Unique CAC hose problem *hi res photos*

StanCRD · **Posted:** Wed Feb 24, 2010 2:44 pm

First off,
I want to thank all the forum members for all the info provided, it may have taken me alot longer to solve this.

I just bought my 2006 CRD limited a few weeks ago and on the initial test drive I heard a "woosh" sound from under the driver dash and could smell a strong diesel odor. The truck seemed to drive well based on my limited run. I ended up buying it mostly because it had very low mileage and I new I could find everything I needed on lostKj's if I had problems to fix.

Anyway, first chance I had I changed the oil (mobil1 0w-40) and while I was at it, decided to look at the hose, I thought maybe it could be split as per posts on the forum. Well, I removed it and there was no sign of a split, but it was very oily and the connection to the engine intake was very oily form blowby from the hose.

Well, it turns out the hose was NEVER INSTALLED PROPERLY right from the Factory !. Look closely at the photos. Once I cleaned it fully, I discovered the issue.The hose and clamp were each installed on an opposite angle so the bottom was clamped but the top was not, every time there was enough boost the top of the hose was allowed to "open" and release boost and of course coat the area with blow by.

Can't tell much from here, but you can see all the soot !

Now look at the left where it's clean and follow up to the right, that's the part that was not clamped !

So it looks like the previous owner didn't realize he had this problem and the dealer never found it either which means he suffered poor mileage, lack of power and the odour from it..HOW STUPID DO YOU HAVE TO BE to live with this for 4 years :shock:

WOW !

So, I got'er cleaned up and connected properly and will see how much the mileage has improved. It still seems to lack some power and is not very responsive off the line. I still plan to replace the fuel filter, clean the MAP and add a lift pump. I want to get this CRD at a good base before the GDE.

geordi · **Posted:** Wed Feb 24, 2010 3:44 pm

The previous owner probably bought into the BS of "Diesels are slow and dirty and stinky" rather than wondering about the bad performance.

I've FELT my CRD on it's high-performance days, and the difference is amazing from when it is getting bad information from one of the sensors. I only wish I knew which sensor was failing so I could fix it.

Of course... No codes when I need them. :roll:

CATCRD · **Posted:** Wed Feb 24, 2010 8:02 pm

Welcome to the forum. Good job finding that problem.

I don't think any CRDs are responsive off the line. The faster you floor it, the longer the turbo lag, seems like. GDE helps some.

StanCRD · **Posted:** Tue Mar 02, 2010 1:12 am

Well after running thru another full tank of diesel with the CAC hose connected properly, I have not noticed a big difference in power strangely enough but a huge increase in mileage. It's jumped about 8mpg !. 90% of my drive is hwy and I usually cruise at about 120KPH (75mph)
it's pretty close to what I saw for the Transport Canada mileage rating of 8.5L/100KM (27mpg)

I'll be doing a 1000+kms this week, but this time I'm going to do the ORM before I go and see what that does. I'm going to try and seal up the open connections so I don't short anything out if I need to connect it back (keep moisture and dirt out). If I get a chance on the weekend I'll pull the MAP and see what that looks like. I have 41,652km (25,881 miles) on it now, pretty sure the fuel filter has never been changed either. I'm on my first oil change. I know it had 2 changes from the service book (Dealer) and probably one after by a regular service station (non - mopar oil filter is the give away) but no idea what oil they used. right now it's mobil1 0W-40. I used mobil1 in my 300,000km 4runner and I swear by that stuff, it didn't leak or burn any oil till I sold it.

I'll update my findings as I keep making mods to max out the fuel mileage.

danoid · **Posted:** Tue Mar 02, 2010 9:51 am

It's not easy to tell with factory misbuilds. I went a year and a half with a misbuilt shifter in my Camaro - never knew it. First time I drove it out of the dealership with it 'fixed' I couldn't drive it. The shift throw was cut in half. My hand made the motion I was used to and the shifter stopped halfway through. It kept coming out of my fingers.

The dealership tried to blame me at first, until I pointed out that there were no marks in the paint from the lower attachment bolt. If a bolt had ever been installed, it would have scratched the paint. Therefore the shifter had only one bolt from the factory, and after a year and a half, that bolt worked loose.

I had never driven another Camaro SS with the Hurst shifter, and neither had anyone at the dealership. No one knew how long the shift throws were supposed to be, so until we took it apart and looked, no one knew there was a problem.

StanCRD · **Posted:** Mon Mar 08, 2010 6:32 pm

OK, just came back from a business trip of just over 800kms with the ORM. I carefully calculated my mileage and got 27.67 US mpg or 8.5L/100km for us metric folks.
Transport Canada says this truck is supposed to get 8.5L/100km. I was hoping the ORM would make a bigger difference. Again over 90% of my trip was on cruise at 120KPH (about 75mph).

I was hoping to see a bigger improvement but it has made only a very small difference. Now I'm wondering if GDE will actually be able to give me 10% more.
I still need to check my MAP, the only other service item is the fuel filter but I having trouble getting one (WIX or GKI here in Toronto) I'm not going near the 'stealership' . Prices in Canada are much higher here than the US. For example I need another Radio Bezel, from the online sources I can get it for $46 USD, the local 'stealership' was $92.25 :shock:

, after that, I didn't bother asking how much a fuel filter was. Next thing will be to modify the exhaust. I'm probably going to cut out the muffler and restrictive sections and weld in some 2.5" stainless.

WolverineFW · **Posted:** Mon Mar 08, 2010 6:49 pm

StanCRD wrote:

OK, just came back from a business trip of just over 800kms with the ORM. I carefully calculated my mileage and got 27.67 US mpg or 8.5L/100km for us metric folks.
Transport Canada says this truck is supposed to get 8.5L/100km. I was hoping the ORM would make a bigger difference. Again over 90% of my trip was on cruise at 120KPH (about 75mph).

You'll see better mileage going slower, ORM or not. Anything over 110KPH I find increases the "throwing a brick into the wind aerodynamics" exponentially in my experience. I have gotten the best economy with the cruise control set at 100-110KPH on long trips.

Unique CAC hose problem hi res photos

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