Intercooler DOA

RFCRD · **Posted:** Wed Jun 14, 2006 8:47 am

Goglio704 wrote:

Welcome to the group. I wasn't taking a shot at you. I went to three dealers before I bought my CRD. 2 out of the three told me stuff that was correct for the Dodge Pickups with Cummins, but wrong for the CRD.

That's OK, the dealer where I bought mine filled their first CRD with gasoline. :shock:

What's better is that the customer was standing there watching. :shock:

GreggD · **Posted:** Wed Jun 14, 2006 7:50 pm

RFCRD wrote:

Goglio704 wrote:

Welcome to the group. I wasn't taking a shot at you. I went to three dealers before I bought my CRD. 2 out of the three told me stuff that was correct for the Dodge Pickups with Cummins, but wrong for the CRD.

That's OK, the dealer where I bought mine filled their first CRD with gasoline. :shock:

What's better is that the customer was standing there watching. :shock:

Did the customer start yelling, screaming, flailing their arms, etc while this was happening? :shock:

The fuel filler cap is GREEN and has the words "DIESEL FUEL ONLY" on it for a reason. :!:

RFCRD · **Posted:** Wed Jun 14, 2006 9:48 pm

GreggD wrote:

RFCRD wrote:

Goglio704 wrote:

Welcome to the group. I wasn't taking a shot at you. I went to three dealers before I bought my CRD. 2 out of the three told me stuff that was correct for the Dodge Pickups with Cummins, but wrong for the CRD.

That's OK, the dealer where I bought mine filled their first CRD with gasoline. :shock:

What's better is that the customer was standing there watching. :shock:

Did the customer start yelling, screaming, flailing their arms, etc while this was happening? :shock:

The fuel filler cap is GREEN and has the words "DIESEL FUEL ONLY" on it for a reason. :!:

I get the impression this customer wasn't too bright. It gets better, Service Manager told he's in for regular service every 3000 miles, the only one who brings their CRD in for regular service. Then he asked me why I wasn't in every 3000 miles. I am convinced they don't have a clue.

GreggD · **Posted:** Thu Jun 15, 2006 7:29 pm

RFCRD wrote:

GreggD wrote:

RFCRD wrote:

Goglio704 wrote:

Welcome to the group. I wasn't taking a shot at you. I went to three dealers before I bought my CRD. 2 out of the three told me stuff that was correct for the Dodge Pickups with Cummins, but wrong for the CRD.

That's OK, the dealer where I bought mine filled their first CRD with gasoline. :shock:

What's better is that the customer was standing there watching. :shock:

Did the customer start yelling, screaming, flailing their arms, etc while this was happening? :shock:

The fuel filler cap is GREEN and has the words "DIESEL FUEL ONLY" on it for a reason. :!:

I get the impression this customer wasn't too bright. It gets better, Service Manager told he's in for regular service every 3000 miles, the only one who brings their CRD in for regular service. Then he asked me why I wasn't in every 3000 miles. I am convinced they don't have a clue.

Sounds a bit like the inmates are running the asylum to me. :shock:

Danno · **Posted:** Thu Jun 15, 2006 7:32 pm

Wheee! I get my CRD back tomorrow! New intercooler, and EGR. I did see 3 other big boxes that my tech had set aside by my CRD, I just wonder what those were. Cant wait to see how much better it runs.

GreggD · **Posted:** Thu Jun 15, 2006 7:49 pm

Danno wrote:

Wheee! I get my CRD back tomorrow! New intercooler, and EGR. I did see 3 other big boxes that my tech had set aside by my CRD, I just wonder what those were. Cant wait to see how much better it runs.

Good to hear that Danno!

I wish I could say the problem with mine has been resolved. Both the Service & Assistant Service Mgrs. have been playing phone tag with STAR for the last two days, with no results. I'm still getting the "P0401" & "P0299" codes, & because of them my Liberty is getting crappy mileage. I'm talking using about a 1/4 of a tank to go about 80 miles. The ASM mentioned to me that it was to the point that I could invoke the Lemon Law regarding the EGR repairs. It's a funny thing that about 40% to 50% of the CRD owners are having the same trouble. I'm not trying to get a brand new Jeep, I just want the one I do have not to have these recurring problems.

T^2 · **Posted:** Thu Jun 15, 2006 8:16 pm

GreggD wrote:

Danno wrote:

Wheee! I get my CRD back tomorrow! New intercooler, and EGR. I did see 3 other big boxes that my tech had set aside by my CRD, I just wonder what those were. Cant wait to see how much better it runs.

Good to hear that Danno!

I wish I could say the problem with mine has been resolved. Both the Service & Assistant Service Mgrs. have been playing phone tag with STAR for the last two days, with no results. I'm still getting the "P0401" & "P0299" codes, & because of them my Liberty is getting crappy mileage. I'm talking using about a 1/4 of a tank to go about 80 miles. The ASM mentioned to me that it was to the point that I could invoke the Lemon Law regarding the EGR repairs. It's a funny thing that about 40% to 50% of the CRD owners are having the same trouble. I'm not trying to get a brand new Jeep, I just want the one I do have not to have these recurring problems.

Have they checked the EGR Air Flow Control Valve? I had the same two codes the last time I had the EGR replaced (I've had two EGR's replaced). I didn't get the vehicle home from the EGR replacement and the two codes where back. I took it back in and they found, after further troubleshooting, that the EGR Air Flow Control Valve was stuck open (causing insufficient EGR flow). They replaced the EGR Air Flow Control Valve and that''s the last I've had problems.

Just as an FYI. The parts replaced for the EGR Air Flow Control Valve:

Part # - Description
---------------------------------
5142799-AA - Valve EGR 14033001
5142806-AA - T/Body EG 14033001
5142613-AA - Gasket EG 9001004

Goglio704 · **Posted:** Thu Jun 15, 2006 8:19 pm

T^2 wrote:

GreggD wrote:

Danno wrote:

Wheee! I get my CRD back tomorrow! New intercooler, and EGR. I did see 3 other big boxes that my tech had set aside by my CRD, I just wonder what those were. Cant wait to see how much better it runs.

Good to hear that Danno!

I wish I could say the problem with mine has been resolved. Both the Service & Assistant Service Mgrs. have been playing phone tag with STAR for the last two days, with no results. I'm still getting the "P0401" & "P0299" codes, & because of them my Liberty is getting crappy mileage. I'm talking using about a 1/4 of a tank to go about 80 miles. The ASM mentioned to me that it was to the point that I could invoke the Lemon Law regarding the EGR repairs. It's a funny thing that about 40% to 50% of the CRD owners are having the same trouble. I'm not trying to get a brand new Jeep, I just want the one I do have not to have these recurring problems.

Have they checked the EGR Air Flow Control Valve? I had the same two codes the last time I had the EGR replaced (I've had two EGR's replaced). I didn't get the vehicle home from the EGR replacement and the two codes where back. I took it back in and they found, after further troubleshooting, that the EGR Air Flow Control Valve was stuck open (causing insufficient EGR flow). They replaced the EGR Air Flow Control Valve and that''s the last I've had problems.

Just as an FYI. The parts replaced for the EGR Air Flow Control Valve:

Part # - Description
---------------------------------
5142799-AA - Valve EGR 14033001
5142806-AA - T/Body EG 14033001
5142613-AA - Gasket EG 9001004

Thanks for the post. I wondered how often the EGR was getting replaced when the Flow Control was really at fault.

Danno · **Posted:** Thu Jun 15, 2006 8:37 pm

Yep, they replaced it about a month ago. Then 2 miles later the EGR went. Seriously, Just 2 miles out of the dealer and it went bad.

Greg, I cant believe STAR is giving you/dealer the runaround on that, Its a known problem and its a fairly straight forward fix. If you got a good service writer on your side your usually gtg, but then again star can be a real stopping point. Might be time for the Lemon Law threat at least. I love this little beast, but any more issues and its gone. I need a reliable vehicle to get my little ones around safe.

GreggD · **Posted:** Thu Jun 15, 2006 8:40 pm

Goglio704 wrote:

T^2 wrote:

GreggD wrote:

Danno wrote:

Wheee! I get my CRD back tomorrow! New intercooler, and EGR. I did see 3 other big boxes that my tech had set aside by my CRD, I just wonder what those were. Cant wait to see how much better it runs.

Good to hear that Danno!

I wish I could say the problem with mine has been resolved. Both the Service & Assistant Service Mgrs. have been playing phone tag with STAR for the last two days, with no results. I'm still getting the "P0401" & "P0299" codes, & because of them my Liberty is getting crappy mileage. I'm talking using about a 1/4 of a tank to go about 80 miles. The ASM mentioned to me that it was to the point that I could invoke the Lemon Law regarding the EGR repairs. It's a funny thing that about 40% to 50% of the CRD owners are having the same trouble. I'm not trying to get a brand new Jeep, I just want the one I do have not to have these recurring problems.

Have they checked the EGR Air Flow Control Valve? I had the same two codes the last time I had the EGR replaced (I've had two EGR's replaced). I didn't get the vehicle home from the EGR replacement and the two codes where back. I took it back in and they found, after further troubleshooting, that the EGR Air Flow Control Valve was stuck open (causing insufficient EGR flow). They replaced the EGR Air Flow Control Valve and that''s the last I've had problems.

Just as an FYI. The parts replaced for the EGR Air Flow Control Valve:

Part # - Description
---------------------------------
5142799-AA - Valve EGR 14033001
5142806-AA - T/Body EG 14033001
5142613-AA - Gasket EG 9001004

Thanks for the post. I wondered how often the EGR was getting replaced when the Flow Control was really at fault.

The EGR Air Flow Control Valve was replaced last December. I thought that they had replaced the EGR valve for a 4th time. 2 days later, the EGR valve did go out. I know the control valve is working properly. It opens & closes like it's supposed to. When closed, with the intercooler hose off, the engine idles smoothly, & the engine tries to go dead when it opens.

Danno · **Posted:** Sat Jun 17, 2006 3:02 pm

Got the CRD back last night, Ran reallly good, better than ever. New Intercooler and EGR and a bunch of gaskets.
But, when I checked the oil level this morning I noticed the engine had oil stains all over it! I have no clue where it came from so I gave the engine a good degreasing so I could better see where its coming from If it comes back.
Could the open ccv have done that?

Just wonderful, and on a Saturday morning after all the dealers are closed.

RFCRD · **Posted:** Sat Jun 17, 2006 5:40 pm

Danno wrote:

Got the CRD back last night, Ran reallly good, better than ever. New Intercooler and EGR and a bunch of gaskets.
But, when I checked the oil level this morning I noticed the engine had oil stains all over it! I have no clue where it came from so I gave the engine a good degreasing so I could better see where its coming from If it comes back.
Could the open ccv have done that?

Just wonderful, and on a Saturday morning after all the dealers are closed.

If you are running an open vent and have the hose down the front of the engine (like some posted photos) it can draft and spatter on the motor.

Danno · **Posted:** Sat Jun 17, 2006 8:56 pm

Ahhh, that explains it then. Ill bet it vented out and the fans shot it all over the engine. Right now I have it zip tied to the side of the radiator..

RFCRD · **Posted:** Sat Jun 17, 2006 10:20 pm

Danno wrote:

Ahhh, that explains it then. Ill bet it vented out and the fans shot it all over the engine. Right now I have it zip tied to the side of the radiator..

Might want to look at using one of the holes in the unibody box-frame. Shove the hose down inside the frame, let the fog and oil run inside the frame. Worked well on my old Olds diesel.

Leader · **Joined:** Tue Feb 16, 2016 11:30 pm **Posts:** 9

Hello. New to the forum. I just removed everything on the front of my KJ to do the timing belt at 121.000 only to find out that it was already done. I noticed oil in the intercooler when I tilted out. I let it drain for two days in my house so it would warm up. I then got a hold of a friend of mine who works on ford power strokes and he told me about a catch can. To make a long story short, I came back to this site for more info on how to work on this jeep since this is my first diesel. I noticed a discussion about a coke bottle catch can. I'm having a hard time visualizing the design. Any pics out there? I was thinking of making one out of PVC with the ccv hose going in at the top and just having a drain valve at the bottom. Do I need to vent this back to the turbo like the factory? Thanks for the info. The site has helped out a lot.

jws84_02 · **Posted:** Wed Feb 17, 2016 12:01 pm

Wow. Waking up an old thread. Any who, a minor point, removing the entire front isn't necessary to do the timing belt. But if anyone prefers doing it that way than so be it.

Oil in the intercooler isn't uncommon. Just make sure you have 6.3 quarts of oil with a normal filter or 7 quarts with the bigger filter.

Some on here also use a provent

Leader · **Joined:** Tue Feb 16, 2016 11:30 pm **Posts:** 9

Thanks for responding. When I removed the air inlet hose, I noticed that the hose clamp to the turbo was loose. Also when I removed the ccv to see if I could clean it I removed the top and found out that someone was there too and removed the element and never replaced it. So now I'm wondering if I put a inline filter from the ccv to the air inlet hose going to the turbo. Any thoughts? Thanks

WWDiesel · **Posted:** Wed Feb 17, 2016 1:58 pm

Most on here install a ProVent filter or similar filter and leave it connected to the inlet boot.... :wink:

Do not vent to atmosphere (EHM) as CCV system requires some vacuum to function properly which is supplied by the inlet of the turbo....
There are several threads on this forum concerning the reasons why this system needs to be connected, do a search...

Sir Sam · **Posted:** Wed Feb 17, 2016 10:23 pm

Wow almost 10 years, that has to be a record right?

Lancer · **Posted:** Fri Feb 19, 2016 3:32 am

Sir Sam wrote:

Wow almost 10 years, that has to be a record right?

No - a record is a circular plastic thing with a hole in the middle! I'll go now.

Intercooler DOA

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