CRD Puzzle SOLVED

Smacker · **Posted:** Sat Jul 14, 2012 4:33 am

Loss of power with lots of black smoke, constant air in fuel filter ( returns after a few minutes of driving)
and a p0299 ( Turbo Underboost Condition) as soon as I stomp the go pedal.
There is also a slight loss of coolant (1 QT per month) with a puff of white smoke when starting once in a while.
I am original owner and have always been fond of the little tractor but this is about to drive me nuts…
I have checked the following:
Removed boost hoses and checked for leaks rips or tears. (twice)
Removed air box to turbo Connector and checked, also twice.
Pressurized boost hoses thru CAC cooler to 15# to check for leaks, NONE. 16 # will shoot a beer can about 30 feet.
Checked vacuum to turbo controller in and out, up to spec.
Turbo spins freely with no noticeable play.
Turbo variable vane control arm has ½’ to ¾’ movement with vacuum removed..
ACV valve opens on shut down and when manually shut, springs back open.
Cleaned Map sensor twice, along with Maf sensor.
Changed Fuel and air filter and checked for mice in airbox.
Tried a can of seafoam with Italian tune up.
I have been reading posts for about a month and have not been able to nail down the problem. I have not had the CRD to the dealer since it was neutered,
And have been avoiding them like the plague. I have been leaning toward a head gasket replacement to possibly cure the coolant leak and puff of white smoke.
But I can’t figure out the Underboost condition.

Any suggestions or ideas would be welcome!!

GreenDieselEngineering · **Joined:** Sun Jun 07, 2009 5:10 pm **Posts:** 1111

It is feasible the EGR valve is partially stuck open and bleeding boost out the exhaust. It may be worth while to remove the valve, clean and reinstall. Are there any other fault codes?

Smacker · **Posted:** Sat Jul 14, 2012 11:37 am

GreenDieselEngineering wrote:

It is feasible the EGR valve is partially stuck open and bleeding boost out the exhaust. It may be worth while to remove the valve, clean and reinstall. Are there any other fault codes?

I got an overboost code one time, but haven't seen it lately.

papaindigo · **Posted:** Sat Jul 14, 2012 11:53 am

For EGR cleaning see viewtopic.php?f=5&t=59352&p=659410#p659410 and viewtopic.php?f=5&t=62495

naturist · **Posted:** Sat Jul 14, 2012 5:26 pm

You might also check the intercooler for leaks. The black smoke and underboost suggest an air leak SOMEPLACE. I recall somebody on here found a broken intercooler once.

The coolant loss is small enough to be a lot of things. There are hoses down near the turbo and EGR valve that could be leaking . . . I had THAT problem once upon a time myself. Leak was small, like yours, and fixed by changing those hoses. There have also been instances of leaky coolant reservoir and caps. The cap is easily available from NAPA and other stores, it's a universal one. The reservoir, however, is special to this vehicle, and expensive, although I have a used (but intact) one I could sell you cheap if yours is leaking. (I replaced mine with new, thinking it had a leak that turned out in fact to be a head gasket.) I wound up having to replace the head too (cracked in at least two places) for about $3500 (did the timing belt and water pump while we were in there.)

good luck!

Sir Sam · **Posted:** Sun Jul 15, 2012 12:36 am

Just to be clear, you have verified that the VGT actuator moves during normal operation(IE watch the rod move while someone else revs up the engine?)

The plastic line can melt between the solenoid and the actuator, you pull a vacuum on it and it appears good, but its melted shut.

Smacker · **Posted:** Sun Jul 15, 2012 2:42 am

GDE:wasen't sure if the EGR was even functional after the tune, but could possibly be the cause of underboost. The EGR has not been touched in 100k miles.

Papaindigo: thanks for the link, I have been searching, but couldn't find it....

Naturist: I pressurized the intercooler with boost hoses attached and its air tight.....

Sir Sam: I disconnected the vacuum line while watching the linkage and got 1/2" to 3/4" rod movement, but will verify action with throttle.

Thanks for the Help, hope to get Libby back to torqy tractor status soon!!

Will update when I get back home.............

Smacker · **Posted:** Sat Jul 21, 2012 9:40 pm

What a job removing the EGR and ACV.(6 hrs and a pile of black crap in the Intake after the ACV) Cleaned and reinstalled and still low boost P0299. Checked the boost linkage again and found maybe 1/4" to 1/2 " movement when disconnected from vacuum and 1/4" while engine is revving with no load. Might tear off and clean the vane controller on the top of engine to see if that helps. I noticed black goo dripping from it when I disconnected the hose. I think I'm getting closer to the problem. Seems the turbo linkage should move more than 1/2"! IDK

Smacker · **Posted:** Sun Aug 12, 2012 1:26 pm

Puzzle follow up: Ordered a new vacuum modulator and should be here tomorrow. Installed a Facet lift pump and bypassed the turbo modulator and the power has returned. I guess my problems came from multiple symptoms and problems showing up at the same time. Will update when Vac Modulator is installed...

Hoosier CRD · **Posted:** Mon Aug 13, 2012 6:27 am

Smacker wrote:

What a job removing the EGR and ACV.(6 hrs and a pile of black crap in the Intake after the ACV) Cleaned and reinstalled and still low boost P0299. Checked the boost linkage again and found maybe 1/4" to 1/2 " movement when disconnected from vacuum and 1/4" while engine is revving with no load. Might tear off and clean the vane controller on the top of engine to see if that helps. I noticed black goo dripping from it when I disconnected the hose. I think I'm getting closer to the problem. Seems the turbo linkage should move more than 1/2"! IDK

1/2" is about right. This linkage moves the unison ring for the vanes on the exhaust side of the turbo. This is a precise adjustment set during turbo assembly and should not be field adjusted. Hope this helps.

FWIW,

Hoosier CRD

eric f150 · **Joined:** Mon Aug 13, 2012 9:04 am **Posts:** 5

I would spend a bit more time trying to find out whats wrong with the fuel system. Without enough fuel you will never build enough boost. Have you found out why there is air in the filter housing?
A Pinhole somwhere in the fuel line could cause air to be sucked in but not always leak out since its under vacuum not pressure. also check at the fuel heater plug. Somtimes just sticking shop air into the filler neck will pressurize the system enough to find fuel leaking out.

Smacker · **Posted:** Thu Aug 16, 2012 9:16 pm

The saga continues, Installed new vacuum modulator to turbo and a new map sensor and still get P0299 as soon as I stomp on the go pedal. But on the bright side I am gaining a few spare parts for future repairs...........

Smacker · **Posted:** Mon Aug 20, 2012 6:07 pm

After beating my head against the wall and trying to find what I was overlooking everything was telling me the turbo vanes were stuck and not opening. I ran all over town today running errands and got the Liberty nice and hot, put a Mityvac vacuum pump on the turbo vane controller and pumped to 30# vacuum several times and released. Then drove to a Steep grade about a mile from the house and was planning on spending a few hours of WOT going up this 2 mile grade. Stopped at bottom of hill and reset the CEL P0299, shut off overdrive and proceeded to drive it like I stole it. First run kicked the CEL back on within a 1/4 mile, black smoke billowing like I was on fire and almost got to 40mph, stopped about 1/2 way up hill and punched it again and the turbo came alive. The black smoked cleared up and speed shot to 85MPH!!! Came down the hill and reset the P0299 code again and started up the grade again. She ran like a scalded dog, no CEL and no smoke. :pepper:

Would like to thank everyone who chimed in with clues to this problem. I had Jeep to dealer a week ago for L27 control arm recall and almost had them look at it. Not...........
I just couldn't do it. Thanks again LOSTJEEPS!!!!!!!!!!!!!!!!

Randy B · **Posted:** Mon Aug 20, 2012 6:21 pm

Glad to hear you got her fixed

msilbernagel · **Posted:** Tue Aug 21, 2012 1:47 am

Note to the moderators!

Let's add "Drive it like you stole it!" to the list of mandatory scheduled routine maintenance. :JEEPIN:

Seriously.. probably mandatory for FCV, EGR, and Vane controller health. Perhaps the CAT as well.

Mark

Hammy713 · **Posted:** Tue Sep 04, 2012 11:17 pm

Just so I understand this correctly, the problem was it not being driven hard enough so by doing so fixed the issue?

msilbernagel · **Posted:** Wed Sep 05, 2012 1:49 am

Yes.

Carbon build up in the variable vane assembly of the turbo can cause problems, and exercising the turbo through it's full range seems to help avoid letting it build up to the point where it prevents normal operation.

You just take it to a nice hill and stomp on it every once in a while!

Mark

geordi · **Posted:** Wed Sep 05, 2012 2:36 am

Great news!!!! glad it is working for you, and all it cost was some diesel fuel out the tailpipe.

Sent from my iPad using Tapatalk HD

Hoosier CRD · **Posted:** Wed Sep 05, 2012 6:14 am

Sounds like the good ole "Italian Tune-Up" works again. Glad you got your mongrel running better.

Hoosier CRD

wifes05crd · **Joined:** Wed Jul 04, 2012 8:28 am **Posts:** 22

As a fairly new owner of our '05, how much black smoke is normal when putting your foot in it? After hard acceleration from dead stop (great fun), I look back and can see there is some smoke but it doesn't seem excessive and it doesn't continue. Its more like a one time event. We have GDE Eco Tune. Thanks for any comments.

CRD Puzzle SOLVED

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