(Edit 15-12-2023) I'm not giving this baby up anytime soon. Shop took the head off and no, this engine didn't die at all. After they wiped coolant off the piston, it was pretty spotless. Headgasket failed between no.4 and coolant channel. The pressure in coolant system forced coolant out through overflow (and I believe, I heard it dripping on piston!). Why it failed on the exact spot that I questioned 6,5 years ago, I don't know...
Mech checked the block surface and all is well. They faced the head, it is completely serviced, valve seats ground, nice and tight. New lifters, valve stem seals and original headgasket. We'll see if the oil pressure channel pose problems in the future, but now I have a reciept..
(Edit 12-11-2023) On way home (15 min drive) cabin heating cold/completely gone. Temp got to 90-95 degC. Looked under hood, ejection of coolant from overflow hose. Suspected thermostat (but cabin heater should still work???) cold radiator, then suspected waterpump impeller loosened from shaft. Shaft turned with aux belt OK. Well I made it home at under 100 degC and no low coolant at critical level, level OK. 20m before parking engine running erratically. I now suspect headgasket/bent rod because of a possible loosened impeller? Stuck closed t-stat should still well allow coolant to pass by cabin heater? Time will tell when I get the diagnosis.
(Edit 19-10-2023), just about to enter 439 k-territory. All good, but plan for 2024 is new rear brake anchor plates/dust shields and possibly rear axles, old ones are cracked in outer boots but no leaks yet.
(Edit 26-08-2021, 411 k km on the clock, the new (used) propshaft has now served me for 21 k km and runs very well, very smooth. The new front center sleeve has not shifted, according to the red markings shown in the video. That's a good thing. I found no leaks from the gearbox output seal.
-Although I installed a rebuilt clutch master cylinder since the old one was tired, after 30 years and leaking in rare instances, but could be pumped up by a few pedal strokes, so I could drive home).
The propshaft adventure is my most comprehensive W201 project to date. Bigger than the headgasket fun IMO.
(Re-uploaded with more read time for the frozen clips with text.)
I hope you enjoyed this video. Please use due diligence - work at your own risk.
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