When it rains it pours FIXED!!

FITZv2 · **Posted:** Tue Apr 02, 2013 11:12 pm

Alright first I want to start by saying even though this is my first post it is because for some reason my old account won't log in so I created a new one and thank you for all of your advice so far on previous post (on old account).
Also I have read SAMs noob guide

On to the problem/ problems?

Trouble first started when I was getting air leaking into the fuel system. I started by changing the fuel filter (it has the gen2 fuel filter head) and taking out the quick disconnect you can get to without dropping the tank. Didn't fix it so I went ahead and did a in tank lift pump with the IIRC airtech m7181e? Or whatever the one everyone on here recommends. I believe this fixed my air in fuel problem (it took a while to get all the air out of the system but has been air free the last 2 test drives) while I was doing stuff I noticed a antifreeze leak that looks like it is coming from my EGR cooler. Anyone had this problem before? That is item #1 that may or may not be related to what else I have going on.

Problem #2: It still has a stutter like it did with the air leak but it has a different sound to it. It seems like a missing cylinder to me so I was thinking maybe the air in the fuel system took out an injector. So I checked the return on each injector and they are all the same and don't seem out of spec on amount of return. (I didn't have a way of measuring 25ml a minute) but measured each one for 1 minute and they all seemed consistent to each other and about 25ml. So I'm kind of ruling out injectors unless anyone has anything else to check. The stutter is noisy and when in 4th or 5th gear at low rpms it shakes the vehicle.

Problem #3: this might be related to either 1 and/or 2 but it is putting out significantly more smoke then usual. It is black in color and does it under load not at idle. My jeep used to run very clean maybe a small puff when leaving from a stop. Now it looks like my old 7.3L ford used to... I was thinking maybe a boost hose (I haven't had a chance to pull them off and check for tears yet but they are OEM hoses and feel kind of soft just squeezing them). I thought this might relate to the stutter as well but not sure.

I believe that sums up the problems I'm having so now for some info on the jeep itself. It is a 2006 2.8L with about 118,XXX miles. Had the timing belt and water pump done at 110,000 (I know a little late). I do oil changes regularly with rotella T6 5w40. I drive a lot of highway and I am very easy on the throttle. I just did the EHM when I did the lift pump so it probably doesn't count. I don't have a GDE tune yet, I was literally going to order one the night it started acting up :furious:

I think that pretty much sums everything up anything I left out let me know. Thank you for any advice.

CATCRD · **Posted:** Tue Apr 02, 2013 11:50 pm

#1 sounds like the egr cooler or coolant hoses to the egr valve leaking. Not uncommon.

#3 sounds like it could be a split boost hose. Especially running the stock ones over 100k. MAP sensor could need serious de- gunking too.

ChooChooman74 · **Posted:** Tue Apr 02, 2013 11:53 pm

Welcome to the forum.

Sorry that you are having issues with your CRD. As for #3, I am going with either Leaky Hose, Intercooler, or Sticky turbo vanes...and have you cleaned you MAP sensor??

I hope other, more knowledgeable people will be by to assist you. I try not to throw out too many answers, since I don't want to lead people down the wrong path.

65Corvair · **Posted:** Wed Apr 03, 2013 12:06 am

For #2, it sounds like torque converter shudder, or at least that is when I was experiencing shudder on my jeep.
Do you still have the stock torque converter?

ChooChooman74 · **Posted:** Wed Apr 03, 2013 12:09 am

If #2 happens when you give it a lot of pedal, and you are in the 1600 to 1800 RPM range, it could be Torque Converter Shudder.

FITZv2 · **Posted:** Wed Apr 03, 2013 12:27 am

I forgot to add I just cleaned the map before doing the EHM it was pretty nasty but I clean it about every 10,000 miles (it wasn't near as bad as the first time I cleaned it)

Thank you everyone, I will check the EGR hose and cooler. I was thinking the hoses too will try and get those popped off tomorrow. I was thinking about upgrading to samco's anyways.

Also I have seen a little oil on the intercooler passenger side near about 4 or 5 inches down from the boost hose so maybe I have a intercooler problem?

As to #2 I was thinking possibly TC but the engine doesn't sound right which was leading me away from it. Did your engine sound bad when you replaces your torque converter. I do still have the stock TC so I could see it being an issue.

Hexus · **Posted:** Wed Apr 03, 2013 6:46 am

Do you have a CEL? A failed EGR/FCV combo would create a lot of the black smoke, limp mode, etc.

GDE Tune will handle most of that, if that's the issue.

x2 on checking the turbo hoses, specifically check the CAC hose that runs from the air box to the turbo inlet, check the bottom of the hose that connects to the turbo itself, they usually go there first for some reason.

The Mishimoto hoses work well, I have them (long story, thanks wife) and they're great and look good. Of course the Samco's work well too as many here will attest. To save more money, the newer OEM's work just fine as well, they just aren't as snazzy.

Best of luck, keep us updated!

Joe Romas · **Posted:** Wed Apr 03, 2013 7:56 am

How careful were you about dirt when you changed the fuel filter? A tiny spec can foul an injector :dizzy:

FITZv2 · **Posted:** Wed Apr 03, 2013 2:31 pm

I don't have any CEL's nor have throughout any of this fiasco. I will take a close look at hoses tonight and update what I find.

@Joe Romas: I wasn't medical grade clean, but I didn't set the filter down or anything so it should have been clean.

GreenDieselEngineering · **Joined:** Sun Jun 07, 2009 5:10 pm **Posts:** 1111

The rocker arms can wear out in this engine. Yours is showing the symptoms of worn rocker arms. No codes, less oomph, more smoke and some cylinder imbalance. If you can measure the MAF sensor after waiting a minute at idle. This data can help judge rocker condition. Hopefully this is not your problem.

FITZv2 · **Posted:** Wed Apr 03, 2013 3:27 pm

GreenDieselEngineering wrote:

The rocker arms can wear out in this engine. Yours is showing the symptoms of worn rocker arms. No codes, less oomph, more smoke and some cylinder imbalance. If you can measure the MAF sensor after waiting a minute at idle. This data can help judge rocker condition. Hopefully this is not your problem.

I have been crossing my fingers hoping no one would mention this and that I was just being paranoid... I have been reading all the rocker posts and thought their symptoms sounded similar... I don't have a way of measuring the MAF sensor, is their a more special tool the a OBDII Reader? Would the stealership or local shop have the stuff? I read on one post to pull of the air inlet hose and check for blow back and popping? Is that what the MAF would be showing?

kjjet · **Posted:** Wed Apr 03, 2013 6:59 pm

I agree with GDE. Sounds like the first stage of rocker failure.

If you have a failed rocker, It will pop and blow from the intake. I don't think you broke one yet. They are just not opening the valves enough.

I would start with a SEGR or GDE tune to stop EGR. It may be stuck open. Without a operating EGR you can make a blocking plate or remove the EGR system all together. When your sure no EGR is stuck open. Do you still have the problem? Now things really point at the rockers.

If you get as far as wanting to remove the intake to inspect the rockers? MP me and I will send you a procedure to do so.

Good luck.

FITZv2 · **Posted:** Wed Apr 03, 2013 11:12 pm

I pulled off both intercooler hoses and neither one has any rips or tears and actually look like they are in good shape, well looking a little closer I noticed oil seeping around on the intercooler. Maybe cracked? I was going to try and clean the EGR and see if that changes anything. I want to do a tune I just don't know if I should be spending that kind of money when I might have some expensive fixes coming up. The wallet is a little tight and I need to make sure I can get it running before I put money in a tune.

@kjjet that would be awesome if you sent the procedure just so I can have them on hand if I go down that road.

FITZv2 · **Posted:** Tue May 14, 2013 6:09 pm

Well it has been a long process, but I tore into it and as everyone had thought it was indeed rockers! One of the rockers was broken in half (exhaust side front one on cylinder 3) and on the 3 behind that one all of the needle bearings were shot. So it was pretty much running on 2 cylinders. Sadly the shot bearing caused it to dig into the cam so i had to do a exhaust cam as well. It all up and running though now! I took everyone's advice and got a GDE tune so it wont happen again. Man that tune is awesome! It is running better then it ever has! I just wanted to thank everyone on here for all of your input, advice and help.
:pepper:

Hexus · **Posted:** Tue May 14, 2013 7:08 pm

Glad to have been of help in any small way. Most of us have been there.

When it rains it pours FIXED!!

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