Serious engine power loss – KJ CRD 2006

[kennytj]

Hi guys,
I am having serious issues with my Jeep KJ CRD 2006 which has lost all power when under load at engine speeds over 1500 rpm. It all happened suddenly after completing a 7,500 km extended trip across Oz where there the car did not skip a beat. I have surfed numerous forums but have now become stumped and am hoping someone has seen these symptoms/defect before.

The engine idles fine and only starts surging when I increase to speeds above 1500 rpm and it appears the engine is starved for either fuel or air. The turbo seems to be working fine.

So far I have checked the following with no luck:
Air filter – was dirty, now cleaned
Boost control sensor – was blocked, now cleaned
Replaced fuel filter
Boost pressure solenoid fliter – clean
Boost pressure solenoid – tested electrically fine

Initially there was no CEL and I did not have access to a scanner. After calling the NRMA for a stickybeak he scanned it and came up with the code P0299 – Boost pressure control. To be honest he had no real idea and just cleared the code for me. Most recently I took it to a local repco mechanic who after about an hour was pretty stumped. The codes he pulled were:
P1001 – Ignition switch off time
P0201 – Injector cylinder 1
P0300 – Random multiple cylinder miss fire
P0299 – Boost pressure control

The car does not seem to be misfiring and idles perfectly. It only starts surging when put under load and I am of the impression that some of the codes can be false and generated from another defect. As an aside the CEL is not illuminated, even after attempting to drive it for a few kms.

I am not desperate to have the car running at the moment and would like to try and fix it cheaply myself rather than go cap in hand to a Jeep dealer. Can anyone offer me some good advice or clues...?

kennytj

[Pipeliner]

Sounds very similar to the symptoms I had recently - turned out to be a small split in a turbo hose (about 30-40mm long). Mine didn't throw any codes at all to start with, then finally produced a low boost code.

have you checked the turbo hoses to and from the intercooler?

[glend]

Yeah, as Pipes says, I'd start with a hose check, especially if your still running stock hoses. Feel around them with your hands as someone tries to rev the engine, it doesn't take much of an opening to lose boost. You could also have a loose hose clamp and maybe the hose has pushed off the neck a little to allow a leak. The third possibility is the EGR pipe flange, which has been known to break just at the Exhaust manifold connection end (under the heat shield below the coolant reseviour bottle). There were a batch of those pipes that had bad welds on the flange end piece. When they break there they allow the exhaust pressure to bleed out through the hole and then you have degraded turbo pressure which means low to no boost. You'll need a dealer to fix that. Hopefully it's just the hoses, and turbo hoses can be ordered from a number of online sources in Oz, get teh Samco silicon hoses as repalcements and then you'll never have to worry about them again. Hyperflow usually has them in stock.

http://www.hyperflow.com.au/index.ph...ucts&id=TCS380

[kennytj]

Pipes and glend,

Right on the money with the defect - thanks heaps. Pulled off the charge air cooler hoses and found the charge air cooler outlet hose with a 50mm split on it. Will follow up on the samco silicon hoses as a suitable replacement. I assume they are still much cheaper than the Jeep equivalent.

Interesting to note there was minor oil residue throughout the inside of both hoses. I figure they are original fit and have been there since build. Any idea how much carry through is normal - or any at all?

kennytj

[glend]

If you clean that up really good and wrap it in silicon tape it might work for you until the replacement hoses arrive. Any good silicon tape will do the job, they go by the name of Rescue Tape if sold at ARB but Sailor tape at Bunnings is pretty much the same thing.

Oil inside the hoses is normal if you don't run an oil recovery system (like the Provent). Oil is what destroys the original equipment hoses (which were not fuel rated). You won't have any problems with the Samco silicon hoses.

[kennytj]

Glend,

Thanks for that. I now remember seeing stuff on the air/oil separator system and will follow that up. Is there any point to trying to clean out the oil that will be within the charge air cooler, and if so, any tips on how to do it without pulling the cooler out?

kennytj

[SeaComms]

I find it amazing that two mechanics can look at a vehicle, especially when one of them pulls a low boost fault code and no one spots the 2in split in a turbo hose? LOL.

Take it to the AJOR forum and within an hour or so the correct diagnosis is offered