Mine is a 2005 with 113k miles. I've owned since 91k. Thanks to all on the forum I've learned a lot. This is my first post. The problem started with a loud "whoosh" coming from the engine mostly near 2000 rpms. I figured it was a turbo, intercooler, or hose problem...i was somewhat right.
I run mine with MAP unplugged nearly since I've owned it, which you will see was lucky for me. So in trying to diagnose the problem I plugged it back in and tried to run the jeep. It ran absolutely terrible. Horrible loud noises coming from the engine. Sputtering and Whooshing. So I figured I'd start tearing into the EGR and intake to see what was going on.
Here was the Problem. The metal threaded cap that is on the EGR valve FELL OFF!!! I was losing all my boost pressure through the pipe leading to the intake and out this hole in the EGR. Then when I connected the MAF sensor, there was turbulent flow as the boost pressure was trying to escape and the exhaust gas was trying to enter. Believe me you never want to here the noises it was making coming from your Jeep.
To find all this out, I had to dismantle the intake elbow, EGR, and all pipes running to it. In this process, I found out I had a devastating problem occurring in my intake elbow. It was nearly totally corroded with soot. I mean I had about 1 -1.5 inch diameter opening left for my turbo air to enter the engine. Please see the scary images.
Here was my solution. I completely cleaned the intake elbow....of course. I also had to find a threaded plug to recap the EGR. Then I cut the EGR tube leading to the intake leaving about 2 inches of pipe. Then I crimped and folded the 2 inch stub pipe and applied some RVT sealant just in case and reattached to my intake elbow. I reattached the remaining pipe back on the EGR, but turned it upside down so it is now running out of the bottom of the engine bay down past the starter. I plan on attaching an extension to it and running it out the side or back of the vehicle...basically a secondary exhaust. You can run ORM or not. It doesn't matter. No more EGR gasses for me!! After seeing my intake, you will never want the chance of exhaust gases entering the engine again !!
Everything is back together and my little Diesel has never been better. Everything is improved. MPG's are up 3-4. Averaging 25 now and 29 on a recent trip. Guess that's what happens when the engine can Breath. So...Beware!!! Check you intake tube!! Also check the cap on the EGR as it may be coming lose. Finicky, but Fun Jeeps....aren't they??
