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200 tdi

1595 Views 41 Replies 5 Participants Last post by  Zebratruck
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I’m looking this engine over for install in my Ninety.

Rotated it over and pulled the pan. Small metal bits stuck in a little bit of sludge in the pan and a little on the pick up screen. Not greatbut not a huge surprise.
I’m looking down into the engine and see this round thing, about 1/2” in dia. Fish it out with the magnet. Not sure what this is??

I did the timing belt and have rotated the engine a bunch and it all sounded smooth, I guess this fell into the engine when I rotated it.
Any ideas?

It looks like there’s some gator spring pieces from a seal. Someone’s been in this engine since it was new so maybe someone replaced a seal and knocked a few small pieces of spring out of a seal?


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Here's the 200Tdi manual.

In your photo "Connecting rod to cap" under "Tdi engine" shows the same torque figure I quoted earlier.

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Is it possible to fit the T seals and the rear main without the seal guide tool #270304? Or, anyone have specs on how to make a set?
Is it possible to fit the T seals and the rear main without the seal guide tool #270304? Or, anyone have specs on how to make a set?
I’d read around a bit. There are a few techniques, including coating the seal in RTV to lube and seal it. Another option is skipping the seal and filling the cavity with an RTV like Right Stuff. Whatever you do, use the best materials and care possible. Pulling everything apart again to fix a leak there sucks.
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For what it's worth, here are the torque settings for the 200tdi Overhaul Manual. Shows the same as what erover said: 56-62nm

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Thanks. I’m waiting on rod and main bearings to show up today, then finish up the bottom of the engine. The finish up the back which now I see I need to make some kind of sleeve
/tool to let this clutch hosing seal slip over the end of the crank.
The white conical plastic piece that comes with the new seal is the tool to slip the seal on.
I don’t have that. Gonna have to make something out of plastic.
Never seen a rear seal come without that piece. Are you sure?

It’s seen here

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I’m sure. This is the orange rubber seal. Pic in a minute.
I’m having trouble rolling the new main bearings in. #1 just doesn’t want to cooperate. 3 & 2 went in ok, 4 jumped in and 1 is giving me the middle finger.
I’m sure. This is the orange rubber seal. Pic in a minute.
I'd consider picking up one of the green ones. Then you'll have a spare and the tool. I believe they're sold as Corteco or OEM.

I’m having trouble rolling the new main bearings in. #1 just doesn’t want to cooperate. 3 & 2 went in ok, 4 jumped in and 1 is giving me the middle finger.
Hard to help remotely. I usually question everything I'm doing when something like this happens. Are the bearings new? Are they good quality? Are they the same thickness? Are they in the correct orientation? Is there a small burr in the way? There are oversized bearings with different part #s for when shafts are ground.
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The rods and mains are in and torqued. A buddy said, that one’s tight because you have the timing belt on and it’s pulling down a little.
I torqued #3 & #4 and I tapped very gently and got the bearing in.
Brand new stock size bearings. Plenty of assembly lube in everything.
I’m sure. This is the orange rubber seal. Pic in a minute.
I’m pretty sure my corteco seal was orange and it came with the plastic tool. As did a Victor Reintz seal. Where are you? Perhaps someone close by you has one they could give you. It’s just a cheap piece of plastic.
I’m in Pittsburgh, PA. I’m just going to make one out of a 2 liter plastic bottle.
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I fired the engine tonight! Sounds good, no leaks.
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Now working on removing the 12j



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It’s in! Lots more to do but I have it looking to the finish line.

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