We have a Liberty '05 CRD that we are having some issues with. Started with it dying on hills when pushed at higher speeds. Mechanic couldn't find an issue with it until it did it while he was in it. He said it was going into limp mode. We had the EGR removed and a bypass system by Sasquach put in in hopes that would fix the problem. Next we replaced the fuel pump (we think previous owner had modified the fuel pump system to be outside of the fuel tank). Ran fine for about a week and then once again started having it die on hills and now it's just getting worse. Anyone have any idea what might be going on with it, or had the same thing happen?

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2005 Liberty Limited CRD, 150K miles. Enjoying the mountains of Colorado

Is there a check engine light? Can you scan for codes somehow. Sometimes you can get an overboost code if you are climbing hills which will cause limp mode.

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2006 CRD - GTB2056 turbo by Dieselguy86, Eco Trans Tune, Lift Pump, Week's, HDS Tstat, Racor Filter, ARP's, OME 790's+Top Plate, JBA 2.5", JBA UCA, Moab's+265/75R16, ARB Bull Bar, 4.10's, TrueTracs

Please clarify what you mean by "Next we replaced the fuel pump (we think previous owner had modified the fuel pump system to be outside of the fuel tank)." The KJ CRD fuel pump is the CP3 fuel injection pump (functions like a "puller" pump as opposed to a "pusher" pump typically mounted inside the fuel tank) mounted on the front of the engine and driven by the timing belt. I strongly doubt your mechanic replaced the CP3. It is possible the PO installed a lift pump between the fuel tank and the fuel filter head on the firewall in front of the driver or dropped the fuel tank and replaced the fuel level sending unit with a combined fuel level sending unit/fuel pump. Either of those installation if done properly would have no relation to your problem.

Have you:
1. checked to see if there is air in the fuel filter head and that you have the 2gen filter head - see SirSam's NOOB guide
2. checked the air filter to see if it's clean?
3. checked the CAC hoses for leaks or if soggy with oil - must pull off vehicle to check.
4. while CAC hoses are off check air box to turbo hose for tear just in front of turbo inlet
5. cleaned MAP sensor
6. as noted mass-hole checked for trouble codes. NOTE not all trouble codes will trigger a CEL light.

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Sold to LOST member my 05 Ltd, GDE Stg II turbo + TCM tune, SunCoast TC w. Transgo kit, Steiger window regulators, Samcos, Fumoto valve, 2nd gen filter head with Lub. Spec. bleeder, Hayden clutch & 11 blade fan, inverted spare, P-1 battery, BF Goodrich Long Trail TAs, Etecno1 glow plugs, timing belt at 50K miles/8 yrs

Have you:
1. checked to see if there is air in the fuel filter head and that you have the 2gen filter head - see SirSam's NOOB guide
2. checked the air filter to see if it's clean?
3. checked the CAC hoses for leaks or if soggy with oil - must pull off vehicle to check.
4. while CAC hoses are off check air box to turbo hose for tear just in front of turbo inlet
5. cleaned MAP sensor
6. as noted mass-hole checked for trouble codes. NOTE not all trouble codes will trigger a CEL light.[/quote]

Thanks for suggestions, will start checking these tonight and share findings. Not completely sure about the fuel pump mod, just reported what husband said. When we had mechanic remove EGR he said the fuel pump had gone out and also replaced that...assume it was the modified one replaced. It's a guessing game most times with diesel mechanic, he had never worked on a CRD before and since we live in small town we take what we can get.

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2005 Liberty Limited CRD, 150K miles. Enjoying the mountains of Colorado

Check the fuel filter. May be plugged. I had this happen a lot when I ran bio diesel and my fuel was not dry enough before pumping it in. If you have a check engine lite on and the code P0093 is present, it was usually the fuel filter for me.

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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.

I would double check the new fuel pump the mechanic installed. Most, if not all, of the lift pumps make a ticking noise when you turn the key to run position for 15 seconds or so (don't start the engine, just listen) and then do #1 as papaindigo suggested.

My theory is the new lift pump fixed it....until it quit. Diesel engines just will not run with air in the system and the CRD is notorious for the suction pump pulling in air through leaky fuel lines.

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2005 Sport CRD 130k
Yeti's Stage II DIY Hot Tune
Weeks stage 1&2 EGR Delete
Florida HD billet TC [500+flbs torque]
DIY T'stat Mod {Kap's design}
'03 Ram TCM

Update***Finally got a chance to have Jeep scanned. Had a few codes P0093 (fuel system leak) P0403 (EGR) P1140 (exhaust problem) and P1265 (software). We are going to do some checking tomorrow (fun labor day...not) and see if we can detect any of the problems mentioned. I should have clarified the problem with limp mode has been going on for well over a year, but getting worse. At first it only happened at higher speeds on hills but now it happens at any time for no apparent reason. Thanks for the help, it's great to see there are still awesome people that are willing to share their knowledge.

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2005 Liberty Limited CRD, 150K miles. Enjoying the mountains of Colorado

The p0403 and p1140 are both related to your EGR removal. They can be ignore for now but there are solutions for them.
The p1265 is a bad glow plug. You will want to get this fixed before winter. And get rid of the factory ceramic glow plugs and install metal ones.

Focus your attention on the p0093 fuel leak.
Unplug the two wire connectors on the fuel filter head. Carefully inspect them for any hint of a fuel leak.
If leaking, you will need a new fuel filter assembly.

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U.S. Army Retired