Dean, I’ve been following your thread for a year, ever since your Jeep began making noise prior to the big fail. I haven’t posted anything here before because I don’t have a CRD, but I just wanted to say I admire your logical process and your stick-to-it-iveness! This thread is a gold mine for CRD engine repairs (with excellent photos and written descriptions), but it’s also inspiration for the courage to even attempt this kind of repair work. Engine repairs can seem scary but you make them accessible and doable. And interesting. Thanks and good luck. I’ll be waiting for you to fire it up.

After a year I don't automatically remember where each one goes,

Since you will most likely be removing the fuel tank to clean and dry...
One of the very bestest things you can do for your CRD is to drop in a lift pump in place of the existing sending unit.
There are many ways to do it, the fastest and easiest in-tank solution is from Sasquatch Parts.
https://shop.sasquatchparts.com/products/in-tank-lift-pump-for-jeep-liberty-crd-5143160aa/
The more expensive but much more time saving is the plug and play wiring loom.
https://shop.sasquatchparts.com/products/plug-and-play-in-tank-lift-pump-wiring-harness-for-jeep-liberty-crd/
For mine, I modified my oem loom, and pulled a nearly new pump unit from a wrecked 1 ton at a local yard, as the Sasquatch loom option was not available yet.

Looking at the rebuilt head photos, I was trying to figure what glow plug you have in cylinder #2. Bosch? #1, #3, and #4 kind of started ringing alarm bells. Those look very much like the original ceramic plugs that are prone to breaking off and destroying pistons, valves, heads, etc. I urge you to check and be sure they are absolutely not. Change them if they are. Please. these are fun little rigs once the niggles are all worked out. I'd hate for someone to have to go through all you have for the last year all over again, or actually consider dumping the rig, over missing something this small but important.

Hello Dean! Glad to hear and see the golden nugget back in it's setting! Isn't it amazing how much it stirs the blood to hear an engine you've overhauled fire up and not blow up? Aural motivation of the finest sort!

GordnadoCRD,

After looking at the product description of the drop-in Sasquatch in-tank pump, it mentions helping to eliminate water in fuel problems. That makes it sound like normal, modern, click-together fuel line connectors are more reliable in a pressurized line. If this is correct, then an in-tank pump is certainly a good idea. I would not want to go through this again, and neither would my wife.

Apparently the 1-ton wreck you got yours from was a 1-ton Dodge Cummins? I can modify my wire loom too and save an extra $230. plus S & H. (They are out of stock right now and I'd have to join a wait list) It seems the new $160 Sasquatch pump does not come with a connector.

I should put a pressure gauge or light in the dash for lift pump pressure. If it were to fail I would never know it until the next blow up.

Dean.

Thanks for taking a close look at the repaired head. (And thank you layback40 for suggesting I post pictures of the repaired head) The one odd glow plug is from a 2006 CRD engine. The tip was blown off the #2 glow plug. I saw evidence of the tip bouncing around that cylinder before it shot out through the exhaust port, or pulverized.

I wish now I had put the 2006 glow plug in #3 cylinder because that is the only one that requires taking off the intake elbow to remove. However, with the EGR and block heater removed, plus the engine painted yellow, I can see them easily.

Dean.

Quite honestly, it's unlikely in Hawaii to actually require glow plugs anyway, if your battery is healthy. Just wanted to make sure you weren't in jeopardy of the Ceramic plugs ruining all your hard work.

I can sell you my brand new, never installed, 7v eteckno glow plugs. I've been reading they're not going to work well for my climate so I'm off to the store for some 5 volters.

If you need help, holler, I can look a mine for a reference and can send pictures if needed. Probably others willing to help as well if needed...