Hi All, have not posted here in many moons.
I have been driving the heck out of my 82 300TD for over 6yrs now, avg over 500 mi/wk. The car is my DD/work horse, I do not consider it one of my projects cars, although I have done alot of work to it. Its a pretty nice car which has been very good to me. Car has over 330k now.

I generally can find answers by searching around here with no need for posting, but need some help with these.

Long story short:

Engine tired, infact had quite a bit of blow by when i bought it with 168K. The other day on highway it seemed to blow HG or cracked head or something. Overheated very quickly, blew coolant out hard, smells burnt, oil in coolant.

I have an 85 TD engine I removed from very good running car w/220K. I drove it on a long trip prior to removal and am comfortable that it is a good engine. The cam looks like new, and everything else seems to indicate it is in fine shape so I will swap this into my 82. I am resealing all the common leak points, installing some new bosio's, gp's, belts, hoses, etc. May do Tchain but it sure seems in good shape so not sure on that. i do have a new Tchain for it though.

Question: the 85 motor has the electronic thing on IP and hall sensor.
I have swapped one of these motors in to a 79 in the past and just left it disconected. Ran fine like this, does thing effect timing?

Also, what is the air recirc thing on turbo? anything I should do with it?

Along with this motor, i want to install a 4spd manual trans. I have everything to do this, except need to shorten the shift rods and DS still.

Question: I removed the flexplate from the 85 motor with out marking it (!%!&!*!) I thought for sure that it would only go on one way but obviously I was mistaken. I brought the FP and a 240D FW to a machine shop and asked them to match balance. The 240D FW needed 10.8G removed to match the FP. 10.8G sounds like very little, is it possible that this may be consisdered with in the limits of "zero balance", if so I would bring the 240D FW back and have it balanced to zero, instead of the 10.8G it is now. The 85 FP has quite a few holes on one side, but shop said only 10.8g, I know of other make flywheels that are considerd zero balance that are out 30g, so i am hoping 10.8G is with in zero balance teritory.

There are no witness marks on either flywheel/flex plate, I used emory cloth and magnifying glass and could not see anything at all.
The crank on the 85 617 has two small stamped lines in the back of it but they are crooked with a random location and do not seem to reference anything.

Should I rebalance the 240D flywheel to zero and go with it?.

Should i start it up on a cart prior to installing, if there are vibes will I notice them when testing this way?

I already installed a 2;88 R end in this car and I think I have a handle on everything else, except i can not seem to find a 240D auto cross member, anyone know where to find one?

One last thing, what is the best option for pilot bearing in the 85 crank? Should i try to open it up (hone?) to fit an MB pilot bearing? or should I go with an S10 pilot bearing and have a brass bushing made to fit it in crank?

Thanks for any and all suggestions!!!