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??

Don't do the secondary exhaust trick, just plug it.
You want all of the exhaust going through your turbo to get the best boost.
Diverting any of the exhaust away from the turbo will reduce what is going
through it. Some may put forth the Detroit/EPA speak on the quantity of exhaust
is minimal and will not effect your boost. To be honest, if you like to listen to
crap like that, there are plenty of Political Campaign Commercials on the air.

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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

Thanks for the advice. I have noticed a subtle difference or decline in power and boost when having the EGR functional and diverting exhaust into the atmosphere. I will just continue to run ORM. In future plans of adding a GDE tune, I do not want ANY soot particulates entering intake even if it maybe slight with a tune. The intake elbow was nearly closed off with soot and I can imagine how the rest of the Manifold (where I can't see) is covered with soot.

There are multiple ways of dealing with EGR valve. I wanted to show my experience of how after 91k of running stock with CCV oil and EGR gases entering intake can plug up the engine. I went ORM and EHM shortly after I bought it , after reading this forum, and now very glad I did.

I've also have read many posts about loud air movement or WHOOSHING sounds coming from engine. As it maybe a common problem of CAC hose cracks, it may also be that the silver cap on the EGR valve has fallen off allowing all the boost out the EGR valve. I'm not sure why there is a threaded cap on the end of the valve opposite the wiring connection. Maybe it was intended as a clean-out. But, It can works its way off and this maybe the cause of loud WHOOSH and loss of power. Installing a $25 boost gauge from Auto zone has given me a lot more peace of mind after dealing with this issue.

Keith from GDE has prevously clarified on this forum that with any of his tunes, exhaust gas NEVER enters the intake manifold, so there is no need to do anything with your EGR when you go with GDE.

GDE ECM tunes keep the EGR valve closed almost all the time. However, if you happen to have your foot to the floor, then suddenly back off and then immediately jump back to the floor, the ECM opens the EGR momentarily to bleed off excess pressure during this fairly infrequent circumstance (though NOT to the intake) to protect the turbo from overspeeding and potentially being damaged.

BTW, this is a feature of the OEM software, as specified by VMM.

SEGR keeps the EGR closed all the time, disabling the OEM turbo overspeed protection.

It IS critical to keep soot both out of the intake (otherwise it plugs up) and the oil (drastically shortens engine life).

It is just easier than you may have thought.

DOC

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2005 KJ CRD Ltd Detroit TrueTrac Bilsteins G2 GDE "HOT" ECU GDE TCM "Tow Tune" "euro" TC SEGR Weeks Elbow New HG at 130K ARPs Clean CAT aFe Filter Magnaflow Exhaust EHM Cumminos In-Tank Lift Pump Hayden Fan Clutch Nylon Fan VH Enabled with GDE lower shutoff point Recalibrated Temp Gauge Tekonsha Prodigy Sears P-1 ZDDP

That is a helluva story--thanks for posting.

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2006 CRD w/99,300 miles
F31 from a previous life
EHM @ 42K, ProVent @ 79K
GDE Eco Tune & TCM @ 46K
Engine mounts replaced @ 55k/93k, Timing Belt @ 90k
Lift Pump @ 97k
OME Lift, 1.5''
Kenwood TM-V71 Ham Radio / Cobra C75WX CB
Surf Racks

Thanks for posting those pics. That's great info. Thank you EPA. There is an environmental cost to ruining a good engine prematurely.

If I understand you correctly, you actually had the EHM for most of the mileage so just imagine how much worse that would have been with oil mixed in. Black peanut butter. And all of this would get in the head and valve runners. Further, you were running the ORM and still got all this soot. So glad I got the GDE tune.

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HERS:'16 WK2 Limited EcoDiesel - GDE hot
HIS: '06 Liberty CRD - EHM , GDE eco, Brite Box, Stanadyne FM100, Cummins lift pump, OME lift
'06 Dodge/Cummins - Play truck; a couple of fans, a proper cam shaft, and man handled electrons by EFILive 500/900
'01 Dodge/Cummins - Work truck; Lots of mods

Yup that is what diesel soot mixed with oil vapor looks like. Yuk. Honestly, I'm surprised it isn't worse. I remember the days on here when some said it couldn't or wouldn't happen with these rigs. Most of them were of the trade it every two or three years mindset. From their point of view, I guess it never did happen.

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Matt B.

05 Limited CRD. Bought it new. 112k on the clock now.

GDE Eco-tune, rear differential drain plug (drilled and tapped the pumpkin), transmission pan drain plug, Fumoto oil valve, fuel filler neck restriction removed, front hitch, Hayden fan clutch, Sears P1 battery since 08, Mobil 1 5w40, 5 volt glow plugs, DIY timing belt at 109k