I 2nd post #8. I didn't do anything special when I removed the spindle to replace the lower ball joint, though a support wouldn't hurt. I use cut 4x4 fence posts for such things.

As long as you can align the front-end, it will be fine. Probably would have been fine w/ the bent spindle if it didn't bump the shock. Our 96 Voyager was hit on the side, bending the strut tower inward. I replaced the strut but couldn't get that wheel camber proper (leaned in too much), but it drove straight and fine. I eventually pushed the strut support back (porta-power) when I had the tranny out, and got it perfect. The main thing is to ensure toe-in is correct and all parts are tight.

Most of the problems you found are typical. I agree that if it starts right up on a cold morning, the compression is probably good. Watch for the HF diesel compression test gage kit on sale. I recall getting for ~$25. My 1985 required a block heater to start on cold mornings (=35 F here) when it had ~250 psig compression. The engine failed a year later at 330K miles. If a cylinder measures >400 psig it is excellent. They will still start with 300 psig down to freezing. Also, check the glow plugs (easy regular task - measure resistance of each to gnd at connector, replace any open ones).

The cracked air filter bracket is an endemic problem. I retrofitted a 1985 CA frame-mounted air cleaner to my 1984. I began that on my 1985 after installing an earlier engine (search post). Others use an aftermarket conical air filter w/ silicone tube to turbo inlet. Either way, you must manage the PCV blow-by oil (several ways).

If you get air in the IP, I don't know how long it takes to work thru. Shouldn't happen if you purge air upstream after a main fuel filter change, per the manual. Once in the IP and outlet tubes, you crack the tube nut on each injector (engine running) until fuel dribbles out. Otherwise, perhaps that injector may never pop open to purge the air, with the air bubble sitting there like a spring, absorbing IP pulses.

The door and fender are easy bolt-on replacements. Too bad you couldn't get those swapped in CA. You get extra credit if the replacements are the correct color.

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1984 & 1985 CA 300D's
1964 & 65 Mopar's - Valiant, Dart, Newport
1996 & 2002 Chrysler minivans