OK, here's the problem.

About 2 weeks ago, my CEL came on. I took car to Jeep Dealer. They said the code showed the EGR is bad and needed to be replaced. Problem with that is, I have the SEGR mod installed so EGR is bypassed so couldn't show it was bad.

The CEL has been on for 2 weeks. It went off for a day or so, then came back on. Today, it went off again for an hour or so, then back on. BUT, the thing that happened in addition to the CEL thing today was, I was on the interstate. I floored it to pass another car. My car did not accelerate. It didn't exactly bog, but it did not accelerate at all. The motor revved, but would only go up to 3000 rpm. Not a tick further.

I can accelerate to hwy speeds the normal way, by gradually gaining speed, just no sudden acceleration. At lower speeds, with no sudden acceleration, the car runs fine too. Also, my fuel mileage is going all over the place. You can sit and watch it go up and down on the overhead console when the car is idling.

I am continuing to look for someone to see if they know how to fix whatever is wrong with it but have yet to find a shop that won't just give me the run around.

Any idea what the cause of this type of thing would be? And why would a code reader say it was bad EGR when it obviously can't be?

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jwalker
Home is Knoxville, TN
Currently full-timing in our RV

The SEGR simply modifies the MAF signal to emulate EGR flow. That is what triggers a CEL, if there is no drop in MAF output when the EGR is commanded. If the SEGR was not installed and you disconnected the EGR valve, that would trigger the CEL too.

But you haven't posted what the specific code is, as that will identify the real problem. Perhaps you have a loose connection in your wire splices or the power resistor connection broke.

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'05 Liberty CRD B100, SEGR - SOLD

'01 Beetle TDi B100, EGR delete
'83 Mercedes 240D B100, no EGR

--- SEGR Builder ---

x2...........

_________________
'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

FWIW, I've had the exact same condition with a P0069 MAP/Correlation error. I've cleaned my MAP (T-map) sensor soo many times to attempt a fix for this mess. Each time after cleaning the boost returned. Earlier cleanings uncovered crud. later cleanings was just mild crud and soot. it has been weeks now with now loss of boost BUT my CEL is still on and won't clear for nothing. AND yes I own and installed a SEGR but is currently bypassed because for some reason only an EE can explain to me, each time I energize the circuit the BOOST becomes intermittent. Making things stressful, this is my wifes DD so I can't afford ANY issues except maybe the CEL. I don't know if this helps anyone else out there. I wish everyone the best of luck with theirs. MAYBE someday I can find a fix for this??? or maybe not. My TDI hasn't been difficult. What a shame. Could be a great vehicle but now it's just average.

dom

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Jetta TDI '01
Liberty CRD '06
Kubota B2910 '00

The code it is throwing is P0401.

Even if I have a loose connection or something broke in the SEGR, why would I have the loss in boost power?

BTW, Tim installed the SEGR himself, so I know it is installed correctly.

You are speaking a little bit of foreign language to me here when you say, "The SEGR simply modifies the MAF signal to emulate EGR flow. That is what triggers a CEL, if there is no drop in MAF output when the EGR is commanded."

Please reiterate in "blonde" terms please

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jwalker
Home is Knoxville, TN
Currently full-timing in our RV

FYI - JL Rockies had the dealer tell him he had a bad EGR - when the Turbo hoses died.
and acceleration problems - sounds like a turbo hose.

here's his thread
http://www.lostjeeps.com/forum/phpBB3/viewtopic.php?t=36155&postdays=0&postorder=asc&start=0

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2005 CRD
stuff
Skeptic quod gratis asseritur, gratis negatur

Code 0401 is insufficient EGR flow. The SEGR disconnects the EGR and substitutes a "fake EGR" in the form of the power resistor (insdie the SEGR box). That much seems to be in place. You may have an issue with the SEGR box where the EGR signal or the flow control valve (FCV) signal is not making into the SEGR box, so you may have a bad wire splice in one of those two areas.

If you have a bypass plug, install it instead of the SEGR box and see if the CEL goes away. It might take a few starting cycles unless you have a code reader to clear the 0401. If the 0401 code will not go away, you probably have a wire splice issue with the SEGR install. If the code goes away, you have a problem in the SEGR box -- I can fix this (under warranty )if you ship it to me.

If you don't have a bypass plug, I can make one for you. Just PM me and tell me what polarity the pins in the SEGR box are. I don't know if I built your box or not, so if you know the pinout, that is useful too. I can build a bypass plug without that info if you ship me the box as well.

I don't know if you follow that, I apologize, I don't know how to speak "blonde".

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'05 Liberty CRD B100, SEGR - SOLD

'01 Beetle TDi B100, EGR delete
'83 Mercedes 240D B100, no EGR

--- SEGR Builder ---

Basically, the SEGR is lying to the ECM, which she doesn't mind a'tall because he's only telling her what she wants to hear - when she doesn't like what she's hearing, she reacts in an alarming fashion - thus the CEL - the SEGR bypass plug is a lie-detector\truth-enhancer, reconnecting the sensors and modules to the ECM

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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

Let me translate.

ECM = Wife
SEGR = Husband

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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

I don't have a whooshing sound or black smoke. The car seems to run fine except for no boost and wildly wavering fuel mileage.

But, I will look at the hose anyway. You never know, that might be what is wrong.

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jwalker
Home is Knoxville, TN
Currently full-timing in our RV

In the immortal words of Larry the Cable Guy..."Now that's funny... I don't care who you are"

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jwalker
Home is Knoxville, TN
Currently full-timing in our RV

I can't find the bypass plug (don't remember ever having one, but that doesn't mean I don't

I have no idea how to tell you what the polarity is nor the pinout. I don't know how to unattach the SEGR box to send it to you. Tim installed it. I just watched. He shrink tubed all the splices.

But, even if this was the problem with the CEL, why would I have the loss in boost power and wildly wavering mileage issue also?

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jwalker
Home is Knoxville, TN
Currently full-timing in our RV

IF your SEGR kit was a standard kit like the rest out there in internet land built in a metal box with a 9 pin AMP connector, the harness can be removed and a bypass plug installed. If that fixes your issues, you know there is a problem with the SEGR. It sounds like you need to consult Tim to get the details. He could give me the proper info for me to build a bypass if he doesn't have the parts.

Your bad mileage and unstable boost might be caused by erratic signals or noise resulting from a SEGR or SEGR wiring failure, or it could be something unrelated. But until you find the cause of the 0401 code and rectify it, which can most definitely be caused by the SEGR, it's hard to continue.

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'05 Liberty CRD B100, SEGR - SOLD

'01 Beetle TDi B100, EGR delete
'83 Mercedes 240D B100, no EGR

--- SEGR Builder ---

Thanks UFO. I talked to Tim again. He said he would make a a bypass. I'll look at the SEGR again and see what kind of box it's made of just to be sure.

Meanwhile, I'm going to check for wiring problems with the SEGR, leaks in the turbo hoses and air in the fuel line where the hockey puck is. Checking those things won't hurt and I just may find the problem there.

Will let you know if I find anything out of whack.

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jwalker
Home is Knoxville, TN
Currently full-timing in our RV

Ok, REALLY GOOD NEWS and sorta kinda bad news...

I stopped at 3 different Auto Parts stores today. None of them could get my car to throw a code, even though the CEL was still clearly on. One even ran the code reader on the specific Chrysler mode. No code there either.

Hmmmm, wonder why Jeep dealer told me I had a P0401 and a bad EGR?

I got under the hood this afternoon. Went straight to the SEGR box. Unplugged the harness from the box. Upon examining the pins in the harness, there was a couple of pins and pin holes with a bit of corrosion. So, I think, hmmmm... no prob, must have gotten a little wet. I'll just clean off the contact points, and put some dielectric grease on them to keep the corrosion from happening in the future.

By now I am getting a big smile on my face as surely the corroded contacts are what has been causing the problems.

It's never that simple is it? Nope, not this time either.

I pick up the SEGR box. Hmmm, it's not supposed to make THAT sound? I shake the box. Oh no, it can't be!

I get the screwdriver, open the box, and TA DA!!! It's COMPLETELY FULL of water. Corroded, nasty, groady WATER!!!

Everything in there was corroded goo

Funny though that nothing was leaking OUT of the box. No water came out until I took all the screws out and removed the lid.

Anyway, I called Tim. (good thing I have saved his number from when I was in AZ) He said to send him the box and he would try to salvage it. I told him I thought it was beyond salvaging but he said he'd try anyway.

So, I get in the car, and take it for a drive to see if it is now "fixed".

YUP, boost power is back. Runs like a new car!

Barring any other gremlins that might pop up, I guess the problem has been located. Now to get a new SEGR box and figure out how to keep water out of it. I guess the only way to do that is mount it under the dash. Just not sure how to do that exactly, but will ponder on it.

While I was under the hood, I checked the turbo hoses and "hockey puck" where the fuel filter is.

The hose on the top left is really oily. I couldn't get to the one on the lower right, but I am going to assume it is just as bad. So looks like a new set of SAMCO's will be coming my way very soon.

The push button on the "puck" was squishy (sorry, don't know another way to describe it). I pumped it until hardened up. Still might need to be bled, but for right now the car is running fine, so will just keep a watch on it.

Right now, I am just happy to have found the problem without having to take out a mortgage to pay Jeep to do their "fix".

P0401 must be "Jeep language" for, "We haven't gotten our Government bail out money yet, so we are going to get it from each customer who comes in here... $700 at a time

Thanks to everyone who made suggestions as to what the problem might be. You saved me at least a paycheck's worth of $'s by narrowing the problem down for me

Y'all are the BEST!!!!!

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jwalker
Home is Knoxville, TN
Currently full-timing in our RV

I had no idea it got wet like that under the hood. It's really easy to mount the box under dash. There is an unused hole in the firewall, just pop the plug and route the harness through. You really want sheathing on it though as there are metal edges around the hole. The cable dumps right below the brake booster and fits in the wire harness channel that runs across the top of the firewall. When the SEGR harness is run into the back of that channel, and spliced in there, you cannot tell there is a mod to the Jeep.

I'm not surprised auto parts stores can't read the codes. I have a cheap code reader that works fine with every other OBDII vehicle I've tested it on, but the CRD is strange. I can get mine to work, but it takes a real touch not obvious to a parts monkey.

Yeah, 0401 is dealer-speak for bad EGR. Welcome to the club that knows better.

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'05 Liberty CRD B100, SEGR - SOLD

'01 Beetle TDi B100, EGR delete
'83 Mercedes 240D B100, no EGR

--- SEGR Builder ---

The problem you had passing with no power at 3000 rpm is typical to the CRD. I've experianced the same unnerving situation. I start to pass someone who is doing 45 mph, my transmission upshifts and my rpms go to 3000. At 3000 rpm's this diesel engine has no power at all and cannot excellerate, it may even loose speed. This sets up a very dangerous situation on a two lane road. I was going slightly uphill at the time.

I've never noticed that. It sounds like he had some wiring faults due to a mod gone bad. If you have such an issue without the SEGR, check for a plugged air filter or fuel system fault like a plugged fuel filter or air in the fuel head.

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'05 Liberty CRD B100, SEGR - SOLD

'01 Beetle TDi B100, EGR delete
'83 Mercedes 240D B100, no EGR

--- SEGR Builder ---

Tim Wulf...

I understand what you are talking about but that is not what my problem was. My SEGR box was flooded which seems to have made the computer go haywire.

I agree it takes a second or 2 to get to boost speed if you floor the accelerator. I akin it to a slingshot type thing. But once it gets all the hamsters wound up, it shoots forward like a rocket.

UFO has made a good suggestion to try. Maybe that will remedy your problem.

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jwalker
Home is Knoxville, TN
Currently full-timing in our RV

Was with another club member, an 08 JK, going to a meeting/run on Saturday and we got to a pretty aggresive grade. He started to slow and told me on our FRS Radios the hill is getting to his Jeep and he is already down to 4th on his manual-- This is 45 MPH- I go around him and downshift and FLEW by him-- RPM's at 3k plus.
Boost/power/acceleration was NO problem.
Still got to reroute my SEGR box to inside cab though and still need to install my lift pump mod also.
At least with me power is no problem even in high rev.
And no CEL's of any kind!!
FWIW
Roland

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2006 CRD LTD 2.8L VM Motori turbo,CAC, 100K-new timing belt
ORM-SEGR, Trans cooler, CLIII hitch front/rear, Journey HD controller
Mopar skids,"Stone Soup" rails, KK clevis fork 1" mild lift w/Daystar stops
215x85 LRD BFG Commercial A/T's, Rola Rack, V6 airbox, Fumoto valve
10K winch, B5 Biodiesel (ULSD CP3 lube)
Its a Diesel baby!