2005 Liberty CRD, approx 90k miles.

The engine has had an EGR light/code since 60k miles and I never bothered to fix it due to how much they wanted for a silly valve. I also have heard that the GDI tune eliminates the EGR code and I will be purchasing the GDI engine and tranny tune shortly.

However, engine is now showing an additional code: low turbo boost.

The motor still runs great with no problems other than an 'occasional' flutter sound after it is coming off of boost, and generally while cooler outside (although not always). This is only intermittent.

It is still under warranty (only until May this year) but the warranty company says they will not cover turbo repairs until the EGR code is addressed (even though the turbo code is very new), and the dealership is following a turbo repair flowchart that says "address EGR issues before anything else".

Any ideas what could be the issue or how to resolve? I hate the idea of spending 700 bucks to repair the EGR and still not know if the turbo has significant issues or not (especially if the GDI tune fixes the EGR), but the warranty is running out quickly.

Thoughts?

Thanks!

You might clear the EGR code by cleaning the valve as described in this thread:
viewtopic.php?f=5&t=59352

The low turbo boost code is likely related to a split in one of the 2 factory turbo hoses that run from the turbo to the intercooler and from there back to the engine. Take both hoses off and carefully inspect them particularly on the under side. Splits can be small and hard to see or very large and obvious. The fix for both is to install Samco hoses (http://www.boostcontroller.com/index.php?category=328) allthough I understand there is an improved factory hose for the turbo to intercooler side. There is lot's of chat on the this forum regarding this issue that you can find with the search function. See for example viewtopic.php?f=5&t=60050&p=666863#p666863.

I cannot say for sure, others may know, but I suspect if you get the GDE tune and have someone like Autozone clear the EGR CEL that you won't get that CEL code anymore without doing the referenced fix as the usual failure mode for the EGR is closed.

By the way when you have the turbo hoses off that a close look at the air intake hose from your air cleaner to the turbo. That hose has a nasty habit of decaying, also from oil, and falling apart down just before the engine end right near where the hose from the "hockey puck" on top of the engine "Ts" into the air intake hose. A replacement is available on line or from a dealer. It's not very pricey and the dealer price shouldn't be much more than online when you factor in shipping.

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Sold to LOST member my 05 Ltd, GDE Stg II turbo + TCM tune, SunCoast TC w. Transgo kit, Steiger window regulators, Samcos, Fumoto valve, 2nd gen filter head with Lub. Spec. bleeder, Hayden clutch & 11 blade fan, inverted spare, P-1 battery, BF Goodrich Long Trail TAs, Etecno1 glow plugs, timing belt at 50K miles/8 yrs

Your egr valve is stuck shut which would be the P0401 code. When air control valve closes to force exhaust gas into the intake, it is unable to because of the egr valve being stuck closed. The fluttering sound is caused by this. Remove the butterfly in your air control valve and see how much better your vehicle runs. Then I would get the GDE tune when you are ready to make the purchase. I went through this same scenerio with my CRD...

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2006 Liberty CRD 275K, JBA 2.5 with Fox Shocks, GDE Turbo Kit, GDE TCM Tune, Suncoast TC, OEM fuel filter housing converted to fit Caterpillar Fuel Filter 1R-0749, OEM themostat housing modified to accept Hemi 203 F thermostat.

Been through the DEQ test with these mods yet?

Good question. Anyone been through a state smog check which reads the OBD codes and a FCV that is not working?

AFAIK the GDE tune blocks the CEL for the flow control valve. So the light will no go on, and it makes no difference driving. I have two OBD readers one picks up the P1140 code and one does not. The current California smog test calls for 1) check smog gear is not modified 2) is CEL light on? 3) a 10 second view of exhaust for opacity and 4) hook up their reader for codes. Not sure whether their reader will see the P1140 code or not, or if it that code will not matter. Will find out around September.

If the Flow control valve is still working, I'd recommend simply removing the plug and capping it with an appropriate dust barrier. Removing the butterfly is a lot more invasive and simply unplugging it won't sent a fault.

Dan

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2005 Silver CRD Limited
245/75R16 GoodYear Duratracs
Fumoto drain | ProVent CCV Filter
Stanadyne FM100 filter | Cummins fuel pump
GDE Eco | SEGR | BoulderBars | FrankenLift | Frankenskids

Took my stock CRD through the DEQ test today. It had been having P0401 codes off and on.
The code cleared a few days ago and the CEL was off when I drove into the test station, but came on when they were testing. The technician hooked up his scanner and told me that the whole ECU was malfunctioning. He didn't realize that it had a diesel engine until I reminded him. When I told it him that it was a non-standard OBDII system, he said that he would have to talk to a supervisor. After he returned, he told the clerk to issue new registration tags. I left with the CEL still illuminated.

I plan to clean the EGR soon, but it would have been even sooner if the CRD had failed the test.

The Harbor Freight scanner now shows another code that looks like "1'112".

Texas does not check Diesel emissions (although I passed - before he realized it was a diesel)
but you can't have a CEL on.

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2005 CRD
stuff
Skeptic quod gratis asseritur, gratis negatur

I have another year before DEQ. I have since put the butterfly back in now that I have GDE tune. I had it out for trouble shooting. One could run with it out until a GDE tune was purchased. I would hate to see anyone waste their time taking the EGR valve out and cleaning it if they are possibly going to buy a GDE in the future...

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2006 Liberty CRD 275K, JBA 2.5 with Fox Shocks, GDE Turbo Kit, GDE TCM Tune, Suncoast TC, OEM fuel filter housing converted to fit Caterpillar Fuel Filter 1R-0749, OEM themostat housing modified to accept Hemi 203 F thermostat.