Fix It

Removing the EGR valve from the 2.8-liter diesel engine in a Jeep Liberty can be time-consuming. Fortunately, with a little effort and a lot of patience, you can do it yourself and save on an otherwise large repair bill. The EGR valve is located on the back of the engine, just below the intake manifold on the drivers side of the engine. The valve bolts in place with four 8-millimeter bolts that are hidden below the manifold, so you will not be able to see them.

Instructions

1

Open the hood of your Jeep and locate the negative battery cable on the battery. Loosen the pinch bolt with a wrench then lift the cable off the battery and set it aside.

2

Position a catch basin under the passengers side of the radiator and remove the petcock from the radiator tank, allowing the coolant to drain from the system. Once the coolant has stopped draining, replace the petcock.

3

Remove the bolts from the top of the engine cover on the engine, using a socket and ratchet. Lift the cover off the engine and set it aside.

4

Locate the EGR valve on the back of the engine near the drivers side head. Remove the clamps from the cooling lines on the EGR valve then pull the two coolant lines off the valve.

5

Remove the four 8-millimeter bolts from the EGR valve with a wrench then separate the valve from the engine block. A ratcheting wrench may be necessary to remove the 8-millimeter bolts.

Replacing the fuel/water separator on the 2.8-liter diesel engine in your Jeep Liberty is not something that you need to do regularly, but when the time comes, a new separator assembly is available from the Jeep dealer. The fuel/water separator is important, as it works to remove moisture and sediment from the diesel fuel before it enters the fuel rails and engine. Water can damage the engine and cause it to run poorly or not at all.

Instructions

1

Disconnect the negative cable from the battery, using a wrench to remove the retaining bolt. Isolate the negative cable from the battery while you work.

2

Locate the fuel/water separator on the firewall of your Liberty. It is to the left of the engine, directly in front of the driver. Locate the two electrical connections on the front of the separator. Depress the locking tab on the connectors and remove them from the separator body. Lay the wiring connections aside.

3

Remove the hose clamp on the large fuel line at the front of the separator using a flat-head screwdriver. Pull the hose off the fitting and push it aside. Locate the second fuel line on the passengers side of the separator. Remove the hose clamp from the line with a flat-head screwdriver and pull it off the fitting.

4

Remove the two bolts that secure the separator to the firewall of the Jeep, using a socket and ratchet. Pull the assembly off the firewall. Position the new separator on the firewall and install the retaining bolts. Tighten the bolts to 63 in.-lbs. with a torque wrench.

5

Connect both fuel lines to the fittings on the new separator. Attach the hose clamps and tighten them with a flat-head screwdriver. Do not overtighten them or you will damage the rubber hose and it will fail prematurely.

6

Attach the wiring harness connectors to the front of the assembly. They are different so you cannot plug them in wrong. Push the connectors in until they snap into place.

7

Reconnect the negative cable to the battery. Reattach the retaining bolt and tighten it with a wrench.

Industrial Injection Diesel Performance is a supplier of fuel injection parts and turbochargers. They are located in Salt Lake City, Utah. However, they have registered dealers throughout the United States and Canada.

Prodcuts

Industrial Injection Diesel Performance offers a wide range of products including injection pumps, turbochargers, fass pumps, fuel pumps and flow injectors. These products may be used with diesel vehicles from major companies such as GM, Ford and Dodge.

Services

The company offers an exchange program for most of their products. They also offer Bosch-certified repair and performance improvement services. All their technicians are certified.

Return Policy

Industrial Injection Diesel Performance accepts return and exchanges as long as they are done within 30 days of the purchase date and the original receipt is presented. All products must be inspected before a return or exchange can be accepted.

The muffler on the 1998 Dodge 3500 Diesel is the main component that prevents the diesel engine running too loud. The exhaust pipe that is attached to the exhaust manifold on the front of the engine travels under the truck and into the muffler. As the sound of the engine travels through the muffler, the baffles inside of the muffler cause the sound to exit in a quieter manner. Over time, the excessive heat that travels through the muffler, will cause the inside of the muffler to rust and not perform properly.

Instructions

1

Park your 1998 Dodge 3500 Diesel on a flat surface and engage the parking brake. Wait one to two hours for the muffler and the exhaust system to cool down.

2

Slide under the rear of the truck and locate the front of the muffler. The exhaust pipe that travels from the engine is mounted to the front muffler port by a metal clamp with two mounting bolts.

3

Saturate the two mounting bolts completely with the rust inhibitor spray or the penetrating oil. Position a socket and a breaker bar onto one of the mounting bolts. Slowly turn the bolt counterclockwise to see how tight the bolt is fastened. If the bolt is still tight, spray more of the rust inhibitor or the penetrating oil on the mounting bolts and repeat the process with the breaker bar and socket until the bolt is loose. Follow the same step with the other mounting bolt. Once the bolts are loose, use a ratchet to finish unscrewing the bolts.

4

Finish loosening and removing the two mounting bolts from the clamp with a ratchet and a socket. Pull the mounting bolts out of the clamp and knock the clamp off of the muffler port with a hammer.

5

Slide the end of a flathead screwdriver into the end of the muffler. Pry the end of the muffler port upward off the exhaust pipe. Make sure the entire front muffler port is pried up off of the exhaust pipe. Try and pull the muffler loose from the exhaust pipe. If the muffler is still stuck, use the hammer to tap the front of the muffler loose from the exhaust pipe.

6

Pull the muffler off the rubber hanger that holds the muffler in place. Slide the muffler out from under the truck. Position the new muffler under the truck and into the rubber hanger.

7

Slide the front port of the muffler over the exhaust pipe. Reconnect the clamp over the exhaust clamp and the muffler with the two mounting bolts. Tighten the bolts down tight with the ratchet and socket. Finish torquing the mounting bolts with the breaker bar and a socket.

Oldsmobile manufactured an eight-cylinder engine with a displacement of 5.7 liters from 1978 to 1985. This engine has multi-port fuel injection, which requires an injection pump. This same 5.7-liter diesel engine appears in a variety of vehicles from General Motors during this period, such as the Chevrolet Caprice from 1980 to 1984. The procedure for removing the injection pump is the same for all full-size Chevrolet cars with diesel engines made from 1979 to 1989.

Instructions

1

Remove the negative battery cable with a socket wrench, so that you do not inadvertently start the engine. Disconnect the air cleaner assembly from the valve covers, including the air filter. Detach the air crossover, and cover the intake manifold with screen cover No. J-26996-1.

2

Disconnect the return spring for the throttle rod, and detach the throttle rod from the intake manifold with a socket wrench. Remove the bell crank from the intake manifold. Detach the transmission and throttle cables from the brackets of the intake manifold.

3

Remove the fuel lines from the fuel filter, and disconnect the fuel filter with a socket wrench. Detach the fuel send line from the fuel injection pump. Disconnect the rear brace for the air compressor.

4

Detach the fuel return line from the fuel injection pump. Release the clamps from the fuel return line, and disconnect the fuel return lines from the fuel injector nozzles with a pair of box-end wrenches.

5

Disconnect the three retaining nuts for the fuel injection pump with injector pump wrench No. J-26987, and remove the fuel injection pump from the vehicle. Plug the fuel lines and nozzles with clean cloth to keep debris out of them.

Since the introduction of the 260D car in 1936, the Mercedes Benz company has been focused on diesel-powered automobiles and its cars are still on the cutting edge of todays diesel vehicles. To keep your Mercedes running smoothly, its advisable to own some of the specialized Mercedes diesel tools.

Engine Tools

If you need to remove the pre-combustion chambers on your diesel motor, use a slide hammer with a threaded adapter or get the special slide hammer adapter with two different threads. Other specialized wrenches and sockets include the pre-chamber retainer ring pin wrench, which removes and installs the threaded retainer ring of the pre-chamber, and a multi-spline socket to remove the pre-combustion chamber retainer ring on later injection diesel models. For the glow plugs, you can use a glow plug bore reamer, which is a pencil-type reamer that removes the carbon deposit from the glow plug holes. This reamer comes for turbo or non-turbo diesels. Many other tools, like hex head sockets, used to access the head bolts, can be used for both diesel and gasoline Mercedes Benz cars.

Cylinder Head and Engine Timing Tools

If you need to adjust the valves of your diesel engine, a pair of diesel valve adjusting wrenches and retaining nut holders come in handy. The diesel spring plate holding wrench will hold the retaining nut as you adjust the valves. To check the compression, get a compression gauge and an adapter. The gauge comes with a hose and the adapter of your choice. Make your car run its best with some new glow plugs, or analyze your old plugs with the glow plug analyzer, which tests 12-volt glow plug systems in the newer model diesel engines. To reach the deep port injectors and the glow plugs easily, a diesel compression adapter extension can be used.

Injection Tools

Test your cars opening pressure, the spray pattern and the cleaning injectors with a diesel injection nozzle tester. You can get this tool in a kit, which includes a gauge and the pump and steel adaptor lines. This kit is adaptable for gasoline injectors, too. A specialized diesel fuel pressure tester lets you measure the fuel pressure in high pressure CDI-type engines and a timing tool allows you to calculate the start of the fuel delivery with the RIV method. To maintain your timing while working on the pump, use a diesel pump lock pin, which locks the pump cam. The diesel drip tube helps you adjust the start of the fuel delivery and a vacuum control adjusting roller can measure the vacuum pressures on the control valve. A diesel nozzle socket and an injection socket are helpful tools, too.

Diesel fuel injection systems are much like that of gasoline injection systems in that they are prone to some of the same types of problems. However, diesel injectors are able to withstand certain conditions that gasoline injectors cannot. Having information on the pros and cons of diesel injection performance can be beneficial to auto owners.

Performance Pros

In diesel fuel injection systems, fuel is shot directly into each cylinder of the vehicles diesel engine. For this reason diesel injectors were built to perform under extremely high temperatures. Diesel injectors also can perform at pressures much too great for gasoline injectors to handle.

Performance Cons

Diesel fuel injection performance can suffer due to the fact that diesel fuel is known for clogging injectors. It also doesnt help that diesel fuel lacks the lubrication necessary to flow freely through the injectors. Some type of additive is often needed to assist with lubrication in diesel fuel injection systems.

Performance Tips

To make sure that a diesel injection system is performing properly, a digital pyrometer can be used to reveal the temperatures of the cylinders in the diesel engine. Cylinders with lower readings indicate issues with fuel delivery performance.

Although diesel fuel injectors perform using greater pressures than gasoline injectors, they are still prone to the same issues. Diesel fuels with low sulfur are actually more likely to cause issues with fuel injectors than regular gasoline. Having information on the equipment used to test for problems with a vehicles injectors can be beneficial to automobile owners.

Significance

Fuel injectors can suffer clogging issues from deposits left behind from the diesel fuel. Heavy wear, as well as leaks, are things for which vehicle owners should check. Diesel fuel also fails to provide proper lubrication, which can cause the fuel to not flow though the injectors as smoothly as it should.

Pyrometer

One type of test equipment that can be used to check diesel fuel injectors is called a digital pyrometer. Each engine cylinders temperature is revealed when using a digital pyrometer, indicating the specific cylinder thats not up to par. Low temperatures in one cylinder often means a problem with fuel injection.

Ohmmeter

Another type of test equipment used for checking fuel injectors in diesel engines is an ohmmeter. The ohmmeter tests the resistance of glow plugs as their resistance rises according to engine temperature. Because of this, a low glow plug resistance reading means no heat is being produced from a particular cylinder. This in turn can indicate injector issues.

Ford produced an eight-cylinder, 7.3-liter diesel engine from 1995 to 2002. This engine was frequently turbocharged and typically appeared in heavier trucks, beginning with the 3/4-ton pickups. Each cylinder has its own fuel injector, which delivers fuel to that cylinder at high pressure. You can remove each fuel injector on a Ford 7.3-liter diesel engine independently of the other injectors without removing the fuel rail from the engine.

Instructions

1

Disconnect the valve cover with a socket wrench. Unplug the electrical connector from the fuel injector and disconnect the drain plugs on the oil rail. Disconnect the oil deflector by removing its mounting screw with a socket wrench. Disconnect the outboard retaining bolt for the fuel injector.

2

Place the fulcrum of the Injector Remover No. T94T-9000-AH1 above the cylinder head and below the fuel injectors hold-down plate. Attach the injector remover to the cylinder head with the remover screw for the injector remover. Tighten the screw until the fuel injector comes out of the injector bore.

3

Discard the copper washer on the fuel injector. Use the Rotunda Injector Sleeve Brush 104-00934-A to remove any sealant residue from the injector bore and clean the injector bore with a shop towel. Coat the new fuel injector in engine oil and install a new copper washer to the injector. Place the fuel injector into its bore.

4

Position the end of the Injector Replacer No. T94T-9000-AH2 below the fuel injector and above the hold-down plate. Align the threaded hole in the cylinder head with the hole on the injector replacer tool. Install the bolt for the injector replacer tool to fasten the tool to the cylinder head. Tighten the bolt to fully seat the fuel injector into the injector bore on the cylinder.

5

Install the oil deflector, fuel rail drain plug and oil rail drain plug with a torque wrench. Torque the oil deflector mounting bolt to 108 foot-pounds. Torque the drain plug for the fuel rail to 96 foot-pounds and torque the drain plug for the fuel rail to 53 foot-pounds. Attach the electrical connector for the fuel injector and replace the valve cover with a socket wrench.