The 200 tdi appeared to be in good shape except for seepage at rear main seal. But before installation, I figured it was worthwhile to go over the engine. So I pulled the flywheel and discovered it was actually the flange between the windage tray and the rear flywheel housing that was leaking. It appeared that the windage tray had been tightened down to the engine block without checking that it was perfectly aligned with the block at the rear and as a result a leak started. Looking at the manual, it appears this setup was improved on the 300 tdi.
But, while I was in there... I pulled a rod cap and was surprised to discover a sizable nick in #4 rod journal. So the entire bottom end is now apart and the crankshaft has been sent to a machine shop for polishing. They checked it and were able to polish it up without going to undersize journals.
I've also, since its apart anyway, pulled apart the timing cover to replace the belt, and I'm glad I did as I discovered a stripped holding stud on the idler pulley, which the machine shop welded up and retapped.
Finally, I decided if its that far along I should pull the head and clean up the valve train. I'm just doing that now, and will re-lap the valves and install new oil seals.
I checked the piston bores for roundness and a wear lip at the top and they appear to be excellent, so I'm not pulling the pistons. Finally, I'm going to test the rod and crank journal nip as per the manual, torquing to spec, then removing one nut and measuring the clearance.
So, not really a rebuild, just a freshening up, but while its sitting here on the engine stand, it just seemed to be the right time to do it.
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