I had a coolant leak this morning near the EGR valve area. I drove it to the nearest dealer and after inspection I was informed that the leak derived from a broken coolant hose attached to the EGR vale.

The service manager said it will take 3 1/2 hours labor to replace 3 hoses around the EGR valve. Total $478.00.

I can't believe that replacing a small hose takes so much time.

I need some feedback ... Is this a difficult job?

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2006 Liberty Limited CRD, Deep Beryl Green, Yeti tune, Arp studs, new cams, rockers, lifters, TB. "Green Monster"
2005 Liberty Sport CRD, Deep Beryl Green, GDE Hot Tune, ARP studs. "Rocket"
1982 Fiat 124 Spider Convertible. "Fiona"

it's not "difficult" but there's lot's of stuff to pull off to get to the EGR valve. Might as well have them put in a new valve while they're there.

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2006 CRD http://www.UtahPowderCoatings.com/ http://www.gorecon.com/ I'm kind of a big deal.
RL rear bumper, ARB front bumper, Mile Marker winch, Power Tank, Skids by Mopar & Skid Row, RL Super Skink Sliders, 235/85R16 MTR, Air Flow Snorkel, DTT, 4.10 gears, Frankenlift II, Katskin leather, JL Audio stereo, Rosen video.

I wonder if you cant just bypass the EGR cooling considering you have the ECO tune?

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20 year owner of Libby CRD!
2006 LTD Bright Silver loaded with all the needed mods, CCV intact.
Equipped with HDS thermostat, plenty of heat, faster warm-ups, increased fuel mileage.

Rubber plugs could be installed on the feed and return ports for the EGR cooler. This would solve the leak issue much cheaper...sorry racertracer, it did not come to mind earlier today. There are some other benefits to doing this besides solving your leak.

By blocking the coolant flow to the EGR cooler, the coolant flowrates to the cabin heater core and oil cooler will increase. This means better heating during the cold winter months, with slightly cooler oil temps in stable running and even better for towing heavy loads.

One port is on the upper block (drivers side) just behind the intake throttle and air inlet elbow, these both need to be removed to access the port. The other port is just above the thermostat. There is a 3-way plastic elbow and the EGR circuit is the top port on the Y elbow and flows through a steel tube across the top of the engine. This end can be plugged at the Y fitting.

Definitely DO NOT do this if not running a GDE tune as it will cause the EGR valve to fail and more lights on the cluster!

Good idea flman!!

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Providers of wholly developed aftermarket solutions for the KJ CRD.
(248) 977 - 9531

That sounds good. What size plugs would they be and where could we find them?

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TWO Identical 2005 Liberty Sport CRDS
#1 CRD, 174,000 miles. Eco tune, Samco hoses. Mobil1 0-40w used since day one
#2 CRD 143,000 miles. Bought used (unknown history) with 100,000 miles. Samco hoses.
Eco tune, new rockers, and 5 volt glow plugs installed at 124,000 miles

I got the car back today and they replaced 2 small hoses.

1. part # 5170054-AA Hose 1 ea. $40.00
2. part # 5170053-AA Hose 1 ea. $40.00
3. part # 5003552-AB Clamp, Oil 4 ea. $5.00
4. part # 4596424-AA Clamp, hose 4 ea. $3.25
5. part # 68048953 Antifreeze 2 ea $24.15

Plus 3 hours labor @ $98.00

$473.31 total

I wish I knew about the plug repair earlier.

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2006 Liberty Limited CRD, Deep Beryl Green, Yeti tune, Arp studs, new cams, rockers, lifters, TB. "Green Monster"
2005 Liberty Sport CRD, Deep Beryl Green, GDE Hot Tune, ARP studs. "Rocket"
1982 Fiat 124 Spider Convertible. "Fiona"

Could only one port be plugged, one that is easy to reach making for a simple fix? This would allow for a quick reconnect if one decided to sell the CRD and bring it back to its original state.

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2006 Liberty Limited CRD, Deep Beryl Green, Yeti tune, Arp studs, new cams, rockers, lifters, TB. "Green Monster"
2005 Liberty Sport CRD, Deep Beryl Green, GDE Hot Tune, ARP studs. "Rocket"
1982 Fiat 124 Spider Convertible. "Fiona"

I had a leaky EGR valve coolant hose. The dealer mechanic forgot to tighten a worm drive clamp fully after installing a new EGR vale assembly. My very slight drip (only when warm) would loose about a qt. of coolant per day! I really appreciated the low coolant alarm. FYI, I found the coolant in stock at NAPA. IIRC, it was about $12 per gallon.

I was able to access the hose and clamp by removing the fuel filter (still attached to the fuel lines) and filter mounting base from the firewall. I don't see how you could get to it otherwise.

3 hours for a dealer mechanic seems a bit excessive to me. It might take ME 3 hours, though.

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Past CRD's: 2005 and 2006
Past diesels include: 6 VW TDI's, 4 VW NA's, 83 Chevy NA G20 Conversion Van, 82 Mercedes 300TD
Other past vehicles: 40 Porsches, 50 Air Cooled VW's, etc.

Only those who do not move do not die...but are they not already dead? Jean Behra

GDE: Don't you need to interconnect the two hoses as to not stop flow? Or is the EGR fitted in a 'bypass' system?

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Cherokee 2,5 CRD: sold - Wrangler TJ 2.5: gone - Touareg V10 TDI: new toy

Solo Liberty en Español: Jeepliberty.es

The top port on the EGR valve should be the supply (branched off from the EGR cooler inlet) and the bootom port returns to teh EGR outlet. The coolant pressure drop across the EGR provides enough delta to cause a small flowrate around the EGR valve for cooling. You could block these off, but it would lead to an even earlier valve sticking issue.

_________________
Providers of wholly developed aftermarket solutions for the KJ CRD.
(248) 977 - 9531