 to each other.
Good luck

engine turned up today. As I feared they have just cut all the loom and pipes rather than unclipping them. So that's half my day just removing old cables and pipes. Great. More hours I don't want to do. The owner is going to really hate my labour bill.

well engine is in and running like new. New clutch fitted. And about 10000000000 new jubilee clips.

Still have the old engine and might take it apart to actually find out what the issue was and why it hydro locked up but that will be when I have a few hours to myself. Some time next year maybe. Hahaha.

Glad its done and time for a cold beer. I will NEVER personally buy a fiat.