NEWB. 2.5 CRD engine barley goes

kjhighlander · **Posted:** Wed Jul 07, 2010 1:08 pm

Long winded but please bare with me.

The 2004 kj incurred a dark smoking problem a few days ago. This was not constant but random. We soon heard an engine noise only when driving at a constant speed say 60mph to when it sounded like the engine began to race but there was no difference to the rpms. This was only occasional but the kj did feel like it was possibly missing where it felt like it was briefly i.e 1 second pulling back and then going normally and then a second later feeling like it was being restricted in power again.

The kj had to drive approx 50 miles and after approx 25 miles the boost disappeared. The kj drove just like any diesel jeep bar the turbo boost was missing. The boost occasionally and partially came back. Got home and pulled the inlet pipes off etc and physically checked the turbo whilst still fitted to the jeep. The impellers were intact. No scoring on the walls, looseness or roughness when turning the impellers. Blew and sucked into the diaphragm and you could hear it moving so all seemed ok. Put everything back together and the folks drove it for one day and it appeared to be a little lumpy but still boosted but now worse than ever.

It drove fine for 1 day and now it doesn’t even drive like a diesel. The jeep constantly spews out black smoke under any pedal control. Its started idling rough and has zero boost. The jeep struggles to rev to 3000rpm and has now started a loud engine rattle when @ 2600 to 3000 rpm. It occasionally revs to 4000 rpm where as before it freely reved to this. Whe it revs to 3000 rpm it drops a few hundred rpm and just sits there.

Removed the EGR valve and checked for being suited up. The piston may have been a little sticky so it was cleaned and worked till it freely moved with assistance of pushing down with the aid of a screwdriver handle. Checked the filter to the small paper filter and in and out pipes are clear to the egr. The inn pipe is sucking away where the out is doing nothing, Out is to the egr.(I think that’ the correct way round with 1 connector larger than the other so there in the correct position).

Cleaned the plastic part on top of the rocker cover (dont know the name) that has a connecting pipe to the air inlet elbow that connects to the air box with throttle body cleaner. This model does not have a MAF.

The jeep is worse than ever. Sorry for no technical terms. We have no code reader and the diagnostic light is NOT on. Air filter is a little dirty but not too bad. Not really sure the best way to go about checking to see if it’s over fuelling. Any help welcome before the kj goes to jeep for diagnostics or more.

P.S. The jeep usually got babied everywhere it drove to what i told my folks is a bad idea as the egr does not get cleaned out and he had over filled it somehow by a half litre of oil to what I understand is 0.528 US liquid quarts and has since been drained to an acceptable dipstick level. We don't have a diesel manuel but only the petrol to what is no use to us here. Ive looked online but dont believe ive found the answer unless something that has been checked i.e the egr is faulty but appeared ok

Anyone

ATXKJ · **Posted:** Wed Jul 07, 2010 1:55 pm

Howdy
Well - no one in the US has experience with the 2.5, so this is a guess.

what you're describing is exactly what the 2.8 does when it blows a turbo hose.
so I'd inspect hoses and the Charged Air Cooler - if you 'pulled the inlet pipes off' - that sounds like part of it - check the rest and any connectors.

linewarbr · **Posted:** Wed Jul 07, 2010 1:58 pm

Sounds to me like you burst one of the boost hoses - one runs turbo-to-intercooler, the other runs intercooler-to-intake. I know that the Euro 2.5 CRD's have hoses, but since most on here have the North American 2.8 CRD, I'm not sure if burst hoses is a common problem for the 2.5. You may have more luck if you post in the "Liberty CRD. . . . Love that Torque" section, here viewforum.php?f=5 Or maybe a mod could move this thread?

The boost hoses would be the first thing I would check, but they wouldn't explain the engine hanging on to rpm's, that would be an idle function.

Is it a manual trans or an auto? What is your location?

kjhighlander · **Posted:** Wed Jul 07, 2010 2:36 pm

Hi, Its a 5 speed manual and im in the UK. The boost pipes appear to have no damage even though they are perspiring oil. They do feel soft after being off the car for a day. Is this normal with the hoses on the 2.8. I initially thought it was a nackered turbo but after inspecting the vanes and rotation all appeared well. The diaphram could be heard operating when a vacume was created. The solenoid that operates the EGR could be heard operating when idling. Is there any real way to check the EGR is actually working correctly as connecting a plunger to the diaphram part does not activate the plunger/piston. The poston does however move when pushed in but a fair bit of force is to be applied.

ATXKJ, Where about is the Air charge cooler located.

Thanks for the replys

kjhighlander · **Posted:** Wed Jul 07, 2010 2:54 pm

Sorry. I just thought. is the air charge cooler the intercooler.

ATXKJ · **Posted:** Wed Jul 07, 2010 5:31 pm

kjhighlander wrote:

Sorry. I just thought. is the air charge cooler the intercooler.

Yes.

On the 2.8 the Closed Crankcase Ventilation system blows oil into the intake before the turbo
it coats the hoses and they eventually fail - some of the new replacements have a liner that prevents the oil from damaging the hoses. I don't know what the 2.5's used - but I do know that TonyCRD in Euro LOST was pushing for the Samco Si hoses - so I think the factory ones had the old material.

fyi Euro section http://www.lostjeeps.com/forum/phpBB3/viewforum.php?f=103

kjhighlander · **Posted:** Wed Jul 07, 2010 6:48 pm

It would appear to have been fitted with a new air intake elbow prior to my folks buying their jeep so that is in mint condition for now. Id removed the breather earlier and flushed it out with carb cleaner but it wasnt particularly dirty. You have both been very helpful. Salden77 has a similar problem to where it appears both our kj have gone into limp mode but he has very little exhaust smoke, some things are similar. I however do not have a MAF but will be watching his postings closley. Tomorrow ill check the fuel filter and proceed from there. Your fuel filter, is that located beside the tank or is it in the engine bay. The petrol manual shows it beside the tank but I recall seeing a white metal tank in the engine bay refrencing to draining excess water from the fuel system I think. I haven't since gone out to check as the weathers really poor and its pitch black.

Regards

Ive just gone through the euro link that you supplied and low behold the fuel filter in the engine so again thank you for your help and links. Its been EXTREEMLY helpful. I simply was rushing and not looking in the correct places to start with.

ATXKJ · **Posted:** Wed Jul 07, 2010 8:39 pm

The 2.8 filter head is in the same place as the 2.5 - however the 2.8's is molded plastic - the original leaks air in and there's a new design now. The 2.5 has a cast metal head (probably produced by Racor) that should not leak.

FYI - Tony also posts a lot over at KJ country http://www.jeepkj.com/forum/
although they don't talk about CRD's as much

tonycrd · **Posted:** Fri Jul 09, 2010 11:59 am

Going on the syptoms you posted:

Check if no one by mistake filled it with petrol in stead of diesel (easy to smell)

Check the MAP sensor. See this, if you go by the pics I guess you get the idea what to do.

http://www.jeepkj.es/limpieza-del-map-s ... 97-10.html

English/ check halfway down: http://www.ausjeepoffroad.com/forum/sho ... hp?t=67074

Then I would take of the exhaust as close as possible to the engine. Then start it.

You may have a clogged cat or muffler.

You can download my '02-'04 2.5 CRD manual here:

http://www.easy-share.com/1911274889/2.5CRD.pdf

Sir Sam · **Posted:** Fri Jul 09, 2010 2:03 pm

this sounds like the symptoms of a boost hose failure. Check them throughly, and make sure they are not leaking at the clamps.

Also, clean your MAP, it is possibly a very dirty map could cause this, or even a bad MAP.

This is the 2.5 MAP:

(the Bosch sensor on the right)

NEWB. 2.5 CRD engine barley goes

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