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HOME1998 Jeep TJ SportMods/TechPlease find me at the forum if you have any questions!
Website Last Updated: 5/19/2008
Random Image Photo by Jina!
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Problem with accessing the Forum? eMail me at access @ dailydriventj D0T c0m
Michael can also be found in JeepForum.com and Jeepsunlimited.com under the user name 'Michael_K'.
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Fuel Pump Assembly Repair Yes! You can repair them! ◆◆◇◇ Medium Introduction
The dealer claimed that the whole fuel pump assembly has to be replaced and it cost like $300 for the part and another $200 for the labor as they have to lower the WHOLE gas tank. I have very hard time believing anyone in the automotive repair shops as many shops tried flat out LYING to me. So my search began to see if it is indeed true that the whole fuel pump assembly has to be replaced. After a few days of search, I found Fuel Pump King store under eBay. I purchased the repair kit and the fuel pump regulator for under $140 (shipped) about 2 years ago. The fuel filter was missing from the kit and Mike from Fuel Pump King overnited the filter to me the next day! What a great service!
That got me wondering if the dealers really replace the whole part. They might just do what I did and charge the customer a lot more than they should. I am not saying they do that, but it is sure possible judging from the availability of the parts for the repair!!
Symptom It Fixed Hard to start when cold. Long crank before start up.
Tools Needed Socket and Ratchet Set Floor Jack Phillips Head & Flat Head Screw Driver Strap Wrench A Third Hand Various Wrenches
Job Hours 3-4 Hours at Leisure Pace
Procedure
1. Run the jeep as empty as you can without stalling the engine.
2. Make sure there is a fire extinguisher ready and make sure it is rated for flammable liquid.
-Pull out the fuel pump relay. (Located inside Power Distribution Center, next to the air filter box.) -Crank the engine. The engine will probably start and sputter then die.
4. Let the exhaust pipe cool down to prevent burns.
5. Disconnect Negative Batter Cable.
7. Remove 8 Screws that hold the plastic fuel filler bezel.
8. Put the tank filler cap back on to prevent contamination of the tank.
9. Cut zip tie that holds the axle vent and the fuel filler hose together.
-Fuel Line is the closest one toward you. Grab the gray tab with a long nose plier then pull the black part of the fuel line away from the metal part. The gray tab stays on the metal fuel line. -EVAP Line is on top of the Fuel Line. Just pull the rubber line off of the metal line. -Electrical Connector is shown left of the Fuel Line. Slide the red tab, then pull the connector.
11. Place a floor jack underneath the fuel tank center where the protrusion is, raise it just so that you have slight upward push on the tank. Don't lift the vehicle!! You can damage your tank and fuel pump assembly!
14. Lower the fuel tank but as you do so, have someone watch the fuel filler line to clear out of the opening near the shock.
15. Clean the top of the fuel tank of large debris to prevent contamination.
17. You should be able to remove the fuel pump assembly. There is rubber gasket that sits between the pump and the tank. Don't let the gasket drop into the tank and watch out for the float! If you have the whole assembly as a replacement skip to step 26.
26. Put the new fuel pump regulator back on to the assembly with the same orientation the old one came off of. Put the metal tab back on top of the regulator.
27. Put fuel pump assembly back into the tank, make sure you sandwich the rubber O ring between the assembly and the tank!
28. Put the lock ring on. Tighten it with the strap wrench (I hope you remember how tight it was when you were removing them). According to factory specification, it takes 45 ft.lbs.
29. Reverse the tank removal process. Tighten the nuts(7) to 12 ft.lbs. Make sure you reconnect the electrical, fuel line, EVAP lines back together.
30. Put the fuel pump relay back on.
31. Put the negative cable back on the battery.
32. Turn the key to on position but do not crank. Leave it on for 2 seconds to fill up the fuel line. Repeat several times and crank the engine. It should fire right up!
33. Enjoy the quick starting engine again!!
If you have any questions or recommendations, please let me know!!
Disclaimer I tried my best to document as much as possible along with pictures. I hope you find them useful. However, do use the information provided here "as-is". DailyDrivenTJ.com or the author does not warrant or assume any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, or process disclosed. Use the information at your own risk.
Written by Michael on 4.1.2006.
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Jeep®, Wrangler, Liberty, Wagoneer, Cherokee,
and Grand Cherokee are copyrighted and trademarked to Daimler-Chrysler Corporation. All materials presented in DailyDrivenTJ.com should only be used for entertainment. :) DailyDrivenTJ.com does not warrant or assume any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, or process disclosed. DailyDrivenTJ.com
has DailyDrivenTJ.com is hosted by SiteGround.com Copyrighted © 2006 DailyDrivenTJ.com - All right reserved. |
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