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 Post subject: Special tools 6828 and 9663
PostPosted: Sun Sep 23, 2018 10:39 am 
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I posted this question on the JeepKJ forum and I thought I would try it here.

I need special special tools 6828 and 9663 in order to diagnose fuel problems on my Liberty CRD. I've tried Mopar Essential tools, Amazon and Ebay as well as other sites and can't find them. Does anyone have any idea where I can find these tools or know appropriate substitutes? Special tool 6828 is a fuel pressure gauge and special tool 9663 is an adaptor needed to connect the pressure gauge to the fuel filter fuel head.

I would appreciate any help. I don't like replacing sensors or, God forbid, a fuel pump without doing some diagnosis.

Thanks


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 Post subject: Re: Special tools 6828 and 9663
PostPosted: Sun Sep 23, 2018 11:57 am 
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Joined: Mon Mar 24, 2008 10:26 pm
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Location: West Coast, Canada
Did you ask GDE if he rents those ones?

Sent from my SM-N910W8 using Tapatalk

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2006 Liberty CRD Limited

Provent @ 43,000 km
SEGR in progress
SAMCO Sport hoses @ 48500 km
Goodyear Wrangler Duratrac LT225/75R16


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 Post subject: Re: Special tools 6828 and 9663
PostPosted: Sun Sep 23, 2018 12:27 pm 
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Location: Central GA
Nmichiganjeep1 wrote:
I posted this question on the JeepKJ forum and I thought I would try it here.
I need special special tools 6828 and 9663 in order to diagnose fuel problems on my Liberty CRD. I've tried Mopar Essential tools, Amazon and Ebay as well as other sites and can't find them. Does anyone have any idea where I can find these tools or know appropriate substitutes? Special tool 6828 is a fuel pressure gauge and special tool 9663 is an adaptor needed to connect the pressure gauge to the fuel filter fuel head.
I would appreciate any help. I don't like replacing sensors or, God forbid, a fuel pump without doing some diagnosis.
Thanks

What is your Jeep's symptoms or problem?
If you post issues here, there are several highly qualified members who may be able to offer you some sound advice and solutions without the need for any special tools and / or the adaptor. :D

_________________
05 Jeep Liberty CRD Limited :JEEPIN:
Blk Brush Guard/Hella's/LED's
Ironman Springs/Bilstein's
Yeti Stg4 MaxTune
Weeks ElbowKit/BatteryTray
NO FCV/EGR
Samcos/ProVent
SunCoast/Transgo
Carter Intank-pump
2mic.Sec.Fuel Filter
Flowmaster/NOcat
V6 Airbox
GM11 blade fan/NAPA HDclutch
Ironrock Trilink
98 Dodge Cummins, 5"exh. Viair, Huge K&N


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 Post subject: Re: Special tools 6828 and 9663
PostPosted: Sun Sep 23, 2018 1:09 pm 
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Location: Tallahassee, Florida
I would concur with WWDiesel; we need a bit of information on your problem. Just to belabor the obvious the KJ CRD does not have an in tank fuel pump rather it has a CP3 belt driven injection pump on the front of the engine. The CP3 "pulls" (just like an old style engine mounted gasser fuel pump) fuel from the tank thru the fuel filter AND then passes fuel under pressure to the fuel rail on top of the engine. Between the fuel tank and the CP3 there is very little "pressure" on the system; in fact that's known to result in air in the fuel issues and air is sucked into the system as fuel is pulled from the tank. Sources of air include quick disconnect fittings at the tank; leaks in the filter head (bad seal at the bleeder; bad seal on the primer pump shaft; burnt seal at the plug for the fuel heater element; etc). The common fix for air in the fuel problems, other than replacing the 1st gen filter head, is an in tank or in line fuel pump.

Bottom line is we need hints as to whether the fuel problem you think you have is between the tank and the CP3 or internal to the CP3 or between the CP3 and the fuel rail.

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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


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 Post subject: Re: Special tools 6828 and 9663
PostPosted: Sun Sep 23, 2018 2:54 pm 
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pap, his statement "special tool 9663 is an adaptor needed to connect the pressure gauge to the fuel filter fuel head" leads one to believe his problem is on the suction side of the CP3, but certainly more info is surely needed to offer sound advice.

_________________
05 Jeep Liberty CRD Limited :JEEPIN:
Blk Brush Guard/Hella's/LED's
Ironman Springs/Bilstein's
Yeti Stg4 MaxTune
Weeks ElbowKit/BatteryTray
NO FCV/EGR
Samcos/ProVent
SunCoast/Transgo
Carter Intank-pump
2mic.Sec.Fuel Filter
Flowmaster/NOcat
V6 Airbox
GM11 blade fan/NAPA HDclutch
Ironrock Trilink
98 Dodge Cummins, 5"exh. Viair, Huge K&N


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 Post subject: Re: Special tools 6828 and 9663
PostPosted: Sun Sep 23, 2018 4:02 pm 
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Location: Tallahassee, Florida
Could be but I cannot find a link to a Miller tool #9663 and I would not expect issues on that side of the CP3 unless related to air in fuel. An easy check for that is a bit of clear vinyl tube spliced in between the filter outlet and the rubber outlet hose (cost maybe $4 for vinyl and a simple hose fitting.

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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


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 Post subject: Re: Special tools 6828 and 9663
PostPosted: Sun Sep 23, 2018 5:20 pm 
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Wow, thanks for the attention.
Here is the background to my problem. I have a 2005 Liberty CRD. It left me stranded at the grocery store. I came back the next day and got it started but it started very hard with a lot of smoke and coughing but it evened out and by the time I got home it was running fine with good power. A couple days later I started it up and drove it to school and back but it started hard and ran with low power. I thought I got a bad tank of fuel so I replaced the fuel filter. I bled the fuel system and was able to start it and drive it but with the same problems. The next time I tried starting it it just would not start. I checked codes and got a P0093 code. Oregon Fuel Injection says this means it is not getting fuel and gave several remedies including replacing the filter but most remedies require the special tools to diagnose the problem. The problem could be anything from a bad crankshaft or camshaft position sensor or a bad continuous rail fuel pressure solenoid among other things including, God forbid the CP3 fuel pump.

I don't want to replace 3 or 4 good sensors before finding the one that is the problem. The Jeep has the updated fuel filter head. When I have time I will bleed the system again just to make sure. I personally think it is the fuel rail pressure solenoid but would like more information before I start buying parts.

Also I removed the EGR and reflashed the engine with a Green Diesel Eco-tune.

Thanks again everyone for your help, I appreciate it.


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 Post subject: Re: Special tools 6828 and 9663
PostPosted: Sun Sep 23, 2018 8:22 pm 
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Location: Green Cove Springs FL
You will need a way of reading fuel rail pressure.
To do that I recommend getting a ELM 327 OBD Bluetooth adapter and the TorquePro app for android.

I suspect your problem is the fuel rail pressure sensor or it’s connector. It’s about midway in the rail.
When the fault happens again, unplug the sensor.
It will have reduced power but should run smoother.

_________________
Bought my '05 CRD on June 2nd '07, used with 29,000 miles.
intake elbow and EGR delete. 5 volt bosch glow plugs
Yeti stage 2 ECU tune. Straight pipe exhaust. DIY intercooler hoses
Provent and modified factory 180F thermostat
Replaced cylinder head (cracked) at 160,000 miles + ARP studs
2.5 inch lift, JBA upper arms, 235-85-16 tires.
Still love it.


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 Post subject: Re: Special tools 6828 and 9663
PostPosted: Wed Sep 26, 2018 6:49 pm 
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Guys, I bought a Blue Driver scan tool and it basically says anything that can possibly go wrong with the fuel system might be the problem. It is nice in that it lists the problems in order of likelihood. I've already changed the filter. This weekend I will install a clear hose from the fuel filter to the CP3 pump and see what I get there. Then I'll work on getting the fuel out of the tank because I still think I may have gotten some bad fuel.

I'm still trying to find a fuel pressure / vacuum meter to help with diagnosis.
I'll keep you advised as things progress.

Any more ideas are welcome. Thanks everyone. Have a great evening.


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 Post subject: Re: Special tools 6828 and 9663
PostPosted: Thu Sep 27, 2018 7:21 pm 
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Joined: Fri Mar 20, 2015 2:11 pm
Posts: 687
Location: markham, ontario
maybe you should check injectors. Just a thought...


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 Post subject: Re: Special tools 6828 and 9663
PostPosted: Fri Sep 28, 2018 8:26 pm 
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If the fuel is bad I'll have to check the injectors too. I have to get the bad fuel out first.
Thanks rankom.


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 Post subject: Re: Special tools 6828 and 9663
PostPosted: Sat Sep 29, 2018 6:11 pm 
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Joined: Fri Mar 20, 2015 2:11 pm
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yes , if fuel is bad you need to get it out, injectors dont like bad fuel, so yes need to check them , i do have old jumper tube with capped welded end so that is my home made tool to cap injectors one at the time to see which one is sticking open , so let as know how is going with your diagnoses so we can give you more ideas


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 Post subject: Re: Special tools 6828 and 9663
PostPosted: Thu Oct 04, 2018 5:18 am 
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FWIW: If you have not dropped the tank before (like me), remember to unscrew the three screws that mounts the filler cap unit to the body before you start lowering the tank. This will enable you to drop the tank a couple of inches in order to unscrew the pipe clamp of the feed pipe to the tank and pop the pipe of BEFORE you drop the tank completely. I did not realize that the breather pipe got trapped below the feed pipe and I nearly severed it due to the weight of the fuel in the tank. The breather pipe (that needs to come out with the tank) is clipped to the feeder pipe with a plastic clamp that you can see and undo from the bottom. There is also a black earth wire clipped to the body inside the feeder tunnel that needs to be disconnected should you want to remove the feeder pipe.

With reference to your P0093 (fuel system large leak detected) fault code, when I replaced the injectors that was also the code displayed after I opened up the high pressure side. I trust that you will get the problem sorted out soon.

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Ludi Neethling
South Africa
2005 Jeep KJ CRD 2.8 (6 M/T)
Susp:Ironman Coils, Shocks new bushes and ball joints
Therm: Replaced
EGR: Cleaned, re-installed
CCV Catch Can
MAP sensor: Cleaned
Injectors: Repl
Alt pulley: Repl
Serp Belt: Repl
Crank Pos Sens: Replaced
T/B & W/P: Repl @ 200k Km
Repl Cer GP with Etechno 7V GP 212k Km
Repl CCV


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 Post subject: Re: Special tools 6828 and 9663
PostPosted: Wed Oct 10, 2018 12:16 pm 
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Thanks guys. It is on my list of things to do to drop the tank this week and drain the fuel. I needed a break from working on cars for a while partly because I needed a break from mental frustration as well as get other stuff done. And thank you, Ludi, for the caution on dropping the tank. I didn't think of that.


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 Post subject: Re: Special tools 6828 and 9663
PostPosted: Wed Oct 17, 2018 8:02 pm 
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Well guys, I replaced the fuel rail pressure sensor and no luck. I will try replacing the fuel rail pressure solenoid next. This isn't so easy because it requires special torquing specifications and you have to use an open end wrench. I have a crows foot socket wrench for my torque wrench on order so when that gets here I'll give that a try.


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