About a week ago the clubbie began to get real loud with the diesel rattle. I was used to the noise - cold weather noise, but this time it was really rattling! After I returned from vacation Playa Del Carmen, I took it in. The following was found:
1. Part 40582 replaced timing chain check out, heard loud noise while engine was running, looked up Bulletin M11 02 07. Removed valve cover and found that the top timing chain guide was broken. Installed special tool to measure chain tention. Chained measured 71MM. Installed special tools to lock engine in place. Found that the cams were out of time. Replaced all related parts of the bulletin and programmed car.
I was told that the cam bolt basically fell of when they opened it up...a little more driving and I would have a DEAD engine!

Also had recall work done - replaced Aux water pump.

Additionally they found that the Vacuum pump was a permanent failure - "Part 40582 replaced vacuum pump due to pump being too tight causing the cam to almost not turn".

I was lucky, all this work with N/C at 40,500 miles. Car is A LOT quieter and smoother running with NO CHATTER. Seems tighter too, for some reason.

 

Glad that you got it all straightened out, now go motor

 

Follow up:
This morning I started her up, NO RATTLE - it was very quite. I would suggest that if anyone is experiencing the cold weather "rattle" or "chatter" they should get the drive belt fixed. The rattle or chatter is NOT a normal thing if it goes away after getting the cams and drive train repaired!
This is the quietest the clubbie has ever been, feels like a new car again! Also noticed that the car was reprogrammed and the Auto on headlights was disabled - I like that. Also the three blinks at half way was disabled (need to reinstate).