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feel really bad for you, sorry i knew you were a girl i put him by accident ha ha!!! you read it before i could edit it lol. Is strange though, in 4 years of starlet ownership i have seen maybe 2-3 posts on melted pistons and those were usually due to injector failure etc, now i have seen two posts in the same month!! I was convinced timing was the problem, now with you as well I am certain with it, either that or we have just be REALLY unlucky lol!!

I am going back to TD next Thursday, so i will get them to double check everything, particularly timing!

Look familure http://s422.photobucket.com/user/mctaggart999/media/IMG-20130316-WA0000_zpsbc60c9e6.jpg.html'> http://s422.photobucket.com/user/mctaggart999/media/IMAG0216_zpscd694f07.jpg.html'>

Ha ha thanks for the comments, although what is the issue with running standard fuel lines, they are metal pipes the same as the ep82 and there were clean as a whistle, as for the hitting the rev limiter while i was running it in, I had already done over 1000 miles on the engine so it was well run in already!! So would appreciate you not talking utter shite, pistons dont melt because you built a bad engine. Its down to timing/fueling or the map! Reading this i am livid though with funny onions car, the piston damage is EXACTLY the same as mine WTF!!! All 4 of mine had gone too while driving at 100mph+

It looks like it was a timing problem by all accounts, right pain the butt that one! I have just dropped the can with the engine still to have the bores honed and take 0.001" off, hoping to have the bores all cleaned up for the new pistons and rings. Then its a mad dash to put it all back together by next Thursday for a lovely drive to Manchester!! Loads to do and it doesnt help that I am working outside, so weather is a big factor! Hoping to get the car back tomorrow, so i can start putting it back together on the weekend, then i can run the piston rings in just before i go up. :)b

you can run the TD04 on the stock ECU and stock injectors no problem, you just need a RRFPR and a FCD, you can run 200hp no problem at 1.0bar on the stock ECU or if you get it mapped with emanagement blue you can probably hit 200hp running less boost at more like 0.8-0.9bar which will be more friendly to your stock internals. It is worth spending £50 on an uprated walbro fuel pump though to ensure you get decent fuel rail pressure, the stock one will do but it will be old and not worth running the risk. Hope that helps I have made a TD04 guide for starlets on you tube, search my username mctaggart99