I've added a 5th CRD to my fleet! Decided to buy a project again and try to get it going. Previous owner was a member here and posted about it in January. Here is a link to his thread: viewtopic.php?t=83790

Many guessed a glow plug. Some guessed it was a dropped valve. I took the head off and here is what I found:



As you can see, the valve snapped off and is embedded in the piston. Here is what the head looks like:



And of course, the cylinder liner could not escape without a couple scratches:



I have a spare engine. I can swap engines or repair this one. Have not decided which way to go yet. Can I pull the piston without removing the engine?

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My collection of CRD's:
2005 Deep Beryl Green Pearlcoat
2006 Light Khaki Metallic Clearcoat
2006 Inferno Red Crystal Pearlcoat
2006 Midnight Blue Pearlcoat
2006 Gold Limited
2015 Black Ecodiesel
2015 Black Ecodiesel 2

Jey you know the answer , you need to pull engine out. but I'm glad that i pulled cylinder head off when i got my kj 100 miles on it , so i just did preventive maintenance ,rockers tb wp kit , but i want to do it properly to see pistons and liners and send cylinder head for valve inspections and cleaning. as i asked questions many times why this engine dropping valves ? we know the answer ,, but my own insurance is very cheap , yes i had to spend some money for head gasket kit and machine shop fee , but that is just my old school again ,, rip it a part and look inside good

I don't think you can, and I'm not sure it would be worth it if you did.

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2005 Liberty CRD Limited
DIY Garage Remanufactured Engine with GDE Full Torque Eco Tune from mile zero.
ARP Studs
Cummins Lift Pump
Transgo HD2 Reprogramming Kit
DIY Rebuilt Tranny Pump
Suncoast Torque Converter
2nd Generation Fuel Head
Sears P1 Battery
Hot Diesel Solutions Thermostat

So we have another dropped valve to add to a list that appears to be growing. I had exactly the same problem, but on #3 cylinder. I am really starting to question whether something is happening to the cause these valve stems to become weak/brittle and break off.


Good luck on your repair. I ended up dropping $3600 to get mine back on the road. But that also included $500 for a new CP3 and $180 for a new MPROP, $125 for a new fuel head & $130 for a lift pump. None of the was required, but spent as I was trying to root cause the problem step-by-step (or $ by $). I did however get a used cylinder head for $100 and a used piston/sleeve for $100.

PS - yes, you need to pull the engine. The alternative requires dropping the entire front suspension/axle to get access to the bottom of the engine. If you have a hoist pulling the engine is easier.

Part Qty Price Total
Cam gear holding tool 1 $54.00 $54.00
Cam locking tools 1 $30.00 $30.00
Lift pump 1 $130.00 $130.00
Fuel head 1 $125.00 $125.00
CP3 1 $500.00 $500.00
MPROP 1 $180.00 $180.00
Piston & connecting rod 1 $153.00 $153.00
Connecting rod bolt 2 $1.60 $3.20
Turbo oil return bottom seal 1 $6.99 $6.99
Cylinder head 1 $150.00 $150.00
Valve stem seals 1 $29.95 $29.95
EGR delete kit (stage 1 & 2) 1 $289.90 $289.90
Inspect injectors 3 $40.00 $120.00
Injector 1 $435.00 $435.00
Rockers 3 $29.95 $89.85
Rear main seal 1 $44.95 $44.95
Turbo intake tube 1 $61.20 $61.20
Gasket set with bolts 1 $239.95 $239.95
Crankshaft position sensor 1 $50.00 $50.00
Lower rad hose 1 $57.95 $57.95
Timing belt tensioner 1 $99.95 $99.95
Timing belt idler pulley 2 $38.50 $77.00
Fan clutch 1 $38.79 $38.79
ARP studs 2 $153.30 $306.60
Rebuild/test cylinder head 1 $367.00 $367.00
$3,640.28

Was yours an exhaust valve?
Looks like the one in this thread is.

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U.S. Army Retired

Makes me wonder if i should buy all new valves this summer

Sent from my SAMSUNG-SM-N920A using Tapatalk

I seriously considered the same. But exh valves are $18.95 and int valves are $14.95. That's another $300 on top of an already expensive build. But honestly my wonder/concern continues to grow on why these valves seem to just randomly snap. I think its is time to start a thread dedicated to discussing this subject. Don't want to hijack your thread....