Cherokee, Grand Cherokee, 1999-2005

Fuel Pump

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Removal & Installation




NOTE
Fuel tank removal will be necessary for fuel pump module removal.


WARNING
The fuel system is under a constant pressure, even with the engine off. Before servicing the fuel pump module, the fuel system pressure must be released.

  1. Drain fuel tank and remove tank.
  2.  
  3. Thoroughly wash and clean area around pump module to prevent contaminants from entering tank.
  4.  
  5. Disconnect fuel line at filter/regulator.
  6.  
  7. The plastic fuel pump module locknut is threaded onto fuel tank. Install Special Tool 6856 to fuel pump module locknut and remove locknut. The fuel pump module will spring up when locknut is removed.
  8.  
  9. Remove module from fuel tank.

    Click image to see an enlarged view

    Fig. The top view of fuel tank and fuel pump module

  10.  

To install:


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.  
  3. Using a new gasket, position gasket and fuel pump module into opening in fuel tank.
  4.  
  5. Apply clean water to gasket and locknut threads.
  6.  
  7. Position locknut over top of fuel pump module.
  8.  
  9. Rotate module until molded arrow 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.
  10.  
  11. Install Special Tool 6856 to locknut.
  12.  
  13. Tighten locknut to 55 ft. lbs. (74 Nm).
  14.  
  15. Rotate fuel filter/fuel pressure regulator until its fitting is pointed toward front of vehicle (12 o'clock position)
  16.  
  17. Connect fuel line at filter/regulator.
  18.  
  19. Install fuel tank.
  20.  


NOTE
Fuel tank removal will be necessary for fuel pump module removal.


WARNING
The fuel system is under a constant pressure, even with the engine off. Before servicing the fuel pump module, the fuel system pressure must be released.

  1. Drain fuel tank and remove tank.
  2.  
  3. Thoroughly wash and clean area around pump module to prevent contaminants from entering tank.
  4.  
  5. Disconnect fuel line at filter/regulator.
  6.  
  7. The plastic fuel pump module locknut is threaded onto fuel tank. Install Special Tool 6856 to fuel pump module locknut and remove locknut. The fuel pump module will spring up when locknut is removed.
  8.  
  9. Remove module from fuel tank.

    Click image to see an enlarged view

    Fig. The top view of fuel tank and fuel pump module for the 4.7L engine

  10.  

To install:


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.  
  3. Using a new gasket, position gasket and fuel pump module into opening in fuel tank.
  4.  
  5. Apply clean water to gasket and locknut threads.
  6.  
  7. Position locknut over top of fuel pump module.
  8.  
  9. Rotate module until molded arrow 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.
  10.  
  11. Install Special Tool 6856 to locknut.
  12.  
  13. Tighten locknut to 55 ft. lbs. (74 Nm).
  14.  
  15. Rotate fuel filter/fuel pressure regulator until its fitting is pointed toward front of vehicle (12 o'clock position)
  16.  
  17. Connect fuel line at filter/regulator.
  18.  
  19. Install fuel tank.
  20.  

  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Fuel tank
     
    Fuel lines
     
    Fuel pump module locknut
     
    Fuel pump module
     

  6.  

To install:

  1. Install or connect the following:

    Fuel pump module with a new gasket. Rotate the module until the arrow is pointed toward the front of the vehicle, on all models except Grand Cherokee. The arrow must pointed toward the rear of the vehicle.
     
    Locknut. Torque the locknut to 55 ft. lbs. (74 Nm).
     
    Fuel lines
     
    Fuel tank
     
    Negative battery cable
     

  2.  
  3. Start the engine, check for leaks and repair if necessary.
  4.  

  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
    CAUTION
    The fuel system is under a constant pressure (even with the engine off). Before servicing the fuel pump module, the fuel system pressure must be released.

  2.  
  3. Drain the tank.
  4.  
  5. Release fuel system pressure.
  6.  
  7. Raise vehicle.
  8.  
  9. Thoroughly clean area around fuel fill fitting and rubber fuel fill hose at rear of fuel tank.
  10.  
  11. Loosen clamp at tank fitting and disconnect rubber fuel fill hose at fuel tank fitting. Using an approved gas holding tank, drain fuel tank through this fitting.
  12.  
  13. Loosen clamp and disconnect rubber fill hose at tank fitting.
  14.  
  15. At rear of tank, disconnect fuel pump module electrical jumper connector from body connector.
  16.  
  17. At rear of tank, disconnect EVAP lines and from lines and.
  18.  
  19. At front of tank, disconnect fuel and EVAP lines and from lines and.
  20.  
  21. Support tank with a hydraulic jack.
  22.  
  23. Remove bolts and at right side of fuel tank.
  24.  
  25. Remove bolts at left side of fuel tank.
  26.  
  27. Lower tank for removal.
  28.  
  29. Note rotational position of module before attempting removal. An indexing arrow is located on top of module for this purpose.
  30.  
  31. Position Special Tool 9340, or equivalent, into notches on outside edge of lockring.
  32.  
  33. Install 1 / 2 inch drive breaker bar to tool 9340.
  34.  
  35. Rotate breaker bar counter-clockwise to remove lockring.
  36.  
  37. Remove lockring. The module will spring up slightly when lockring is removed.
  38.  
  39. Remove module from fuel tank. Be careful not to bend float arm while removing.
  40.  

To install:

Click image to see an enlarged view

Fig. Installing the fuel module (1) breaker bar, (2) tank, (3) tool 9340, (4) module, (5) locking ring-2005 Grand Cherokee


NOTE
Whenever the fuel pump module is serviced, the rubber seal (gasket) must be replaced.

  1. Using a new seal (gasket), position fuel pump module into opening in fuel tank.
  2.  
  3. Position lockring over top of fuel pump module.
  4.  
  5. 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 driver-s side of vehicle.
  6.  
  7. Install Special Tool 9340 to lockring.
  8.  
  9. Install 1 / 2 drive breaker into Special Tool 9340.
  10.  
  11. Tighten lockring (clockwise) until all seven notches have engaged.
  12.  
  13. Position fuel tank to hydraulic jack.
  14.  
  15. Raise tank until positioned to body.
  16.  
  17. Install and tighten bolts to 50 ft. lbs. (68 Nm).
  18.  
  19. Remove hydraulic jack.
  20.  
  21. Connect EVAP, ORVR, fuel and NVLD lines at front and rear of tank.
  22.  
  23. Connect fuel pump module electrical jumper connector to body connector.
  24.  
  25. Connect rubber fill hose to tank fitting and tighten clamp.
  26.  
  27. Lower vehicle.
  28.  
  29. Fill fuel tank with fuel.
  30.  
  31. Start engine and check for fuel leaks near top of module.
  32.  

 
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