Jeep XJ. Manual — part 352
(4) Place the key way on the pump shaft to the 11
o’clock position as viewed from the front of pump.
Install the pump into the rear of timing gear cover
while aligning key way on pump shaft into pump
gear.
(5) Install and snug the 3 injection pump mount-
ing nuts. This is not the final tightening sequence.
(6) Remove the special gear puller and adapter
tools from timing gear cover.
(7) Install the injection pump drive gear nut.
Tighten nut to 88 N·m (65 ft. lbs.) torque.
(8) Remove the access plug and plug washer at
rear of pump (Fig. 36). Thread special dial indicator
adapter tool VM.1011 (Fig. 37) into this opening.
Hand tighten only.
(9) Attach special dial indicator tool VM.1013 into
the adapter tool (Fig. 37)
(10) Using a socket attached to the front of the
crankshaft, rotate the engine in a counter-clockwise
direction until the dial gage indicator stops moving
(20–25° before TDC).
(11) Set the dial indicator to 0mm. Be sure the tip
of the dial indicator is touching the tip inside the
adapter tool.
(12) Rotate the engine clockwise until special
alignment tool VM# 1043 can be inserted through the
hole in the bottom of the clutch housing, stopping the
flywheel rotation. This position is #1Cylinder TDC
Compression. Engine must be at TDC #1 com-
pression firing stroke.
(13) The gauge reading should be at 0.55 mm
(with new gears installed specification should
be 0.59–0.60mm). If not, the pump must be rotated
for adjustment:
(a) Loosen the three injection pump mounting
nuts at the mounting flanges. These flanges are
equipped with slotted holes. The slotted holes are
used to rotate and position the injection pump for
fuel timing. Loosen the three nuts just enough to
rotate the pump.
Fig. 35 Injection Pump Mounting Nuts
1 – MOUNTING FLANGE
2 – SLOTTED HOLES (3)
3 – PUMP MOUNTING NUTS (3)
Fig. 36 Access Plug at Rear of Pump
1 – ACCESS PLUG
2 – WASHER
Fig. 37 Installing Dial Indicator and Special Adapter
Tools
1 – DIAL INDICATOR TOOL
2 – ADAPTER TOOL VM1011
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FUEL SYSTEM—2.5L DIESEL ENGINE
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REMOVAL AND INSTALLATION (Continued)
2000 JEEP CHEROKEE
(b) Rotate the pump until 0.55 mm is indicated
on the dial indicator gauge. If while rotating the
pump the 0.55 mm specification is passed do not
attempt to rotate the pump in the opposite direc-
tion. You must rotate the pump back below the
0.25 mm specification and start the procedure over
from the start of the TDC procedure. This will pre-
vent a false reading due to gear backlash.
(c) Tighten the three pump mounting nuts to 30
N·m (22 ft. lbs.) torque.
(d) Recheck the dial indicator after tightening
the pump mounting nuts. Gauge should still be
reading 0.55 mm.
(14) Remove dial indicator and adapter tools.
(15) Install access plug and washer to rear of
injection pump.
(16) Install plug at timing gear cover.
(17) Install and connect the four high–pressure
fuel lines to the fuel injection pump. Also connect
fuel lines at the fuel injectors. For procedures, refer
to High–Pressure Fuel Lines in this group.
(18) Install electrical connector at engine coolant
temperature sensor.
(19) Connect electrical connector at fuel shutdown
solenoid.
(20) Connect the main engine wiring harness to
the glow plugs.
(21) Connect the fuel timing solenoid pigtail har-
ness to the engine wiring harness.
(22) Connect the overflow valve/banjo fitting (fuel
return line assembly). Replace copper gaskets before
installing.
(23) Connect the rubber fuel return and supply
hoses to metal lines at pump. Tighten hose clamps to
2 N·m (20 in. lbs.) torque.
(24) Install generator assembly.
(25) Install engine accessory drive belt. Refer to
Group 7, Cooling System for procedures.
(26) Install negative battery cable to battery.
(27) Start the engine and bring to normal operat-
ing temperature.
(28) Check for fuel leaks.
FUEL INJECTORS
Four fuel injectors are used on each engine. Of
these four, two different types are used. The fuel
injector used on cylinder number one is equipped
with a fuel injector sensor (Fig. 38). The other three
fuel injectors are identical. Do not place the fuel
injector equipped with the fuel injector sensor
into any other location except the cylinder
number one position.
REMOVAL
(1) Disconnect negative battery cable at battery.
(2) Thoroughly clean the area around the injector
with compressed air.
(3) Remove the fuel drain hoses (tubes) at each
injector (Fig. 39) being serviced. Each of these hoses
is slip–fit to the fitting on injector.
Fig. 38 Fuel Injector Sensor — #1 Cylinder
1 – NEEDLE MOVEMENT SENSOR
2 – FUEL INJECTOR (NUMBER 1 CYLINDER ONLY)
3 – COPPER WASHER
4 – SENSOR CONNECTOR
Fig. 39 Fuel Injector—Typical
1 – FUEL INJECTOR
2 – LINE FITTING
3 – HIGH-PRESSURE FUEL LINE
4 – FUEL DRAIN TUBES
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FUEL SYSTEM—2.5L DIESEL ENGINE
14 - 19
REMOVAL AND INSTALLATION (Continued)
2000 JEEP CHEROKEE
(4) Remove the high–pressure fuel line at injector
being removed. Refer to High–Pressure Fuel Lines in
this group for procedures.
(5) Remove the injector using special socket tool
number VM.1012A. When removing cylinder number
one injector, thread the wiring harness through the
access hole on the special socket (Fig. 40).
(6) Remove and discard the copper washer (seal) at
bottom of injector (Fig. 38).
INSTALLATION
(1) Clean the injector threads in cylinder head.
(2) Install new copper washer (seal) to injector.
(3) Install injector to engine. Tighten to 70 N·m
(52 ft. lbs.) torque.
(4) Install high–pressure fuel lines. Refer to High–
Pressure Fuel Lines in this group for procedures.
(5) Install fuel drain hoses (tubes) to each injector.
Do not use clamps at fuel drain hoses.
(6) Connect negative battery cable to battery.
(7) Bleed the air from the high–pressure lines. Refer
to the Air Bleed Procedure section of this group.
FUEL TANK
REMOVAL
(1) Disconnect negative cable from battery.
(2) Insert fuel siphon hose into fuel filler neck and
push it into the tank.
(3) Drain fuel tank dry into holding tank or a
properly labeled diesel safety container.
(4) Raise vehicle on hoist.
(5) Disconnect both the fuel fill and fuel vent rub-
ber hoses at the fuel tank.
(6) Disconnect fuel supply and return lines from
the steel supply line (Fig. 41).
The fuel reservoir module electrical connec-
tor has a retainer that locks it in place.
(7) Slide electrical connector lock to unlock.
(8) Push down on connector retainer (Fig. 43) and
pull connector off module.
Fig. 40 Wiring Harness Through Socket
1 – FUEL INJECTOR
2 – WIRING HARNESS (NUMBER 1 CYLINDER ONLY)
3 – SPECIAL SOCKET
4 – FUEL INJECTOR SENSOR (NUMBER 1 CYLINDER ONLY)
Fig. 41 Fuel Tank Connections at Front of Tank
1 – FUEL SUPPLY LINE CONNECTION
2 – FUEL PUMP MODULE CONNECTOR
3 – FRONT OF FUEL TANK
4 – EVAP CANISTER VENT LINE CONNECTION
Fig. 42 Fuel Fill/Vent Hose Index Marks
1 – FUEL TANK
2 – CLAMP INDEX MARKS
3 – TANK INDEX TANGS
4 – HOSE INDEX MARKS
5 – FUEL FILL HOSE
6 – CLAMP INDEX MARKS
7 – CLAMPS
8 – FUEL VENT HOSE
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FUEL SYSTEM—2.5L DIESEL ENGINE
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REMOVAL AND INSTALLATION (Continued)
2000 JEEP CHEROKEE
(9) Use a transmission jack to support fuel tank.
Remove bolts from fuel tank straps.
(10) Lower tank slightly. Carefully remove filler
hose from tank.
(11) Lower the fuel tank. Remove clamp and
remove fuel filler tube vent hose. Remove fuel tank
from vehicle.
INSTALLATION
(1) Position fuel tank on transmission jack. Con-
nect fuel filler tube vent hose and replace clamp.
(2) Raise tank into position and carefully work
filler tube into tank. A light coating of clean engine
oil on the tube end may be used to aid assembly.
(3) Feed filler vent line thorough frame rail. Care-
ful not to cross lines.
(4) Tighten strap bolts to 9 N·m (80 in. lbs.).
Remove transmission jack.
CAUTION: Ensure straps are not twisted or bent
before or after tightening strap nuts.
(5) Connect
module
electrical
connector.
Place
retainer in locked position.
(6) Lubricate the fuel supply and return lines with
clean 30 weight engine oil, install the quick connect
fuel fitting. Refer to Tube/Fitting Assembly in the
Fuel Delivery section of this Group.
(7) Attach filler line to filler tube. Pull on connec-
tor to make sure of connection.
(8) Fill fuel tank, replace cap, and connect battery
negative cable.
FUEL RESERVOIR MODULE
REMOVAL
WARNING:
THE FUEL RESERVOIR OF THE FUEL
MODULE DOES NOT EMPTY OUT WHEN THE TANK
IS DRAINED. THE FUEL IN THE RESERVOIR WILL
SPILL OUT WHEN THE MODULE IS REMOVED.
(1) Disconnect negative cable from battery.
(2) Drain fuel tank dry into holding tank or a
properly labeled diesel safety container.
(3) Raise vehicle on hoist.
(4) Use a transmission jack to support the fuel
tank. Remove bolts from fuel tank straps. Lower
tank slightly.
(5) Clean area around fuel reservoir module and
tank to keep dirt and foreign material out of tank.
(6) Disconnect fuel lines from fuel module by
depressing quick connect retainers with thumb and
fore finger.
(7) Slide
module
electrical
connector
lock
to
unlock.
(8) Push down on connector retainer and pull con-
nector off module.
(9) Using Special Tool 6856, remove plastic locknut
counterclockwise to release pump module (Fig. 44).
(10) Carefully remove module and o-ring from tank.
(11) Discard old o-ring.
INSTALLATION
(1) Thoroughly clean locknut threads and mating
fule tank threads. Use a soap/water solution. Do Not
use carburetor cleaner to clean threads.
(2) Apply clean water to the o-ring seal and place
on the mating fuel tank threads.
Fig. 43 Module Connector Retainer and Lock
1 – PUSH DOWN ON RETAINER
2 – CONNECTOR LOCK
Fig. 44 Fuel Reservoir Module Lock Nut Removal
1 – SPECIAL TOOL 6856
2 – LOCKNUT
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FUEL SYSTEM—2.5L DIESEL ENGINE
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REMOVAL AND INSTALLATION (Continued)
2000 JEEP CHEROKEE
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