So far all has gone well on the rebuild of the 300tdi. The new cylinder head looks to be good and has cleaned up well. Fitting the new pistons has been a little more difficult as they were very tight, but all went back together ok. Firing up for the first time was a bit of a worry. I'd glaze busted the cylinders and put the pistons in with a little grease as they were v tight, so when it finally did start to turn over it would have some lubrication. When it did fire up though a good deal of that stodgy grease burnt off with a bit of smoke. What the heck though, it fired up and I ran it for about 15 mins on tick over-1500rpm.
All sounds good eh, so why the 'but…' in the title, well after the 15 mins or so the starter kicked in (no joke it did) and everything sounded very bad. I turned the engine off, but when ever the key is in position II or III the starter engages. Suspects so far are… a trapped cable during the rebuild (though I can't see anything), a buggered starter, or switch/electrical. I'm starting with the leccy side of things as this is the cheapest thing to repair.