Well, looks like I am in need of a head gasket. Looking back I think I have been living with this for awhile. I am at the point now where it overheats on anything other then a mild drive, the coolant consumption is at a liter a day and the tank bubbles like a hot tub.

Unless somebody wants to get a hell of a deal on a CRD with a ton of new parts and options I am resigned to doing this myself by my wallet.

I will add the ARP studs because it seems like a good thing to do so parts wise $7-800 I am guessing. Might as well inspect the rockers as well.

Questions I have-
Can the ARP studs pull the head tight or does this sound like I am past that point?

Can the head be resurfaced? I know the FSM says no but.....

I have freshened up the mating surface on motorcycle heads using a sheet of glass and 120 wet sandpaper and mineral oil. Think I can get away with it on this head?

Can I get the head gasket alone with out the bolts?

Man I really don't want to do this.

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2005 Sport CRD
GDE Eco Tune
245/75 on Moabs
Magnaflow (ish) exhaust

First of all you might get lucky and be able to just do the studs but check all your rockers and Cams since you will have it open anyway. But since yours seems to be pretty far gone I would call GDE and see if they have any Head gaskets left. I have also had my head resurfaced and valve seats redone without and issue but the machince shop didnt see a point really since everything looked great. So unless it just looks crappy i would just put a gasket on it stud it and call it done. Oh and a new thermostat and all new gaskets while your at those can also be had from GDE (Green Diesel Engineering).

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My CRD Build Thread
Soon to Come:more lights

You might get away with just new studs, but I wouldn't count on it. You might also get away with studs and a head gasket; again, don't count on it. The real threat here is a cracked head. This seems to happen a lot with this head, for some reason. Inspect it very carefully indeed for cracks, lest your new gasket be for naught.

Mine cracked between intake valves on two of the cylinders. Should you find yours also cracked there's nothing for it but to replace the head. I understand that it is possible to weld and repair such cracks, but that this is well beyond the abilities of almost everyone.

And yes, your description of the symptoms as well as the coolant loss rate says it is well beyond time to fix the problem. Best of luck.

Given the amount of work involved just to get to the top of the head, I would geek for a reman head and be done with it. GDE may have gaskets. Small warpage the studs may be able to deal with, but there is a limit.

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Grid power- the one true essential

2005 Liberty CRD- ARP studs, Fumoto, Hayden FC, inline Tstat, ETechno 7v GP, Platinum P1, in-tank lift pump.
1983 Volvo D24T
1981 Volvo D24
Dodge Cummins TD
Case 580B
Mitsubishi MT180 diesel
Kubota BX25 diesel