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  #1  
Old September 23rd, 2013, 11:43 AM
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Jeff Payne
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200tdi refreshing

I'm doing some maintenance items to a 200tdi before fitting in the 110. Timing belt, tensioner and water pump replaced in the front along with oil seals.

Now in the back when I'm going to replace the rear main seal I notice that there are only four bolts holding the flywheel housing to the block.
Looks like there should be eight more, including the bolts at the bottom into the ladder frame. Anybody know what those ones are?

Since I have never done this before I'm wondering if I should change the clutch friction plate or the pressure plate. Pics attached for reference.

Anything else I should be looking at while I'm at it?
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  #2  
Old September 23rd, 2013, 11:55 AM
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I cant speak to the bolts but can say since you are in there do it..
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I would rather keep the parts in storage
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  #3  
Old September 23rd, 2013, 12:11 PM
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Since the holes are there and counter bored for socket head cap screws, I would install them. I helps with keeping everything from squidging around. I had to modify my flywheel housing just for this very thing. Yes, all those should be filled with bolts.
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  #4  
Old September 23rd, 2013, 12:46 PM
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Discovered that the bottom ones are the same threads as everything else back there. I'm running a tap through them to clean everything up a bit.

It makes me a little concerned about the rest of the engine considering there should be 200% more bolts on this one part.
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  #5  
Old September 23rd, 2013, 01:00 PM
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I think the bottom ones were allen head
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  #6  
Old September 25th, 2013, 09:06 AM
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Does anyone have a 200tdi air filter housing?
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  #7  
Old September 26th, 2013, 08:46 AM
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It is much easier to replace all of the clutch parts now.
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  #8  
Old September 26th, 2013, 08:59 AM
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I went ahead and ordered new clutch bits. It will never be easier than now so I went for it.
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  #9  
Old October 26th, 2013, 01:34 PM
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Now I'm on to cleaning up intake and exhaust manifolds and putting on a new gasket. Three of the exhaust ports look dry and and one of the valves appears to be leaking. Normal or ordinary? Doesn't look like a good thing to me.
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  #10  
Old October 26th, 2013, 01:41 PM
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Also, I'm not certain about the condition of the turbo. The thought of a runaway diesel is rather concerning so I'm wondering if there is any way to do a layman's inspection and get a reading on the health of the turbo. The whole exhaust system is rather rusty and crusty

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  #11  
Old October 26th, 2013, 01:52 PM
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What the hell? That was depressing to watch.
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  #12  
Old October 26th, 2013, 01:54 PM
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I would definitely replace the clutch, pressure plate, and throwout bearing. Its a lot easier to do it with the engine out of the vehicle. I would especially do it if you haven't driven it with the current clutch.
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Old October 26th, 2013, 02:09 PM
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Also, replace the pilot bushing. And the clutch fork with a reinforced one. And, definitely put in those bolts. Without them, the rear main seal won't.
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  #14  
Old October 26th, 2013, 02:24 PM
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I did the clutch stuff including friction plate, pressure plate and release/throw out bearing, rear main seal and rear gasket with all the bolts.

What is pilot bushing?
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  #15  
Old October 26th, 2013, 02:34 PM
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Goes in the end of the crank & supports the gearbox input shaft.
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Diesels.....great when they're going and so easy to work on.
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  #16  
Old October 26th, 2013, 02:34 PM
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This is on the verge of shipfitters disease.

Check for play in the turbo shaft, some lateral play is OK (shaft sliding back and forth on bushings) but any wobbly play to it means its on its way out. I would not worry about the valve guide seal now.

I had my flywheel resurfaced for the new clutch with my 200tdi, not sure if it was necessary but it seemed the right thing to do. I also changed the flywheel housing to block gasket.
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  #17  
Old October 26th, 2013, 02:42 PM
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Quote:
Originally Posted by transientmechanic View Post
This is on the verge of shipfitters disease. Check for play in the turbo shaft, some lateral play is OK (shaft sliding back and forth on bushings) but any wobbly play to it means its on its way out. I would not worry about the valve guide seal now. I had my flywheel resurfaced for the new clutch with my 200tdi, not sure if it was necessary but it seemed the right thing to do. I also changed the flywheel housing to block gasket.
Lol. I'm afraid so. This is the first time I have done any of these things and there have been a few red flags so far when looking it over so now everything that looks out of whack makes me question the whole lump.

Thanks for your patience.
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  #18  
Old October 26th, 2013, 02:53 PM
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Adam, I've always been advised that on a cold engine there should be some perceptible radial play in the turbo shaft (wobbly as you refer to it). This to account for expansion when hot and provide clearance for oil to flow around the shaft as it is supposed to.
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  #19  
Old October 26th, 2013, 03:03 PM
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I have heard conflicting reports on that. Typically there are some discrepancies depending on how big of a turbo you are working with. The 200Tdi T25 is microscopic compared to most gas engine turbos. I think that any play beyond a barely perceptible amount may be cause for concern... but I am definitely not a Tdi turbo expert.
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  #20  
Old October 26th, 2013, 03:15 PM
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After looking closer at mine there is a tiny bit of play along the shaft but much more in the wobbly direction.
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