Quote:
Originally Posted by Jimarilo
Indeed, I am starting to think this engine is more trouble than it's worth. A nice merc 300 straight 6 would be a lot less trouble.
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How so? You mean the OM603? They are far more expensive to maintain and get parts for and harder to work on. Cylinder heads fail all the time, flawed castings. Trap oxidizers always plugging, injection pump delivery valves constantly leaking. The D24T is a much better engine with far fewer inherent issues, speaking here from firsthand experience working on both day in and day out for years back when I was an employee in a professional shop.
Quote:
Originally Posted by Jimarilo
Just changing the rocker cover gasket is a bleeding nightmare to change, especially if the nuts on the injector side are rusty and seized. It is probably just a matter of time before it starts leaking again on the exhaust side
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14 nuts from my memory, maybe 16... Easy access with a regular 10mm socket on all of them, are we missing something here?
The updated style rubber one piece gasket is not common for leaking and is even reusable. Once you get one of those in there, it's set for good.
Quote:
Originally Posted by Jimarilo
I took the cambelt cover off to have a look at the belt as I am still in contemplation mode regarding the belt change, as I need so many specialist tools before attempting the replacement.
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Total number of special tools is something on the order of a half dozen depending on what you are doing and needing exactly. Pretty standard for any diesel engine, it's the nature of the beast. You are absolutely correct that you do need the right tools.... but it's usually not a deal breaker. Very easy and inexpensive to improvise with slightly modified 2.5L 5cyl TDI cambelt tool set also, which is widely available for example on UK Ebay.
Quote:
Originally Posted by Jimarilo
So with the slack on the adjusting pulley side, I slackened the adjuster bolt and let the adjuster take up any slack, which it did. What a difference that made, no stuttering when pulling away or when changing up the box and a little less lumpy on tick over.
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Glad to hear the engine is running better
, but am I reading you right that you made adjustments to cam and IP timing by altering belt tension, without using the tools to verify timing? It's always nice to know what timing setting you are running -- might be valuable to check it now. If changing the timing improved it this much, then there could still be further room for improvement, if for example the last fellow who did the belts failed to get timing adjusted correctly (perhaps hence your improvement from playing with timing). In other words you may still have not seen the best of it yet.
Quote:
Originally Posted by Jimarilo
The air intake pipe that goes over the rocker cover has evidence of oil in it so suggests the engine is breathing heavy and at 165K I am thinking it is in need of a rebuild ......but is it worth it ??
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Like on any other diesel engine, the crankcase vent tube will -- and should -- have some oil vapor in it. That's the reason it is there.
Evidence of some oil presence in the CCV tube is NOT an indication of poor engine health by any means. Especially not on an engine that runs well, starts easily, and doesn't consume excessive amounts of oil. Those factors, and a compression test, are your real indicators of engine health. As ngoma already pointed out.
From everything I am hearing so far, you have a nice car and engine that could use a little attention but sounds like it's in sound basic condition and is most certainly worth the effort to keep it up.
Welcome to the board!