Lost Power, soot all over engine

wilco549 · **Posted:** Mon Aug 15, 2016 11:38 am

Last night I just left home and lost power. I limped back home and raised the hood, soot everywhere and diesel smoke coming from the turbo area. The day before I had a P0299 underboost error but it ran fine. I figure it must be the gasket between the manifold and turbo, or worse, a cracked turbo. Will dig into it the evening. :banghead:

jws84_02 · **Posted:** Mon Aug 15, 2016 4:27 pm

I would check the cac hoses first

wilco549 · **Posted:** Mon Aug 15, 2016 7:37 pm

Checked that first but it would blow oil with a blown CAC hose, not soot.

It appears I have two problems:

- V "banjo" clamp at turbo discharge is distorted and not sealing....ordering a new one tonight.
-Major exhaust leak under the compressor portion of the turbo. It appears two nuts are missing that attaches the turbo to manifold. Now to figure out what size they are.

geordi · **Posted:** Mon Aug 15, 2016 8:15 pm

IDparts sells those nuts, are the studs still intact? They are 13mm "pinch" nuts and the thread size (IIRC) is m8x1.25

wilco549 · **Posted:** Mon Aug 15, 2016 8:23 pm

Thanks! Studs are there. Makes me wonder if the dealer used the right nut when they changed the turbo at 30k. Any ideal what size or source for the V clamp? I'm striking out so far.

diesel_guy86 · **Posted:** Mon Aug 15, 2016 8:58 pm

That v-clamp is a special one, so not just any one will work. The flanges are extra thick so the clamp is about 2x as wide as a normal one. You might have to go to a jeep dealer or find it online. Either way it will have to be ordered.

geordi · **Posted:** Mon Aug 15, 2016 9:10 pm

I may have one laying around, but that is called a "marman" clamp from what I remember.

Looking around on Google shows them fairly quickly, so it may just be a matter of measuring the size and finding a supplier.

joe_ · **Posted:** Fri Aug 19, 2016 2:40 pm

Found the clamp in the 2005 parts catalog under the exhaust system section, part number is 52128847AA.

wilco549 · **Posted:** Fri Aug 19, 2016 3:37 pm

Thanks Joe_, I actually found one on ebay and have it on order. My local stealership couldn't find one!

I had to order the turbo inlet gasket too since the missing nuts and resulting exhaust leak has apparently blown mine out. Looks like the turbo is going to be a bear to get off, especially the two top nuts. Anyone have any advice on how to go about removing them....other than having someone else do it? :BINGO:

jws84_02 · **Posted:** Fri Aug 19, 2016 3:46 pm

Start by drenching them in pb blaster and let them sit awhile. I have always remove the airbox and other crap so I have a clear shot at it. I then can use a combination on extensions to get them off without busting my knuckles. If the pb blaster works(which it always has for me) you can get my with using 1/4" drive to give yourself more room

wilco549 · **Posted:** Fri Aug 26, 2016 2:36 pm

Got the beast back together last night. Some of the bolts are a PITA to get to but I made it. I'm fairly confident that the dealer did not correctly installed the new turbo/EGR system back in '06-'07 because the new one always made a high pitched spool up noise. When we complained they just said it was normal and supposed to do that. After finding two of the turbo to manifold bolts missing (the two hard ones to get to under the compressor) which resulted in a toasted manifold gasket and the mangled exhaust clamp and fixing them the noise is gone. Just a little spool-up noise that I consider normal. :BANANA:

undrgnd · **Joined:** Sat Mar 26, 2016 4:47 am **Posts:** 194

wilco549 wrote:

Got the beast back together last night. Some of the bolts are a PITA to get to but I made it. I'm fairly confident that the dealer did not correctly installed the new turbo/EGR system back in '06-'07 because the new one always made a high pitched spool up noise. When we complained they just said it was normal and supposed to do that. After finding two of the turbo to manifold bolts missing (the two hard ones to get to under the compressor) which resulted in a toasted manifold gasket and the mangled exhaust clamp and fixing them the noise is gone. Just a little spool-up noise that I consider normal. :BANANA:

Quick question, how did you take of the manifold heat shield? It's got a long peice that sits under the thermostat that I can't get off. Any advice would be appreciated.

Cheers

Chris

geordi · **Posted:** Sat Aug 27, 2016 11:12 am

You removed all three bolts? There is one hidden on the side. Everything in this car has to be secured with at least 3 bolts.

If you got them all... Grab it from the back end closest to the turbo and yank straight up. Should come out.

Boss · **Posted:** Sat Aug 27, 2016 4:54 pm

Ha, so true

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undrgnd · **Joined:** Sat Mar 26, 2016 4:47 am **Posts:** 194

geordi wrote:

You removed all three bolts? There is one hidden on the side. Everything in this car has to be secured with at least 3 bolts.

If you got them all... Grab it from the back end closest to the turbo and yank straight up. Should come out.

Hahah darn hidden bolts!!! Thanks Geordi

geordi · **Posted:** Sat Aug 27, 2016 7:44 pm

No worries - Even after working on so many of these things, I still repeat the mantra to myself when taking things apart: There's ALWAYS one more bolt.

Dang things are annoying like that! The important stuff doesn't have enough bolts, the useless things have too many! There is no reason other than being stupid, that the thermostat needed 3 bolts into the head. 2 would have been plenty and locked it down just fine for the job it had to do - Especially with the 4th bolt to the viscous heater providing extra support.

But those heat shields... Daffy. I'm actually driving this CRD around with at least a couple of those not completely installed (or at all for one of the shields IIRC) and nothing has happened.

Lost Power, soot all over engine

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