Well it finally happened to me. I took it to the dealer last week to have the filter head replaced because of a burnt connector. While it was there I had them replace the EGR which was throwing a code. They also scanned a faulty glow plug. After the glow plug was replaced they, it was still showing bad, so they replaced the ECM. They also replaced a turbo boost sensor.

Here is what they replaced on the first repair

5166555-ab valve egr
56044671-ac module gl
5142577-aa glow plug
56044562-cf module po
52129237-aa separator

On the way home from the dealer the the MIL came back on. About 30 minutes later it goes into what I guess is limp mode, it would not shift higher than 2nd or 3rd gear. I pulled over, and restarted the engine, and it did not happen again. The next morning it dies as soon as she starts it, and then about 100 yards down the road at a stop sign.




So we pick it up tonight and drive back home, about 30 miles, with no issues.

second repair
63031593-aa sensor ai
rl044737-aj module tr
The ticket also says "found TSB 08-016-05"


My wife drops me off at work so I can pick up my truck. On the way back home, less than 3 miles, she says it goes back into limp mode. I take it out for a drive, about 2 minutes later it goes back into limp mode, and a few minutes later the trans temp light comes on, I had not driven it over 35 mph. We let it sit for about 10 minutes, and the light goes off, and drove it back home in limp mode.


Any ideas????

Also, the MIL is not lit this time

A couple of more updates. I bleed a bit of air out of the filter head. It was a bit, but once I installed the filter with the gasket crooked, and it had a lot more air in it then. I also took it to auto zone and had it scanned, no codes. I took it for a 10 mile drive, and it did not go back into limp mode.

One idea that has is that the air in the system cause the limp mode, and I was driving too fast in too low of a gear, which caused the trans temp light. But why would this not throw a code, I think "mass fuel loss" or something like that.

http://www.wjjeeps.com/tsb/tsb_wj_0801605.pdf


Maybe your problem.

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2005 sport crd-SOLD No regrets

According to the paper work, they did that tsb, and the MIL light is not on and I do not have any codes. I need to look at the date on it though, but I glanced at it last night, and it did not appear to be new, even though they said they replaced it.

Well it did the same thing to my wife tonight, went into limp mode, and then trans temp light came on, with no CEL. I purged the air out, and restarted it and let it run for five minutes and shut it off. I cracked the bleeder valve, and after just five minutes more air came out. All of the fittings were tight, but when I reached under, the water in fuel sensor was loose, i could turn it with one finger. I tighten it up and let it run for another five minutes. This time when I opened the valve, no air. Hopefully this is what was wrong(but with my luck it is not).

After supper I will take it for a drive and see what happens. If this fixed it, this would go along with my idea in my last post, but still does not explain why no CEL being triggered with the jeep going inot limp mode.

Took it for a drive after supper and she drove it to work this morning( about 30 miles). I think that I am going to unplug the fuel heater. I had it unplugged before this mess, but with the CEL for the EGR, I am not sure if this causes a CEL or not.

Does any one else have any ideas if it starts acting up again?

Thanks

The fuel heater will not generate a CEL. Is your fuel head staying full of fuel, or do you have lots of air purging out of it? Before something went "snap" in my primer bulb, I would only have to push the primer 2 or 3 times to get all the air out. Now my primer seems to have punctured itself and doesn't seem to ever get all the air out. I'm actively looking to fit a Racor in it now. That stock fuel head is such a POS.

If you can rule out air in your fuel lines, I'm not sure what else could be wrong. You say you are getting an EGR error? I can't imagine that would shut you down, but hopefully SEGR units should be available in a while, that will take care of all the EGR issues....

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'05 Liberty CRD B100, SEGR - SOLD

'01 Beetle TDi B100, EGR delete
'83 Mercedes 240D B100, no EGR

--- SEGR Builder ---

30 miles is greater than 3mi or 10mi, your previous record for CEL, tho it is a strange mathematical coincidence: 3x10=30 - looks like you may have it fixed, and the CEL may have been massive fuel leak, an interpretation of air leak - wow, ya gotta new TCM and a bunch of other stuff - way cool, totally exemplifying the shotgun method of troubleshooting........................

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'05 CRD Limited
Pricol EGT, Boost
GDE Hot '11; EDGE Trail switched
SEGR; Provent; Magnaflow;
Suncoast T\C, Transgo Tow'n'Go switch;
Cummins LP module, Fleetguard filter, Filterminder
2.5" Daystar f, OME r; Ranchos; K80767's, Al's lifted uppers
Rubicons, 2.55 Goodyears
Four in a row really makes it go

click23: Do these guys drive Subarus? Lots of parts no results.

Have you installed a lift pump?

My lift pump solved my lousy running at higher speeds and I found my leak fast.

When I get time I will pull the Quote out of "Diesel-Engine Management by Bosch 4th Edition" pointing out that the Common Rail System REQUIRES a SUPPLY PUMP. Chrysler was smoking crack when they thought they can suck fuel out of the tank with out air leaks.
As stated before,"you can not defy the Laws of Physics"

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2006 Pearl Green CRD
Magnaflow 2 1/2" Cat Back
KJ Extra Leg Room Brackets, Carter Lift Pump, V6 Airbox, ORM
Fuel cooler, Oil Separator, Progard 7
Gauges EGT Boost Trans Temp Oil Pres, Michelin LXT AT2 245 70 R16
7,000# Draw Tight hitch, PML EX Deep Trans Pan
Centrifuge, SunCoast, Transgo, RAM TCM, InMotion Stage 2
Wife's 99 TDI VW Beetle

Still no CEL, but it went into limp mode tonight. My wife drove it home, and when almost home, it went into limp mode. I purged the air, and drove it back out, limp mode again, about 1000 feet down the road. I pulled over and I again had air in the filter head, after I had just primed, about 15 or so pumps to purge it all out.

Although I had a CEL the first time, I think this was from the bad turbo boost sensor. After it was replaced, no CEL but at least 4 limp modes. The limp mode only happens after the car has warmed up(driven at least 30 miles), and usually the jeep had stopped for a few minutes.

It is going back into the shop tomorrow. The Chrysler warranty, with this whole fiasco and rebuilding the rear end, it has already paid for itself.

I see a lift pump solution, followed by a filter head when fuel sprays out instead of sucking air. I'm still amazed the service technicians who work on these cannot properly diagnose this issue; how stupid can they be?

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'05 Liberty CRD B100, SEGR - SOLD

'01 Beetle TDi B100, EGR delete
'83 Mercedes 240D B100, no EGR

--- SEGR Builder ---

warp2diesel, most of those parts go back to problems I actually had, EGR, burnt plug on separator, bad glow plug, etc. The only thing that I do not think was needed was the TCM, I think it all goes back to an air issue, probably on the filter head. At this time no lift pump. It is under warranty, and I do not want to do anything that could cause any issues with it, but I might be rethinking that. Yes I am familiar with magnuson moss, it can be a big hassle.

Since the fuel system is made by Bosch I would assume they know what they're doing. You people really need to quit with the mandatory lift pump crap. See the obscene photo thread with the guy from Texas with over 100,000 milesSTOCK and zero problems. Far too many people are running a stock fuel system and have zero problems for you to claim the stock fuel system inadequate.

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2005 sport crd-SOLD No regrets

from what GMCTD is saying... bosh, the one who indeed designed the system, says it needs a supply pump, aka a lift pump

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Trevor

'05 Limited CRD Inferno Red Pearl Coat
Home made provent installed @ 35443, SEGR installed @ 35466, Fumoto valve @ 37500, trans and transfer case skid, In tank pump installed @ 43500, Suncoast TC & Transgo Shift Kit @ 44730, EGT, Boost, Trans temp gauges, Samco hoses, Rebuilt Trans w/ HD454RFE kit @ 56K, Inmotion Stage 2 @ 56K

Far too many get leaks and shut down, often at dangerous times. No, a lift pump is common sense.

Click23, if you want a useable vehicle that will survive the warranty period, consider the in-tank pump solution. It is the most elegant and least visible. You can even pull the fuse and disable the pump if you need to hide it. And you will NEVER have filter head priming issues again.

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'05 Liberty CRD B100, SEGR - SOLD

'01 Beetle TDi B100, EGR delete
'83 Mercedes 240D B100, no EGR

--- SEGR Builder ---

I would have to agree with this quote. Out of the thousands of KJ diesels that were sold both in the US and Europe with this exact configuration, the percentage of people that have had issues is smaller than you think with the "majority" of people here that have problems representing a small faction of owners, and of the people who have seen to it to retrofit the limp pump, there's not a 100% success rate of curing the ailments.

The other quote shown above regarding the Bosch handbook - that's not entirely true. For decades, engines with mechanical fuel pumps sucked fuel from the tank to the engine and it worked just fine. The application on the KJ was specifically designed the way it is by Bosch to be a self-lifting system. The biggest misconception is that the fuel head is not∫ˆ a Bosch component, instead made by a company called Ufi Filters, and the design of the filter head was constrained by factors set forth by the customer. The Bosch book is right in that a supply pump is required, but you must remember that the supply pump on this engine isn't electrical - and that's okay.

MrMopar64, why would going into limp mode not cause a CEL? I would think that anything serious enough for a limp mode would be serious enough for a CEL

The trans temp light on will cause a limp mode.

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2005 sport crd-SOLD No regrets

The trans temp light was from the limp mode, not the other way around.