Firstly the engine was rebuilt in June 2012 new parts included the following:- pistons, rings, big ends, small ends, new water pump, new temp gauge, new injector pump, new turbo, head was cleaned and checked for cracks and valves re-seated, the engine re-build was built at 420,000km. while under warranty we found it was using excessive oil and water, we tried a thicker diesel oil but it kept using oil, about a litre of oil a 1000km after taking to four local mechanics they all said the valve guides were faulty, the head was taken off and I saw that the valve guides were egg shaped they were replaced, the head was put on and oil was still being used and water was still being lost. I took the landrover to KLR Landrover dealer and he said that the head at 420,000km should be thrown away because they become to soft, a new head was put on clocked 4000km and found that the water was ok but I used 1/2 litre of oil. I did a service at 5,000km I clocked 320km and found I had to put 1 1/2 litres of oil in the engine. A new head was installed along with a new water pump and a new thermostat was replaced and a new VDO temp. guage was installed. While on xmas holiday the guage was showing temp of 130 deg in 40 deg heat while towing a caravan of approx. 1400kg. We also found that the car was over fuelling and blowing out a lot of black smoke on to the front of the van. Klr knows about the black smoke and is going to adjust the timing to reduce the black smoke. Before the re-build the engine never used any oil and every 5000km service it would show full on the dipstick before it was drained. The only issue I had was loss of water which indicated a head gasket. Before the re-build the temp gauge would show normal when pulling a van on hot days its only since the re-build we have been having these problems.
The only reason I went for a complete re-build was so that it would last till I retired.
To answer your question we were losing oil with the old head on and new head on.
New temp gauge has not yet been independently checked thinking it may be a faulty sendor. how would I check to see if it is faulty?
Many thanks for your help.