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 Post subject: Re: Timing belt and Turbo change-out
PostPosted: Sun Oct 15, 2017 9:42 pm 
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I've got the turbo in-place with the 4 exhaust manifold nuts tightened on the studs. (This turbo has been changed before and the last guy put in studs)

The catch-22 is regarding the oil return tube. If I loosely install the tube before putting the turbo in-place, then I can't get to the last stud nut. If I install the stud nut, then install the tube, then the tube-gasket-retainer-bolts are a huge magic show.

When my rage cools off, I'll go back out and give it another go.

_________________
2005 Jeep Liberty 2.8L CRD 248
Kona, Hawaii (Big Island) USA

Changed Turbo.
100,000-mile service.
Replaced harmonic balancer.
Noise in front axle or 3rd member - removed loose chain in transfer case.
Rebuilt engine - replaced #3 cylinder, piston, valves, head repair. Removed EGR.
Sheared bolts on TC. Replaced flex plate, TC, bolts.


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 Post subject: Re: Timing belt and Turbo change-out
PostPosted: Sun Oct 15, 2017 9:49 pm 
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The rattle is in the area of the right-side, like the turbo. (The water pump is nearby)

Maybe I have two problems, but the two sounded like they could be one. Rattle/clang at idle, plus big black smoke on acceleration or uphill climb, plus squealing noise, plus low power (surging), plus engine malfunction light & code P0299.

Now that the turbo has come out and is sound, I could have two problems. Clogged and/or leaking boost circuit, worn out water pump.

_________________
2005 Jeep Liberty 2.8L CRD 248
Kona, Hawaii (Big Island) USA

Changed Turbo.
100,000-mile service.
Replaced harmonic balancer.
Noise in front axle or 3rd member - removed loose chain in transfer case.
Rebuilt engine - replaced #3 cylinder, piston, valves, head repair. Removed EGR.
Sheared bolts on TC. Replaced flex plate, TC, bolts.


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 Post subject: Re: Timing belt and Turbo change-out
PostPosted: Sun Oct 15, 2017 9:52 pm 
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Posts: 693
I'm going back out now to glue the oil return gasket to the turbo body, then install the tube (into block first, then do the magic show of bolting the tube holder onto the turbo).

_________________
2005 Jeep Liberty 2.8L CRD 248
Kona, Hawaii (Big Island) USA

Changed Turbo.
100,000-mile service.
Replaced harmonic balancer.
Noise in front axle or 3rd member - removed loose chain in transfer case.
Rebuilt engine - replaced #3 cylinder, piston, valves, head repair. Removed EGR.
Sheared bolts on TC. Replaced flex plate, TC, bolts.


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 Post subject: Re: Timing belt and Turbo change-out
PostPosted: Sun Oct 15, 2017 9:54 pm 
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Posts: 693
I put the new turbo in, just in case there really is something wrong with the old turbo.

_________________
2005 Jeep Liberty 2.8L CRD 248
Kona, Hawaii (Big Island) USA

Changed Turbo.
100,000-mile service.
Replaced harmonic balancer.
Noise in front axle or 3rd member - removed loose chain in transfer case.
Rebuilt engine - replaced #3 cylinder, piston, valves, head repair. Removed EGR.
Sheared bolts on TC. Replaced flex plate, TC, bolts.


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 Post subject: Re: Timing belt and Turbo change-out
PostPosted: Sun Oct 15, 2017 10:02 pm 
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Location: Oregon Coast Dairy Country. Land of stumps, dumps, and "Liquid Pumps"
Quote:
big black smoke on acceleration or uphill climb, plus squealing noise, plus low power (surging), plus engine malfunction light & code P0299.

This sounds like a boost hose (charge air system) leak. I don't know if a EGR backflow leak would squeal............

....... just thought of another thing that could rattle-clank. Check the tube that goes from the rear of the exhaust manifold, around behind the head, to the EGR system. If that clamp came loose it could make a noise like that. It could also explain the huffing exhaust soot, as well as (in case of an EGR backflow leak) loss of boost, power, .....

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'06 Lbrty Sprt CRD 150K

Sasquatch
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CAT-elimntr
Weeks Stg1&2 EGRfix
PV-200
BLING
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IDParts
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YETI Custom Tune
Flowmaster 8325508
Carter P76611M
GM 12611872
Hayden 2986
GM 15976889
PATC Custom Billet
2010 Ram Hemi Trans
Sonnax 44957
Transgo kit
Cooper 51770


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 Post subject: Re: Timing belt and Turbo change-out
PostPosted: Sun Oct 15, 2017 10:03 pm 
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Location: Oregon Coast Dairy Country. Land of stumps, dumps, and "Liquid Pumps"
CaptainDean wrote:
I'm going back out now to glue the oil return gasket to the turbo body, then install the tube (into block first, then do the magic show of bolting the tube holder onto the turbo).

:lol: Whatever works!

_________________
'06 Lbrty Sprt CRD 150K

Sasquatch
DSS Turbo
CAT-elimntr
Weeks Stg1&2 EGRfix
PV-200
BLING
vent gauges

IDParts
head
cams
rockers
Timing set
ARP studs
eTn1 GX2123 5v GPs

YETI Custom Tune
Flowmaster 8325508
Carter P76611M
GM 12611872
Hayden 2986
GM 15976889
PATC Custom Billet
2010 Ram Hemi Trans
Sonnax 44957
Transgo kit
Cooper 51770


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 Post subject: Re: Timing belt and Turbo change-out
PostPosted: Sun Oct 15, 2017 10:49 pm 
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GordnadoCRD wrote:
Quote:
....... just thought of another thing that could rattle-clank. Check the tube that goes from the rear of the exhaust manifold, around behind the head, to the EGR system. If that clamp came loose it could make a noise like that. It could also explain the huffing exhaust soot, as well as (in case of an EGR backflow leak) loss of boost, power, .....


Thanks GordnadoCRD,

I did notice that hose and wondered what it is. I've quit for the night and let the rain blow through. Beer taste much better than grease.

The Liberty may sit for a week while I go back to work. But I plan to continue with the timing belt and water pump before getting back on the road.

Dean.

_________________
2005 Jeep Liberty 2.8L CRD 248
Kona, Hawaii (Big Island) USA

Changed Turbo.
100,000-mile service.
Replaced harmonic balancer.
Noise in front axle or 3rd member - removed loose chain in transfer case.
Rebuilt engine - replaced #3 cylinder, piston, valves, head repair. Removed EGR.
Sheared bolts on TC. Replaced flex plate, TC, bolts.


Top
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 Post subject: Re: Timing belt and Turbo change-out
PostPosted: Mon Oct 16, 2017 11:28 pm 
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Now that I've had a chance to cool down, I've thought of a way to install the turbo oil return pipe...

Start with the rubber pipe bushing installed in the block.
Put some gasket sealer on the end of the pipe on mating surface at the turbo. Let set-up overnight.

Prepare the assembly:
Use some soft gasket sealer to hold the 2 screws in the flange to the turbo connection, partially sticking through.
Work an o-ring up from the bottom of the pipe to hold the flange nearly at the top of the pipe.

Installation:
Start by installing the pipe in the block bushing and get the flange in place with captive screws.
Use a 1/4" drive screwdriver-socket handle plus extension to start both screws.
Once they are started, it's all over but the tightening.

I hope my plans work.

Dean.

_________________
2005 Jeep Liberty 2.8L CRD 248
Kona, Hawaii (Big Island) USA

Changed Turbo.
100,000-mile service.
Replaced harmonic balancer.
Noise in front axle or 3rd member - removed loose chain in transfer case.
Rebuilt engine - replaced #3 cylinder, piston, valves, head repair. Removed EGR.
Sheared bolts on TC. Replaced flex plate, TC, bolts.


Top
 Profile  
 
 Post subject: Re: Timing belt and Turbo change-out
PostPosted: Tue Oct 17, 2017 4:18 am 
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Joined: Sat Aug 27, 2016 9:12 pm
Posts: 2505
Location: Oregon Coast Dairy Country. Land of stumps, dumps, and "Liquid Pumps"
Best of luck!

I hope the silicone sealer doesn't prevent the drain pipe flange from sealing against the gasket properly at the turbo.

_________________
'06 Lbrty Sprt CRD 150K

Sasquatch
DSS Turbo
CAT-elimntr
Weeks Stg1&2 EGRfix
PV-200
BLING
vent gauges

IDParts
head
cams
rockers
Timing set
ARP studs
eTn1 GX2123 5v GPs

YETI Custom Tune
Flowmaster 8325508
Carter P76611M
GM 12611872
Hayden 2986
GM 15976889
PATC Custom Billet
2010 Ram Hemi Trans
Sonnax 44957
Transgo kit
Cooper 51770


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 Post subject: Re: Timing belt and Turbo change-out
PostPosted: Wed Oct 18, 2017 12:44 am 
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Thanks for the attention GordnadoCRD. Being here without any other Jeep friends, it's good to have some companionship from the Internet. I cannot imagine how Mark Watney (fictional character) managed to survive on Mars all alone and without communication until he found and fixed the original Mars rover that he located about a thousand kilometers away.

The drain pipe flange is supposed to have a gasket, but I lost it in the framework of the jeep underbelly. Now that I've regained my composure, I can probably find it again.

Instead of the gasket, I put a thin (1/32"-1/16") layer of silicon gasket sealer on the mating face of the pipe flange. It seems that is what the last owner did -- probably in the same fit of indignation.

Dean.

_________________
2005 Jeep Liberty 2.8L CRD 248
Kona, Hawaii (Big Island) USA

Changed Turbo.
100,000-mile service.
Replaced harmonic balancer.
Noise in front axle or 3rd member - removed loose chain in transfer case.
Rebuilt engine - replaced #3 cylinder, piston, valves, head repair. Removed EGR.
Sheared bolts on TC. Replaced flex plate, TC, bolts.


Top
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 Post subject: Re: Timing belt and Turbo change-out
PostPosted: Wed Oct 18, 2017 1:12 am 
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Joined: Sat Aug 27, 2016 9:12 pm
Posts: 2505
Location: Oregon Coast Dairy Country. Land of stumps, dumps, and "Liquid Pumps"
Getting mine fit with the studs may have been a stroke of luck, but it really seemed comparatively easy, a relief from fighting to get the bolts in from the bottom.

Something you might consider, is use the stud and nut on the outside attachment when dropping the turbo in and inserting the drain tube into the block below, then add the bolt to the inside hole later. Once you get one properly located, getting the next one in should be easier than trying to do it blind with no reference. Possibly even just use the little bolts and leave them loose. I just was so disgusted with them at that point I didn't want to look at them again.

I glued the gasket to the turbo drain flange face after trying the whole afternoon the previous day. I think that also helped.

I dropped many small things in that area. If you don't find them above the front crossmember, or in the U channel on the top edge of the frame, There is a V intersection where the inner fender joins up to the outside edge of the frame. Thin and small things sometimes fall into that, and "disappear".

_________________
'06 Lbrty Sprt CRD 150K

Sasquatch
DSS Turbo
CAT-elimntr
Weeks Stg1&2 EGRfix
PV-200
BLING
vent gauges

IDParts
head
cams
rockers
Timing set
ARP studs
eTn1 GX2123 5v GPs

YETI Custom Tune
Flowmaster 8325508
Carter P76611M
GM 12611872
Hayden 2986
GM 15976889
PATC Custom Billet
2010 Ram Hemi Trans
Sonnax 44957
Transgo kit
Cooper 51770


Top
 Profile  
 
 Post subject: Re: Timing belt and Turbo change-out
PostPosted: Thu Oct 19, 2017 3:12 am 
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Joined: Thu Oct 05, 2017 2:22 am
Posts: 693
CaptainDean wrote:
I've thought of a way to install the turbo oil return pipe...

Put some gasket sealer on the end of the pipe on mating surface at the turbo. Let set-up overnight.

Prepare the assembly:
Use some soft gasket sealer to hold the 2 screws in the flange to the turbo connection, partially sticking through.
Work an o-ring up from the bottom of the pipe to hold the flange nearly at the top of the pipe.Dean.


Here is the oil drain pipe prepared as above...
Image


And here is a close-up of the flange. Notice the o-ring holding up the flange and the captive screws...
Image

_________________
2005 Jeep Liberty 2.8L CRD 248
Kona, Hawaii (Big Island) USA

Changed Turbo.
100,000-mile service.
Replaced harmonic balancer.
Noise in front axle or 3rd member - removed loose chain in transfer case.
Rebuilt engine - replaced #3 cylinder, piston, valves, head repair. Removed EGR.
Sheared bolts on TC. Replaced flex plate, TC, bolts.


Top
 Profile  
 
 Post subject: Re: Timing belt and Turbo change-out
PostPosted: Thu Oct 19, 2017 4:30 am 
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Joined: Sat Aug 27, 2016 9:12 pm
Posts: 2505
Location: Oregon Coast Dairy Country. Land of stumps, dumps, and "Liquid Pumps"
I'm hoping the best for you. 1 and done, and no leaks.

_________________
'06 Lbrty Sprt CRD 150K

Sasquatch
DSS Turbo
CAT-elimntr
Weeks Stg1&2 EGRfix
PV-200
BLING
vent gauges

IDParts
head
cams
rockers
Timing set
ARP studs
eTn1 GX2123 5v GPs

YETI Custom Tune
Flowmaster 8325508
Carter P76611M
GM 12611872
Hayden 2986
GM 15976889
PATC Custom Billet
2010 Ram Hemi Trans
Sonnax 44957
Transgo kit
Cooper 51770


Top
 Profile  
 
 Post subject: Re: Timing belt and Turbo change-out
PostPosted: Fri Oct 20, 2017 12:42 am 
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Got home and had another hour of sunlight so I attempted to put in the oil drain tube.

Got the bottom in the rubber bushing and one screw started. :BANANA:

The flange was a little askew but could pry it into place with a screwdriver. After a couple screwdriver bombings on the forehead :dizzy: , and the flashlight falling down and leaving the battery cover inside the Jeep framework; it was time to quit.

I will continue on Saturday with a much smaller task list -- get in one bolt.

Dean.

_________________
2005 Jeep Liberty 2.8L CRD 248
Kona, Hawaii (Big Island) USA

Changed Turbo.
100,000-mile service.
Replaced harmonic balancer.
Noise in front axle or 3rd member - removed loose chain in transfer case.
Rebuilt engine - replaced #3 cylinder, piston, valves, head repair. Removed EGR.
Sheared bolts on TC. Replaced flex plate, TC, bolts.


Top
 Profile  
 
 Post subject: Re: Timing belt and Turbo change-out
PostPosted: Sat Oct 21, 2017 4:35 pm 
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Last bolt is in !! :BANANA: Tightened and connected everything and so far no leaks.

Got an automotive stethoscope and listened. Found the clattering-clunk in the water pump.

My wife only knows one part in the engine and that's it. She guessed it correctly. She will now tell me "...I told you so !" :goink: Ha ha!

Going to start the 100,000 mile service now. (Timing belt, water pump, idler pulleys kit) Thanks for the advise everyone and the prompting to change it all while I'm at it.

Dean.

_________________
2005 Jeep Liberty 2.8L CRD 248
Kona, Hawaii (Big Island) USA

Changed Turbo.
100,000-mile service.
Replaced harmonic balancer.
Noise in front axle or 3rd member - removed loose chain in transfer case.
Rebuilt engine - replaced #3 cylinder, piston, valves, head repair. Removed EGR.
Sheared bolts on TC. Replaced flex plate, TC, bolts.


Top
 Profile  
 
 Post subject: Re: Timing belt and Turbo change-out
PostPosted: Sat Oct 21, 2017 9:01 pm 
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CaptainDean wrote:
Last bolt is in !! :BANANA: Tightened and connected everything and so far no leaks.
Got an automotive stethoscope and listened. Found the clattering-clunk in the water pump.
My wife only knows one part in the engine and that's it. She guessed it correctly. She will now tell me "...I told you so !" :goink: Ha ha!
Going to start the 100,000 mile service now. (Timing belt, water pump, idler pulleys kit) Thanks for the advise everyone and the prompting to change it all while I'm at it.
Dean.

You are on the right track, keep going, and if you have questions, just ask! :wink:

_________________
Supporting Vendor and Moderator of LOST
05 Jeep Liberty CRD Limited :JEEPIN:
Ironman Springs/Bilstein/Shocks
Yeti StgIV Hot Tune
Week's BatteryTray
No FCV/EGR
Samcos/ProVent
SunCoast/Transgo
Carter Intank-pmp
2mic.Sec.Fuel Filter
Flowmaster/NO CAT
V6Airbox/noVH
GM11 Bld.fan/HDClutch
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98 Dodge Cummins 24 Valve


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 Post subject: Re: Timing belt and Turbo change-out
PostPosted: Sun Oct 22, 2017 1:56 am 
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Thanks WWDiesel,

Today I got the serpentine belt off along with the serpentine idler pulleys and tensioner. Tomorrow I'll get the timing cover off, the timing pins installed and the timing belt off. I expect to change the front half of the water pump and start putting things back. I don't expect to finish tomorrow.

One question: How big of deal is there to deleting the viscous heater? I cannot see a need for it in the tropics.
Question two: Will the engine cooling system continue to provide heat for the cabin? Occasionally I do use the heater on a chilly morning.

Dean.

_________________
2005 Jeep Liberty 2.8L CRD 248
Kona, Hawaii (Big Island) USA

Changed Turbo.
100,000-mile service.
Replaced harmonic balancer.
Noise in front axle or 3rd member - removed loose chain in transfer case.
Rebuilt engine - replaced #3 cylinder, piston, valves, head repair. Removed EGR.
Sheared bolts on TC. Replaced flex plate, TC, bolts.


Top
 Profile  
 
 Post subject: Re: Timing belt and Turbo change-out
PostPosted: Sun Oct 22, 2017 4:32 am 
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Joined: Sat Aug 27, 2016 9:12 pm
Posts: 2505
Location: Oregon Coast Dairy Country. Land of stumps, dumps, and "Liquid Pumps"
1) To remove it from use is easy, just unplug the clutch connector or remove the relay in the power distribution box. To remove it physically isn't difficult, but will require a shorter serpentine belt and modified routing. I'm fairly certain Flash has removed it, and Mountainman has removed both the VH and the AC compressor, which is different yet.
No matter which way you choose, you will still need to re-route the coolant around it. It performs no function other than heat, and that only when it's cold, so you probably wouldn't even know it's not there had someone else removed it.
In your case, it's probably better off, because it's one less clutch and clutch bearing to go out. (completely different from the AC clutch and bearing too :banghead: )
The bearing on mine was out when I bought it, and I'd already gone through the headache of replacing the bearing before I found out it wasn't important, or I'd have just removed it as well.
When I was replacing the bearing on the device, I was wondering why the heck they put such small hoses on the water pump! Folks here straightened me out in short order.

2) Yes, as long as you connect the inlet and outlet together somehow, the cabin heater will work as well as it does with it, just the temperature will not rise as quickly. I don't think you'll miss it unless you live up in the snow zone.

_________________
'06 Lbrty Sprt CRD 150K

Sasquatch
DSS Turbo
CAT-elimntr
Weeks Stg1&2 EGRfix
PV-200
BLING
vent gauges

IDParts
head
cams
rockers
Timing set
ARP studs
eTn1 GX2123 5v GPs

YETI Custom Tune
Flowmaster 8325508
Carter P76611M
GM 12611872
Hayden 2986
GM 15976889
PATC Custom Billet
2010 Ram Hemi Trans
Sonnax 44957
Transgo kit
Cooper 51770


Top
 Profile  
 
 Post subject: Re: Timing belt and Turbo change-out
PostPosted: Sun Oct 22, 2017 1:06 pm 
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CaptainDean wrote:
Thanks WWDiesel,
One question: How big of deal is there to deleting the viscous heater? I cannot see a need for it in the tropics.
Question two: Will the engine cooling system continue to provide heat for the cabin? Occasionally I do use the heater on a chilly morning.
Dean.

Answers to both questions.
No big deal, just simply remove the relay for the viscous heater in the Power Distribution Center under the hood. It's location is labeled in the cover!
Heater will still work just fine; my relay has been unplugged for several years now and I have not been able to tell a difference. Coolant will still flow through the viscous heater normally to the heater core and function regardless of whether or not the relay is plugged in or not. It may be a little slower to provide heat in much colder climates...
Having it unplugged removes a small about of drag from the engine on colder days! :wink:

The viscous heater provides no pumping or mechanical action whatsoever to the coolant, it simply heats a viscous fluid (like what's in your fan clutch) within the body of the unit and the coolant passes simply passes through the units heat exchangers on its way to the heater core but does not actually come in direct contact with the viscous fluid but picks up convected heat from it when the heater is in service.

If you choose to totally remove the heater unit, it will require a shorter belt, and I believe from past conversations on LOST by others, requires adding another grooved idler pulley to align the belt and clear, keep it off, the tensioner pulley. I toyed with this idea a couple years back but decided at the time it simply was not worth the hassle. If my VH clutch ever craps out, I may go the shorter belt route. I have some idler pulley numbers on file for shorter belt install consideration if needed. Others on here who have already done this mod may can supply the necessary part numbers...

:SOMBRERO:

_________________
Supporting Vendor and Moderator of LOST
05 Jeep Liberty CRD Limited :JEEPIN:
Ironman Springs/Bilstein/Shocks
Yeti StgIV Hot Tune
Week's BatteryTray
No FCV/EGR
Samcos/ProVent
SunCoast/Transgo
Carter Intank-pmp
2mic.Sec.Fuel Filter
Flowmaster/NO CAT
V6Airbox/noVH
GM11 Bld.fan/HDClutch
IronrockArms/wwdieselMount

98 Dodge Cummins 24 Valve


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 Post subject: Re: Timing belt and Turbo change-out
PostPosted: Sun Oct 22, 2017 2:52 pm 
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Thanks WWDiesel,

If it's more than simply removing the viscous heater & fuse and installing a shorter accessory belt then I'll wait for another time. Getting an unnecessary unit out of the engine compartment is my goal; I like an uncluttered engine.

Thanks for the viscous heater explanation and the offer of part numbers. I'll keep that in mind. For now, I will continue with the timing belt and water pump project.

At the end of today's project, I will have to clean and inspect the boost system. I watched Git It Garage's "Jeep Liberty CRD Diesel EGR Delete" YouTube video. I may have to clean the throttle and ERG area next.

Dean.

_________________
2005 Jeep Liberty 2.8L CRD 248
Kona, Hawaii (Big Island) USA

Changed Turbo.
100,000-mile service.
Replaced harmonic balancer.
Noise in front axle or 3rd member - removed loose chain in transfer case.
Rebuilt engine - replaced #3 cylinder, piston, valves, head repair. Removed EGR.
Sheared bolts on TC. Replaced flex plate, TC, bolts.


Top
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