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 Post subject: UK BASED: Jeep CRD LTD Failed MOT Emissions, whats wrong??
PostPosted: Sat Nov 05, 2022 5:51 pm 
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OK clever people, what's going on here? Under mild acceleration to redline, all OK, no smoke, engine runs smooth, returns back to good tickover. Give it a fast accelerate to redline, big puff of black smoke and then totally rough running at idle, to the point the whole engine shudders and almost cuts out. Give it a few seconds, idle comes back and ticks over OK. Give it another easy rev to redline, all OK, a hard, fast rev to the redline gives the misfiring, shudder on the engine at tickler and plunges of Black smoke.
When I press the bleed pump on the filter head, it takes 4-5 pumps to get the plunger to go hard after the hard acceleration and rough running issue. Feels like there's air getting into system or the injection pump can't keep up with demand? There's no fuel pump in tank AFAIK, the HP pump is run off the cambelt. Its common rail diesel, so HP to a fuel rail, injectors triggered by ECU and any excess pressure in rail returned to tank.
Néw diesel filter and washers fitted, bled OK, starts on the button hot and cold.
I've also changed the intercooler pipes, from turbo to intercooler and intercooler to throttle body. Have checked the one from airbox to incoming side of turbo as well. Cleaned MAF and MAP sensors and throttle body intake. New air filter fitted. Only thing I can't do is remove and clean EGR valve as its so difficult to get to.
After all the effort I put in to do the welding on both side sills, I'm reluctant to give up on it!
Will do research on EGR valve removal.
Seems odd that it passed emissions ok last year on MOT and has only done 450 miles since then, perhaps sitting around not used not good for it?
BTW,no codes on code reader, so would seem to be a mechanical issue rather than an electronic one?
Any suggestions welcome! Thanks in advance!
Unable to load video here, so posted on Youtube here: https://youtu.be/mRYKDB0ugVo


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 Post subject: Re: UK BASED: Jeep CRD LTD Failed MOT Emissions, whats wrong
PostPosted: Thu Nov 17, 2022 2:43 am 
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Hello, mickeywillis!

It does indeed sound like you have a fueling problem; how is causes the black smoke is a bit of a mystery.... there may be two problems at play here.

It sounds like it is over-fueling on hard acceleration causing the black smoke. Does your engine have an aftermarket engine tune? A lot of tunes cause over-fueling conditions.

However, because it appears it is pulling a lot of fuel under that hard acceleration, the demand for fuel under those conditions is outpacing the ability of the fuel system from the fuel tank to the CP3 pump to supply that demand, hence the stuttering and rough idle.

In North America at least, KJ Liberty, (Cherokee), CRD vehicles DID NOT get an in-tank fuel lift pump, even though the petrol versions did; the likely cause of this being penny pinching by the bean counters at Daimler/Chrysler. Many CRD owners here have discovered similar fuel starvation problems to what you are experiencing. The solution is the installation of an in-tank fuel lift pump, and because the gas versions of the KJ Liberty/Cherokee had a lift pump, there is a plug-in at the rear of all of the wiring harnesses in all KJ Liberty/Cherokee vehicles to power that pump. All you need, therefore, is an in-tank fuel lift pump and the pigtail to run power from the plug-in at the back of the wiring harness to the pump.

The pump you want to use to cure the fuel starvation issues you are having is an Airtex E7181M or equivalent. I believe there is a pigtail still made by both Sasquatch Parts or I.D. Parts if you do not want to make up your own pigtail.

https://shop.sasquatchparts.com/product ... y-28l-crd/

https://www.idparts.com/liberty-crd-lif ... oduct_tabs


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 Post subject: Re: UK BASED: Jeep CRD LTD Failed MOT Emissions, whats wrong
PostPosted: Thu Nov 17, 2022 12:31 pm 
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Joined: Sat Aug 24, 2013 11:36 pm
Posts: 6705
Location: Central GA
Sounds like you have the typical fuel starvation problem that these vehicles came from the factory with.
First course of action to repair fuel starvation problem is to install an intank fuel lift pump. This solves the air in fuel issues forever.
These vehicles came wired from the factory for the intank fuel pump, all that is missing is the fuel pump and the wiring from under the rear seat to the top of the fuel tank.

See this web page for more information and how it is done:> http://www.auerbach.ca/kj/lift_pump/default.html
The necessary Aptiv (formerly Delphi) wire end terminals can be purchased individually from Mouser Electronics at:> https://www.mouser.com/c/?q=delphi%20terminals
if you want to add the two additional wires to your existing wiring harness like many owners do. Cost is only about $25.00 for wire and wire ends as opposed to purchasing an expensive premade wiring harness.

Wire Terminals: Aptiv APEX 2.8 Series Terminals 16 AWG to 14 AWG Bulk Automotive Connectors
male, 14-16 gauge wire (1 required)
female, 14-16 gauge wire (2 required)
I would strongly suggest ordering several of each in case you damage one during the install process on the wire since they are so cheap.
The specialized bare wire crimp tools are available on Amazon and a few other places if you want to order one.
Example:> https://www.amazon.com/Fryic-Terminal-I ... B07LF4K3VK
:SOMBRERO:

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Supporting Vendor and Moderator of LOST
05 Jeep Liberty CRD Limited :JEEPIN:
Ironman Springs/Bilstein/Shocks
Yeti StgIV Hot Tune
Week's BatteryTray
No FCV/EGR
Samcos/ProVent
SunCoast/Transgo
Carter Intank-pmp
2mic.Sec.Fuel Filter
Flowmaster/NO CAT
V6Airbox/noVH
GM11 Bld.fan/HDClutch
IronrockArms/wwdieselMount

98 Dodge Cummins 24 Valve


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 Post subject: Re: UK BASED: Jeep CRD LTD Failed MOT Emissions, whats wrong
PostPosted: Fri Nov 18, 2022 8:09 am 
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WWDiesel:

Thank you for posting the parts necessary for making our own lift pump pigtails.

You wouldn't happen to know where to hook this up to the fusebox, (if necessary)?


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 Post subject: Re: UK BASED: Jeep CRD LTD Failed MOT Emissions, whats wrong
PostPosted: Fri Nov 18, 2022 12:59 pm 
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Joined: Sat Aug 24, 2013 11:36 pm
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TURBO-DIESEL-FREAK wrote:
WWDiesel:
Thank you for posting the parts necessary for making our own lift pump pigtails.
You wouldn't happen to know where to hook this up to the fusebox, (if necessary)?

The fusebox comes prewired from the factory for the intank lift pump, so it requires NO modification or additional wiring.
All the necessary wiring is already in place all the way to a connector that is located under the rear seat on the drivers side.
Installation requires adding two wires from this connector to the connector on top of the fuel tank. Two APEX/Delphi wire ends will have to be added into the plugin connector at the fuel tank module, and one into the connector that plugs into the female connector under the rear seat.
Please Note: 2006 models have additional wires in the C307 connector due to the 4 wheel antilock brake system. I have a drawing for the 2006 models if anyone needs it.

See pictures:

FUEL PRIMING INTANK LIFT PUMP RETROFIT WIRING REQUIREMENTS:
Image

FUEL PRIMING PUMP RELAY & FUSE LOCATIONS IN TIPM:
Image

_________________
Supporting Vendor and Moderator of LOST
05 Jeep Liberty CRD Limited :JEEPIN:
Ironman Springs/Bilstein/Shocks
Yeti StgIV Hot Tune
Week's BatteryTray
No FCV/EGR
Samcos/ProVent
SunCoast/Transgo
Carter Intank-pmp
2mic.Sec.Fuel Filter
Flowmaster/NO CAT
V6Airbox/noVH
GM11 Bld.fan/HDClutch
IronrockArms/wwdieselMount

98 Dodge Cummins 24 Valve


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 Post subject: Re: UK BASED: Jeep CRD LTD Failed MOT Emissions, whats wrong
PostPosted: Sun Nov 20, 2022 2:51 pm 
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Joined: Sat Apr 15, 2017 3:48 am
Posts: 456
Location: White River in the Bush South Africa
Welcome to LOST! :wink:

Have you read Sams Noob Guide?...has some good tips.
You will notice in the Noob Guide that the Fuel Filter assembly is different to yours in that the Export Models have a nice Raycor Filter Head installed...similar but not exactly the same as the Raycor Heads installed by most members here!

What year is your Export CRD?
How did you check for Error Codes?

When you replaced the Fuel Filter are you sure that the original Rubber Washer at the bottom of the filter did not remain behind so that it ends up with having two washers in place when you fit the new filter!

How did you clean the MAP Sensor....these are very delicate and must not be brushed...I use "Brake Cleaner" in an Aerosol Can to clean it as per Sams Noob Guide!

Do you have access to the Jeep KJ Service Manuals?

They can be downloaded here for all Models except the 2004 Model and there is a section for "2.5_2.8 export diesels" which has some further advise and Parts Catalogues are also there.

The Service Manuals gives advice on how to check for leaks at the individual Injectors and at other points and has the Wiring Diagrams.

I have a 2002 2.5L Export Diesel with a fixed-vane turbo so the are some differences to yours!

http://www.colorado4wheel.com/manuals/Jeep/KJ/

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2002 Export CRD


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