05 CRD Running Rough...Throwing Several Codes

FireWalker · **Joined:** Sun Oct 09, 2022 12:40 pm **Posts:** 10

Need help. Has anyone experienced this.
2.8l started running really rough. I have disconnected each fuel injector one at a time and they all change the engine idle when disconnected. Changed fuel filter and no noticeable difference, still running real rough. I tried shaking the engine wire harness and no change. OBD is throwing the following codes: P0670, P0562, P0610, P0204, P0203, P0202, P0201, P0303, P0101, P0700 and P0714. Any help from anyone that has experienced this is greatly appreciated!

Billybob · **Posted:** Wed Oct 19, 2022 8:00 am

You can download the KJ Manuals here: www.colorado4wheel.com/manuals/Jeep/KJ/

I have not read up on those errors yet....busy replacing Serpentine Belt, Tensioner pulley etc.

Trouble with the 2005 CRD is that it has a Front Control Module (FCM) located inside the engine bay near the battery...about the size of a large cigarette box.

This has one connector on it which can get dirty from exposure to the elements.

If this FCM fails you need to try get one from a Breaker Yard but they are in great demand!

Or have you actually found your problem in the meantime?

WWDiesel · **Posted:** Wed Oct 19, 2022 11:53 am

With that many "P" codes, it almost has to be an electrical wiring issue, a main connector issue, or an ECM and / or Front Control Module issue.
The codes are all over the place, no way that many systems would all go bad all at once at the same time.

I would suggest to start with; checking wiring harnesses in and around the engine and check connectors/pins to ECM and Front Control Module.
Then reset codes and see what comes back if anything.
:SOMBRERO:

FireWalker · **Joined:** Sun Oct 09, 2022 12:40 pm **Posts:** 10

I apologize that I haven't gotten back as I was sent out of town for work and just got back. I really appreciate the replies! I decided to open it up today because its time for another Timing belt change. It doesn't appear that it has jumped time and the belt looks in good condition. I will replace anyway. I did take the map sensor out to clean and it broke when i was cleaning it. Not sure if the little probes on the inside are typically that sensitive but i have ordered a new one. Before I took it apart I disconnected one injector at a time and each one change the already rough idle to rougher. I think my next step is removing the valve cover and inspecting rockers unless someone has a better idea? Thanks community!

FireWalker · **Joined:** Sun Oct 09, 2022 12:40 pm **Posts:** 10

Also I appreciate. the heads up on the FCM and definitely will check that. I have already checked the ECM connector

FireWalker · **Joined:** Sun Oct 09, 2022 12:40 pm **Posts:** 10

WWDiesel I appreciate that reply. I am a little concerned about maybe electrical too. Do you think that points to FCM or ECM? Don't think its the harness

WWDiesel · **Posted:** Fri Oct 21, 2022 10:09 pm

FireWalker wrote:

WWDiesel I appreciate that reply. I am a little concerned about maybe electrical too. Do you think that points to FCM or ECM? Don't think its the harness

Those P codes are all over the place, so it is hard to point a finger at one module.
Again, I would clear the codes and see what comes back and report.

FireWalker · **Joined:** Sun Oct 09, 2022 12:40 pm **Posts:** 10

I erased the codes and let it run for a minute exactly. The only codes now that are showing so far is P0073 (MAP Sensor) which I am aware of and have ordered and P0303 (Cylinder 3 Misfire) which has been consistent. So far I'm no longer getting the P0201, P0202, P0203 and P0204. The turbo also is making a loud popping through the intercooler. Could that be related to the P0303 issue? Or is it an issue that you have heard of? Maybe I'm just paying too close attention haha

FireWalker · **Joined:** Sun Oct 09, 2022 12:40 pm **Posts:** 10

Also I have verified that when I unplug Injector 3 while running it does make the engine run worse. There is a noticeable difference.

WWDiesel · **Posted:** Sat Oct 22, 2022 4:13 pm

If you are getting a loud popping noise back through the intake, you have some rocker/lifter damper issues or a valve issue.

Time to pull the intake/valve cover for inspection.

FireWalker · **Joined:** Sun Oct 09, 2022 12:40 pm **Posts:** 10

Well good call. Pulled the valve cover and the whole exhaust side was devastated lol. Ordering all new rocker/lifters, Timing Belt kit, water pump, Thermostat, PCV, Glow Plugs (Original 7 volt believe it or not), Serpentine Belt kit with idlers and tensioner, 11 Blade GM fan and heavy duty fan clutch and getting this great Jeep back on the road. What is your opinion on the cam shafts? Replace? Do they typically need replaced at 233,000 miles and/or after this sort of failure?

FireWalker · **Joined:** Sun Oct 09, 2022 12:40 pm **Posts:** 10

Also, do you recommend HD Timing Belt or Standard?

WWDiesel · **Posted:** Sun Oct 23, 2022 9:42 pm

Q1. Well if heavy duty is better, I would go with it. All I have ever used is the Gates belt as that was what was available and recommended in the past. The newer HD belt has just started being offered.
Q2. If the cam lobes are not damaged or scarred up, I would reuse them. You hardly ever read of anyone reporting having to replace a cam when a rocker/lifter failure happens.

With that much mileage on your engine, you should seriously consider pulling the head and replacing all 8 exhaust valves. I know it is a lot of additional work and costs, but if you have have been reading all the posts lately on this forum about exhaust valve failure when vehicle mileage gets closed to ~200k, you should be aware of the consequences and the possible catastrophic damage that can occur if an ex. valve breaks. :grim:

You can read all about it on this thread:> viewtopic.php?p=951391#p951391

You would be real pissed if you put all that time and money into fixing your engine and then an exhaust valve breaks off completely destroying your cylinder head and a piston and possibly the piston liner, and in a few rare cases a cracked block or broken connecting rod.
A broken exhaust valve has the potential to completely destroy your diesel engine. Not trying to scare anyone, just stating facts, it has happened before and been reported on this forum by a few unfortunate souls.

If you pull the head, many owners opt to go back with APR head studs instead of the torque to yield head bolts which have a history of losing tension over time and allowing the head gasket to start leaking.

All the parts you need is available from IDParts.com including rockers/lifters and ARP Head Studs. https://www.idparts.com/arp-head-stud-k ... -4044.html

FireWalker · **Joined:** Sun Oct 09, 2022 12:40 pm **Posts:** 10

Thank you for the info, pulled the head and in Nashville Head Works now getting taken care of. I will be sure to let everyone know when it comes back alive. Just ordered a little over $2000 in parts from ID Parts and GM 11 Blade fan and Heavy Duty Clutch from Napa. Trying to bullet proof so definitely got the ARP head bolts with the head gasket kit. Anything else anyone can think of while I'm on the engine journey?

FireWalker · **Joined:** Sun Oct 09, 2022 12:40 pm **Posts:** 10

Does anyone know what the cylinder head resurface tolerance is by chance?

WWDiesel · **Posted:** Wed Nov 16, 2022 11:09 pm

FireWalker wrote:

Does anyone know what the cylinder head resurface tolerance is by chance?

Straight from the Factory Service Manual: "The cylinder head itself is not resurfacable."

The minimum cylinder head thickness is 89.95mm (3.541 in.)
Do not have the head milled - there isn't enough extra material (thickness) in the head to perform machining.

The head comes from the factory with a thin nickel coating on the head gasket mating surface, so if you machine the head it will remove this coating.
Also removing (machining) any material from the head can also create clearance issues between the top of the piston and the valves.
This is an "interference" engine and clearances are already really close.
The picture below shows just how close the valves are to the sealing surface.

05 CRD Running Rough...Throwing Several Codes

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