05 Limited CRD Rebuild

03black · **Posted:** Sun Jul 05, 2020 11:32 pm

Hello fellow diesel enthusiasts,

So I just picked up an 05 Limited CRD that has a cracked cylinder head. The P.O. had a dealership take it all apart but the tech did not label any of the parts nor put it back together! The cylinder head has been verified that its cracked just under the valve seats on cylinders 1&2.

So now its in my garage and I have laid out all the parts on the floor and started to clean them up while I wait for a new head from VM and parts from IDparts. I think I pretty much know where everything is supposed to go with the exception of this one part. I have the FSM and I can't find any reference to it. I'll posted a pic and hope it comes through but its about 3.5" long steel tube with threads at both ends. At one end, inside it accepts a very large Allen key that it would seem that it screws into something. It was covered in oil/carbon//soot.

Does anyone have an idea what this is and where does it go, assuming it is actually goes with this engine?

Thanks for any help you guys can provide. I already own an 05 3.7L Limited and used this place to help rebuild that one with the vast knowledge of you guys on here.

Mountainman · **Posted:** Mon Jul 06, 2020 12:26 am

Fairly certain that that doesn't belong to the engine as I've disassembled and reassembled quite a few of these.

03black · **Posted:** Mon Jul 06, 2020 12:41 am

Thanks Mountainman, I was thinking the same thing too but was unsure. Now brings up the question what else extra parts are there or if anything is missing

WolverineFW · **Posted:** Mon Jul 06, 2020 1:39 am

Never seem that part before either and I have had the head off mine.

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03black · **Posted:** Mon Jul 06, 2020 1:59 am

Yeah they torn down everything all the way to the block. I get the fun task of putting the pieces back together

Ordered new/used/test engine head from VM Specialist and have these parts coming in:
Head gasket kit w/ APR studs
Rocker/Lifter set
PCV/CRD Valve o-rings
Timing belt kit
Timing belt gasket kit
Timing belt tensioner bolt
Serpentine belt
Throttle body to elbow o-ring
Injector Seals & o-ring set
Water pump
Thermostat ONE
Turbocharged oil feed seal
Vacuum pump seals

I Hope that's everything I would need to put this engine back together. Need to do a little carbon clean up on the block and cylinder heads. We'll see how that goes.

03black · **Posted:** Mon Jul 06, 2020 6:41 pm

Ok fellas I have another one for you....does this belong on our engine and if so, what does it go to?

Thanks

jws84_02 · **Posted:** Mon Jul 06, 2020 7:48 pm

Yes those are the injector hold downs

03black · **Posted:** Mon Jul 06, 2020 10:55 pm

jws84_02 wrote:

Yes those are the injector hold downs

Great thank you! I had no idea....onto the next puzzle piece.

Mountainman · **Posted:** Tue Jul 07, 2020 1:38 am

Anytime

Don't forget blue locktite on the balancer bolts, and your turbo is likely shot

03black · **Posted:** Tue Jul 07, 2020 11:07 am

Mountainman wrote:

Anytime

Don't forget blue locktite on the balancer bolts, and your turbo is likely shot

So I felt for turbo shaft play and there was none. The variable vane actuator arm was a little stuck/sticky so I cleaned the exhaust side of the turbo by spraying some oven cleaner through it, let it sit for 10 mins, rinsed thourghly with de-mineralized water, and lastly used some carb cleaner to displace any water. Now I can push the arm all the way to the calibrated stop. Hoping that it will be good to go when I refire up this engine.

PZKW108 · **Joined:** Sun Apr 06, 2014 5:23 pm **Posts:** 461

03black wrote:

Hello fellow diesel enthusiasts,

So I just picked up an 05 Limited CRD that has a cracked cylinder head. The P.O. had a dealership take it all apart but the tech did not label any of the parts nor put it back together! The cylinder head has been verified that its cracked just under the valve seats on cylinders 1&2.

So now its in my garage and I have laid out all the parts on the floor and started to clean them up while I wait for a new head from VM and parts from IDparts. I think I pretty much know where everything is supposed to go with the exception of this one part. I have the FSM and I can't find any reference to it. I'll posted a pic and hope it comes through but its about 3.5" long steel tube with threads at both ends. At one end, inside it accepts a very large Allen key that it would seem that it screws into something. It was covered in oil/carbon//soot.

Does anyone have an idea what this is and where does it go, assuming it is actually goes with this engine?

Thanks for any help you guys can provide. I already own an 05 3.7L Limited and used this place to help rebuild that one with the vast knowledge of you guys on here.

If one of the treaded end is M21, it might be part of an injector puller !

03black · **Posted:** Wed Jul 08, 2020 7:37 pm

PZKW108 wrote:

If one of the treaded end is M21, it might be part of an injector puller !

Hummm I don't know, never seen one before. But I could go to the hardware store and see if a M21 nut spins on.

geordi · **Posted:** Thu Jul 09, 2020 3:04 am

That is NOT an injector puller part - at least not for this engine. The injectors can't come out with being side-loaded (where the hard line connects) and the Miller tool - if the dealer monkeys even had that - doesn't use that part anywhere either.

Not sure what that is or where it came from, but it wasn't from the CRD.

When the head arrives from the UK, take it to a machine shop and have them pressure test it. Then replace all the valves in it with brand new from IDparts. The VM Specialist is a "breaker" or boneyard over there, and they have said to several of my customers that they were "replacing all the valves" before sending a head.... And what arrived had valves that were NOWHERE CLOSE TO NEW. They had been cleaned, sure.... But cracked at the bases, covered in hard deposits, and obviously worn. I trust that they have parts that will fit. But not anything beyond that, b/c they have been claiming this "test engine" nonsense for at least 4 years now. I don't think there's that many test engines to be had, but this engine IS used in the black cabs and in minivans over there, so there are LOTS of used engines running around to pull from. Caveat Emptor.

03black · **Posted:** Thu Jul 09, 2020 10:47 am

geordi wrote:

That is NOT an injector puller part - at least not for this engine. The injectors can't come out with being side-loaded (where the hard line connects) and the Miller tool - if the dealer monkeys even had that - doesn't use that part anywhere either.

Not sure what that is or where it came from, but it wasn't from the CRD.

When the head arrives from the UK, take it to a machine shop and have them pressure test it. Then replace all the valves in it with brand new from IDparts. The VM Specialist is a "breaker" or boneyard over there, and they have said to several of my customers that they were "replacing all the valves" before sending a head.... And what arrived had valves that were NOWHERE CLOSE TO NEW. They had been cleaned, sure.... But cracked at the bases, covered in hard deposits, and obviously worn. I trust that they have parts that will fit. But not anything beyond that, b/c they have been claiming this "test engine" nonsense for at least 4 years now. I don't think there's that many test engines to be had, but this engine IS used in the black cabs and in minivans over there, so there are LOTS of used engines running around to pull from. Caveat Emptor.

Hey Geordi,

Thanks for chiming in and clarification on the part.

As for the head, yes I was going to send head to machine shop to pressure check it. However, you now you have me worried about having possibly bad valves. I hear what your saying about the "test engine". I also suspect that there was a limited supply of them. But for the price from VM vs. online was substantial that I was willing to take the chance. In email conversation with them, they assured me that they disassemble the head, clean it, pressure test it, reprofile the seats, and resurface the valves. All the engines were from test, development, or low miliage warranty claim engines and have been in "storage" since 2009, so I'll take that with a grain of salt since I can't physically verify myself. Hopefully, it will still be the right decision

geordi · **Posted:** Fri Jul 10, 2020 10:20 pm

You will be fine, they aren't going to spend the energy to do anything other than hot tank the heads - and that's OK. The cost of replacing the valves is just the cost in parts, about $300, and then you will KNOW that it has new valves. You don't need to do anything with the seats, springs, keepers, or guides as in most cases those are all just fine. Just lap the valves in with compound, clean, and you will be good to go.

03black · **Posted:** Sat Jul 11, 2020 1:18 am

geordi wrote:

You will be fine, they aren't going to spend the energy to do anything other than hot tank the heads - and that's OK. The cost of replacing the valves is just the cost in parts, about $300, and then you will KNOW that it has new valves. You don't need to do anything with the seats, springs, keepers, or guides as in most cases those are all just fine. Just lap the valves in with compound, clean, and you will be good to go.

Sounds good. I'm at a point now that I'm just waiting on parts to arrive in the mail. Cleaned up the valve/cam cover and since the jeep already has a SEGR it didn't have that much soot/carbon build up. In addition, I physically removed the EGR and all of its coolant plumbing and made some block off caps to go on the exhaust manifold and FCV.

WWDiesel · **Posted:** Sat Jul 11, 2020 1:46 am

03black wrote:

Sounds good. I'm at a point now that I'm just waiting on parts to arrive in the mail. Cleaned up the valve/cam cover and since the jeep already has a SEGR it didn't have that much soot/carbon build up. In addition, I physically removed the EGR and all of its coolant plumbing and made some block off caps to go on the exhaust manifold and FCV.

Don't forget to remove the butterfly out of the FCV. :wink:

03black · **Posted:** Sat Jul 11, 2020 11:13 am

WWDiesel wrote:

Don't forget to remove the butterfly out of the FCV. :wink:

I knew I forgot to do something.....you guys are great!

03black · **Posted:** Sat Jul 11, 2020 11:23 am

So while I'm waiting on parts, I started to research thermost housing. I live out here in the desert with temps hitting in the low 100's. I'm worried about cracking the new head due to lack of coolant flow. I have a new mopar housing coming in but i hear they are unreliable.

I see a few people manufacture a new housing but for now I think that is way out of my price range. I know I don't want to use an inline stant thermostat so that leaves me what ???? What have you guys done?

Mountainman · **Posted:** Sat Jul 11, 2020 12:57 pm

The OEM stats won't crack your head,they just fail open 95% of the time in under 50k miles. So they just waste fuel and money. Get an HDS stat...

05 Limited CRD Rebuild

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