Liberty, Wrangler, 1997-2005

Fuel Pump

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Removal & Installation





Click image to see an enlarged view

Fig. Top view of fuel tank and fuel pump module


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. 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.
  6.  
  7. Remove module from fuel tank
  8.  

To install:


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

  1. Using a new gasket, position fuel pump module into opening in fuel tank.
  2.  
  3. Position locknut over top of fuel pump module.
  4.  
  5. Rotate module until 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.
  6.  
  7. Install Special Tool 6856 to locknut.
  8.  
  9. Tighten locknut to 45 ft. lbs. (62 Nm) torque.
  10.  
  11. Rotate fuel filter/fuel pressure regulator until its fitting is pointed to 10 o'clock position.
  12.  
  13. Install fuel tank.
  14.  

  1. Before servicing the vehicle, refer to the Precautions section.
  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.  


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.

This vehicle is equipped with an ORVR (On-Board Refueling Vapor Recovery) system. Because of this, the fuel tank may be drained the conventional way through the filler cap opening. On this model, the fuel tank is mounted to the vehicle skid plate. The skid plate is mounted to vehicle body. The tank and skid plate are removed as one assembly.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove fuel filler cap.
  4.  
  5. Perform the fuel system pressure release procedure as described elsewhere in this group.
  6.  
  7. Disconnect negative battery cable.
  8.  
  9. Using an approved portable gasoline siphon/storage tank, drain fuel from tank through filler cap opening.
  10.  
  11. Remove 8 screws retaining plastic fuel filler bezel to body. Remove plastic fuel filler bezel.
  12.  
  13. To prevent contaminants from entering tank, temporarily install fuel cap to fill hoses.
  14.  
  15. Remove right/rear tire/wheel.
  16.  
  17. Remove wheelhouse liner at right/rear wheel.
  18.  
  19. Remove vertical support bracket to gain access to ORVR vapor line.
  20.  
  21. A vapor line connects the fuel tank to the EVAP canister and NVLD pump. This connection is made near the right/rear corner of the fuel tank. Carefully disconnect this vapor line. Be very careful not to bend or kink the vapor lines. If vapor lines leak, a Diagnostic Trouble Code (DTC) will be set.
  22.  
  23. Cut plastic tie wrap securing rear axle vent hose to fuel fill hose.
  24.  
  25. Disconnect fuel tank electrical connector at left/front of fuel tank.
  26.  
  27. Disconnect 2 vapor lines at left/front of fuel tank.
  28.  
  29. Disconnect quick-connect fitting from fuel supply line at front of fuel tank.
  30.  
  31. The fuel tank and skid plate are removed as an assembly. Centrally position a transmission jack (or equivalent lifting device) under skid plate/fuel tank assembly. Secure tank assembly to jack.
  32.  
  33. Remove three skid plate-to-body nuts at front of tank. Remove one of the nuts through access hole on skid plate.
  34.  
  35. Remove four skid plate-to-body nuts at rear of tank. Do not loosen tank strap nuts.
  36.  
  37. Lower the tank assembly.
  38.  
  39. Disconnect fuel filler hose at tank. Before disconnecting, mark and note the hose rotational position in relation to tank fitting.
  40.  
  41. To separate tank from skid plate, remove two protective caps at tank strap studs and remove tank strap nuts.
  42.  
  43. Remove both straps and remove tank from skid plate.
  44.  
  45. Note rotational position of module before attempting removal. An indexing arrow is located on top of module for this purpose.
  46.  
  47. Position Special Tool 9340 into notches on outside edge of lockring.
  48.  
  49. Install 1 / 2 inch drive breaker bar to tool 9340.
  50.  
  51. Rotate breaker bar counter-clockwise to remove lockring.
  52.  
  53. Remove lockring. The module will spring up slightly when lockring is removed.
  54.  
  55. Remove module from fuel tank. Be careful not to bend float arm while removing.

    Click image to see an enlarged view

    Fig. Fuel tank front mounting nuts-Wrangler



    Click image to see an enlarged view

    Fig. Fuel tank rear mounting nuts-Wrangler



    Click image to see an enlarged view

    Fig. ORVR vapor line-Wrangler



    Click image to see an enlarged view

    Fig. EVAP canister/NVLD pump location-Wrangler



    Click image to see an enlarged view

    Fig. Top of fuel tank-Wrangler

  56.  

To install:

  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 front of vehicle.
  6.  
  7. Install Special Tool 9340 to lockring.
  8.  
  9. Install 1 / 2 inch drive breaker into Special Tool 9340.
  10.  
  11. Tighten lockring (clockwise) until all seven notches have engaged.
  12.  
  13. Place fuel tank into skid plate. Wrap straps around tank with strap studs inserted through holes in skid plate. Tighten strap nuts to attain 30 mm (+/-2 mm) between bottom of nut to end of strap stud. Do not over tighten nuts.
  14.  
  15. Install two protective caps to tank strap studs.
  16.  
  17. Connect fuel fill hose at tank. Tighten hose clamp.
  18.  
  19. Raise skid plate/fuel tank assembly into position on body while carefully guiding plastic vapor lines and fill hose.
  20.  
  21. Install four skid plate mounting nuts at rear of tank. Tighten to 141 inch lbs. (16 Nm) torque.
  22.  
  23. Install three skid plate mounting nuts at front of tank. Tighten to 141 inch lbs. (16 Nm)torque.
  24.  
  25. Remove tank jacking device.
  26.  
  27. Carefully connect the vapor line.
    NOTE
    Be very careful not to bend or kink the vapor lines. If lines leak, a Diagnostic Trouble Code (DTC) will be set.

  28.  
  29. Install EVAP canister bracket.
  30.  
  31. Install wheelhouse liner at right/rear wheel.
  32.  
  33. Install right/rear tire/wheel.
  34.  
  35. Connect electrical connector at of fuel tank.
  36.  
  37. Connect vapor line at left/front of fuel tank.
  38.  
  39. Connect quick-connect fitting to fuel supply fitting.
  40.  
  41. Use a new plastic tie wrap to secure rear axle vent hose to fuel fill hose.
  42.  
  43. Position fuel fill bezel to body. Install eight screws and tighten.
  44.  
  45. Fill fuel tank. Install filler cap.
  46.  
  47. Connect negative battery cable to battery.
  48.  
  49. Start vehicle and inspect for leaks.
  50.  

The fuel filter is attached to the front of the fuel tank.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:
    NOTE
    Once the nuts are removed, the plate must be removed by applying a heat gun to melt the adhesive. Take care to avoid bending the plate.


    WARNING
    Lift the module out slowly and carefully until you can secure the rubber gasket. If you-re not careful, the gasket will fall into the tank.



    Negative battery cable
     
    2 rear cargo hold-down clamps by drilling the rivets
     
    4 fuel pump module access plate nuts
     



    Click image to see an enlarged view

    Fig. Top view of the fuel pump module-Liberty



    Fuel lines at the module
     
    Electrical connector by first sliding the red tab, then pushing the gray tab
     
    ORVR hose
     
    Module lockring
     
    Module from the tank
     



    Electrical connector from the upper module section

    Click image to see an enlarged view

    Fig. Fuel pressure regulator-Liberty

     
    Fuel pressure regulator
     
    Fuel return line
     
    Upper module section
     

  6.  
  7. Drain the tank through the module opening.
  8.  
  9. Remove or disconnect the following:

    Lower module section by pushing gently on the release tab while sliding the lock tab upward
     

  10.  
  11. Installation is the reverse of removal.
  12.  

 
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