Liberty, Wrangler, 1997-2005

Fuel Pump Module

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Removal & Installation




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 and remove fuel tank.
  2.  
  3. Note rotational position of module before attempting removal. An indexing arrow is located on top of module for this purpose.
  4.  
  5. Position Special Tool 9340 into notches on outside edge of lock ring.
  6.  
  7. Install 1 / 2 inch drive breaker bar.
  8.  
  9. to tool 9340.
  10.  
  11. Rotate breaker bar counter-clockwise to remove lock ring.
  12.  
  13. Remove lock ring. The module will spring up slightly when lock ring is removed.
  14.  
  15. Remove module from fuel tank. Be careful not to bend float arm while removing
  16.  

To install:


CAUTION
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 lock ring 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 front of vehicle.
  6.  
  7. Install Special Tool 9340 to lock ring.
  8.  
  9. Install 1 / 2 inch drive breaker.
  10.  
  11. into Special Tool 9340 (3).
  12.  
  13. Tighten lock ring (clockwise) until all seven notches have engaged.
  14.  
  15. Install fuel tank.
  16.  



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Fig. Top of fuel pump module



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Fig. Access plate

The fuel pump module is divided into 2 sections, upper and lower. To service the check (control) valve, replace only the upper section. To service the fuel gauge sending unit, remove the upper section. To service the electric fuel pump, fuel pressure regulator or primary inlet filter, remove both sections and replace lower section.


NOTE
Fuel tank removal will not be necessary for fuel pump module removal. Access is from rear cargo area.


NOTE
Four cargo hold-down clamps are located inside the vehicle on the floor of the rear cargo area. Remove the 2 rearward mounted clamps by drilling out the clamp rivets.

  1. Fold carpeting forward to gain access to fuel pump module access plate.
  2.  
  3. Remove 4 fuel pump module access plate nuts.
  4.  
  5. While applying heat from a heat gun, carefully pry up fuel pump module access plate. Take care not to bend plate.
  6.  
  7. Thoroughly clean area around top of pump module to prevent contaminants from entering fuel tank or fuel lines.
  8.  
  9. Release fuel system pressure.
  10.  
  11. Disconnect 2 fuel lines at fuel pump module by pressing on 2 buttons at sides of fitting.
  12.  
  13. Disconnect electrical connector at top of fuel pump module by sliding red colored tab first to unlock, and push grey colored tab down for removal.
  14.  
  15. Disconnect ORVR hose clamp and hose at pump module fitting.
  16.  
  17. Remove module lockring using a brass drift and hammer (counter-clockwise).
  18.  
  19. Carefully lift upper section of pump module from fuel tank exposing connections (lift upper section from tank very slowly until rubber gasket can be retained. If not, gasket will fall into fuel tank.)
  20.  
  21. Disconnect electrical connector at bottom of upper pump module section.
  22.  
  23. Disconnect fuel pressure regulator at bottom of upper pump module section. Press on 2 locking tabs.
  24.  
  25. Disconnect fuel return line at bottom of upper pump module section. Press on 2 locking tabs.
  26.  
  27. Remove upper section of pump module from fuel tank.
  28.  
  29. Using an approved gas holding tank, drain fuel tank through pump module opening. If check (control) valve, or, only upper section of pump module is being serviced, tank draining is not necessary. If any other fuel pump module component is being serviced, the tank must be completely drained to the bottom.
  30.  
  31. To remove lower section of pump module from fuel tank:
  32.  
  33. Using finger pressure, push on plastic release tab while sliding lock tab upward.
  34.  
  35. The sides of pump module are equipped with tension springs. These springs hold module to bottom of fuel tank into 2 formed guides. Release module assembly from these 2 guides by sliding toward right side of fuel tank.
  36.  
  37. Lift assembly from fuel tank.
  38.  

To install:


CAUTION
Whenever fuel pump module is serviced, pump module gasket must be replaced.

  1. Position lower section of fuel pump module assembly into fuel tank.
  2.  
  3. The bottom of fuel tank has 2 formed guides. Lock module assembly into these 2 guides by sliding toward left side of fuel tank.
  4.  
  5. Push down on plastic tab to lock module to fuel tank guides.
  6.  
  7. Connect fuel supply line to bottom of upper pump module section.
  8.  
  9. Connect fuel pressure regulator to bottom of upper pump module section.
  10.  
  11. Connect electrical connector to bottom of upper pump module section.
  12.  
  13. Position pump module into fuel tank. Notch on module must be facing rear of tank.
  14.  
  15. Position lock ring to module. Tap lockring using a brass drift and hammer (clockwise) until rotated up to built-on stops.
  16.  
  17. Attach (snap on) 2 fuel filter fuel lines to top of fuel pump module.
  18.  
  19. Connect hoses/lines to ORVR components.
  20.  
  21. Fill fuel tank with fuel.
  22.  
  23. Start engine and check for fuel leaks.
  24.  
  25. Apply silicone sealant to bottom of fuel pump module metal access plate.
  26.  
  27. Install fuel pump module metal access plate and 4 nuts. Tighten nuts to 26 inch lbs. (3 Nm) torque.
  28.  
  29. Position carpet and install 2 new cargo clamp rivets into each cargo hold-down clamp.
  30.  

 
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