Jeep Wagoneer/Commando/Cherokee 1984-1998

Fuel Rail

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Removal & Installation



Except 5.2L and 5.9L Engines

See Figures 1, 2 and 3


CAUTION
Fuel system pressure must be relieved before disconnecting any fuel lines. Release fuel system pressure at the test connection using a suitable pressure gauge with a pressure bleed valve. Take precautions to avoid the risk of fire whenever working on or around any open fuel system.

  1. Disconnect the negative battery cable and remove the fuel tank filler cap.
  2.  
  3. Relieve fuel system pressure.
  4.  
  5. Tag and disengage the injector wire harness connectors.
  6.  

On models with automatic transmission, it may be necessary to remove the automatic transmission throttle pressure cable and bracket to remove the fuel rail assembly.

  1. If located on the fuel rail, disengage the vacuum line from the fuel pressure regulator.
  2.  
  3. Disconnect the fuel supply line from the fuel rail and , if equipped, the fuel return line from the fuel pressure regulator.
  4.  
  5. Remove the fuel rail retaining bolts.
  6.  
  7. Remove the rail by gently rocking it until all the injectors are out of the intake manifold.
  8.  



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Fig. Fig. 1: Remove the fuel rail retaining bolts



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Fig. Fig. 2: Disengage the vacuum line from the fuel pressure regulator, if equipped



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Fig. Fig. 3: Remove the fuel rail by gently rocking it until all the injectors are out of the intake manifold

To install:
  1. Position the injector tips into the correct intake manifold bore and seat the injectors.
  2.  
  3. Install and tighten the fuel rail retaining bolts to 20 ft. lbs. (27 Nm).
  4.  
  5. Engage the fuel injector wire harness connectors.
  6.  
  7. Connect the fuel lines and , if necessary, the vacuum line to the fuel pressure regulator.
  8.  
  9. Install the fuel tank cap and connect the negative battery cable.
  10.  
  11. Start the vehicle and check for leaks.
  12.  

5.2L and 5.9L Engines

See Figure 4

  1. Relieve the fuel system pressure as outlined in this section.
  2.  
  3. Disconnect the negative battery cable and remove the air duct from the throttle body.
  4.  
  5. Remove the throttle body assembly from the intake manifold. Refer to the proper procedure in this section.
  6.  
  7. If equipped with air conditioning, remove the A-shaped A/C compressor-to-intake manifold support bracket.
  8.  
  9. Tag and disengage the fuel injector electrical connectors.
  10.  
  11. Disconnect the fuel line at the side of the fuel rail and remove the fuel rail retaining bolts.
  12.  
  13. Remove the rail by gently rocking the left and right fuel rail until all the injectors are out of the intake manifold.
  14.  



Click image to see an enlarged view

Fig. Fig. 4: If equipped, remove the A-shaped compressor bracket

To install:
  1. Apply a small amount of engine oil to the injector O-rings.
  2.  
  3. Position the injector tips into the correct intake manifold bore and seat the injectors by pushing down on the left and right fuel rails until the injectors are firmly seated.
  4.  
  5. Install and tighten the fuel rail retaining bolts to 17 ft. lbs. (23 Nm).
  6.  
  7. Engage the fuel injector wire harness connectors.
  8.  
  9. Install the A/C compressor bracket, if equipped.
  10.  
  11. Install the throttle body assembly. Refer to the proper procedure as outlined in this section.
  12.  
  13. Engage the fuel line at the side of the fuel rail and install the air duct.
  14.  
  15. Connect the negative battery cable, start the vehicle and check for leaks.
  16.  

 
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