Jeep Cherokee 1999 Electronic Service Manual page 1259

14 - 16 FUEL SYSTEM—2.5L DIESEL ENGINE
REM OVAL AN D I N STALLAT I ON (Cont inue d)
Fig. 29 Fuel Level Sensor Release Tab
(3) Rem ove t h e en gin e a ccessor y dr ive belt . Refer
t o Gr ou p 7, Coolin g Syst em for pr ocedu r es.
(4) Rem ove t h e gen er a t or a ssem bly.
(5) Rem ove t h e r u bber fu el r et u r n a n d su pply
h oses fr om t h e m et a l lin es a t t h e pu m p (F ig. 30).
Fig. 30 Fuel Injection Pump
(6) Rem ove t h e elect r ica l con n ect or a t en gin e cool-
a n t t em per a t u r e sen sor.
(7) Discon n ect t h e F u el In ject ion P u m p elect r ica l
con n ect or a t fu el pu m p (F ig. 30).
(8) Discon n ect t h e m a in en gin e wir in g h a r n ess
fr om t h e glow plu gs.
(9) Discon n ect t h e fou r h igh –pr essu r e fu el lin es
fr om t h e fu el in ject ion pu m p. Also discon n ect fu el
lin es a t t h e fu el in ject or s. F or pr ocedu r es, r efer t o
H igh –P r essu r e F u el Lin es in t h is gr ou p. P la ce a r a g
ben ea t h t h e fit t in gs t o ca t ch excess fu el.
(10) Rem ove t h e plu g fr om t im in g gea r cover.
(11) Th e "Top Dea d Cen t er " (TDC) com pr ession fir-
in g st r oke for t h e #1 cylin der ca n be det er m in ed a s
follows:
(a ) Usin g a socket a t t a ch ed t o t h e fr on t of t h e
cr a n ksh a ft , r ot a t e t h e en gin e clockwise u n t il spe-
cia l a lign m en t t ool VM# 1035 ca n be in ser t ed
t h r ou gh t h e h ole in t h e bot t om of t h e clu t ch h ou s-
in g, st oppin g t h e flywh eel r ot a t ion . Th is posit ion is
TDC or 180° a wa y fr om TDC. En g in e m u s t be a t
TD C #1 c o m p re s s io n firin g s tro k e .
(b) To ver ify t h a t you a r e a t TDC. Rem ove t h e
oil fill ca p fr om t h e cylin der h ea d cover a n d t h e
a lign m en t t ool fr om t h e clu t ch h ou sin g.
(c) Rot a t e t h e cr a n ksh a ft on e-qu a r t er t u r n clock-
wise a n d cou n t er-clockwise wh ile obser vin g t h e
r ocker a r m t h r ou gh t h e oil fill ca p h ole. If t h e
r ocker a r m m oves you a r e n ot a t TDC.
(d) If TDC wa s fou n d con t in u e, if n ot r ot a t e t h e
cr a n ksh a ft on e r evolu t ion u n t il t h e a lign m en t t ool
ca n be r e-in st a lled in t h e flywh eel. You a r e n ow a t
TDC for t h e #1 cylin der com pr ession fir in g st r oke.
Ma r k t h e da m per a n d t im in g cover for r efer en ce t o
TDC. Rem ove t h e a lign m en t t ool fr om t h e clu t ch
h ou sin g.
(12) Rem ove a ccess plu g a n d plu g wa sh er a t r ea r
of pu m p (F ig. 31). Th r ea d specia l dia l in dica t or a n d
a da pt er t ool VM.1011 (F ig. 32) in t o t h is open in g.
H a n d t igh t en on ly.
(13) Sligh t ly r ot a t e t h e en gin e in a cou n t er-clock-
wise dir ect ion u n t il t h e dia l ga u ge in dica t or st ops
m ovin g (20°-25° befor e TDC).
(14) Rem ove in ject ion pu m p dr ive gea r n u t (F ig.
33).
(15) A specia l 3–piece gea r
VM.1003 (F ig. 34) m u st be u sed t o r em ove t h e in jec-
t ion pu m p dr ive gea r fr om t h e pu m p sh a ft .
(a ) Th r ea d t h e a da pt er (F ig. 35) in t o t h e t im in g
cover.
(b) Th r ea d t h e gea r pu ller in t o t h e in ject ion
pu m p dr ive gea r (F ig. 35). Th is t ool is a lso u sed t o
h old t h e gea r in syn ch r on iza t ion du r in g pu m p
r em ova l.
(c) Rem ove t h e t h r ee in ject ion pu m p–t o–gea r
cover m ou n t in g n u t s (F ig. 36). CAU TION : Th is
s te p m u s t be d o n e to p re v e n t in je c tio n p u m p
d a m a g e .
(d) In st a ll t h e dr ive bolt in t o t h e gea r pu ller
(F ig. 35). Tigh t en t h e dr ive bolt t o pr ess (r em ove)
t h e dr ive gea r fr om in ject ion pu m p sh a ft wh ile
X J
r em ova l t ool set