CRD Intake elbow clogging

tomasnc · **Posted:** Sun Mar 02, 2014 6:05 pm

I posted a few days ago on the lack of power from my CRD. I have a new fuel filter and still zero improvement.
With no change in power I am trying to narrow down my options. Mileage is 146,000

http://i.imgur.com/2Loj2we.jpg

How many members have experienced a restriction as severe as this one the weeks101 posted? The air flow restriction has to be extreme.

I don't where else to look besides the restricted air flow.
My CAC hoses are sound.

Thanks,

Tom

thermorex · **Posted:** Sun Mar 02, 2014 8:26 pm

Depending on the mileage with egr on, I can see this buildup in an engine with 120-150k. Mine ran with maf unplugged from 80k to 120, when I did tune it with gde and replaced the rockers. My elbow had about half that buildup.

mass-hole · **Posted:** Mon Mar 03, 2014 11:30 am

FTW: http://www.lostjeeps.com/forum/phpBB3/viewtopic.php?f=5&t=78238

tomasnc · **Posted:** Mon Mar 03, 2014 11:59 am

Mass,

Thanks, I have been following that thread. I have the CRD in the shop now and am opening up the intake and hope there will lay my problem.
I have now air in the system and just enough power to move the car around the yard.

I drove over to a neighbors shop and was hoping his computer would tell something. His reader showed the 3.7L and 2.4L gas engines. No diesel engine listed and I have no CEL so I'll have to trouble shoot old school style.

WWDiesel · **Posted:** Mon Mar 03, 2014 1:14 pm

And they dare to call this pollution control? B.S. :evil:

Pass the Kool-Aid please....if you believe this. :5SHOTS:

This is the very reason anyone with a CRD needs to disable the EGR valve and take the CCV out of the turbo intake pipe... :2cents:

weeks101 · **Joined:** Mon Jul 30, 2012 3:29 pm **Posts:** 747

Was it a gradual or sudden loss of power?

tomasnc · **Posted:** Mon Mar 03, 2014 1:47 pm

Weeks101.

Sudden loss of power. I have found that 3 out of 4 injectors are leaking. The injector closest to the firewall is bubbling.
I'm wanting to pull the the intake pipe and see how badly plugged it is.

tomasnc · **Posted:** Mon Mar 03, 2014 7:48 pm

So.... this is what we did today

1. Swapped out a turbo I had from my first CRD. The turbo on this engine had major shaft movement on both axes. My 90,000 mile engine's turbo was like new compared to my 146,000 current engine.
2.Installed SAMCO hoses from the old CRD.
3.Cleaned air filter, etc.

Put it all back together and very little change if any :banghead:

Something I have noticed is that the engine will not rev higher than 3000 RPM. This is true with air filter installed or removed and with the CAC hoses installed or not.

I have not played with the EGR flow control valve. The photos that weeks101 posted are alarming... this is that only restriction that I can think that may be killing my power?

Other than the FACET inline boost pump I'm at wits end.

Thanks,

Tom

WWDiesel · **Posted:** Mon Mar 03, 2014 9:31 pm

Got my FCV elimination kit today from Weeks101, good looking kit well worth the money. Started removing parts to install kit.
My OEM elbow crud buildup was not near as bad as some posted.
While in there, removed the EGR valve, EGR cooler and all associated plumbing, and FCV/elbow. Made a lot of room!

Anybody need some parts? :lol:

Plan to finish tomorrow evening. Getting old gasket off intake seems to the be the biggest problem, that sucker is really stuck on there. :banghead:

Pictures:
Parts removed

New space

tomasnc · **Posted:** Mon Mar 03, 2014 9:38 pm

How are you blanking off the cooler opening?

IIRC the weeks101 kit comes with on one cover plate.

WWDiesel · **Posted:** Mon Mar 03, 2014 10:07 pm

All coolant lines have been removed. Replaced "Y" on top of motor with a straight fitting. Plugged hose on side of head under intake. Exhaust is blanked with plate.
Bunch of junk removed and gone off of the motor... :rockon:

Jay ne Ohio · **Joined:** Sun Dec 12, 2010 5:49 pm **Posts:** 216

tomasnc wrote:

I posted a few days ago on the lack of power from my CRD. I have a new fuel filter and still zero improvement.
With no change in power I am trying to narrow down my options. Mileage is 146,000

My guess: broken rocker. My red 2006 had two broken rockers at 122k and lacked power. I was on the same path as you. I tried fuel filter, replaced injector (code was misfire on cyl 1), blocked off EGR, checked timing. Finally opened it up and found the broken rockers:

weeks101 · **Joined:** Mon Jul 30, 2012 3:29 pm **Posts:** 747

tomasnc wrote:

Sudden loss of power. I have found that 3 out of 4 injectors are leaking. The injector closest to the firewall is bubbling. I'm wanting to pull the the intake pipe and see how badly plugged it is.

Did you pull the intake elbow yet? Was it clogged?

A sudden loss of power suggests a more sinister issue. A gradual loss of power would point to intake elbow clogging, but this has been reported to also cause rocker failure. Rocker failure certainly would cause a sudden loss of power.

Probably not the answer you're looking for. Probably time to pull the cover and inspect your rockers.

If you need replacements, IDParts has them for a fair price:

Full Set: http://www.idparts.com/catalog/product_ ... ts_id=3065
Individual: http://www.idparts.com/catalog/product_ ... ts_id=3064

tomasnc · **Posted:** Thu Mar 13, 2014 1:14 am

Seth, thanks for the reply.

I just received the rockers.

Are any members using a Perma-tex liquid gasket in lieu of the OEM gasket?

rotordriver · **Joined:** Mon Mar 28, 2011 8:35 pm **Posts:** 44

Did you ever find the problem? My CRD is doing the exact same thing. Max rpm 3000 and it is not the rockers.

CRD Intake elbow clogging

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