Topic: KJ DIY NIGHTMARE (Read 16385 times)

rob.79 · « **on:** March 28, 2008, 07:57:28 PM »

:shock:
Hi all,
i'd like to tell you how much fun i had recently repairing my 2002 2.5CRD KJ LIMITED
It started one sunny afternoon in october, when my KJ started to randomly cut out, at some of the worst moments, on roundabouts and on the motorway! being a mechanic with access to diagnostic equipment
i plugged her in, but nothing was found? i checked the obvious, fuel timing, i could't fault it, so off to the local jeep dealer for some help, they where happy to take my cash, but couldn't find any problem at the time of testing, and said there master tech, suspected a fault within the high pressure fuel pump, and that a new unit was almost £1000.
so, i searched high and low, no second hand units to hand and recon specialists telling me they have not seen many and they don't know if they can do anything with my old unit, i chased up a unit from bosch, and after some chasing found a new unit for £550, woo.
so i fitted the new pump, took me a full day, but with some painted on timing marks and a big hammer i managed, did it fix the problem , "did it B&$£OX" :cry: :cry:
how stressed was i at this point, so i had a cuppa and weighed up the situation, i took a look and found that to take off the head, you need the injectors out, due to the injectors being through the cam cover and the hole in the cam cover being smaller than the injectors. bet the injectors wont come out!!!!!! so my only option, after trying pullers and sliding hammers and pepsi and raising the whole jeep off the ground with an engine hoist attached to the injector and left for 24 hours.
so i spent 2 whole days with a small 8th drill(several 8th drills) demolishing £800 worth of injectors so i could remove the cyl head and press out the remiander of the injectors, which took a 15ton press and a big hammer to remove,
so now the jeep has new fuel pump, 4 new injectors as well as new head gasket ,bolts, seals, oil filter, etc. and i'm £1800 lighter, lucky me.
if your still awake after reading this, thank you, i just needed a good rant and wanted to share my experiance, i'm keeping the KJ and hoping it keeps going trouble free for a long time..........

MOCAJ · « **Reply #1 on:** March 28, 2008, 08:02:53 PM »

well done but ouch

tim_aka_tim · « **Reply #2 on:** March 28, 2008, 08:29:40 PM »

Oooouch! Feel for you mate. There's only one thing that can relieve your money from you faster than a Jeep - that's a Jeep with a VM engine...
Bugger :evil:

kj lad · « **Reply #3 on:** March 28, 2008, 09:35:17 PM »

OOOOOOO....... Maybe I ought to change to a TJ quicker than anticipated!

How many miles had it done?

Ian

MOCAJ · « **Reply #4 on:** March 28, 2008, 09:44:01 PM »

40k on the clock, it was a good truck apart from the usual lower ball joint issues

changed twice in that period

rob.79 · « **Reply #5 on:** March 28, 2008, 10:04:41 PM »

kj lad · « **Reply #6 on:** March 28, 2008, 11:40:14 PM »

Where in the north east Rob? I'm in Teesside. Had my 2002 2.5 CRD KJ from new with no major issues. Lower BJ's and upper BJ's changed twice in 56k miles. But mine is lifted so I expect some issues with suspension, but those costs for your repairs!!!!!!!!!!!!

Ian

rob.79 · « **Reply #7 on:** March 29, 2008, 09:55:24 AM »

hi ian,
not far away mate, in costa del DURHAM, the KJ had ball joints replaced by the dealer befor i bought it, so hope i'll not be replacing those to soon, i did here there was some sort of product recall for them? as for the repair costs, i dread to think what it would have cost if i'd left it in the hands of the old jeep dealer to sort it out!!!!!!!!! :shock:
pleased i'm able to have a go at things myself.....

MuckShifter · « **Reply #8 on:** March 29, 2008, 01:53:51 PM »

Blimey Rob,
Rotten luck with the 'kj' - well done for sorting it :wink:

http://www.jeep.com/webselfservice/jeep/index.jsp

Doug

kj lad · « **Reply #9 on:** March 29, 2008, 11:12:14 PM »

The LBJs were changed on recall. This was my second LBJ change. The first I did myself. If they go again I'm getting some Moog BJs from America. I now have the Jeepin by Al's UCA with removal BJs and adjusted angles for lifted KJs on my Jeep now.

I tend to do most of my own work. If I get stuck my brother helps out because he's a mechanic.

Ian

Bishops Finger · « **Reply #10 on:** March 29, 2008, 11:23:44 PM »

Owch....glad ya sorted it.....thought GC rear diff issues were costly.... :roll:

Alan whitlock · « **Reply #11 on:** March 30, 2008, 03:17:58 PM »

at least i can take the vm to bits really easy....but that sounds like a bad job!

wazza · « **Reply #12 on:** March 30, 2008, 10:04:10 PM »

that bad crack, sorry to hear about your trouble's but atleast you've sorted it!!!!

its nice to see some jeepers in the area, im in darlington, we should meet up some time!!!

Steve54 · « **Reply #13 on:** May 31, 2008, 11:01:45 AM »

Yeah, seems to be a few of us, where do you guys go for some off road action?

Bishops Finger · « **Reply #14 on:** May 31, 2008, 09:37:26 PM »

Err off road :lol:

...where are you located..

Steve54 · « **Reply #15 on:** May 31, 2008, 10:21:33 PM »

Sorry, thought it was in my info thing on the left. I'm in Teesside.

Bishops Finger · « **Reply #16 on:** May 31, 2008, 10:28:33 PM »

I'd guess Kirton or Langdale then......

wazza · « **Reply #17 on:** June 01, 2008, 12:12:04 PM »

anywhere really, langdale was last weekend, robin hoods bay, houghtenly spring, kieldar, thirsk, then there's also tong, frickly, korc altho not been there yet hopefully next month :-D

not been any firther south than that yet, but there's still time.

rob.79 · « **Reply #18 on:** June 02, 2008, 11:15:42 PM »

hey,
dont get to use pc much, usually out or working, also dont get to play with the jeep too much, would like to tho, dont realy fancy breaking it!i,ve been along the odd green lane or two while on hols in the lakes, but other than that just a few muddy fields, herd there was a pay and play not far from me in weardale? but also herd it was closing? may have a weekend near whitby and try a drive around langdale..... are there many, if any places left to drive a 4x4 in the north east anyway? :-)

Roland · « **Reply #19 on:** June 04, 2008, 11:50:33 AM »

I'm really glad to see there are a few more Jeepers in the NE. :oops:
BTW I'm in Durham/Witton Gilbert , the home of 2 YJ's :wink:

wazza · « **Reply #20 on:** June 04, 2008, 09:53:45 PM »

im in darlington.

1 XJ 4ltr
an
1 ZJ 4ltr

an there might soon be a cj in the family :-D

Bubba · « **Reply #21 on:** June 04, 2008, 10:09:01 PM »

tell us more

wazza · « **Reply #22 on:** June 04, 2008, 10:10:43 PM »

nope

cos i havn,t seen it or even spoke to the bloke bout it yet, i just know i want it!!!!! :grinyes:

Bubba · « **Reply #23 on:** June 04, 2008, 10:17:41 PM »

ok cool

Roland · « **Reply #24 on:** June 05, 2008, 06:13:48 AM »

:shock: :shock:

Author Topic: KJ DIY NIGHTMARE (Read 16385 times)

rob.79

kj lad

rob.79

kj lad

rob.79

MuckShifter

kj lad

Bishops Finger

Alan whitlock

wazza

Steve54

Bishops Finger

Steve54

Bishops Finger

wazza

rob.79

Roland

wazza

wazza

Roland