Jeep Wrangler/YJ 1987-1995 Repair Guide

Fuel Filter

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REMOVAL & INSTALLATION



2.5L Engine
1987-90 MODELS

See Figure 1

The filter is located behind a protective shield on the left frame rail, just in front of the shock absorber.


CAUTION
Wear protective goggles to prevent fuel from spraying into your eyes. Have the new filter handy to install immediately.



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Fig. Fig. 1: Fuel filter and shield-all fuel injected models

  1. Raise and safely support the rear end on jackstands.
  2.  
  3. Unfasten the protective shield bolts, then remove the shield.
  4.  
  5. Remove the filter retaining strap bolt.
  6.  
  7. Clamp shut the hose on the inlet side of the filter to prevent fuel from draining once the filter is removed.
  8.  
  9. Unfasten the hose clamps.
  10.  
  11. Remove the filter.
  12.  
  13. Installation is the reverse of removal.
  14.  

1991-95 MODELS

See Figures 1, 2, 3, 4 and 5



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Fig. Fig. 2: Removing the fuel filter shield retaining bolts



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Fig. Fig. 3: After unfastening the two fuel filter shield retaining bolts, remove the shield



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Fig. Fig. 4: Loosening the fuel filter hose clamps



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Fig. Fig. 5: Loosening the fuel filter retaining clamp

Since the fuel filter is located along the frame rail, the vehicle will have to be raised slightly.


WARNING
Before servicing any components within the fuel system, the system pressure must first be released.

  1. Release the fuel system pressure. Refer to the procedure outlined earlier in this section.
  2.  
  3. Raise the vehicle slightly and safely support it with jackstands.
  4.  
  5. Remove the fuel filter shield.
  6.  
  7. Remove the hoses and clamps on both ends of the fuel filter.
  8.  
  9. Wrap a shop towel or clean rag around the hoses to absorb fuel.
  10.  
  11. Remove the hoses from the filter, then discard the clamps and filter.
  12.  
  13. Remove the filter retaining strap bolt and remove the filter from the rail.
  14.  

The ends of the filter are marked for correct installation. Install the filter with the end marked IN towards the fuel tank and the end marked OUT towards the engine.

To install:
  1. Install the new filter between the hoses and position new clamps.
  2.  
  3. Tighten the clamps to 15 inch lbs. (1.7 Nm).
  4.  
  5. Position the filter assembly on the chassis rail.
  6.  
  7. Tighten the strap mounting bolt to 106 inch lbs. (12 Nm).
  8.  
  9. Install the fuel filter shield.
  10.  
  11. Lower the vehicle.
  12.  

4.0L Engine

See Figure 1

Since the fuel filter is located along the frame rail, the vehicle will have to be raised slightly.


WARNING
Before servicing any components within the fuel system, the system pressure must first be released.

  1. Release the fuel system pressure. Refer to the procedure outlined earlier in this section.
  2.  
  3. Raise the vehicle slightly and safely support it with jackstands.
  4.  
  5. Remove the fuel filter shield.
  6.  
  7. Remove the hoses and clamps on both ends of the fuel filter.
  8.  
  9. Wrap a shop towel or clean rag around the hoses to absorb fuel
  10.  
  11. Remove the hoses from the filter, and discard clamps and filter.
  12.  
  13. Unfasten the filter retaining strap bolt and remove the filter from the rail.
  14.  

The ends of the filter are marked for correct installation. Install the filter with the end marked IN towards the fuel tank and the end marked OUT towards the engine.

To install:
  1. Install the new filter between the hoses and clamp.
  2.  
  3. Tighten the clamps to 15 inch lbs. (1.7 Nm).
  4.  
  5. Position the filter assembly on the chassis rail.
  6.  
  7. Tighten the strap mounting bolt to 106 inch lbs. (12 Nm)
  8.  
  9. Install the fuel filter shield.
  10.  
  11. Lower the vehicle.
  12.  

4.2L Engine

See Figure 6

This engine has a throwaway cartridge filter in the line between the fuel pump and the carburetor. To replace it:

  1. Remove the air cleaner as necessary.
  2.  
  3. Put an absorbent rag under the filter to catch spillage.
  4.  
  5. Remove the hose clamps.
  6.  

If equipped with the original wire hose clamps, screw-type band clamps are recommended for replacement.

  1. Remove the filter and short attaching hoses.
  2.  
  3. Remove the hoses if they are to be reused.
  4.  
  5. Assemble the new filter and hoses.
  6.  

The fuel filter for this engine has two outlets. The additional one is to return fuel vapors and bubbles to the tank so as to prevent vapor lock. Be sure to position the tank line outlet above the line leading to the carburetor.

  1. Install the filter, then tighten the clamps.
  2.  
  3. Start the engine and check for leaks. Discard the rag and old filter safely.
  4.  



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Fig. Fig. 6: Fuel filter removal and installation-4.2L engine

 
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