Victory! (Almost)

mtgstuber · **Joined:** Tue Sep 13, 2011 4:15 pm **Posts:** 66

It seems I was one of the first of the rash of rocker arm failures. My CRD died in September 2011. I found this forum while I was looking for answers. At the time, the best guidance was (roughly): "your rockers may be trashed, your timing belt likely skipped a notch." Now we know that rocker failure is likely to happen if you haven't disabled the EGR, and there's a handy how to. In between a heavy travel schedule (I was gone more weeks last year than I was home), and being on the leading edge of the wave of failures, it's taken me over 18 months to get it back together.

But at long last I have, and it runs! :BANANA:

It runs just as well as when it was new, if not better.

My thanks to those of your that have answered my questions, and those of others, and provided helpful advice. You guys rock!

When it was all said and done, I ended up tearing it all the way down to the head gasket, as I was getting an exhaust valve leak on the second cylinder. I had the head cleaned and the valves replaced by an outside shop, everything else I did myself. At this point I have new Eurocam rockers, a new timing belt (including water pump), new 7 volt stainless steel glow plugs, SAMCO Turbo hoses, new radiator hoses, a 2nd Gen Fuel head and an inline 195 degree thermostat. My GDE tune should be here next week.

Today I got to the bottom of my (unrelated) ABS issue. I ended up replacing the passenger front wheel hub, as well as repairing a frayed wire to the passenger rear sensor.

I'm almost at the point where I can start thinking about things I want to do, rather than have to do to this thing. (i.e. putting in a lift pump, upgrading the suspension, moving the rear spare mount, adding fog lights and DRLs).

I've still got an issue though. While the engine is running quite nicely, and I've got plenty of power, I'm getting a buzzing noise from the boost pressure solenoid area. I'll note that when I took it on its first test drive, I managed to pop the one end of the Samco hose off the turbo. I immediately pulled over and reinstalled it. I'll also note that the vacuum line that goes from the boost pressure solenoid over to the turbo ends up being pushed a little by the CAC hose, such that the rubber 90 degree elbow ends up being more like 60 degrees.

I've recorded a short video so you can hear it. http://youtu.be/Bi8cU1p0rd0 I did some googling and found a post or two on the topic, but my much resolution.

Any notion why it's buzzing? Should I just replace it? Will that actually make a difference? Also, does anyone have a good picture of how the vacuum line should route between the boost pressure solenoid and the turbo? I'm wondering if that's part of my problem.

I'm sooo close. Please help me get this last bit resolved. Thanks!

papaindigo · **Posted:** Sun Jun 09, 2013 8:37 am

That's an interesting sound and I have no clue why it's buzzing. You might want to try the boost pressure solenoid bypass (viewtopic.php?f=5&t=70602&p=757348&hilit=boost+solenoid#p757348) to see if the buzz stops and/or just replace it (PN 4606226AC and doesn't cost much).

Vacuum line routing referencing the image at the above link. There is a hard plastic line coming off the tower just left of the red #1; that line runs down and along (is secured to) what looks like a metal line below the red #2; then behind the coolant line off the bottom left of the coolant tank (rubber line partially encased in metal sleeve); then to the turbo variable vane actuator housing routing behind the CAC hose so that the "jog" in the line sets it back about 1/2" from the CAC line so that 90 degree elbow is not bent.

mtgstuber · **Joined:** Tue Sep 13, 2011 4:15 pm **Posts:** 66

Thanks papaindigo. That post and the routing instructions were very helpful. I rerouted the vacuum line to the turbo. I had it in front of the coolant line, rather than behind. The line is no longer tweaked.

I did the bypass. I got good power, but no real change versus without the bypass, so I started playing with disconnecting things. Having bypassed it, I disconnected the boost pressure solenoid, and the noise was still there. Given that, the only possible culprit seemed to be the vacuum modulator. I disconnected that, and sure enough, the noise is gone.

So what does the electric vacuum modulator DO? (Other than provide some vacuum line plumbing) I tried finding it in the FSM and failed. (I tried a text search, as well as the index, turbo, engine, and electrical sections.)

racertracer · **Posted:** Sun Jun 09, 2013 2:31 pm

almost soundslike your turbo vanes are hitting something stationary.... check that out right Pronto

papaindigo · **Posted:** Sun Jun 09, 2013 4:08 pm

racer - that's not impossible and certainly worth checking but he says he has good power and the constant "buzz" doesn't sound that metal on metal or even a bearing noise.

mtgstuber - I replied to your email. While I cannot tell you how that assembly works I can tell you that at least part of its purpose is to provide vacuum to the turbo variable vane actuator but you already know that. The boost pressure solenoid's purpose is to keep vacuum stored in that tower looking thing when the engine is shut down so your turbo will work first thing; hence the comment in the bypass instructions about building vacuum before the turbo will work. Exactly why that thing on the side has a filter, which of course implies it's sucking in air, I have no clue as I would assume that the vacuum is pulled via the line that runs to the firewall under the coolant tank and of course I have no clue why it would buzz.

mtgstuber · **Joined:** Tue Sep 13, 2011 4:15 pm **Posts:** 66

It's definitely not the turbo, though I appreciate the warning. The noise is definitely coming from the EVM (I shoved my ear up near it), and if I unplug it the noise goes away. When I had everything torn down I checked closely for play in the turbo. It seemed spot on. (No unreasonable radial or lateral play).

I plan to get a new one in the AM and see what that does for me.

CATCRD · **Posted:** Mon Jun 10, 2013 8:26 pm

Mine makes the same noise once in a great while. I just smack it and it stops. Try it.

mtgstuber · **Joined:** Tue Sep 13, 2011 4:15 pm **Posts:** 66

I like it, but this one is the wife's. I really need it to just work. I'm out of town (again) so she installed the new EVM this morning. New tires, an alignment, and new ujoints on the drive shaft, and it's running very very smoothly. My lovely wife noted that it's almost too smooth, as she found herself up at 83 mph without even noticing. I'm afraid having poured all sorts of cash into getting it running, now I'm going to have to start putting cash into a legal defense fund . . . :JEEPIN:

Twigpig · **Posted:** Fri Jun 14, 2013 10:02 am

You can use a piece of fuel line as a stethoscope to really pinpoint a Noise, workS good a buddy of mine showed me that I had never thought of that.

Hope that's not really old news, lol

Twigpig · **Posted:** Fri Jun 14, 2013 10:03 am

You can do that while its running without losing an ear too,....

Hexus · **Posted:** Fri Jun 14, 2013 11:12 am

Reminds me of an old joke:

Quote:

When I went to blow up the van, I burned my lips on the muffler!

Victory! (Almost)

Who is online