I'm in Mexico after driving about 3000 miles with the segr box. About half way down, after buying fuel in Baja a couple of times I've developed a lack of power and big smoke problem. My guess is bad fuel although I've changed the filter it misses and smokes. It kind of feels like the turbo isn't spooling up and maybe injector sticking?
I'm a long way from the border 1 1/2 days to south Texas, and of course these engines are unknown to the jeep dealers here in Mexico. I think I'm going to have to make a semi educated guess and try to fix it myself.
I guess my question would be, are there any components that fail typically and cause these symptoms. It runs but no butt and lots of smoke, clears up from time to time and seems to run better, then shuts down the engine and it starts the process over again.
I don't think it has to do with the segr box but I've also miss placed my bypass plug, I have the wire diagram so I could still create a by pass.
I apologize for the personal problem post, but got to start somewhere.
Maybe someone who has tech experience. I'm stumped.
Even if you can point me in a direction.

Cheers from south of the border

I would first check all your hoses and connections. Look for cracks/loose fittings/ect...especially the inlet trubo hose. Check your intercooler hose to see if it is heavily oiled up and possibly failing. Clean your MAP sensor on the drivers side of your intake (4mm allen wrench I think). I don't know how many miles you have but your CAT could be failing maybe. Make sure you don't have TOO MUCH oil and sucking it thru the intake. Make sure your Air Filter is clean.

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Founder of L.O.S.T.
2006 CRD Sport
Mods: GDE Hot Tune w/ 364#@2000rpm/Air Box /3" Str8 Exhaust/ASFIR Alum Skids/245-75R-16 Cooper STT PRO/OME LIFT w/Clevis & 4 Spring Isos/AirTabs/Rigid 10" S2 LED/4xGuard Ctr Matrix Bumper
Drag Strip:Reac=.1078_60ft=2.224_1/8=10.39@64.8mph_1/4+16.46@80.8mph

My hose has all kinds of black gunky stuff oozing out from around the edges near the radiator. What does it all mean?

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2006 CRD http://www.UtahPowderCoatings.com/ http://www.gorecon.com/ I'm kind of a big deal.
RL rear bumper, ARB front bumper, Mile Marker winch, Power Tank, Skids by Mopar & Skid Row, RL Super Skink Sliders, 235/85R16 MTR, Air Flow Snorkel, DTT, 4.10 gears, Frankenlift II, Katskin leather, JL Audio stereo, Rosen video.

You can get that hise replaced under warranty I think with a newer designed one. Basically the "vavle" on top of your intake is throwing the oil vapor and particles into your air intake tract and leaving deposits in your hose and possibly your intercooler. You can do an EHM or add a Provent to stop it in the future.

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Founder of L.O.S.T.
2006 CRD Sport
Mods: GDE Hot Tune w/ 364#@2000rpm/Air Box /3" Str8 Exhaust/ASFIR Alum Skids/245-75R-16 Cooper STT PRO/OME LIFT w/Clevis & 4 Spring Isos/AirTabs/Rigid 10" S2 LED/4xGuard Ctr Matrix Bumper
Drag Strip:Reac=.1078_60ft=2.224_1/8=10.39@64.8mph_1/4+16.46@80.8mph

I had a not fully seated plug on the MAP sensor cause me those problems with a cel I found it when I cleaned the MAP sensor

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Atlantic Blue 06 CRD Limited (his)
Joined by a 2000 XJ Classic (hers)

It really sounds like you have a blown intercooler hose. Check them out and find some duct tape to get you home.

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05CRD: GDE Hot ECU & TCM tunes, Provent, Cat filter, Facet lift pump, TransGo kit, Florida TC, Samcos, stainless brake lines, HDS thermostat, Renegade light bar,
RL super sliders, Bilstein adjustables, Al's Gen 4.5 Arms, 235/85-16 Duratracs, DTT rear, Elocker front, EVIC+TPMS, Turbo timer, McNally pillar gauges, Weeks Stage II kit.

What color is the smoke? if black it could be a turbo or air supply problem or even a stuck injector. If white it is likely a filter or air in fuel problem. the symptoms that you mention of cutting out but being able to start later are consistent with a plugged filter. If the problem was a CAC hose or intercooler it would not be intermittent. If you can't find the correct size filter down there try disconnecting the fuel lines from the fuel head and putting one of those cheap plastic inline filters between the inlet and outlet lines bypassing the filter head completely. Remember to disconnect the fuel heater plug or you will have a burnt up puck if you don't already have one(its the plug with the heavier wires, I think that they are red and black) I would bet that you have air either getting in through a leak in the filter head or coming out of solution due to the vacuum caused by a plugged filter. Open the bleeder port on the top left side of the filter head and pump the priming plunger, see if air or fuel comes out.

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Manure green 2005 CRD sport4x4, GDE Hot tune, Cat Gut, OE skids, Draw tight hitch, Duramax lift pump, 160K on multiple varieties of fuel, XM radio, Escort live with Redline, fog light mod, GPS, Icom IC7000 all band radio call sign KC9QPF, Grabber AT2s on Soft 8s, FIA grill blanket.

With the help of everybody that has responded to this post I'm making a little progress. First off I cleaned the map sensor, it was totally gummed up with black oil residue. I rerouted the hose from the ccv valve to atmosphere, and plugged the other end. There is oil residue in the intercooler and on the inside of the cooler hoses. It seems like the inter cooler would be a big chore to remove and clean. There appears to be a drain valve on the cooler but I'm not sure how it works. It's plastic and I'm nervous about breaking it.
I have pretty much regained full power and it idles fairly smoothly. I have a lot more rattle and diesel knock until it reaches temperature.
It smokes heavily under load, blackish sooty smoke. The turbo shaft is tight, no wobble, and it hasn't used any oil since the last change about 4k miles.
Are injectors a problem, themilage has decreased over the last 10k or so, occasionally as low as 18-19 mpg, maybe fuel pressure sensor?
again I really appreciate the help.

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06 liberty crd, lift pump, shift kit, segr box

Since your fuel qualality is unknown and suspect a extra strong dose of power service in the silver bottle is in order. Or whatever additive you can find there

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Atlantic Blue 06 CRD Limited (his)
Joined by a 2000 XJ Classic (hers)

Yep - that's definitely watery\old\stale fuel symptom - might behoove you to get a 12v transfer pump, an external filter assy, and a clean 5ga water bottle: pump the fuel into the jug, inspect for the little worm that's s'posed to be in the bottle (or, maybe that's another liquid substance I'm thinking of), transfer the fuel from yer jug thru the filter into the KJ tank - change the fuel filter in the fuel manager head, stick to that procedure during the remainder of yer adventure, and yer good to go.................

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'05 CRD Limited
Pricol EGT, Boost
GDE Hot '11; EDGE Trail switched
SEGR; Provent; Magnaflow;
Suncoast T\C, Transgo Tow'n'Go switch;
Cummins LP module, Fleetguard filter, Filterminder
2.5" Daystar f, OME r; Ranchos; K80767's, Al's lifted uppers
Rubicons, 2.55 Goodyears
Four in a row really makes it go

Well the reset and cleaning of the map sensor made the little guy run great w/lots of smoke for a couple of days but plenty power. Then this afternoon while passing a truck on a two lane road it either hit some sort of over boost switch and shut down. A quick shift into neutral, a restart and it running again but with no boost and it's not smoking. No power, no boost, and no smoke. I limped home and cleaned the map sensor again, not too dirty and it's back to running, making lots of noise (pre ignition rattle), and smoke. There has to be something related to boost pressure? or?

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06 liberty crd, lift pump, shift kit, segr box