I suspect the engine is blowing past the rings but I need to do a compression test to confirm.
This is quite likely given the type of use it is subjected to. Stop/start short distances are the worst for any engine. The oil needs to be hot to work properly, but it is unlikely to reach full temp with local short trips. It takes longer for the oil to reach temp than the coolant. Each time the engine starts, it will be over-fuelled and some excess fuel will pass the rings, washing the bores, leading to wear. This is true of all engines.
I grabbed the crank pulley and gave it a tug and there was a good 5mm of crank float.
I also noticed that a seal for one of the selector forks on the gearbox has failed and has been leaking gearbox oil all over the driveshaft.
Both effects of lots of work. The mileage recorded does not truly reflect the amount of work done. Crank float is probably due to lots of clutch work, always pushing the crank against its thrust washers, especially if it is held at stops rather than selecting neutral.
The oil filter is in a rediculous position and the sump plug design is one of the worse I've seen! I genuinely didn't think it was going to seal when I refitted it. Not sure what size Alan key it was but I didn't have one big enough! A T60 fitted well enough though!
I agree, the filter is difficult to get to, and most filter tools won't go in the small space.
The sump plug is a taper plug, so seals by being tight in the thread. This design has been used well since the internal combustion engine was invented. It was probably popular for other applications long before that. Think, taper plug in a beer barrel. Only issue is if overtightened, and that's down to the operative, not the design. No leaking washer. It uses a 12mm hex key, although maybe not now as you've used a torx on it, but new plugs are cheap. (and shiny)
Design flaws aside I'm quite dissapointed with how this car is lasting. I would have expected this of a 100k engine, not a 30k/3year old motor!
The engine wear is almost certainly due to the conditions of use, not the design or build quality. These are very strong reliable engines, capable of very high mileages, (with a head gasket at about 50k) and have been around with few changes since about 1985.
Thanks for the advice though guys! Convinced my parents yesterday it's time to let the little panda go! They're thinking of replacing it with a Jimny!
Whatever they buy, if subjected to the same use, will eventually get the same results. When district nurses used bicycles they probably needed tyres, chains and brakes more frequently too.
