Odd noise and loss of power (Intermittent)

Monomer · **Joined:** Tue Mar 10, 2015 2:10 pm **Posts:** 31

Greetings all!

I'm posting on behalf of my Father, who happens to own a nice 06 CRD. Most of my experience is with VW/Audi (both gassers and diesels!) so i'm only slightly lost working on it. (I REALLY wish chrysler had a system like VAGCOM...)

Anyways, This issues comes up intermittent maybe once a month. Both cold temps and warm. Upon Scanning with a generic OBD2 reader, I get a p0300. I didn't think diesels get those! When it happens (and it's never happened when I'm in the jeep) it struggles to get above 30mph, has NO power and likes to stall. Makes an odd ticking noise that my father describes as a ujoint on it's way out. Just started it up and drove a mile, NO ISSUE WHATSOEVER. No odd noises, nothing.

The known issues right now:
-Cracked plumbing going to the turbo
-GP #3 has ceased to be (unrelated issue)
-Charge plumbing is in meh condition
-Crap wiring job to the CKP sensor. Looks to be spliced in with butt connectors.

Stuff that's been done:
-GDE hot ecu tune
-GDE trans tune
-New bullet converter
-GDE GP relay tune thing (5v gp's)
-Fuel pre-filter
-Fuel lift pump
-New thermostat housing to replce the broken in-line one
-Maf and Map cleaned
-EGR deleated

ESP light also came on, but that's likely to be a rear wheel sensor, hopefully unrelated. I think it's eather a massive boost/maf issue or the CKP acting up. Just want to be sure and not throw parts at it. The plumbing (atleast the one I know has a split in it) is getting replaced regardless, but it's not on the charge side so I don't think that's the cause of the issue. Glow plugs will be done as soon as it warms up a bit.

From what it sounds like to me, it's the ECU losing it's mind due to a sensor somewhere, and not fueling properly.

papaindigo · **Posted:** Tue Mar 10, 2015 3:01 pm

More information needed and comments:

Info needed:
1. what plumbing to turbo is "cracked"? - filter to turbo hose, oil feed line, oil drain line, CAC hose, other
2. GP 3 has ceased to be? - if it's an OEM ceramic it needs to be replace immediately as they tend to shed pieces after failing. In addition I note you have the ECU tuned for 5v glow plugs. Are you still running 3 of 4 7v ceramics or 5 v metal OEM? If you are running the OEM 7v ceramics with 5 v programming I don't have a clue what weird things that might or might not do.
3. what do you mean by "charge plumbing"? - if it's the CAC (turbo>intercooler>intake) hose that could easily be your problem.
4. what's the CKP sensor?
5. what kind of fuel lift pump and where is it located? In line is ok but doesn't prevent air in fuel if the quick disconnects by tank are leaking air.

Comments:
1. weakish battery and/or low output from alternator can cause weird ECU behavior. Test alternator output and load test battery.
2. 06s are known for occasional chaffing of the wiring harness INSIDE the bundle behind the fuel filter head which can result in intermittent short problems and attendant weird behavior.

Monomer · **Joined:** Tue Mar 10, 2015 2:10 pm **Posts:** 31

1.Turbo inlet hose, from the filter to the turbo.
2. They are non-ceramic 5v plugs. One is regestering as open, no resistance (#3)
3. Charge plumbing: the hoses with boost. I'm trying to talk him into a semco kit.
4. Crankshaft position sensor, located in a rather tight spot on the top of the bellhousing of the trans, passenger side.
5. Lift pump is a walbro FRB. I installed in right by the tank. Also dropped the tank to uninstall the quick disconnects

I'll test the alternator tomorrow, aswell as the battery. The battery is only a few years old and was checked recently. I looked at the wiring harness months back, shows no wear. I'll double check.

thermorex · **Posted:** Wed Mar 11, 2015 7:59 am

So is the jeep going in limp mode? Usually boost issues have their own code. The p0300, is it a misfire code? I got a misfire code several years ago, due to a faulty injector plug, the fix was to remove the Orange dust ring since that didn't allow the plug to properly seat in the injector, you may have the same issue. First, I'd fix all the turbo related hoses. You can check cps (in jeep world we call this crank position sensor - even though can be confused with cam position sensor, but that's something relatively "new" on jeep engines) with a blow drier or measuring the resistance when warm and cold. You can warm it up to about 230-280 degrees and see if the readings go nuts.
Regarding the fuel pump, is it a flow through and is it confirmed to be working properly?

My take on the battery/alternator: if you start the jeep and it idles fine for a while, the battery is ok but the alternator may not charge properly. Of course, doesn't hurt checking them both since its so easy to do.

Monomer · **Joined:** Tue Mar 10, 2015 2:10 pm **Posts:** 31

The p0300 code is a code for random misfires. I'll be sure to look at the injector electrical harness.

I'd really rather not yank the CPS to check it. They really didn't make it easy to get too. Theirs no spot in a harness anywhere to grab voltages from? Although, I suppose its a PWM sensor...

The lift pump is a flow-through, and well recommended in the VW tdi community. I originally planned to use it for my 1.6td build. Has high enough flow and pressure ratings for use in a crd (from what I gather) It's been on since summer without any issues. I have a pre-filter that's clear, and no bubbles/air in it. Has gobs of power when it's running right.

user113 · **Posted:** Thu Mar 12, 2015 12:12 am

Fuel pump or not, I would suspect air getting into the fuel line, perhaps as the fuel pump sucks it through the tank fitting.

Monomer · **Joined:** Tue Mar 10, 2015 2:10 pm **Posts:** 31

user113 wrote:

Fuel pump or not, I would suspect air getting into the fuel line, perhaps as the fuel pump sucks it through the tank fitting.

The tank quick disconnects are replaced with normal hose. I see zero air bubbles in the pre filter.

thermorex · **Posted:** Thu Mar 12, 2015 6:56 pm

The reason I suggested to take the cps out is that it's easier to warm it up (stove, warmer, hair drier, etc). It's quite a pain to do that and may require you buying a new one if you mess it up while taking it out... Kind of hard to measure it while on the jeep though, unless you have a lift. And the warming problem is still present, as you can idle the engine and cps won't get too hot and will work fine, and could only act up when over some temperature. Fyi, a cps is not that much, I believe I got mine for 70-ish new? Remember it's a jeep not an Audi, lol.

Can it be possible to have an air leak somewhere after the fuel filter (engine compartment)? Is the filter pump hard? Can it be some air after the filter and before the cp3? Normally the cp3 lines are tied pretty well, haven't heard of them getting loose, but can it be from there? I'd guess whatever is passed cp3 you'll see a fuel leak. The only other idea I have is to try reconnect the injector plugs and both rail sensors, maybe something is not touching properly, also see if they go back relatively easy and the Orange rubber does not push them back a bit after they click in.

Whiskey · **Posted:** Sat Mar 14, 2015 11:00 pm

I had the same thing as was described in the first post happen to me tonight, threw the P0300 as well. How ever tonight was the first time it happened. Plugged my OBDII reader in and the only parameter that was out of place was the fuel pressure, at 30-40 mph (which is all I could do) it was reading about 16,000 psi. My dad (who was with me at the time) and I are thinking there is a fuel shut off valve that is sticking and not letting enough fuel through. Does such a thing exist on these jeeps? The engine finally stalled out as I went to get turned around to back into the garage. Cycled the key and it kicked right over and ran perfect. Ran it around the block, flawless, smooth, torquey, everything it's supposed to be. Over the last few weeks when I first start up in the morning and sometimes when I go to leave work the jeep feels a little down on power, then it will all of a sudden spring to life and push me into the seat a bit. Another reason I'm thinking sticky valve if it exists.

olypopper · **Posted:** Sun Mar 15, 2015 2:22 am

Whiskey, you're jeeps problem almost sounds like fuel gelling???

Whiskey · **Posted:** Sun Mar 15, 2015 7:40 am

I'm not saying it wasn't, but it was at least in the mid 40's last night and it's never done that when it's -30 out. However it did stop putting powerservice in a few weeks ago so it could be all the difference it needed.

Odd noise and loss of power (Intermittent)

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