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Power surging problem resolved!
http://www.lostjeeps.com/forum/phpBB3/viewtopic.php?f=5&t=50589		 Page 1 of 1
Author:  kapalczynski [ Sat Feb 27, 2010 6:16 pm ]
Post subject:  Power surging problem resolved!
Original problem was while in cruise control or even manually controlling throttle up a steady slight incline, jeep would surge between medium boost, little boost, medium boost, little boost,etc. Also was only reporting 25mpg hwy (30 on the lying mpg display)at 65mph.

I tracked down my issue to a boost leak in the intercooler. It appeared to be a factory defect as there was no damage to the intercooler, it was NOT leaking form the plastic end caps or seals and was leaking from one of the aluminum cross tubes at the joint with the metal part of the end cap(bad sauder/weld).

*Interesting to note, after cleaning my MAP sensor (coated with oil/soot sludge buildup) i expected to see a large ammount of buildup in the intercooler (90k miles on vehicle), but only found a very thin coating of slick black oil (about a teablespoon after it all drained down to a corner overnight).

I just finished the new intercooler installation and the mpg display is looking better (though it used to be off 5mpg at hwy and about 2mpg in city and may still be). The surging is completely gone and she drives so SMOOTH. Power was about the same, but quicker boost response from non/low boost state.

OLD INTERCOOLER
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PRESSURE TESTING
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MAP SENSOR - In case you were curious this when when I got the vehicle around 89k miles. Also, vehicle had nearly died(felt like I had NO boost and black smoke out the tailpipe) 2 different times before cleaning this. I haven't had a issue since the cleaning (8 months now).
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Author:  linewarbr [ Mon Mar 01, 2010 9:55 am ]
Post subject:  Re: Power surging problem resolved!
Nice work! Where on the intercooler was the leak? Top, near the turbo hose inlet?
Author:  BVCRD [ Mon Mar 01, 2010 11:37 am ]
Post subject:  Re: Power surging problem resolved!
Very interesting how the intake manifold gets saturated with gunk, but there is no build up in the intercooler. It kind of throws the theory about where the disappearing oil is going from overfilling due to a mismarked dipstick.
Author:  JL Rockies [ Mon Mar 01, 2010 3:22 pm ]
Post subject:  Re: Power surging problem resolved!
The dipstick is mismarked?
Author:  kapalczynski [ Mon Mar 01, 2010 3:57 pm ]
Post subject:  Re: Power surging problem resolved!
linewarbr wrote:
Nice work! Where on the intercooler was the leak? Top, near the turbo hose inlet?


Yes, leak was at a sauder joint of one of the aluminum tubes where it connected to the metal end piece close to the plastic intake tube coming from the turbo side. This was NOT the end cap leaking, but just a bad sauder/weld. It looked like a factory defect to me. Too bad it wasn't replaced while under warranty. These are $700 from the dealership, and no aftermarket ones available. Luckily, Thank God, I was able to find one new, in Mopar box from someone that decided after the fact to not rebuild a CRD from a salvage title. I got it for $310 shipped!
Author:  kapalczynski [ Mon Mar 01, 2010 4:01 pm ]
Post subject:  Re: Power surging problem resolved!
BVCRD wrote:
Very interesting how the intake manifold gets saturated with gunk, but there is no build up in the intercooler. It kind of throws the theory about where the disappearing oil is going from overfilling due to a mismarked dipstick.


I haven't heard that theory, but I am new to this stuff. :) I used about a quart between oil changes (9500mi interval) which i figure is normal for a turbo diesel, especially with so much oil vapor going back through the system and getting burned in the regular combustion cycle. Is this normal or what other CRD owners use between changes?
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