Jeep Wrangler TJ. Manual — part 460
REAR TOW HOOK
REMOVAL
(1) Remove the fasteners that attach the rear tow
hook to the frame (Fig. 14).
(2) Separate the tow hook from the frame.
INSTALLATION
(1) Position the tow hook on the frame.
(2) Install the bolts and tighten to 77 N·m (57 ft.
lbs.).
TRANSMISSION SKID PLATE
REMOVAL
(1) Raise
and
support
the
vehicle.
(Refer
to
LUBRICATION
&
MAINTENANCE/HOISTING
-
STANDARD PROCEDURE)
(2) Support the skid plate.
(3) Remove the bolts and remove the skid plate.
(Fig. 15)
INSTALLATION
(1) Position the skid plate in place and support.
(2) Install the bolts and tighten the plate to frame
bolts to 45 N·m (33 ft. lbs.).
(3) Tighten the plate to transfer case skid plate
bolts to 35 N·m (26 ft. lbs.).
Fig. 14 REAR TOW HOOK
1 - FRAME
2 - REAR BUMPER
3 - TOW HOOK
4 - BOLT
5 - NUT
Fig. 15 TRANSMISSION SKID PLATE
1 - FRONT BOLTS (2)
2 - REAR BOLTS (2)
3 - SKID PLATE
TJ
FRAME & BUMPERS
13 - 11
FUEL SYSTEM
TABLE OF CONTENTS
page
page
. . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . 21
FUEL DELIVERY
TABLE OF CONTENTS
page
page
FUEL DELIVERY
. . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
STANDARD PROCEDURE - FUEL SYSTEM
. . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . 3
FUEL PRESSURE REGULATOR
. . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUEL LEVEL SENDING UNIT / SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUEL LINES
. . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUEL PUMP
. . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUEL PUMP MODULE
. . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . . . . . . . . . . . 5
FUEL RAIL/FUEL DAMPER - 2.4L
. . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . . . . . . 7
FUEL RAIL - 4.0L ENGINE
. . . . . . . . . . . . . . . . . . . . . 8
. . . . . . . . . . . . . . . . . . . . . . . 8
. . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . . . . . . . . . . . . . . . . . . . 8
FUEL TANK
. . . . . . . . . . . . . . . . . . . . . . . . . . 9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
. . . . . . . . . . . . . . . . . . . . . . . . . 12
INLET FILTER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
. . . . . . . . . . . . . . . . . . . . . . . . . 15
QUICK CONNECT FITTING
. . . . . . . . . . . . . . . . . . . . . . . . . 16
STANDARD PROCEDURE - QUICK-CONNECT
. . . . . . . . . . . . . . . . . . . . . . . . . . . 16
FUEL DELIVERY
DESCRIPTION
The fuel delivery system consists of:
• the fuel pump module containing the electric
fuel pump, fuel filter/fuel pressure regulator, fuel
gauge sending unit (fuel level sensor) and a separate
fuel filter located at bottom of pump module
• fuel tubes/lines/hoses
• quick-connect fittings
• fuel injector rail
• fuel injectors
• fuel tank
• fuel tank filler/vent tube assembly
• fuel tank filler tube cap
• check valve(s)
• accelerator pedal
• throttle cable
OPERATION
Fuel is returned through the fuel pump module
and back into the fuel tank through the fuel filter/
fuel pressure regulator. A separate fuel return line
from the engine to the tank is not used.
The fuel tank assembly consists of: the fuel tank,
fuel pump module assembly, fuel pump module lock-
nut/gasket, and fuel tank check valve (refer to Emis-
TJ
FUEL SYSTEM
14 - 1
sion Control System for fuel tank check valve
information).
A fuel filler/vent tube assembly using a pressure/
vacuum fuel filler cap is used. The fuel filler tube
contains a flap door located below the fuel fill cap.
Also to be considered part of the fuel system is the
evaporation control system. This is designed to
reduce the emission of fuel vapors into the atmo-
sphere. The description and function of the Evapora-
tive Control System is located in Emission Control
Systems.
Both fuel filters (at bottom of fuel pump module
and within fuel pressure regulator) are designed for
extended service. They do not require normal sched-
uled maintenance. Filters should only be replaced if
a diagnostic procedure indicates to do so.
STANDARD PROCEDURE - FUEL SYSTEM
PRESSURE RELEASE
Use following procedure if the fuel injector
rail is, or is not equipped with a fuel pressure
test port.
(1) Remove fuel fill cap.
(2) Remove fuel pump relay from Power Distribu-
tion Center (PDC). For location of relay, refer to label
on underside of PDC cover.
(3) Start and run engine until it stalls.
(4) Attempt restarting engine until it will no
longer run.
(5) Turn ignition key to OFF position.
CAUTION: Steps 1, 2, 3 and 4 must be performed to
relieve high pressure fuel from within fuel rail. Do
not attempt to use following steps to relieve this
pressure as excessive fuel will be forced into a cyl-
inder chamber.
(6) Unplug connector from any fuel injector.
(7) Attach one end of a jumper wire with alligator
clips (18 gauge or smaller) to either injector terminal.
(8) Connect other end of jumper wire to positive
side of battery.
(9) Connect one end of a second jumper wire to
remaining injector terminal.
CAUTION: Powering an injector for more than a few
seconds will permanently damage the injector.
(10) Momentarily touch other end of jumper wire
to negative terminal of battery for no more than a
few seconds.
(11) Place a rag or towel below fuel line quick-con-
nect fitting at fuel rail.
(12) Disconnect quick-connect fitting at fuel rail.
Refer to Quick-Connect Fittings.
(13) Return fuel pump relay to PDC.
(14) One or more Diagnostic Trouble Codes (DTC’s)
may have been stored in PCM memory due to fuel
pump relay removal. The DRB
t scan tool must be
used to erase a DTC.
SPECIFICATIONS
FUEL SYSTEM PRESSURE
58 psi +/- 2 psi
TORQUE - FUEL DELIVERY
DESCRIPTION
N-m
Ft. Lbs.
In. Lbs.
Accelerator Pedal Bracket
Mounting Nuts
8.5
-
75
Fuel Hose Clamps
3
-
25
Fuel Rail Mounting Bolts -
2.4L
28
-
250
Fuel Rail Mounting Bolts
or Nuts - 4.0L
11
-
100
Fuel Tank Mounting Strap
Bolts
Refer to service manual
text.
-
-
Fuel Tank Skidplate Bolts
16
-
141
14 - 2
FUEL DELIVERY
TJ
FUEL DELIVERY (Continued)
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