Jeep Wrangler TJ. Manual — part 461
SPECIAL TOOLS
FUEL SYSTEM
FUEL PRESSURE REGULATOR
DESCRIPTION
Refer to Fuel Pump Module for information.
FUEL LEVEL SENDING UNIT /
SENSOR
DESCRIPTION
Refer to Fuel Pump Module for information.
FUEL LINES
DESCRIPTION
Also refer to Quick-Connect Fittings.
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES,
FITTINGS OR LINES, THE FUEL SYSTEM PRES-
SURE MUST BE RELEASED. REFER TO THE FUEL
SYSTEM PRESSURE RELEASE PROCEDURE IN
THIS GROUP.
The lines/tubes/hoses used on fuel injected vehicles
are of a special construction. This is due to the
higher fuel pressures and the possibility of contami-
nated fuel in this system. If it is necessary to replace
these lines/tubes/hoses, only those marked EFM/EFI
may be used.
If equipped: The hose clamps used to secure rub-
ber hoses on fuel injected vehicles are of a special
rolled edge construction. This construction is used to
prevent the edge of the clamp from cutting into the
hose. Only these rolled edge type clamps may be
used in this system. All other types of clamps may
cut into the hoses and cause high-pressure fuel leaks.
Use new original equipment type hose clamps.
FUEL PUMP
DESCRIPTION
Refer to Fuel Pump Module for information.
LOCKRING REMOVER/INSTALLER #9340
TEST KIT, FUEL PRESSURE #5069
ADAPTERS, FUEL PRESSURE TEST - #6539
AND/OR #6631
O2S (OXYGEN SENSOR) REMOVER/INSTALLER -
#C-4907
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FUEL DELIVERY
14 - 3
FUEL DELIVERY (Continued)
FUEL PUMP MODULE
DESCRIPTION
The fuel pump module assembly (6) (Fig. 1) is
located on the top of the fuel tank.
The module assembly (6) contains the following
components:
• An internal fuel filter
• A separate fuel pick-up, or inlet filter
• A fuel pressure regulator (4)
• An electric fuel pump
• A lockring to retain pump module to tank
• A soft gasket between tank flange and module
• A fuel gauge sending unit (fuel level sensor)
• Fuel line connection
If the fuel gauge sending unit , electrical fuel
pump, primary inlet filter, fuel filter or fuel pressure
regulator require service, the fuel pump module must
be replaced.
Electric Fuel Pump
The electric fuel pump is located inside of the fuel
pump module. A 12 volt, permanent magnet, electric
motor powers the fuel pump. The electric fuel pump
is not a separate, serviceable component.
Fuel Filters
Two fuel filters are used. One is located at the bot-
tom of the fuel pump module. The other is located
inside the module. A separate frame mounted fuel fil-
ter is not used with any engine.
Both fuel filters are designed for extended service.
They do not require normal scheduled maintenance.
Filters should only be replaced if a diagnostic proce-
dure indicates to do so.
Fuel Pressure Regulator
The fuel pressure regulator is located within fuel
pump module.
Fuel Gauge Sending Unit (Fuel level sensor)
The fuel gauge sending unit (fuel level sensor) is
attached to the side of the fuel pump module. The
sending unit consists of a float, an arm, and a vari-
able resistor track (card).
Fig. 1 TOP OF FUEL TANK
1 - FUEL PUMP MODULE LOCKRING
7 - SKID PLATE
2 - FUEL SUPPLY LINE
8 - FUEL FILL FITTING
3 - ELECTRICAL CONNECTOR
9 - FUEL VENT FITTING
4 - VAPOR LINE
5 - FUEL TANK MOUNTING STRAPS (2)
6 - FUEL PUMP MODULE ASSEMBLY
14 - 4
FUEL DELIVERY
TJ
REMOVAL
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING THE FUEL PUMP MODULE,
THE
FUEL
SYSTEM
PRESSURE
MUST
BE
RELEASED.
(1) Drain and remove fuel tank. Refer to Fuel
Tank Removal/Installation.
(2) Note
rotational
position
of
module
before
attempting removal. An indexing arrow is located on
top of module for this purpose.
(3) Position Special Tool 9340 (3) (Fig. 2) into
notches on outside edge of lockring (5).
(4) Install 1/2 inch drive breaker bar (1) (Fig. 2) to
tool 9340 (3).
(5) Rotate breaker bar counter-clockwise to remove
lockring.
(6) Remove lockring. The module will spring up
slightly when lockring is removed.
(7) Remove module from fuel tank. Be careful not
to bend float arm while removing.
INSTALLATION
CAUTION: Whenever the fuel pump module is ser-
viced, the rubber seal (gasket) must be replaced.
(1) Using a new seal (gasket), position fuel pump
module into opening in fuel tank.
(2) Position lockring (5) (Fig. 3) over top of fuel
pump module.
(3) Rotate module until embossed alignment arrow
points to center alignment mark. This step must be
performed to prevent float from contacting side of
fuel tank. Also be sure fuel fitting on top of pump
module is pointed to front of vehicle.
(4) Install Special Tool 9340 (3) to lockring.
(5) Install 1/2 inch drive breaker (1) into Special
Tool 9340 (3).
(6) Tighten lockring (clockwise) until all seven
notches have engaged.
(7) Install fuel tank. Refer to Fuel Tank Removal/
Installation.
Fig. 2 FUEL PUMP MODULE LOCATION
1 - 1/2
9
BREAKER BAR
2 - TOP OF FUEL TANK (TYPICAL)
3 - SPECIAL TOOL #9340
4 - FUEL PUMP MODULE (TYPICAL)
5 - MODULE LOCK RING
Fig. 3 FUEL PUMP MODULE LOCKRING
1 - 1/2
9
BREAKER BAR
2 - TOP OF FUEL TANK (TYPICAL)
3 - SPECIAL TOOL #9340
4 - FUEL PUMP MODULE (TYPICAL)
5 - MODULE LOCK RING
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FUEL DELIVERY
14 - 5
FUEL PUMP MODULE (Continued)
FUEL RAIL/FUEL DAMPER -
2.4L
DESCRIPTION - 2.4L
The fuel injector rail is used to mount the fuel
injectors to the engine (Fig. 4). On the 2.4L 4-cylin-
der engine, a fuel damper is located near the front
of the fuel rail (Fig. 4).
OPERATION - 2.4L
The fuel injector rail supplies the necessary fuel to
each individual fuel injector.
The fuel damper is used only to help control fuel
pressure pulsations. These pulsations are the result
of the firing of the fuel injectors. It is not used as a
fuel pressure regulator. The fuel pressure regulator is
not mounted to the fuel rail on any engine. It is
located on the fuel tank mounted fuel pump module.
Refer to Fuel Pressure Regulator for additional infor-
mation.
The fuel rail is not repairable.
A quick-connect fitting with a safety latch is used
to attach the fuel line to the fuel rail.
REMOVAL - 2.4L
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT
PRESSURE
EVEN
WITH
ENGINE
OFF.
BEFORE SERVICING FUEL RAIL, FUEL SYSTEM
PRESSURE MUST BE RELEASED.
The fuel rail can be removed without removing the
intake manifold if the following procedures are fol-
lowed.
(1) Remove fuel tank filler tube cap.
(2) Perform Fuel System Pressure Release Proce-
dure.
(3) Remove negative battery cable at battery.
(4) Remove air duct at throttle body.
(5) Disconnect fuel line latch clip and fuel line at
fuel rail. A special tool will be necessary for fuel line
disconnection. Refer to Quick-Connect Fittings.
(6) Remove necessary vacuum lines at throttle
body.
(7) Drain engine coolant and remove thermostat
and thermostat housing.
(8) Remove PCV hose and valve at valve cover.
(9) Remove 3 upper intake manifold mounting
bolts (Fig. 6), but only loosen 2 lower bolts about 2
turns.
(10) Disconnect 2 main engine harness connectors
at rear of intake manifold (Fig. 5).
Fig. 5 MAP SENSOR LOCATION - 2.4L
1 - REAR OF INTAKE MANIFOLD
2 - MAP SENSOR
3 - ALIGNMENT PIN
4 - MOUNTING BOLT (TORX)
5 - ELECTRICAL CONNECTOR
6 - MAIN ENGINE HARNESS CONNECTORS
Fig. 4 FUEL RAIL - 2.4L
1 - FUEL RAIL
2 - MOUNTING BOLTS
3 - TEST PORT (IF USED)
4 - QUICK-CONNECT FITTING
5 - INJ. #1
6 - DAMPER
7 - INJ #2
8 - INJ #3
9 - INJ #4
10- INJECTOR RETAINING CLIP
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FUEL DELIVERY
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