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!
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!
