Mopar FI Kit Install

1. 3/25/1999 Parts Inventory...too many little parts...

2. 3/27/1999 Cleaned the garage. Got propane for the heater (it was in the 40's outside)

3. 3/28/1999 Session #1 (8 hours of work): Real install begins (with some help from a friend)
   Removed radiator (flushed system also)
   Removed air cleaner system
   Removed alternator and PS pump
   Removed water pump
   Removed fuel pump and hoses (had to let things air out a while)
   Removed old dampener
   Removed old upstream/downstream air injection tubes
   Removed plugs and wires
   Removed timing chain and case (lots of slack in the old chain)
   Installed new timing chain (Mopar double roller) and case
   Installed new dampner
   Removed Intake manafold with carb attached (had to cut EGR tube)
   

4. 3/30/1999 Session #2 (90 minutes of work)
   Install O2 sensor
   Install EGR port plug. I got a standard 7/8"-18 steel plug. My old stuff was so rusty I did not want to use it again! I still used the little block disk.
   Install Distributor
   Install Ignition coil and old fuelpump blockoff plate
   Install Intake manafold
   

5. 4/3/1999 Session #3 (4 hours of work)
   Finished installing intake (torqued)
   Removed old ignition coil
   Installed water pump
   Installed thermostat and housing
   Installed temp sensor (in thermo housing)
   Installed MAP sensor
   Installed the new throttle cable
   Removed overflow tank
   Removed washer tank
   Removed old evap canister
   Installed new evap canister (used existing bracket)
   Installed speed sensor
   Installed wiring harness
   

6. 4/10/1999 Session #4 (several hours to route the new fuel line)
   Installed new brake booster connector. The new factory one did not work.
   Installed driver's side 5/16" steel fuel line. I bent it while under the jeep.
   

7. 4/15/1999 Session #5 (all nighter....16 hours)
   Removed all old computers and connected wires
   Installed fuel pump and filter, this took a long time to get it the way I wanted it and without kinking any lines.
   Installed all vacuum tubes, air vents, etc.
   Water tested the computer (put it in a 5gal bucket while running)
   Installed computer where the jack and vacuum can used to be. It did not fit in the new 'correct' location. Since I have dual batteries I had lots of space under the tray.
   Installed the radiator and connected the new electric fan.
   Too many little things.....But I Finished everying! including install of flex-a-lite electric fan
   

So, an estimate of 30-40 hours to do >everything< is not far off.....

Once installed, it took a minute of cranking for the fuel pump to bleed the air from the system (pipes, hoses, fuel rail, etc) once the system got fuel it started right up. I noticed some strange engine idle for several minutes while the computer learned how my engine ran. Things are great now!

The only problem left is sometimes hard starting, I have to crank for several seconds before it starts....
and only a few other small things left, like making the Tach. work again.....

• Engine without air cleaner
• Removal of harmonic ballancer
• Old timing chain (notice slack)
• New timing chain (set to standard timing)
  Note that the new Mopar double roller timing chaing has three timing marks.
  
  • Circle: Standard (stock setting)
  • Triangle: Advanced 4deg
  • Rectangle/Square: Retard 4deg
• New harmonic ballancer
• Old carb and manafold
• Engine with intake manafold removed (note the PS pump tied out of the way)
• More photos shortly...