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 Post subject: Re: Black smoke & little power
PostPosted: Tue Aug 01, 2017 6:23 pm 
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Location: Oregon Coast Dairy Country. Land of stumps, dumps, and "Liquid Pumps"
Mine goes straight to 100 when started up cold, no matter the speed.
Once fully warmed up (10+miles driving) it sets about 50 at idle and 80-100 driving, depending on engine speed.
At 65mph the tach is about 1800, and oil pressure 90ish.
That's with Mobile1 TDT 5W-40.

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 Post subject: Re: Black smoke & little power
PostPosted: Tue Aug 01, 2017 11:53 pm 
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GordnadoCRD wrote:
Mine goes straight to 100 when started up cold, no matter the speed.
Once fully warmed up (10+miles driving) it sets about 50 at idle and 80-100 driving, depending on engine speed.
At 65mph the tach is about 1800, and oil pressure 90ish.
That's with Mobile1 TDT 5W-40.

In the video it had been warmed a little. It was at about 65 at idle when I first started it cold. It looks like the bottom end should still be in good shape. I'm going to start tearing it down tomorrow.

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'06 KJ CRD Limited
ORM, Kennedy Lift Pump, 3" Magnaflow Muffler w/o Cat
ARB Front Bumper w/ custom battery plug, reciever hitch & Zero Start block heater plug in storage box in area for winch

"WISH LIST"
3" Rocky Road Rockfather lift kit
JBA Sway Bar Disconnect
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 Post subject: Black smoke & little power
PostPosted: Wed Aug 02, 2017 12:27 am 
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The pressure would only stay steady because of a relief valve bypassing the oil, otherwise it should increase with rpm.


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2006 CRD - GTB2056 turbo by Dieselguy86, Eco Trans Tune, Lift Pump, Week's, HDS Tstat, Racor Filter, ARP's, OME 790's+Top Plate, JBA 2.5", JBA UCA, Moab's+265/75R16, ARB Bar

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 Post subject: Re: Black smoke & little power
PostPosted: Thu Aug 03, 2017 5:09 pm 
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I got the "valve cover" off today.
The rockers were in bad shape.

5 seized rollers 4 with broke lifters
7 very sloppy rollers
4 marginal

Image

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'06 KJ CRD Limited
ORM, Kennedy Lift Pump, 3" Magnaflow Muffler w/o Cat
ARB Front Bumper w/ custom battery plug, reciever hitch & Zero Start block heater plug in storage box in area for winch

"WISH LIST"
3" Rocky Road Rockfather lift kit
JBA Sway Bar Disconnect
Suncoast T/C
Guage Pod w/ Pyro, Boost, Trans Temp


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 Post subject: Re: Black smoke & little power
PostPosted: Thu Aug 03, 2017 7:20 pm 
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Location: Oregon Coast Dairy Country. Land of stumps, dumps, and "Liquid Pumps"
Good Catch!

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'06 Lbrty Sprt CRD 150K

Sasquatch
DSS Turbo
CAT-elimntr
Weeks Stg1&2 EGRfix
PV-200
BLING
vent gauges

IDParts
head
cams
rockers
Timing set
ARP studs
eTn1 GX2123 5v GPs

YETI Custom Tune
Flowmaster 8325508
Carter P76611M
GM 12611872
Hayden 2986
GM 15976889
PATC Custom Billet
2010 Ram Hemi Trans
Sonnax 44957
Transgo kit
Cooper 51770


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 Post subject: Re: Black smoke & little power
PostPosted: Thu Aug 03, 2017 9:25 pm 
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I will be pulling the head to replace the valves, springs & studs. What else should be replaced? Keepers, retainers, guides, seals, seats? I dont want to be back in here again for a long time.

_________________
'06 KJ CRD Limited
ORM, Kennedy Lift Pump, 3" Magnaflow Muffler w/o Cat
ARB Front Bumper w/ custom battery plug, reciever hitch & Zero Start block heater plug in storage box in area for winch

"WISH LIST"
3" Rocky Road Rockfather lift kit
JBA Sway Bar Disconnect
Suncoast T/C
Guage Pod w/ Pyro, Boost, Trans Temp


Last edited by gt40freak on Thu Aug 03, 2017 10:48 pm, edited 1 time in total.

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 Post subject: Re: Black smoke & little power
PostPosted: Thu Aug 03, 2017 10:01 pm 
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gt40freak wrote:
I will be pulling the head to replace the valves, springs & studs. What else should be replaced? Keepers, retainers, guides, seals, seats? I dont want to be back in here again for a long time.

I would take it to a good quality machine shop and let them check the head thoroughly, springs and retainers should be OK! They should be able to tell you the status of valve guide wear and I would replace valve seals if you can get new ones... They can also check flatness of head with a good true machinist's straightedge and have head milled a thousandth or two to make it flat if necessary. If it were mine I would also have them pressure test it to make sure there are no cracks. Last thing you need is to go through all this work and expense only to find out you have a cracked head!
Last but not least, replace the head gasket with a new one while you got it all apart! But sure and use some Permatex® Copper Spray-A-Gasket® Hi-Temp Sealant on both sides of the head gasket! It will fill any imperfections and help seal the mating surfaces...

:SOMBRERO:

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 Post subject: Re: Black smoke & little power
PostPosted: Fri Aug 04, 2017 10:05 am 
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Been following this thread, my wife's CRD has done the same thing. It was due for a timing belt change then this happened. Rockers were added to the parts list. The only code it threw was "cylinder #1 misfire" and only when running. haven't had time to open it up yet, but I got the injectors out last week and had the tested in a Bosch shop. Came back much the same as the OP's report. These were not the problem. Also went through the harness at the time and found no electrical issues. So, I am hoping for no more damage than a broken rocker.
GT40freak, what did the cam lobes look like after running on stuck rollers?

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 Post subject: Re: Black smoke & little power
PostPosted: Fri Aug 04, 2017 8:04 pm 
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mrhemi wrote:
Been following this thread, my wife's CRD has done the same thing. It was due for a timing belt change then this happened. Rockers were added to the parts list. The only code it threw was "cylinder #1 misfire" and only when running. haven't had time to open it up yet, but I got the injectors out last week and had the tested in a Bosch shop. Came back much the same as the OP's report. These were not the problem. Also went through the harness at the time and found no electrical issues. So, I am hoping for no more damage than a broken rocker.
GT40freak, what did the cam lobes look like after running on stuck rollers?

I took them to a machine shop to clean & check everything. I know it will need cams. At least 2 lobes had no less than 1/8" worn off. After I pulled the head I found that cyl 2 had processed a glow plug tip. There is a few dimples in the head but nothing serious, the piston & liner looks good.

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'06 KJ CRD Limited
ORM, Kennedy Lift Pump, 3" Magnaflow Muffler w/o Cat
ARB Front Bumper w/ custom battery plug, reciever hitch & Zero Start block heater plug in storage box in area for winch

"WISH LIST"
3" Rocky Road Rockfather lift kit
JBA Sway Bar Disconnect
Suncoast T/C
Guage Pod w/ Pyro, Boost, Trans Temp


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 Post subject: Re: Black smoke & little power
PostPosted: Fri Aug 04, 2017 9:05 pm 
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Here's what I got done today. The hardest part was disconnecting the oil lines from the turbo.

Image

Image

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'06 KJ CRD Limited
ORM, Kennedy Lift Pump, 3" Magnaflow Muffler w/o Cat
ARB Front Bumper w/ custom battery plug, reciever hitch & Zero Start block heater plug in storage box in area for winch

"WISH LIST"
3" Rocky Road Rockfather lift kit
JBA Sway Bar Disconnect
Suncoast T/C
Guage Pod w/ Pyro, Boost, Trans Temp


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 Post subject: Re: Black smoke & little power
PostPosted: Fri Aug 04, 2017 10:43 pm 
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Location: Oregon Coast Dairy Country. Land of stumps, dumps, and "Liquid Pumps"
That's quite a chunk of labor!

If you have the head checked out by a machine shop, consider also having them replace all the exhaust manifold studs with better grade ones. The factory ones are really soft.

ALSO $100+ shipping for the pair including spacer shims (they are the originals)

_________________
'06 Lbrty Sprt CRD 150K

Sasquatch
DSS Turbo
CAT-elimntr
Weeks Stg1&2 EGRfix
PV-200
BLING
vent gauges

IDParts
head
cams
rockers
Timing set
ARP studs
eTn1 GX2123 5v GPs

YETI Custom Tune
Flowmaster 8325508
Carter P76611M
GM 12611872
Hayden 2986
GM 15976889
PATC Custom Billet
2010 Ram Hemi Trans
Sonnax 44957
Transgo kit
Cooper 51770


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 Post subject: Re: Black smoke & little power
PostPosted: Sat Aug 05, 2017 11:42 pm 
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GordnadoCRD wrote:
That's quite a chunk of labor!

If you have the head checked out by a machine shop, consider also having them replace all the exhaust manifold studs with better grade ones. The factory ones are really soft.

ALSO $100+ shipping for the pair including spacer shims (they are the originals)

I am going to get new cams. Thanks for offering.

_________________
'06 KJ CRD Limited
ORM, Kennedy Lift Pump, 3" Magnaflow Muffler w/o Cat
ARB Front Bumper w/ custom battery plug, reciever hitch & Zero Start block heater plug in storage box in area for winch

"WISH LIST"
3" Rocky Road Rockfather lift kit
JBA Sway Bar Disconnect
Suncoast T/C
Guage Pod w/ Pyro, Boost, Trans Temp


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 Post subject: Re: Black smoke & little power
PostPosted: Sat Aug 05, 2017 11:52 pm 
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I noticed the oil film on the intake runners is only in cyl 2-4. Cyl 1 only has soot. I already deleted EGR & will be installing a ProVent when everything goes back together this time. The machine shop is cleaning the head & intake. No more intake sludge for me.
Image

_________________
'06 KJ CRD Limited
ORM, Kennedy Lift Pump, 3" Magnaflow Muffler w/o Cat
ARB Front Bumper w/ custom battery plug, reciever hitch & Zero Start block heater plug in storage box in area for winch

"WISH LIST"
3" Rocky Road Rockfather lift kit
JBA Sway Bar Disconnect
Suncoast T/C
Guage Pod w/ Pyro, Boost, Trans Temp


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 Post subject: Re: Black smoke & little power
PostPosted: Sun Aug 06, 2017 6:42 am 
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Location: Oregon Coast Dairy Country. Land of stumps, dumps, and "Liquid Pumps"
gt40freak wrote:
GordnadoCRD wrote:
That's quite a chunk of labor!

If you have the head checked out by a machine shop, consider also having them replace all the exhaust manifold studs with better grade ones. The factory ones are really soft.

ALSO $100+ shipping for the pair including spacer shims (they are the originals)

I am going to get new cams. Thanks for offering.

Nothing wrong with that, Its what I did before even tearing things down.
I figured it was the price of piece of mind, but things were way way better than I expected when I got it apart.

Had I known the only problems were a failed Stigan Turbo and a bunch of idiots rewiring stuff they didn't understand, I would have been several thousand dollars and several months ahead.

_________________
'06 Lbrty Sprt CRD 150K

Sasquatch
DSS Turbo
CAT-elimntr
Weeks Stg1&2 EGRfix
PV-200
BLING
vent gauges

IDParts
head
cams
rockers
Timing set
ARP studs
eTn1 GX2123 5v GPs

YETI Custom Tune
Flowmaster 8325508
Carter P76611M
GM 12611872
Hayden 2986
GM 15976889
PATC Custom Billet
2010 Ram Hemi Trans
Sonnax 44957
Transgo kit
Cooper 51770


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 Post subject: Re: Black smoke & little power
PostPosted: Sun Aug 06, 2017 10:21 am 
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Forgive my ignorance here, but how do you inspect the cams to see if they need to be replaced? I'm about to reinstall the intake ("valve cover") on mine so I want to make sure they are in ok shape before I put it all back together.

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 Post subject: Re: Black smoke & little power
PostPosted: Sun Aug 06, 2017 4:38 pm 
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Location: Oregon Coast Dairy Country. Land of stumps, dumps, and "Liquid Pumps"
one quick way is to put a form of "backlight" so that the cam is between the lighted surface and your vision. Place a straight edge across the raised part of the lobe across where you can see the shiny path that the roller has made. If you see a clear lighted gap where the roller pathway has gone, then that's wear. To measure the wear use a micrometer to measure the difference between the unworn portion of the lobe at the sides, then measure the worn path the same way, and subtract it from the unworn part. The difference is the amount of wear. Digital calipers can also be used for this if you are careful but the results will possibly have more variance. Specs of max wear are not given for the CRD in the FSM but I consider .010" to be extreme.

_________________
'06 Lbrty Sprt CRD 150K

Sasquatch
DSS Turbo
CAT-elimntr
Weeks Stg1&2 EGRfix
PV-200
BLING
vent gauges

IDParts
head
cams
rockers
Timing set
ARP studs
eTn1 GX2123 5v GPs

YETI Custom Tune
Flowmaster 8325508
Carter P76611M
GM 12611872
Hayden 2986
GM 15976889
PATC Custom Billet
2010 Ram Hemi Trans
Sonnax 44957
Transgo kit
Cooper 51770


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 Post subject: Re: Black smoke & little power
PostPosted: Sun Aug 06, 2017 4:43 pm 
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Thanks... That's good information

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 Post subject: Re: Black smoke & little power
PostPosted: Mon Sep 25, 2017 3:10 pm 
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Well, it took me awhile due to my work schedule to get this similar issue to the OP's resolved. The wife's CRD is now back together and running like a champ. I just put a 1000km highway run on it to shake out any bugs (there weren't any) and clean out the engine.
As suspected, it had broken a rocker. Half a dozen more had trashed rollers and were about to fail. This also wiped out the exhaust cam, so both were replaced. The engine was extremely dirty inside, even though it had only 135000km on it. Nasty thing, the EGR system. I opted not to remove the cylinder head, but poured a liquid carbon deposit cleaner into the ports to soften up the mess. The liquid stayed there for over 24hrs, so that indicated no valve leakage. This engine had a GDE tune installed about 3000km before failure, and it was shocking how quickly the oil blackened. So a block off plate was added into one of the EGR lines to insure positive shut off. The flow valve disc was removed as well. It was obvious the the EGR valve was leaking by, even though turned off. I have to be able to pass a biannual emissions inspection, so cannot remove.

So, the list:
Timing Belt Service (ID Parts complete kit)
Utilized the ID Parts Timing Belt Tool Kit. Excellent bang for the buck, worked great.
Rocker arms and cams.
Unplug the CCV oil drain back loop seal (this was covered in a separate post regarding Provent)
Bosch 5V glow plugs (no reflash, so I will update how that works in the Canadian winter)
Fuel Injectors inspected and tested.
EGR block off plate.
Fumoto oil drain valve. (18mm x 1.5mm because the pan was stripped).
Fan shroud mod.
The induction hoses were all changed just prior to the rocker failure.
HDS 001 Thermostat installed prior to the rocker failure. (No T-stat debate please)

I want to thank all the board members and vendors for the assistance and wealth of information.
The beasty fired right up with minimal fuss and runs smoother than it did when we bought it a few months ago.

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2006 KJ CRD, 2006 KJ 3.7L 6spd., 2015 Ram 2500 6.7L 6spd., 2013 Subaru BRZ 6spd., 1969 Dodge Charger R/T 4spd. (Yes it's a Hemi).


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 Post subject: Re: Black smoke & little power
PostPosted: Mon Sep 25, 2017 10:46 pm 
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Location: Oregon Coast Dairy Country. Land of stumps, dumps, and "Liquid Pumps"
Glad things are looking up!

I think that GDE tune will probably help you pass any sniffer test they do.

I can't recall if you mentioned a lift pump, in-tank or otherwise, and I don't see on on your list or sig.

If you don't have one, I recommend putting it next on your list, preferably before winter sets in hard, if you can afford it. Especially as it's your wife's ride?

It's one of the most "worth it" mods you can do, and really not that difficult.

_________________
'06 Lbrty Sprt CRD 150K

Sasquatch
DSS Turbo
CAT-elimntr
Weeks Stg1&2 EGRfix
PV-200
BLING
vent gauges

IDParts
head
cams
rockers
Timing set
ARP studs
eTn1 GX2123 5v GPs

YETI Custom Tune
Flowmaster 8325508
Carter P76611M
GM 12611872
Hayden 2986
GM 15976889
PATC Custom Billet
2010 Ram Hemi Trans
Sonnax 44957
Transgo kit
Cooper 51770


Top
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 Post subject: Re: Black smoke & little power
PostPosted: Tue Sep 26, 2017 1:22 am 
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Location: Somewhere between Heaven and Hell... But it is really hot here on Earth...
Definitely put a lift pump in these. Even if you just get one of the Facet pumps like this:
https://www.amazon.com/dp/B013SG86X0/_encoding=UTF8?coliid=IUU3KUD51BYLM&colid=Q9AAF5DNN7DT

And then mount it in the engine bay between the tank and the filter head - Anything helps the main pump, and you can cut out the quick connect by the tank easily and replace it with a section of fuel hose that slips over the factory lines to eliminate that air leak potential. No it isn't as secure as the in-tank pump, but I've now heard of a couple of the in-tank ones failing, and if that happens you have to drop the tank again. At least with an external it is easy to replace or bypass if it dies on you.


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