Jeep XJ. Manual — part 338
INSTALLATION
(1) Clean recessed area in pump module where fil-
ter/regulator is to be installed.
(2) Obtain new filter/regulator (two new o-rings
should already be installed).
(3) Apply a small amount of clean engine oil to
o-rings. Do not install o-rings separately into
fuel pump module. They will be damaged when
installing filter/regulator.
(4) Install new gasket to top of fuel pump module.
(5) Press new filter/regulator into top of pump
module until it snaps into position (a positive click
must be heard or felt).
(6) The arrow (Fig. 21) molded into top of fuel
pump module should be pointed towards front of
vehicle (12 o’clock position).
(7) Rotate filter/regulator until fuel supply tube
(fitting) is pointed towards front of vehicle (12 o’clock
position).
(8) Install new retainer clamp (clamp snaps over
top of filter/regulator and locks to flanges on pump
module).
(9) Connect fuel line at filter/regulator. Refer to
Quick-Connect Fittings in this group for procedures.
(10) Install fuel tank. Refer to Fuel Tank Removal/
Installation.
FUEL PUMP MODULE
Fuel tank removal will be necessary for fuel pump
module removal.
REMOVAL
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT
PRESSURE
EVEN
WITH
ENGINE
OFF.
BEFORE SERVICING THE FUEL PUMP MODULE,
FUEL SYSTEM PRESSURE MUST BE RELEASED.
Fig. 21 Fuel Filter/Fuel Pressure Regulator
1 – RETAINER CLAMP
2 – FUEL FILTER/FUEL PRESSURE REGULATOR
3 – FUEL SUPPLY TUBE
4 – ALIGNMENT ARROW
Fig. 22 Fuel Filter/Fuel Pressure Regulator Gasket
1 – TOP OF MODULE
2 – GASKET
Fig. 23 Fuel Filter/Fuel Pressure Regulator O-Rings
1 – FUEL FILTER/FUEL PRESSURE REGULATOR
2 – TO FUEL INJECTORS
3 – FUEL SUPPLY TUBE
4 – O-RINGS
5 – FUEL INLET FROM PUMP
6 – FUEL RETURN TO TANK
14 - 14
FUEL SYSTEM
XJ
REMOVAL AND INSTALLATION (Continued)
(1) Drain fuel tank and remove tank. Refer to the
Fuel Tank Removal/Installation section of this group.
(2) Thoroughly wash and clean area around pump
module to prevent contaminants from entering tank.
(3) Disconnect fuel line at filter/regulator. Refer to
Quick-Connect Fittings in this group for procedures.
(4) The plastic fuel pump module locknut is
threaded onto fuel tank (Fig. 24). Install Special Tool
6856 to fuel pump module locknut and remove lock-
nut (Fig. 25). The fuel pump module will spring up
when locknut is removed.
(5) Remove module from fuel tank.
INSTALLATION
CAUTION: Whenever fuel pump module is serviced,
module gasket must be replaced.
(1) Thoroughly clean locknut threads and mating
fuel tank threads. Use a soap/water solution. Do not
use carburetor cleaner to clean threads.
(2) Using a new gasket, position gasket and fuel
pump module into opening in fuel tank.
(3) Apply clean water to gasket and locknut
threads.
(4) Position locknut over top of fuel pump module.
(5) Rotate module until molded arrow (Fig. 24) is
pointed toward front of vehicle (12 o’clock position).
This step must be done to prevent float/float rod
assembly from contacting sides of fuel tank.
(6) Install Special Tool 6856 to locknut.
(7) Tighten locknut to 74 N·m (55 ft. lbs.) torque.
(8) Rotate fuel filter/fuel pressure regulator until
its fitting is pointed toward front of vehicle (12
o’clock position).
(9) Connect fuel line at filter/regulator. Refer to
Quick-Connect Fittings in this group for procedures.
(10) Install fuel tank. Refer to Fuel Tank Installa-
tion in this section.
FUEL PUMP INLET FILTER
The fuel pump inlet filter (strainer) is located on
the bottom of fuel pump module (Fig. 26). The fuel
pump module is located on top of fuel tank.
REMOVAL
(1) Remove fuel tank. Refer to Fuel Tank Removal/
Installation.
(2) Remove fuel pump module. Refer to Fuel Pump
Module Removal/Installation.
(3) Remove filter by prying from bottom of module
with 2 screwdrivers. Filter is snapped to module.
(4) Clean bottom of pump module.
INSTALLATION
(1) Snap new filter to bottom of module.
(2) Install fuel pump module. Refer to Fuel Pump
Module Removal/Installation.
(3) Install fuel tank. Refer to Fuel Tank Removal/
Installation.
Fig. 24 Top View of Fuel Tank and Fuel Pump
Module
1 – ROLLOVER VALVE
2 – RETAINER CLAMP
3 – LOCKNUT
4 – FUEL PUMP MODULE
5 – FUEL FILTER/FUEL PRESSURE REGULATOR
6 – ALIGNMENT ARROW
7 – PIGTAIL HARNESS
8 – FUEL SUPPLY TUBE
9 – EVAP CANISTER VENT LINE
Fig. 25 Locknut Removal/Installation—Typical
1 – SPECIAL TOOL 6856
2 – LOCKNUT
XJ
FUEL SYSTEM
14 - 15
REMOVAL AND INSTALLATION (Continued)
FUEL GAUGE SENDING UNIT
The fuel gauge sending unit (fuel level sensor) and
float assembly is located on the side of fuel pump
module (Fig. 27). The fuel pump module is located
within the fuel tank.
REMOVAL
(1) Remove fuel tank. Refer to Fuel Tank Removal/
Installation.
(2) Remove fuel pump module. Refer to Fuel Pump
Module Removal/Installation.
(3) Remove electrical wire connector at sending
unit terminals.
(4) Press on release tab (Fig. 28) to remove send-
ing unit from pump module.
INSTALLATION
(1) Position sending unit to pump module and
snap into place.
(2) Connect electrical connector to terminals.
(3) Install fuel pump module. Refer to Fuel Pump
Module Removal/Installation.
(4) Install fuel tank. Refer to Fuel Tank Removal/
Installation.
FUEL INJECTOR RAIL/FUEL DAMPER—2.5L
ENGINE
REMOVAL
The fuel damper is not serviced separately.
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT FUEL PRESSURE EVEN WITH ENGINE OFF.
THIS PRESSURE MUST BE RELEASED BEFORE
SERVICING FUEL RAIL.
(1) Remove fuel tank filler tube cap.
(2) Perform Fuel System Pressure Release Proce-
dure as described in this Group.
(3) Disconnect negative battery cable from battery.
Fig. 26 Fuel Pump Inlet Filter
1 – FUEL PUMP MODULE
2 – FUEL PUMP INLET FILTER
Fig. 27 Fuel Gauge Sending Unit Location
1 – FUEL GAUGE FLOAT
2 – PICK-UP FILTER
3 – FUEL GAUGE SENDING UNIT
4 – FUEL FILTER/FUEL PRESSURE REGULATOR
5 – ELECTRIC FUEL PUMP
6 – PIGTAIL WIRING HARNESS
Fig. 28 Fuel Gauge Sending Unit Release Tab
1 – ELECTRICAL CONNECTOR
2 – FUEL GAUGE SENDING UNIT
3 – RELEASE TAB
4 – FUEL PUMP MODULE
14 - 16
FUEL SYSTEM
XJ
REMOVAL AND INSTALLATION (Continued)
(4) Remove air tube at top of throttle body. Note:
Some engine/vehicles may require removal of air
cleaner ducts at throttle body.
(5) Remove injector harness electrical connectors
at each injector. Each injector connector should have
a numerical tag attached identifying its correspond-
ing cylinder (Fig. 29). If not, identify each connector
before removal.
(6) Disconnect fuel supply line latch clip and fuel
line at fuel rail. Refer to Quick-Connect Fittings in
this group for procedures.
(7) Disconnect throttle cable at throttle body. Refer
to Throttle Cable Removal/Installation in this group
for procedures.
(8) Disconnect speed control cable at throttle body
(if equipped). Refer to Speed Control Cable in Group
8H, Speed Control System for procedures.
(9) Disconnect automatic transmission cable at
throttle body (if equipped).
(10) Remove cable routing bracket (Fig. 29) at
intake manifold.
(11) Remove nut securing crankshaft position sen-
sor pigtail harness to fuel rail mounting stud.
Remove clamp and harness from fuel rail mounting
stud.
(12) Clean dirt/debris from each fuel injector at
intake manifold.
(13) Remove fuel rail mounting nuts/bolts (Fig.
29).
(14) Remove fuel rail by gently rocking until all
the fuel injectors are out of intake manifold.
INSTALLATION
(1) Clean each injector bore at intake manifold.
(2) Apply a small amount of clean engine oil to
each injector o-ring. This will aid in installation.
(3) Position tips of all fuel injectors into the corre-
sponding injector bore in intake manifold. Seat injec-
tors into manifold.
(4) Install and tighten fuel rail mounting bolts to
11
63 N·m (100 625 in. lbs.) torque.
(5) Position crankshaft position sensor pigtail wire
harness clamp and wire harness to fuel rail mount-
ing stud. Install nut securing harness to fuel rail
mounting stud.
(6) Connect tagged injector harness connectors to
appropriate injector.
(7) Connect fuel line and fuel line latch clip to fuel
rail. Refer Quick-Connect Fittings in this group for
procedures.
(8) Install protective cap to pressure test port fit-
ting (if equipped).
(9) Install cable routing bracket to intake mani-
fold.
(10) Connect throttle cable at throttle body.
(11) Connect speed control cable at throttle body (if
equipped).
(12) Connect
automatic
transmission
cable
at
throttle body (if equipped).
(13) Install air tube (or duct) at top of throttle
body.
(14) Install fuel tank cap.
(15) Connect negative battery cable to battery.
(16) Start engine and check for fuel leaks.
FUEL INJECTOR RAIL/FUEL DAMPER—4.0L
ENGINE
REMOVAL
The fuel damper is not serviced separately.
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT FUEL PRESSURE EVEN WITH ENGINE OFF.
THIS PRESSURE MUST BE RELEASED BEFORE
SERVICING FUEL RAIL.
(1) Remove fuel tank filler tube cap.
(2) Perform Fuel System Pressure Release Proce-
dure.
(3) Disconnect negative battery cable from battery.
(4) Remove air tube at top of throttle body. Note:
Some engine/vehicles may require removal of air
cleaner ducts at throttle body.
Fig. 29 Fuel Rail Mounting—2.5L Engine
1 – FUEL DAMPER
2 – FUEL INJECTOR
3 – NUMBERED TAG
4 – FUEL RAIL
5 – FUEL RAIL MOUNTING BOLTS/NUTS
6 – TEST PORT
7 – CABLE BRACKET
XJ
FUEL SYSTEM
14 - 17
REMOVAL AND INSTALLATION (Continued)
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