Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSJEEP1987CHEROKEE LIMITEDREPAIR AND DIAGNOSISENGINE PERFORMANCESYSTEMFUEL INJECTION SYSTEM - DIESELREMOVAL & INSTALLATIONINJECTION PUMPINSTALLATION
1987 Jeep Cherokee Limited
Injection Pump: Installation
1987 Jeep Cherokee LimitedSECTION Installation
- Remove screw plug and copper washer from center of 4 high pressure outlets on rear of injection pump. See Fig 1. Install Dial Indicator Support (Mot. 856) in place of screw plug. Insert dial indicator into support. See Fig 1.
- Position nut and lock nut on end of injection pump drive shaft. Lock the 2 nuts together. Loosen cold start throttle cable set screw. Move levers back slightly and rotate clevis pin 1/4 turn to disengage cold start system. See Fig 2.
- Rotate injection pump until piston is at BDC position (Dial indicator will stop moving at this point). Zero dial indicator.NOTE: With injection pump piston at BDC position, the pump shaft keyway should be positioned just before centerline of No. 1 fuel outlet fitting.
- Remove nut and lock nut from pump drive shaft. Insert key in pump shaft keyway. Install injection pump, leaving dial indicator in place. Ensure drive shaft key is aligned with keyway in sprocket. Loosely install pump retaining nuts.
- Install sprocket washer and retaining nut onto pump shaft. Tighten sprocket retaining nut. Remove sprocket holding plate. Rotate crankshaft 3 revolutions. Check timing belt tension. Adjust if necessary.
- Remove screw plug from TDC access hole in cylinder block, and install TDC Rod (Mot. 861). See Fig 3. Slowly rotate crankshaft clockwise, until TDC rod can be inserted into TDC hole in crankshaft counterweight.
- With TDC rod in hole, dial indicator should read .031-.033 in. (.79-.84 mm). This reading represents the amount of pump piston lift. If reading is correct, go to step 10. If reading is incorrect, go to next step.
- To increase piston lift, rotate pump toward engine, and then slowly rotate pump away from engine until correct reading is obtained. To decrease piston lift, slowly rotate pump away from engine until correct reading is obtained.
- Remove TDC rod. Slowly rotate crankshaft clockwise 2 complete revolutions, and insert TDC rod in TDC hole in crankshaft counterweight. Dial indicator should read .031-.033 in. (.79-.84 mm). If reading is incorrect, repeat steps 8 and 9. If reading is correct, go to next step.
- Remove TDC rod from hole, and install screw plug. Remove dial indicator and support. Install copper washer and screw plug. Reconnect fuel pipes. Compress timing control lever and install clevis pin.
- Hold lever against clevis, and tighten set screw. Install and tighten injection pump rear bracket nuts. To complete installation, reverse removal procedure. The fuel return banjo nut is matched and calibrated to pump. If a new pump is installed, a new matched banjo nut must be used.
NOTE:
DO NOT
reverse the 2 fuel line banjo nuts. The delivery line nut has two .1575" (4.0 mm) diameter holes, and the return line nut has a calibrated orifice.
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.