Need tools and resources

dragand021 · **Joined:** Mon Mar 11, 2013 11:52 pm **Posts:** 34

First, let me say, I did read the noob guide, but I'm posting this from my iPad, so pasting the image is not working.

Ok, I am looking for local resources for the CRD repair. I bought the CRD with an engine problem. It would start, barely, run very bad and die. The engine shook a lot. I am taking it apart, and will follow most of the great advices on this board. But, I have a question: where in the Chicago area can I take the injectors to have them tested? Also, more importantly, where can I rent the TB tools from? I exchanged several emails with Keith from GDE ( great guy, btw), but they no longer rent them out, as some tools have gone MIA.

When I took the intercooler off, there was about 1/4 of a cup of oil that leaked out. Is that too much? Also, when I pulled the injectors, there was some sludge on the injector body, all of them. Is that normal?

Any help is greatly appreciated.

dragand021 · **Joined:** Mon Mar 11, 2013 11:52 pm **Posts:** 34

More info:

It is a 2005 CRD, with 143K miles on the dash, however, the previous owner stated, and I found the paperwork that shows that the engine was replaced by the dealer at 77K miles. Th previous owner also said that he had towed the car behind his RV for about 40K miles.

When the car started showing the symptoms, the previous owner took it to one dealer who replaced the starter an the fuel/water separator unit (not just the filter, the whole, redesigned unit). The car ran fine for a few days, and it started the same thing again. He took it to anothe dealer, who claimed that there is no compression on the cyl. #2, and engine teardown is required to further diagnose the issue. The previous owner did not want to spend any more money, and I got the truck.

I found the following codes:

Current Fault Log
------------------
P0102: Mass or Volume Air Flow Circuit Low Input
P0302: Cylinder 2 Misfire Detected

And

P0402: Exhaust Gas Recirculation Flow Excessive Detected
B2TAE: null

I took everything apart, down to the TB, it does not look damaged. I also checked the timing by rotating the CS to the 90 deg past the TDC, and was able to feel both cam locking slots through the head cover cam locking holes, so I am pretty confident that the timing did not slip. Thinking that maybe there is a stuck lifter, but can't go any further without the TB tools.

thermorex · **Posted:** Tue Mar 12, 2013 11:50 am

The locking pins you can make yourself or buy them online:
http://item.mobileweb.ebay.com/viewitem ... 0611413729

The cam sprocket lock tool is definitely a great have, but you really don't need it. I was looking on ebay for a while but I couldn't find one reasonably priced and I won't spend 600+ for one either... You can torque the sprockets using a Vw Jetta cam tool:
http://item.mobileweb.ebay.com/viewitem ... 0298015102

You know you can make the last yourself, right? Lol. Go to Home Depot and get the "L" shaped handles (green in the item above) from hardware (I think they have it on the same aisle with screws and nuts, should be a 3 or 4 ft tall 90 degree corner beam, at least 1/8 thick, it's 10-20 bucks, don't remember exactly), get some graded big nuts and studs (for inserting them into cam sprocket holes) and you're done. All under 30 bucks. You only need that to torque the sprockets to the torque specs, you can gently torque the sprockets so that they won't spin like crazy with the locking cam studs that are already installed when you locked the cam shafts, then you can use your DIY torque tool (or the Vw one above) to torque the sprockets to specs.

thermorex · **Posted:** Tue Mar 12, 2013 11:53 am

thermorex wrote:

The locking pins you can make yourself or buy them online:
http://item.mobileweb.ebay.com/viewitem ... 0611413729

The cam sprocket lock tool is definitely a great have, but you really don't need it. I was looking on ebay for a while but I couldn't find one reasonably priced and I won't spend 600+ for one either... You can torque the sprockets using a Vw Jetta cam tool:
http://item.mobileweb.ebay.com/viewitem ... 0298015102

You know you can make the last yourself, right? Lol. Go to Home Depot and get the "L" shaped handles (green in the item above) from hardware (I think they have it on the same aisle with screws and nuts, should be a 3 or 4 ft tall 90 degree corner beam, at least 1/8 thick, it's 10-20 bucks, don't remember exactly), get some graded big nuts and studs (for inserting them into cam sprocket holes) and you're done. All under 30 bucks. You only need that to torque the sprockets to the torque specs, you can gently torque the sprockets so that they won't spin like crazy with the locking cam studs that are already installed when you locked the cam shafts, then you can use your DIY torque tool (or the Vw one above) to torque the sprockets to specs.

This is a very good write-up on how to use the Vw sprocket tool, scroll all way towards the bottom and you'll see the blue tool the guy is using.
http://www.beesvillebeefarm.com/jeep.html

4x4kingx889 · **Joined:** Sun Jul 17, 2011 6:42 pm **Posts:** 235

Here's my cam holder works great

sent from my sgh-1717 running CM10

thermorex · **Posted:** Tue Mar 12, 2013 1:23 pm

4x4kingx889 wrote:

Here's my cam holder works great

sent from my sgh-1717 running CM10

Lol. Even cheaper than mine!

kjjet · **Posted:** Tue Mar 12, 2013 3:12 pm

4x4kingx889 wrote:

Here's my cam holder works great

sent from my sgh-1717 running CM10

Ha... 4X4kingx889 you gave away my tool!!!!! Nice match. Bet it worked good?

If anyone wants a Timing belt procedure with pic's using a cam holding tool like pictured here just MP me your email address and i will foward it to you.

Geting back to the post. Yes... I would remove the intake for inspection. It is normal to have a build up on the injectors. As far as oil in the intercooler thats from overservicing the oil. It blowes out of the CCV. Lots of dealers try to check compression and say they have a dead cylinder, but soot build up due to rocker failure will give you a low cylinder reading.
All you need to remove everything is a cam holding tool, Cam pins, and a 6mm alen for the fly wheel. MP me your email and i will fwd the procerdure to you.

4x4kingx889 · **Joined:** Sun Jul 17, 2011 6:42 pm **Posts:** 235

Yes, not as nice as yours tho but it cost Me $0.00 :grin:

sent from my sgh-1717 running CM10

dragand021 · **Joined:** Mon Mar 11, 2013 11:52 pm **Posts:** 34

Guys, you rock! Thank you. Ordered parts from IDP las night, should see them on Monday. Hope to pull the head cover/intake over the weekend, and see what the deal is.

kjjet · **Posted:** Thu Mar 14, 2013 8:12 am

Did you get my email? Any questions let me know.

Gokeeper · **Posted:** Thu Mar 14, 2013 8:50 am

If you decide you need some of the Miller tools let me know, I know how hard they are to come across and am willing to rent mine out. I must say though getting a little discouraged GDE stopped due to problems. I have been fortunate so far but you do have very good people and not to good I have learned that.

CRD05il · **Posted:** Thu Mar 14, 2013 2:18 pm

dragand021 wrote:

First, let me say, I did read the noob guide, but I'm posting this from my iPad, so pasting the image is not working.

Ok, I am looking for local resources for the CRD repair. I bought the CRD with an engine problem. It would start, barely, run very bad and die. The engine shook a lot. I am taking it apart, and will follow most of the great advices on this board. But, I have a question: where in the Chicago area can I take the injectors to have them tested? Also, more importantly, where can I rent the TB tools from? I exchanged several emails with Keith from GDE ( great guy, btw), but they no longer rent them out, as some tools have gone MIA.

When I took the intercooler off, there was about 1/4 of a cup of oil that leaked out. Is that too much? Also, when I pulled the injectors, there was some sludge on the injector body, all of them. Is that normal?

Any help is greatly appreciated.

Where in Chicago are you? I am by airport if you need any help just let me know. Also we do have a lost IL meeting soon.

dragand021 · **Joined:** Mon Mar 11, 2013 11:52 pm **Posts:** 34

Gokeeper,

I think I will be OK for now, I will try to make the tools in my friend's machine shop, over the weekend. I got the parts on order and would like to finish it by next weekend. If it doesn't work out, I'll contact you.

Gokeeper · **Posted:** Thu Mar 14, 2013 4:24 pm

Not a problem Make sure you document the tools you make we need pictures.

kjjet · **Posted:** Fri Mar 15, 2013 12:54 pm

dragand021....I just sent you a email with removing the intake procedures. Big job! Hope that helps. Good luck.

KJJET

dragand021 · **Joined:** Mon Mar 11, 2013 11:52 pm **Posts:** 34

CRD05il, I sent you a PM, did you get it?

dragand021 · **Joined:** Mon Mar 11, 2013 11:52 pm **Posts:** 34

Update, I removed the head cover/intake, the rockers are all shot. The intake, past the EGR, is caked with soot/oil mix. Parts should be here tomorrow, as well as the tools I am making.

What is the best way to clean the EGR?

dragand021 · **Joined:** Mon Mar 11, 2013 11:52 pm **Posts:** 34

I was going to post some pictures, but I can't find how.

Leeann · **Joined:** Thu Mar 14, 2013 9:19 pm **Posts:** 523

Upload your photos to Photobucket and link to them (click the chain link symbol on the menubar of the photobucket app while you have the photo you want big on the iPad, then select the one that says IMG Code, switch to Safari, click into the text box, double-tap and select paste).

kjjet · **Posted:** Sun Mar 17, 2013 6:37 pm

dragand021 wrote:

Update, I removed the head cover/intake, the rockers are all shot. The intake, past the EGR, is caked with soot/oil mix. Parts should be here tomorrow, as well as the tools I am making.

What is the best way to clean the EGR?

Well at least you found your problem. Any questions with the procedures, let me know. How do the cams look?
I'm not being smart, but DON'T clean the EGR. Not worth your time. It wont help. Get a GDE Tune or SEGR or keep the MAP disconnested untill you can get one.

Take your time. Clean everything well. Do it right.

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