1) Fault diagnosis (what failed and why)
- Do compression/leak-down and cylinder-by-cylinder oil consumption/smoke checks, and inspect crankcase blow-by. Theory: low compression or high blow-by isolates piston rings/cylinder wear or piston damage; metallic noise or low oil pressure points to bearings/piston skirt damage. How repair fixes it: replacing worn/damaged pistons, rings or reconditioning bores restores sealing and geometry so compression, oil control and clearances return to spec.

2) Preparation and safety
- Disconnect battery, drain coolant and oil, label/remove electrical and fuel connections, remove intake, exhaust, turbo and accessories blocking engine removal or head removal. Theory: full access and safety prevent damage and allow controlled disassembly. How it fixes the fault: gives access to the components that must be repaired/replaced.

3) Decide scope: top-end vs bottom-end
- If only rings/worn bores → top-end (remove head, pistons). If scuffed skirts, damaged pin bores, or damaged crank journals/bearings → full bottom-end (remove engine or separate crankcase). Theory: rings seal the cylinder; severe piston/rod damage often means bearings/crank are affected. How it fixes: choosing correct scope ensures all related failure modes are addressed rather than repeating the failure.

4) Remove cylinder head(s)
- Follow engine-specific sequence: remove timing cover/timing belt/chain tensioner (lock timing), unbolt head in reverse torque order. Mark/cap passages. Theory: head removed to permit piston removal and to inspect valves, combustion faces and head gasket condition. How it fixes: access allows replacing damaged pistons and verifying no valve/contact caused the piston damage.

5) Remove oil pan and sump, timing components and oil pickup if doing bottom-end
- Remove oil pump if needed, clean debris. Theory: oil pan removal reveals rod caps and lets you check for metal debris that indicates catastrophic wear. How it fixes: removes contaminants and allows bearing/pickup inspection/replacement, preventing future oil starvation.

6) Remove connecting rod caps and pistons
- Rotate engine to each cylinder bottom-dead-center, mark rod-to-cap orientation, remove caps, push pistons out through top or bottom depending on engine. Use care with circlips and wrist pins. Theory: rods/pistons separate the reciprocating assembly from the crank; controlled removal prevents damage. How it fixes: allows removal of worn pistons and assessment of cylinder wall condition.

7) Inspect components and measure
- Inspect pistons, rings, skirt scuffing, crown damage, ring lands. Measure cylinder bore out-of-round and taper with bore gauge, measure piston diameter and skirt wear with micrometer, measure rod bearing clearance (journal diameter vs bearing). Measure ring end gap in bore. Theory: dimensions determine whether new pistons/rings fit and whether bores need honing or rebore/liners. How it fixes: correct measurements guide machining or replacement to restore tolerances and oil/control/seal performance.

8) Decide machining (honing vs rebore/line hone)
- If bore wear is slight and cylinder round, light plateau hone to cross-hatch for ring seating. If out-of-round/taper beyond spec → rebore and fit oversize pistons or re-sleeve. Theory: rings require the proper surface finish and clearance to seal; excessive wear requires re-establishing geometry. How it fixes: restores cylinder geometry and surface finish so new rings mate properly, restoring compression and preventing oil blow-by.

9) Inspect crank journals and bearings
- Check journal diameter, taper, surface score; measure with micrometer. If journals damaged beyond spec, grind to undersize and fit undersize bearings or regrind. Check rod alignment. Theory: crank/bearing clearance determines oil film thickness; too large = low oil pressure and knock, too small = seizure. How it fixes: restoring bearing clearances prevents future bearing failure and piston/rod damage.

10) Prepare pistons and rings
- Use OEM pistons or correct oversize replacement. Check piston-to-bore clearance, fit wrist pin bushings, orient piston crown/markings toward timing/front, fit rings by cylinder and stagger ring gaps per spec. File ring end gaps to spec in the actual bore if necessary. Theory: correct piston sizing and ring gaps ensure thermal expansion clearances and ring sealing. How it fixes: proper clearances prevent scuffing and ensure rings seal at operating temp to restore compression and reduce oil consumption.

11) Cleaning and lubrication
- Thoroughly clean carbon and debris from pistons, block, oil galleries. Use assembly lube on bearings, wrist pins, and piston skirts as required. Theory: foreign debris kills bearings and scoring surfaces; assembly lube protects initial start. How it fixes: prevents immediate wear on first start and removes contaminants that cause damage.

12) Piston/ring assembly and installation
- Install rings in correct order and orientation, compress rings with compressor, guide piston into bore squarely. Refit rod caps matching orientation and torque sequence. Use new rod bolts if torque-to-yield; torque to spec in steps and check side clearance. Theory: rings must be correctly placed to seal; correct torque ensures clamping force without distortion. How it fixes: accurate assembly returns dynamic geometry and clamping, preventing loss of compression or rod failure.

13) Re-check rod bearing clearances
- Use plastigage or measure after initial torque; rotate crank to ensure free movement. Theory: verifies oil clearance and that no debris or misassembly is creating binding. How it fixes: confirms correct clearance to maintain oil film and avoid knock.

14) Refit oil pump, pickup, gaskets and oil pan
- Replace seals/gaskets, torque to spec, prime oil system if possible. Theory: clean oil routing and pump ensure lubrication at startup. How it fixes: avoids oil starvation that could ruin new bearings/pistons.

15) Reinstall cylinder head(s) with new head gasket
- Clean surfaces, use dowels/alignment, torque head bolts in factory sequence and steps; replace head bolts if specified. Re-timing and valve lash/shim adjustment as required. Theory: head seal restores combustion seal between head and block; correct timing ensures valves and pistons don't collide and valves operate for correct compression/exhaust. How it fixes: eliminates head gasket leaks and restores compression and combustion timing.

16) Reassemble ancillaries, timing, intake/exhaust and fluids
- Reinstall timing belt/chain, turbo, injectors or carb components, connect sensors and hoses. Refill with fresh oil and coolant. Theory: reassembly restores functional system and prevents contaminants. How it fixes: ensures engine runs with correct fluids and systems to test new components.

17) Start-up and break-in
- Prime oil, start engine, run at varying moderate rpm for break-in following manufacturer guidance (avoid lugging or sustained high rpm). Monitor oil pressure, leaks, smoke, and compression after break-in. Theory: rings seat into the new bore surface during controlled break-in; bearings settle under load and conform. How it fixes: proper break-in helps rings form an effective seal and prevents premature wear.

18) Post-break-in checks and adjustments
- Re-torque head/rod bolts if required by manual, recheck ring gap seating by compression/leak-down, check oil consumption and blow-by. Theory: final adjustments ensure torque relaxation and ring seating occurred properly. How it fixes: confirms the repair restored sealing and clearances and corrects any residual issues.

Key theoretical points summarized
- Compression is restored by ring seal to the cylinder wall and intact head gasket; ring and bore surface finish, ring end gap and piston-to-bore clearance control that seal.
- Oil control is restored by proper ring function and correct surface finish; excessive bore wear or wrong ring orientation allows oil past rings.
- Mechanical noise/knock and low oil pressure usually indicate bearing/crank problems; correcting bearing clearances or regrinding restores hydrodynamic oil film.
- Correct machining and component selection prevent recurrence: undersized or oversized mismatches, improper clearances, or poor surface finish cause early failure.

Final notes (practical constraints)
- Use factory service manual specs for clearances, torques, ring gap, and sequences for ZD30DD and KA23DE; specifics differ by engine.
- Replace fasteners specified as single-use (stretch bolts), and replace piston rings and bearings in matched sets.
- Always measure—don’t guess—on bore, piston, ring and journal dimensions; tolerances are critical.

That is the ordered procedure with the theory and how each repair step addresses the underlying faults.
rteeqp73

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