bordem88 wrote:
hi guys and girls.. i have a kj 2002 2.5 CRD. the two idler pulleys chewed out and timing belt came loose.. i now have a crd with both cam shafts free spinning (no resistance?) how do i get these back in time? and no resistance have i broken somthing?
You have definitely broken a lot of things!
The newer KJs came out with rockers designed to snap off when hitting a piston with an extended valve....the 2.5 CRDs did not have this feature so expect a lot more damage.
You can download the 2002 KJ Service Manual here but rather first download the section called "2.5_2.8 Export Diesel"" as it covers our Export 2.5 CRDs in great detail.....lots of differences to the 2005/6 USA models.
You would need to remove the head completely to see the damage....I would personally try to pick up a similar motor from a Breaker Yard and straight away fit a new timing belt. idlers tensioner etc. The belt is supposed to be replaced every 100,000 miles or within 7 years of age!
There are lots of posts here on how to fix this type of damage....not an easy job as the cam shafts do not have locating pins fitted.
Most of these posts cover the 2.8L USA models but the basics should be the same as long as you refer to the 2.5_2.8 Export diesel manuals I have mentioned above.
Where are you located? The Aussie site
http://www.ausjeepoffroad.com has a large membership with these Export CRDs we have...go to the KJ section... and they will be able to give you some good advice!