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 Post subject: I bought a CRD and I have issues. Rockers?
PostPosted: Thu Jul 11, 2019 11:15 am 
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Joined: Fri Jun 07, 2019 10:02 pm
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Hi, my name is Garrett and I bought a 2005 CRD Sport about a month ago. Here is my story
A little background on me, I’m 25 (today is my birthday), I graduated a mechanical engineer but am working as a manufacturing engineer for a company that makes automotive parts. I have been a machinist for about 10 years, building small air engines and gun parts. I have a 30x40 shop that I am working on turning in to my machine shop (this project is holding that up).

About a month ago I drove 6 hours to pick up this CRD I found on facebook. 110,000 miles with some light-ish body damage. The kicker was that the transmission was on a pallet, being pulled due to the torque converter bolts backing out and the crank adapter bolts shearing. $2500 and $200 fuel it was in my garage.
After doing a lot of reading on there I decided I would try to drill the FP and converter to 3/8-24 just to see if the thing ran before I dropped the money on a good converter and a new FP. About 45 seconds after starting it for the first time I had engine oil running out of the bell housing. Rear main seal was toast, or so I thought. Turns out the sheet metal part and the spacer were missing so, there wasn’t a rear main seal. Ordered rear man kit from squash, ordered a Florida converter and a new FP and bolts from dodge. Got everything put back together around 7pm last night and fired it up. Purred like a kitten, smooth, no drips, fluids were good, happy day. It idled for probably 20 minutes while I was taking it down from the jack stands and aired up a tire. Still smooth, no leaks, was coming up to temp nicely. Time for a drive.
I head down my ¼ mile driveway taking it very easy, concerned about air in the trans dropping fluid level. About half way down I tried rolling in to it, not much happened besides a little turbo spool. Get to the end of the drive and turn around, decide I’m going to roll in to it a little harder. 1st gear ran to ~1600 same with second into 3rd. Rolled in for a 3-2 down shift, jumped to ~2000 rpm but has 0 acceleration. I let out of it, did some thinking and tried it again. Same thing but I looked behind me and there was a big black cloud. About this time I start feeling a weird giggle and turn the A/C off. Something has gone to hell. Pull back up to the shop and its only running on 3 cylinders and spewing ATF. (I used the wrong clips to hold the trans cooler lines on, going to haft to pull the fitting because I for the life of me can’t get the 3/8’s fitting on with that little room.)
I spent the rest of the evening trying to deal with the trans line issue so I have not been able to diagnose the engine issue but here is what I’m thinking.
A. I lost both intake rockers on one cylinder.
B. I have an injector issue.
Knowing the history with this motor, my guess I rockers. It still starts and runs nice until it hits that dead hole.
So far the only option I see is the timing belt, arp, rocker bundle from squash. This thing has 110k on it and I trust it needs a timing belt anyway but I’m not sure I want to spend ~1,400 on this thing.
I am looking for advice and suggestions. Is a kind of dinged up crd worth 4,500? I bought this thing as a replacement for the old 96 300-6 f150 I have adopted as my DD. The money isn’t the issue as long as I could drive this thing for ~25,000 miles and get most of my money back, I seem to change vehicles like I change underwear.
I apologize for the very long write up, I blame the engineer in me for having issues getting words to work.
Thank you all for the help you have unknowingly given me to this point.
Garrett,

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05 CRD Sport with 110,000
Miles I've put on it to date, .5

96 300-6 ford F150
14 tuned 3.5EB F150
Suzuki DR-z 400SM
Suzuki V-Strom 650
Polaris Rzr 1000s


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 Post subject: Re: I bought a CRD and I have issues. Rockers?
PostPosted: Thu Jul 11, 2019 12:19 pm 
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Joined: Sun Dec 12, 2010 5:49 pm
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First off, welcome to the club!

Your diagnosis could be correct. I have a CRD that broke 2 rockers at 122k and the rest were wore out (my guess is the previous owner either used the wrong oil or didn't change the oil often enough). Very similar symptoms, idles fine, but has low power, noise, black smoke when you give it any accelerator. I put a new set of rockers and a new timing belt and it has been good for 50k with no more engine trouble.

But before you tear it down, low boost will also cause low power and smoke. Check to make sure the turbo hoses are good and secure (the orignals tended to rot on the bottom side due to oil puddling and will crack under pressure). I've heard of cracked intercoolers letting boost drop, but I've never had that problem. Check the play on your turbo (I've had a couple turbo failures).

A couple other things to do, Install a new MAP sensor ($20 from a Chevy dealer or $60 from Jeep). Check that the plug on the air box sensor is secure (a loose connection will put the Jeep in limp mode).

If you do pull the head to change rockers, put some steel glow plugs in while it's off. Also a good time to delete the EGR.

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2005 Deep Beryl Green Pearlcoat
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2006 Inferno Red Crystal Pearlcoat
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 Post subject: Re: I bought a CRD and I have issues. Rockers?
PostPosted: Thu Jul 11, 2019 12:40 pm 
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Location: Somewhere between Heaven and Hell... But it is really hot here on Earth...
Another source for parts is IDparts.com and they specialize in the CRD.

Your diagnosis sounds accurate - kudos, especially for being a newbie to this engine! If you want any skilled assistance with this, I'm the traveling CRD tech. This is the ONLY vehicle I work on, and I'm going to be in Oklahoma in about a week so I could add you to the itinerary if you wanted.

I don't know about the resale values (not a car salesman) but I do know that with the right upgrades of my Level 2 service that includes the rockers, ARP studs, and a stage 1 EGR delete, and a timing belt and water pump.... The results will be usable for at least another 50k-75k miles before there is another risk-factor in the design of this engine. Email (button below) if you'd like to discuss your options more, I'm flying back from Denver today so I should have lots of time for posting and email.

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 Post subject: Re: I bought a CRD and I have issues. Rockers?
PostPosted: Thu Jul 11, 2019 1:01 pm 
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Joined: Fri Jun 07, 2019 10:02 pm
Posts: 4
Jay,
Thank you for the welcome and the comments. I have a dead cylinder so I'm not able to diagnose boost issues. i will keep the GM MAP in mind once/ if i get it running.

Geordi,
Thank you for your comments.
Right after i posted I found ID parts, looks like around $800 for Tbelt kit and rockers.

Imo, engines are engines, I grew up looking over my dads shoulder working on the DT466 motors in his fleet and have been in and out of multiple gasses. This one sure does have some (lot) of quarks though.
You will be getting an email from me shortly.

Thank you both,

Garrett,

_________________
05 CRD Sport with 110,000
Miles I've put on it to date, .5

96 300-6 ford F150
14 tuned 3.5EB F150
Suzuki DR-z 400SM
Suzuki V-Strom 650
Polaris Rzr 1000s


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 Post subject: Re: I bought a CRD and I have issues. Rockers?
PostPosted: Thu Jul 11, 2019 3:47 pm 
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Joined: Fri Jun 22, 2007 11:43 am
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Location: Green Cove Springs FL
TheKansasGman wrote:
This one sure does have some (lot) of quarks though.

Like every thing, its chock full of quarks.
Except for the anti-things. Those are full of anti-quarks.

I believe this engine is composed of things and anti-things.
Inevitably, it will annihilate itself. :wink:

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Bought my '05 CRD on June 2nd '07, used with 29,000 miles.
intake elbow and EGR delete. 5 volt bosch glow plugs
Yeti stage 2 ECU tune. Straight pipe exhaust. DIY intercooler hoses
Provent and modified factory 180F thermostat
Replaced cylinder head (cracked) at 160,000 miles + ARP studs
2.5 inch lift, JBA upper arms, 235-85-16 tires.
Still love it.


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 Post subject: Re: I bought a CRD and I have issues. Rockers?
PostPosted: Thu Jul 11, 2019 4:11 pm 
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Joined: Fri Jun 07, 2019 10:02 pm
Posts: 4
flash7210 wrote:
TheKansasGman wrote:
This one sure does have some (lot) of quarks though.

Like every thing, its chock full of quarks.
Except for the anti-things. Those are full of anti-quarks.

I believe this engine is composed of things and anti-things.
Inevitably, it will annihilate itself. :wink:


Thankfully I've not read of any hootises with these.

Garrett

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05 CRD Sport with 110,000
Miles I've put on it to date, .5

96 300-6 ford F150
14 tuned 3.5EB F150
Suzuki DR-z 400SM
Suzuki V-Strom 650
Polaris Rzr 1000s


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 Post subject: Re: I bought a CRD and I have issues. Rockers?
PostPosted: Thu Jul 11, 2019 6:11 pm 
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Joined: Sat Aug 24, 2013 11:36 pm
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Location: Central GA
First thing to do is check compression on the dead cylinder. This will tell you if it is mechanical or possibly an injector problem.
A NOID test light will tell you if you are getting a signal to the injector.
If you got good compression and the injector is getting a signal to fire and you have no strange rattling noises while the engine is running.
Swap two of the injectors temporary and see if the misfiring cylinder follows the injector.
These engines are no different basically than any other diesel engine, just a few small things that you must be aware of before you tear into it.
But there are people on this forum who can guide you.

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 Post subject: Re: I bought a CRD and I have issues. Rockers?
PostPosted: Tue Jul 16, 2019 8:05 am 
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I spent some time yesterday getting the trans cooler lines hooked back up. What a pain.

I think I guessed wrong that I had lost the intake rockers. I say this because there is a very audible "pop" (pretty dam loud really) trailing the firing of #1 cylinder. (this is all based on my supernatural cylinder firing sense)
Also adding to this belief is the fact that its not a "dead" cylinder. from the timing of the vibrations you can tell that its compressing after the exhaust stroke, as well as on the compression.

Unplugging #1 injector removes the intake pop and things smooth out a little. Little bugger still idles pretty smooth despite the dead hole.

They are calling for highs in the 100's this week here in Kansas, need to find a window AC for my shop to help pull out some of the moisture. Other wise, I intend to start into it tonight. Parts will get ordered over lunch. IDparts for timing belt kit, rocker set and studs.

Thank you for stopping by!

Garrett,

_________________
05 CRD Sport with 110,000
Miles I've put on it to date, .5

96 300-6 ford F150
14 tuned 3.5EB F150
Suzuki DR-z 400SM
Suzuki V-Strom 650
Polaris Rzr 1000s


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 Post subject: Re: I bought a CRD and I have issues. Rockers?
PostPosted: Tue Jul 16, 2019 2:16 pm 
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Joined: Tue Dec 16, 2014 9:33 pm
Posts: 519
Location: Jackson,TN
Great ! Hope you don't find anything too bad! Let us know how you do.

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05 Blu Lim, Dayton, GDE HT, 255/75/18 , 210K , H TC
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