hey guys new to the forum and will apretiate any insite from the more experianced crd techs.
the truck has 150k on it, this code was fixed 2 years ago at 95 with an egr valve and maf sensor.
i had a p0101 high or low
timing belt was done at another shop
i have gone through all the normal things
-dirty maf an boost/iat sensor
-air filter
-boost leak
-colapsed hoses
-plugged egr piping
-egr valve cleaned untill it looked like new
-egr cooler also was cleaned untill perfect as it was plugged solid
then i found the egr air control valve was siezed with carbon and the gears were striped off the motor, so it was replaced, and on the first drive the code went stored and stayed gone for a couple drives.

the code came back 2 days later and within a week the truck would not start.
i found a fuel leak at the fuel heater plug and fixed that with an updated filter housing and pigtail. the truck now runs ok again, with lots of power and slightly excessive black smoke. the oil seperator also seems to push out excessive oil into the pcv system but not 100% sure what is normal or what to expect. i do know if it was a cummins pushing out that much air an oil i would be getting it rebuilt.

the code is now p0101 high deviation and faily intermitant as most of the time the light will not even come up on the dash, but will become active an go stored on its own.
i curantly have the intake manifold off an soaking because there was alot of oily soot built up inside.
im wondering if the intake being build up like that has been known to cause this code? or if a timing belt that was slightly out could do this and if there is anything else you experienced crd guys have seen or heard of.
its ripped right apart now so now is the time to check

thank you for any input.

Since you have the intake off, have a look at the rocker arms. Check the rollers for any play, the needle bearings can wear out and you will lose valve lift if they are worn leading to the P0101 code and more smoke.

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Providers of wholly developed aftermarket solutions for the KJ CRD.
(248) 977 - 9531

bang on the money
rocker arm roller bearings are all smoked.
14/16 have play, 8 very excesive
and the other 2 are siezed.

should i be throwing lifters in there also?

Do not use the rockers you have based on that info, they are wasted and will eventually cause some major engine damage if used. Just order a new set of 16 and your engine will thank you...your wallet might not. You should also look at the cams for wear since 2 rockers were seized. Most likely the cams need to be replaced.

Two things I would recommend, use a 10W-40 or 15W-40 oil in summer months and then a 5W-40 oil in the winter. The 0W-40 might not be the best stuff for this engine. Any of our engine tunes will also be very helpful to prevent this issue in the future as the soot loading in the oil is reduced by about 90% with any of our tunes. Hope it all goes back together well. GDE

_________________
Providers of wholly developed aftermarket solutions for the KJ CRD.
(248) 977 - 9531

thanks for the help
i got half the rockers in today with most of my gaskets and injector o-rings, ect. the other 8 and intake gasket are backordered out of the states and not sure when the show up.
good new is the rockers come as an assembly with the lifters at around $90 a piece.
a little pricey, i just hope between the intake being gummed up, the timming a little off, and the rockers this thing is fixed.

another question
i was reading somwhere in here about pump timming
why would the pump need to be timed as its only a high pressure pump that feeds the rail and the pcm controls ignition timing.

also when i pulled the injectors out a small amount of oil and fuel drained down into the cylynder, would i be able to remove the alignment pin in the flex plate to spin the engine over to blow out anything that may have got in there or would i be causing more problems by doing that with the timming belt of and cams off.

thanks eric.

I would not worry about the fuel and oil in the cylinder if it is just a little. It may slide down past the rings while sitting or just get burned when you start it back up.

Pump timing is important as there are 3 plungers in the pump and 4 injectors. The timing is required for pressure wave compensation in the rail in order to have correct volume flow for the pilot injection events. You can just set the timing mark on pump gear to the slash mark on the inner timing cover (just below a bolt on the cover).

_________________
Providers of wholly developed aftermarket solutions for the KJ CRD.
(248) 977 - 9531

got the rest of the rockers and gaskets yesterday and got it put back together
imediatly nticed it idled much nicer.
got the coolant bled and took it for a drive and way less smoke.
and the code hasnt come back up yet.

thanks for all the help.