Does anyone have a diagram for where the EGR is located on CRD? I don't have the FSM, yes, I know I need one. I have to get it inspected soon, and finally am able to get the work done. I am not up to pating the dealership another $800, for the 3rd time, to replace it so it will pass inspection. I have also heard that I can clean the EGR to get it working well enough to pass. Once I get through the inspection, i will have another 2 years to get the GDE to do away with the EGR altogether. Any help that can be provided would be appreciated.

Go to the noob guide and down load the FSM Sir Sam has posted the link to.
It is hidden on the same side of the engine as the starter and above the starter below the intake. Take off the two nuts that mount the fuel filter, flip it over, you don't need to remove it, just get the fuel filter out of the way.
Then you can see the Holy Device that is a Religious Symbol to the cult of Diesel Hating Acid Head Hippies.

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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

cjkrawler

You may not have to take it apart to clean it. I don't know where you live but I would suggest taking it out on a long highway trip and run in hard and fast. Out here in OK the speed limit is 75 on the turnpike. I don't know what it is where you live. But get it hot and floor it every so often to pass. It may take a few hunderd miles of this to clear it out but it works. The last time I had my egr replaced was under warranty at 18K. I now have 115k. I did clean the plumbing from the egr to the intake around 60k. Found a hard crusty buildup inside the egr air flow control valve. The EGR valve itself was clean. The egr air flow control valve is easy to remove and clean. I used brake cleaner and a brush to clean the air flow valve and it did make a difference with the egr flow error codes. Haven't had any egr related codes since.

Good luck

I appreciate the info. I won't be able to take it down the highway here--in the Cleveland area, not enough room to run it consistently. I had the fuel filter out tonight, but without the refernce point, I wasn't exactly sure what I was looking for. I am going to tackle this over the weekend, and pray i can get it right. I love this site, it has been a big help for. I am certain I will be asking more questions.

If you are getting the P0401 code it is likely that the EGR valve is stuck shut. This happened to me. I am thinking that you would not have to remove the EGR to get it working again. I would try spraying a carb cleaner down the EGR feed line that connects to the Air Control Valve. Soaking over night could loosen up the carbon and get it moving again. The EGR is not a fun thing to remove...

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2006 Liberty CRD 275K, JBA 2.5 with Fox Shocks, GDE Turbo Kit, GDE TCM Tune, Suncoast TC, OEM fuel filter housing converted to fit Caterpillar Fuel Filter 1R-0749, OEM themostat housing modified to accept Hemi 203 F thermostat.

Other options are:
1) ORM unplug the MAF sensor on the air cleaner to shut off the EGR and ignore the light, refer to the CRD Tech section.
What I do now. Old Navy was the one who made the discovery.
2) Get a hold of an SEGR and plate the pipe going into or out of the EGR valve.
What is in the plans for me. I most likely will plate the EGR pipe befor I install the SEGR. Turbo Tim and UFO are the experts.
3) There is a tune that reduces the EGR but does not eliminate it and shuts off the light.
If you go with this option, you will need to clean the EGR valve to free it up. I think Danoid (correct me if I am wrong)took his apart and cleaned it. Others have used some kinds of snake oil. Sometimes the road is so rough, the bumps and pot holes will knock it free. Joe Romas has a lot of hands on with small diesels, he has owned, driven, and worked on. So, if you want to go the tune route fix on the EGR problem, talk with him first. You will get the straight scoop, no cryptic care fully worded razzle dazzle techno speak.

To put it into perspective, the EGR valve for a diesel is of no benefit for the engine that it is for a gasser. On the gasser, it acts like a Pseudo-Octane booster and reduces NOX. On a diesel the EGR is there to reduce Nitrous Oxides that are a fixation of Junk Environmental Science. Only under very extreme conditions can NOX turn into smog. Agriculture produces 6.9 times more NOX than all forms of mobile transportation, based upon published EPA documents available for download. A Smart Urea system that would only come on under the Extreme Conditions would make more sense, but unlike the Military, when have you ever seen any sense out of the EPA or CARB.
My personal opinion is that not all of the Hippies who used LSD had the talent to be Musicians, Actors, or Artists. So the rest of the Acid Head Hippies who did not die from an overdose, went to work for Academia, CARB, or the EPA.
So if you are worried about NOX emissions out of your CRD, rip out your lawn and put in AstroTurf.

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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

I will try the carb cleaner first, but I don't have high hopes for it.

Warp, I appreciate the thoughts, but I have to clear the light. If the check engine light is on, it is an automatic fail for the inspection. I also understand you can put in a block off plate, and use a resistor , 190 ohm I believe, and that will clear the CEL. We have been driving the with the CEL light for better than a year now, cause I know what the issue is. I am just I had never thought that I could clean it, so I hadn't looked into it until now.

Again, I really do appreciate all the comments and help.

Just an update, the EGR has been cleaned, and the code is gone. Now I am getting a new code, which I will be posting about. Appreciate all of the help.

FYI - you can't just plug in a resistor - the computer is looking for a varying signal - it'll auto correct for constant.

That's what the SEGR circuit board was all about.

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2005 CRD
stuff
Skeptic quod gratis asseritur, gratis negatur

If you are Worried about NOX emmissions form your lawn mower this would be for you.... I may get one just so I never have to buy gas.

http://www.amazon.com/Scotts-2000-20-20 ... B00004RA3E

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2006 Liberty CRD Limited Deep Beryl Green Metallic Clear coat, Fumoto valve, MH ProVent (removed), GDE Eco tune,
OME 790/948 springs, OME struts, OME N132L shocks, Jeepin by Al A-arms, Hercules Terra Trac AT2 245/75R16
Weeks Stage 1 EGR delete, 5 volt steel glow plugs

haha, I just got rid of one of those last year. It worked ok, but you have to sharpen them several times a season. Too much hassle. The emissions check was successful, it passed. Now I can focus on getting the EGR taken out of the system, and keep the CEL off. Thanks for all the help.