XJ                                                                                              FUEL SYSTEM           14 -...
14 - 2   FUEL SYSTEM                                                                                     XJGENERAL INFORMA...
XJ                                                                                                                  FUEL S...
14 - 4     FUEL SYSTEM                                                                                        XJDESCRIPTIO...
FUEL   FILTER/FUEL PRES-        FUEL SUPPLY TUBE         SURE REGULATOR                 O-RINGS                      FUEL ...
14 - 6    FUEL SYSTEM                                                                                            XJDESCRIP...
FUEL   TEST PORT      PRESSURE   HOSE                 TEST              FUEL FUEL PRESSURE TEST                           ...
FUELADAPTERGAUGE                                                                  #6539 OR #6631                          ...
FUEL RAIL CLIP LINE  LATCH FUEL      VEHICLE                     SURE                                  FUEL   GAUGE       ...
14 - 10    FUEL SYSTEM                                                                                         XJSERVICE P...
INSERTED TUBE END TAB               PULL     PRESS                          REMOVE PULL TAB                               ...
TAB(S)   QUICK-CON-                                  NECT FITTING14 - 12    FUEL SYSTEM                                   ...
FUELRETAINER       PLASTIC       INSTALLATION         PUSH            TUBE      REMOVAL                           PUSH PUS...
SPECIAL           LINE TOOL                FUEL   FUEL RAIL             FUEL LINE14 - 14     FUEL SYSTEM                  ...
FUEL   FILTER/FUEL PRES-        FUEL SUPPLY TUBE         SURE REGULATOR                 O-RINGS                      FUEL ...
FUEL PUMP INLET FILTER   FUEL PUMP MODULE14 - 16      FUEL SYSTEM                                                         ...
FUEL RAIL PORT TEST FUEL     MOUNTING           EQUIPPED)           PRESSURE              BOLTS                  (IF      ...
FUEL RAIL   FUEL RAIL         PLIERS   INJECTOR        FUEL INJEC-                                              INJECTORTO...
XJ                                                                                  FUEL SYSTEM        14 - 19REMOVAL AND ...
CABLE           CLIP   MOUNTING NUTS                                                                                      ...
XJ                                                                                  FUEL SYSTEM        14 - 21REMOVAL AND ...
14 - 22    FUEL SYSTEM                                                                                            XJSPECIF...
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Exj 14

  1. 1. XJ FUEL SYSTEM 14 - 1 FUEL SYSTEM CONTENTS page pageFUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . . . 3 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1FUEL INJECTION SYSTEM . . . . . . . . . . . . . . . . 23 GENERAL INFORMATION INDEX page pageGENERAL INFORMATION GASOLINE/OXYGENATE BLENDS . . . . . . . . . . . 1 FUEL REQUIREMENTS . . . . . . . . . . . . . . . . . . . 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1GENERAL INFORMATION Poor quality gasoline can cause problems such as hard starting, stalling, and stumble. If you experi-INTRODUCTION ence these problems, try another brand of gasoline Throughout this group, references may be made to before considering service for the vehicle.a particular vehicle by letter or number designation.A chart showing the breakdown of these designations GASOLINE/OXYGENATE BLENDSis included in the Introduction Section at the front of Some fuel suppliers blend unleaded gasoline withthis service manual. materials that contain oxygen such as alcohol, MTBE The Evaporation Control System, is also considered (Methyl Tertiary Butyl Ether) and ETBE (Ethyl Ter-part of the fuel system. The system reduces the emis- tiary Butyl Ether). Oxygenates are required in somesion of fuel vapor into the atmosphere. areas of the country during winter months to reduce The description and function of the Evaporation carbon monoxide emissions. The type and amount ofControl System is found in Group 25 of this manual. oxygenate used in the blend is important. The following are generally used in gasolineFUEL REQUIREMENTS blends: Your vehicle was designed to meet all emission reg- Ethanol - (Ethyl or Grain Alcohol) properlyulations and provide excellent fuel economy when blended, is used as a mixture of 10 percent ethanolusing high quality unleaded gasoline. and 90 percent gasoline. Gasoline blended with etha- Use unleaded gasolines having a minimum posted nol may be used in your vehicle.octane of 87. MTBE/ETBE - Gasoline and MTBE (Methyl Ter- If your vehicle develops occasional light spark tiary Butyl Ether) blends are a mixture of unleadedknock (ping) at low engine speeds this is not harm- gasoline and up to 15 percent MTBE. Gasoline andful. However; continued heavy knock at high speeds ETBE (Ethyl Tertiary Butyl Ether) are blends of gas-can cause damage and should be reported to your oline and up to 17 percent ETBE. Gasoline blendeddealer immediately. Engine damage as a result of with MTBE or ETBE may be used in your vehicle.heavy knock operation may not be covered by the Methanol - Methanol (Methyl or Wood Alcohol) isnew vehicle warranty. used in a variety of concentrations blended with In addition to using unleaded gasoline with the unleaded gasoline. You may encounter fuels contain-proper octane rating, those that contain detergents, ing 3 percent or more methanol along with othercorrosion and stability additives are recommended. alcohols called cosolvents.Using gasolines that have these additives will help DO NOT USE GASOLINES CONTAININGimprove fuel economy, reduce emissions, and main- METHANOL.tain vehicle performance.
  2. 2. 14 - 2 FUEL SYSTEM XJGENERAL INFORMATION (Continued) Use of methanol/gasoline blends may result in Chrysler Corporation strongly supports the use ofstarting and driveability problems and damage criti- reformulated gasolines whenever available. Althoughcal fuel system components. your vehicle was designed to provide optimum perfor- Problems that are the result of using methanol/ mance and lowest emissions operating on high qual-gasoline blends are not the responsibility of Chrysler ity unleaded gasoline, it will perform equally wellCorporation and may not be covered by the vehicle and produce even lower emissions when operating onwarranty. reformulated gasoline. Reformulated Gasoline Materials Added to Fuel Many areas of the country are requiring the use of Indiscriminate use of fuel system cleaning agentscleaner-burning fuel referred to as Reformulated should be avoided. Many of these materials intendedGasoline . Reformulated gasolines are specially for gum and varnish removal may contain active sol-blended to reduce vehicle emissions and improve air vents of similar ingredients that can be harmful toquality. fuel system gasket and diaphragm materials.
  3. 3. XJ FUEL SYSTEM 14 - 3 FUEL DELIVERY SYSTEM INDEX page pageDESCRIPTION AND OPERATION PROCEDURE—WITHOUT PRESSURE TEST FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . . . 3 PORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 FUEL FILTER/FUEL PRESSURE REGULATOR . . 4 FUEL SYSTEM PRESSURE RELEASE FUEL GAUGE SENDING UNIT . . . . . . . . . . . . . . 4 PROCEDURE–WITH PRESSUR E FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . 5 TEST PORT . . . . . . . . . . . . . . . . . . . . . . . . . . 9 FUEL PUMP MODULE . . . . . . . . . . . . . . . . . . . . 3 FUEL TUBES/LINES/HOSES AND CLAMPS . . . 10 FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 QUICK-CONNECT FITTINGS . . . . . . . . . . . . . . 11 FUEL RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 REMOVAL AND INSTALLATION FUEL TANK FILLER TUBE CAP . . . . . . . . . . . . . 5 ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . 20 FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 FUEL FILTER/FUEL PRESSURE REGULATOR . 14 QUICK-CONNECT FITTINGS . . . . . . . . . . . . . . . 6 FUEL GAUGE SENDING UNIT . . . . . . . . . . . . . 16 ROLLOVER VALVE(S) . . . . . . . . . . . . . . . . . . . . 5 FUEL INJECTOR RAIL . . . . . . . . . . . . . . . . . . . 17DIAGNOSIS AND TESTING FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . 18 FUEL GAUGE SENDING UNIT . . . . . . . . . . . . . . 9 FUEL PUMP INLET FILTER . . . . . . . . . . . . . . . 16 FUEL INJECTOR TEST . . . . . . . . . . . . . . . . . . . 9 FUEL PUMP MODULE . . . . . . . . . . . . . . . . . . . 15 FUEL PRESSURE LEAK DOWN TEST . . . . . . . . 8 FUEL TANK FILLER TUBE CAP . . . . . . . . . . . . 20 FUEL PUMP CAPACITY TEST . . . . . . . . . . . . . . 8 FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 FUEL PUMP PRESSURE TEST—ALL ENGINES THROTTLE CABLE . . . . . . . . . . . . . . . . . . . . . 21 WITH PRESSURE TEST PORT . . . . . . . . . . . . 6 SPECIFICATIONS FUEL PUMP PRESSURE TEST—ALL ENGINES FUEL SYSTEM PRESSURE . . . . . . . . . . . . . . . 22 WITHOUT PRESSURE TEST PORT . . . . . . . . 6 FUEL TANK CAPACITY . . . . . . . . . . . . . . . . . . 22SERVICE PROCEDURES TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . 22 FUEL SYSTEM PRESSURE RELEASE VECI LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 22DESCRIPTION AND OPERATION Emission Control System for rollover valve informa- tion).FUEL DELIVERY SYSTEM A fuel filler/vent tube assembly consisting of a The fuel delivery system consists of: pressure-vacuum filler cap is used. • the fuel pump module containing the electric Also to be considered part of the fuel system is thefuel pump, fuel filter/fuel pressure regulator, fuel evaporation control system containing the pressuregauge sending unit (fuel level sensor) and a separate relief/rollover valve. This is designed to reduce thefuel filter located at bottom of pump module emission of fuel vapors into the atmosphere. The • fuel tubes/lines/hoses description and function of the Evaporative Control • quick-connect fittings System is found in Group 25, Emission Control Sys- • fuel injector rail tems. • fuel injectors Both fuel filters (at bottom of fuel pump module • fuel tank and within fuel pressure regulator) are designed for • fuel tank filler/vent tube assembly extended service. They do not require normal sched- • fuel tank filler tube cap uled maintenance. Filters should only be replaced if • accelerator pedal a diagnostic procedure indicates to do so. • throttle cable Fuel is returned through the fuel pump module FUEL PUMP MODULEand back into the fuel tank through the fuel filter/ The fuel pump module is installed in the top of thefuel pressure regulator. A separate fuel return line fuel tank (Fig. 1) or (Fig. 2). The fuel pump modulefrom the engine to the tank is not used. contains the following components: The fuel tank assembly consists of: the fuel tank, • A combination fuel filter/fuel pressure regulatorfuel pump module assembly, fuel pump module lock- • A separate fuel pick-up filter (strainer)nut/gasket, and rollover valve (refer to Group 25, • An electric fuel pump • A threaded locknut to retain module to tank
  4. 4. 14 - 4 FUEL SYSTEM XJDESCRIPTION AND OPERATION (Continued) • Fuel gauge sending unit (fuel level sensor) has cooled down, fuel pressure may drop to 0 psi • Fuel supply tube (line) connection (cold fluid contracts), but liquid gasoline will remain The fuel gauge sending unit, pick-up filter and fuel in fuel supply line between the check valve and fuelfilter/fuel pressure regulator may be serviced sepa- injectors. Fuel pressure that has dropped to 0rately. If the electrical fuel pump requires service, psi on a cooled down vehicle (engine off) is athe entire fuel pump module must be replaced. normal condition. Refer to the Fuel Pressure Leak Down Test in this group for more information. Voltage to operate the electric pump is supplied through the fuel pump relay. FUEL GAUGE SENDING UNIT The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module (Fig. 2). The sending unit consists of a float, an arm, and a variable resistor (track). The resistor track is used to send electrical signals to the Powertrain Control Module (PCM) for fuel gauge operation and for OBD II emission requirements. For fuel gauge operation: As fuel level increases, the float and arm move up. This decreases the sending unit resistance, causing the fuel gauge to read full. As fuel level decreases, the float and arm move down. This increases the sending unit resis- tance causing the fuel gauge to read empty. After this fuel level signal is sent to the PCM, the Fig. 1 Fuel Tank/Fuel Pump Module (Top View) PCM will transmit the data across the CCD bus cir- cuits to the instrument panel. Here it is translated into the appropriate fuel gauge level reading. For OBD II emission requirements: The voltage signal is sent from the resistor track to the PCM to indicate fuel level. The purpose of this feature is to prevent a false setting of misfire and fuel system monitor trouble codes. This is if the fuel level in the tank is less than approximately 15 percent of its rated capacity. FUEL FILTER/FUEL PRESSURE REGULATOR A combination fuel filter and fuel pressure regula- tor is used on all engines. It is located on the top of fuel pump module (Fig. 1). A separate frame mounted fuel filter is not used with any engine. Fuel Pressure Regulator Operation: The pres- sure regulator is a mechanical device that is not con- Fig. 2 Fuel Pump Module Components trolled by engine vacuum or the Powertrain ControlFUEL PUMP Module (PCM). The fuel pump used in this system has a perma- The regulator is calibrated to maintain fuel systemnent magnet electric motor. The pump is part of the operating pressure of approximately 339 kPa Ϯ 34fuel pump module. Fuel is drawn in through a filter kPa (49.2 psi Ϯ 5 psi) at the fuel injectors. It con-at the bottom of the module and pushed through the tains a diaphragm, calibrated springs and a fuelelectric motor gearset to the pump outlet. return valve. The internal fuel filter is also part of Check Valve Operation: The pump outlet con- the assembly.tains a one-way check valve to prevent fuel flow back Fuel is supplied to the filter/regulator by the elec-into the tank and to maintain fuel supply line pres- tric fuel pump through an opening tube at the bot-sure (engine warm) when pump is not operational. It tom of filter/regulator (Fig. 3).is also used to keep the fuel supply line full of gaso- The regulator acts as a check valve to maintainline when pump is not operational. After the vehicle some fuel pressure when the engine is not operating.
  5. 5. FUEL FILTER/FUEL PRES- FUEL SUPPLY TUBE SURE REGULATOR O-RINGS FUEL TO TANK RETURN FUEL RAIL PORT TEST FUEL MOUNTING EQUIPPED) PRESSURE BOLTS (IF FUEL INJECTOR NUMBEREDAG FUEL RAIL T TO FUEL INJECTORSXJ FUEL SYSTEM 14 - 5DESCRIPTION AND OPERATION (Continued) tors are used with the 2.5L 4-cylinder engine (Fig. 5). The injectors are attached to the fuel rail. The nozzle ends of the injectors are positioned into openings in the intake manifold just above the intake valve ports of the cylinder head. The engine wiring harness connector for each fuel injector is equipped with an attached numerical tag (INJ 1, INJ 2 etc.). This is used to identify each fuel injector. The injectors are energized individually in a sequential order by the powertrain control module (PCM). The PCM will adjust injector pulse width by switching the ground path to each individual injector on and off. Injector pulse width is the period of time that the injector is energized. The PCM will adjust injector pulse width based on various inputs it receives. During start up, battery voltage is supplied to the injectors through the ASD relay. When the engine is operating, voltage is supplied by the charging sys- Fig. 3 Fuel Filter/Fuel Pressure Regulator tem. The PCM determines injector pulse width basedThis will help to start the engine. A second check on various inputs.valve is located at the outlet end of the electric fuelpump. Refer to Fuel Pump—Description andOperation for more information. Also refer tothe Fuel Pressure Leak Down Test and the FuelPump Pressure Tests. If fuel pressure at the pressure regulator exceedsapproximately 49 psi, an internal diaphragm closesand excess fuel is routed back into the tank throughthe pressure regulator. A separate fuel return line isnot used.FUEL TANK All models pass a full 360 degree rollover testwithout fuel leakage. To accomplish this, fuel andvapor flow controls are required for all fuel tank con-nections. All models have a pressure relief/rollover valve Fig. 4 Fuel Rail and Injectors—4.0L 6–Cyl. Enginemounted on the top of the fuel tank. FUEL RAIL An evaporative control system is used to reduce The fuel rail supplies the necessary fuel to eachemissions of fuel vapors into atmosphere by evapora- individual fuel injector and is mounted to the intaketion and to reduce unburned hydrocarbons emitted manifold (Fig. 4) or (Fig. 5). The fuel pressure regu-by vehicle engine. When fuel evaporates from fuel lator is no longer mounted to the fuel rail on anytank, vapors pass through vent hoses or tubes to a 2.5L/4.0L engine. It is now located on the fuel tankcharcoal canister. The vapors are temporarily held in mounted fuel pump module. Refer to Fuel Filter/Fuelthe canister. When the engine is running, the vapors Pressure Regulator in this group for information.are drawn into intake manifold. Refer to Group 25, Certain engines are equipped with a fuel pressureEmission Control System for additional information. test port (Fig. 4). Not all 2.5L/4.0L engines are equipped with this test port.ROLLOVER VALVE(S) The fuel rail is not repairable. Refer to Group 25, Emission Control System forinformation. FUEL TANK FILLER TUBE CAP The loss of any fuel or vapor out of filler neck isFUEL INJECTORS prevented by the use of a pressure-vacuum fuel tank Six individual fuel injectors are used with the 4.0L filler tube cap. Relief valves inside cap will release6-cylinder engine (Fig. 4). Four individual fuel injec-
  6. 6. 14 - 6 FUEL SYSTEM XJDESCRIPTION AND OPERATION (Continued) Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not oper- ational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine off) is a normal condition. When the elec- tric fuel pump is activated, fuel pressure should immediately rise to specification. NOTE: The fuel pressure test port is used on cer- tain engines only. If used, it will be located on the fuel rail. A sealing cap is screwed onto the test port. All fuel systems are equipped with a fuel tank Fig. 5 Fuel Rail and Injectors—2.5L 4–Cyl. Engine module mounted, combination fuel filter/fuel pressure regulator. The fuel pressure regulator is not con-only under significant pressure of 6.58 to 8.44 kPa trolled by engine vacuum.(1.95 to 2.5 psi). The vacuum release for all fuel fillertube caps is between .97 and 5.0 kPa (.14 and .72 WARNING: THE FUEL SYSTEM IS UNDER CON-psi). This cap must be replaced by a similar unit if STANT FUEL PRESSURE EVEN WITH THE ENGINEreplacement is necessary. This is in order for the sys- OFF. BEFORE DISCONNECTING FUEL LINE ATtem to remain effective. FUEL RAIL, THIS PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURECAUTION: Remove fuel tank filler tube cap before RELEASE PROCEDURE.servicing any fuel system component. This is doneto help relieve tank pressure. (1) Remove protective cap at fuel rail test port. Connect the 0–414 kPa (0-60 psi) fuel pressure gauge (from gauge set 5069) to test port pressure fitting onQUICK-CONNECT FITTINGS fuel rail (Fig. 6). Different types of quick-connect fittings are used to (2) Start and warm engine and note pressureattach various fuel system components. These are: a gauge reading. Fuel pressure should be 339 kPa Ϯ 34single-tab type, a two-tab type or a plastic retainer kPa (49.2 psi Ϯ 5 psi) at idle.ring type. Some are equipped with safety latch clips. (3) If engine runs but pressure is below 44.2 psi,Refer to the Removal/Installation section for more check for a kinked fuel supply line somewhereinformation. between fuel rail and fuel pump module. If line is notCAUTION: The interior components (o-rings, spac- kinked, replace fuel pump module assembly. Refer toers) of quick-connect fitting are not serviced sepa- Fuel Pump Module Removal/Installation.rately, but new pull tabs are available for some (4) If operating pressure is above 54.2 psi, electrictypes. Do not attempt to repair damaged fittings or fuel pump is OK, but fuel pressure regulator is defec-fuel lines/tubes. If repair is necessary, replace the tive. Replace fuel filter/fuel pressure regulator. Refercomplete fuel tube assembly. to Fuel Filter/Fuel Pressure Regulator Removal/In- stallation for more information. FUEL PUMP PRESSURE TEST—ALL ENGINESDIAGNOSIS AND TESTING WITHOUT PRESSURE TEST PORT Use this test in conjunction with the Fuel PumpFUEL PUMP PRESSURE TEST—ALL ENGINES Capacity Test and Fuel Pressure Leak Down TestWITH PRESSURE TEST PORT found elsewhere in this group. Use this test in conjunction with the Fuel Pump Check Valve Operation: The electric fuel pumpCapacity Test and Fuel Pressure Leak Down Test outlet contains a one-way check valve to prevent fuelfound elsewhere in this group. flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not oper-
  7. 7. FUEL TEST PORT PRESSURE HOSE TEST FUEL FUEL PRESSURE TEST RAIL GAUGE FUEL RAIL CLIP LINE LATCH FUEL VEHICLE SURE FUEL GAUGE TESTSPECIAL PRES- TEST TOOL6923 PORT “T”XJ FUEL SYSTEM 14 - 7DIAGNOSIS AND TESTING (Continued) Fig. 7 Adapter Tool 6539, 6631, 6923 or 6541— Typical Fig. 6 Fuel Pressure Test Gauge—Typical Installationational. It is also used to keep the fuel supply linefull of gasoline when pump is not operational. Afterthe vehicle has cooled down, fuel pressure may dropto 0 psi (cold fluid contracts), but liquid gasoline willremain in fuel supply line between the check valveand fuel injectors. Fuel pressure that hasdropped to 0 psi on a cooled down vehicle(engine off) is a normal condition. When the elec-tric fuel pump is activated, fuel pressure shouldimmediately rise to specification. All fuel systems are equipped with a fuel tankmodule mounted, combination fuel filter/fuel pressureregulator. The fuel pressure regulator is not con-trolled by engine vacuum.WARNING: THE FUEL SYSTEM IS UNDER CON- Fig. 8 Installing Adapter Tool and PressureSTANT FUEL PRESSURE EVEN WITH THE ENGINE Gauge—Typical InstallationOFF. BEFORE DISCONNECTING FUEL LINE AT (5) Install latch clip to fuel rail. If latch clip canFUEL RAIL, THIS PRESSURE MUST BE RELEASED. not be fully seated into fuel rail, check for adapterREFER TO THE FUEL SYSTEM PRESSURE tool not fully seated to fuel rail.RELEASE PROCEDURE. (6) Connect vehicle fuel line into adapter tool. Be sure fuel line is fully seated into adapter tool. (1) Release fuel pressure. Refer to the Fuel System (7) Remove protective cap at test port “T” onPressure Release Procedure—Without Pressure Test adapter tool.Port. (8) Connect the 0–414 kPa (0-60 psi) fuel pressure (2) Disconnect latch clip and fuel line at fuel rail. gauge (from gauge set 5069) to test port “T” (Fig. 8).Refer to Quick-Connect Fittings for procedures. This (9) Start engine and note pressure gauge reading.can be found in this section of the group. Fuel pressure should be 339 kPa Ϯ 34 kPa (49.2 psi (3) Obtain adapter tool number 6539 or 6631 (Fig. Ϯ 5 psi) at idle.7). (10) If engine runs but pressure is below 44.2 psi, (4) Connect adapter tool into fuel rail (Fig. 8). Be check for a kinked fuel supply line somewheresure adapter tool is fully seated into fuel rail. between fuel rail and fuel pump module. If line is not
  8. 8. FUELADAPTERGAUGE #6539 OR #6631 TEST PRESSURE TOOL FUEL RAIL FUEL LINE (TO TANK)14 - 8 FUEL SYSTEM XJDIAGNOSIS AND TESTING (Continued)kinked, replace fuel pump module assembly. Refer to Check Valve Operation: The electric fuel pumpFuel Pump Module Removal/Installation. outlet contains a one-way check valve to prevent fuel (11) If operating pressure is above 54.2 psi, electric flow back into the tank and to maintain fuel supplyfuel pump is OK, but fuel pressure regulator is defec- line pressure (engine warm) when pump is not oper-tive. Replace fuel filter/fuel pressure regulator. Refer ational. It is also used to keep the fuel supply lineto Fuel Filter/Fuel Pressure Regulator Removal/In- full of gasoline when pump is not operational. Afterstallation for more information. the vehicle has cooled down, fuel pressure may drop (12) After performing pressure test, install fuel to 0 psi (cold fluid contracts), but liquid gasoline willline into fuel rail. Install latch clip into fuel rail. remain in fuel supply line between the check valveRefer to Quick-Connect Fittings for procedures. This and fuel injectors. Fuel pressure that hascan be found in this section of the group. dropped to 0 psi on a cooled down vehicle (engine off) is a normal condition. When the elec-FUEL PUMP CAPACITY TEST tric fuel pump is activated, fuel pressure should Before performing this test, verify fuel pump immediately rise to specification.pressure by performing the Fuel Pump Pres- Abnormally long periods of cranking to restart asure Test. Use this test in conjunction with the hot engine that has been shut down for a shortFuel Pressure Leak Down Test found elsewhere period of time may be caused by:in this group. • Fuel pressure bleeding past a fuel injector(s). (1) Release fuel system pressure. Refer to the Fuel • Fuel pressure bleeding past the check valve inPressure Release Procedure in this group. the fuel pump module. (2) Disconnect fuel supply line at fuel rail. Refer to (1) Disconnect the fuel inlet line at fuel rail. ReferQuick-Connect Fittings in the Service Procedures to Fuel Tubes/Lines/Hoses and Clamps in this sectionsection of this group for procedures. Some engines of the group for procedures. On some engines, airmay require air cleaner housing removal before line cleaner housing removal may be necessary beforedisconnection. fuel line disconnection. (3) Connect appropriate Fuel Line Pressure Test (2) Connect the appropriate Fuel Line PressureAdapter Tool Hose (number 6631, 6923, 6541 or Test Adapter Tool (number 6539, 6631, 6541 or 6923)6539) into disconnected fuel supply line. Insert other between the disconnected fuel line and fuel rail (Fig.end of Adaptor Tool hose into a graduated container. 9) or (Fig. 10). (4) Remove fuel fill cap. (5) To activate fuel pump and pressurize system,obtain DRB scan tool and actuate ASD Fuel SystemTest. (6) A good fuel pump will deliver at least 1/4 literof fuel in 7 seconds. Do not operate fuel pump forlonger than 7 seconds with fuel line disconnected asfuel pump module reservoir may run empty. (a) If capacity is lower than specification, but fuel pump can be heard operating through fuel fill cap opening, check for a kinked/damaged fuel sup- ply line somewhere between fuel rail and fuel pump module. (b) If line is not kinked/damaged, and fuel pres- sure is OK, but capacity is low, replace fuel filter/ fuel pressure regulator. The filter/regulator may be serviced separately on certain applications. Refer Fig. 9 Connecting Adapter Tool—Typical to Fuel Filter/Fuel Pressure Regulator Removal/In- stallation for additional information. (3) Connect the 0-414 kPa (0-60 psi) fuel pressure (c) If both fuel pressure and capacity are low, test gauge (from Gauge Set 5069) to the test port on replace fuel pump module assembly. Refer to Fuel the appropriate Adaptor Tool. The fittings on both Pump Module Removal/Installation. tools must be in good condition and free from any small leaks before performing the proceed-FUEL PRESSURE LEAK DOWN TEST ing test. Use this test in conjunction with the Fuel Pump (4) Start engine and bring to normal operatingPressure Test and Fuel Pump Capacity Test. temperature.
  9. 9. FUEL RAIL CLIP LINE LATCH FUEL VEHICLE SURE FUEL GAUGE TESTSPECIAL PRES- TEST TOOL6923 PORT “T” SEAT- FUELISC FICE ORI-SEAL BACK-UP SEALNEEDLE BODYARMATURE SPRING ELECTRICAL OUTLET WASHER D GUIDE SPACERWIRE HOUSING INLET TUBE EYELET SEAL BOBBIN SEAL PLASTIC CONNEC- TERMINAL RETAINER SEAL FILTER TOR FUEL INLETXJ FUEL SYSTEM 14 - 9DIAGNOSIS AND TESTING (Continued) ulator Removal/Installation for additional informa- tion. FUEL GAUGE SENDING UNIT The fuel gauge sending unit (fuel level sensor) con- tains a variable resistor (track). As the float moves up or down, electrical resistance will change. Refer to Group 8E, Instrument Panel and Gauges for Fuel Gauge testing. To test the gauge sending unit only, it must be removed from vehicle. The unit is part of the fuel pump module. Refer to Fuel Pump Module Removal/Installation for procedures. Measure the resistance across the sending unit terminals. With float in up position, resistance should be approxi- mately 20 ohms. With float in down position, resis- tance should be approximately 220 ohms. FUEL INJECTOR TEST To perform a complete test of the fuel injectors and their circuitry, refer to DRB scan tool and appropri- ate Powertrain Diagnostics Procedures manual. To test the injector only, refer to the following: Fig. 10 Connecting Adapter Tool—Typical Disconnect the fuel injector wire harness connector (5) Observe test gauge. Normal operating pressure from the injector. Place an ohmmeter across theshould be 339 kPa Ϯ 34 kPa (49.2 psi Ϯ 5 psi). injector electrical terminals. Resistance reading (6) Shut engine off. should be approximately 12 ohms Ϯ1.2 ohms at 20°C (7) Pressure should not fall below 30 psi for five (68°F).minutes. (8) If pressure falls below 30 psi, it must be deter-mined if a fuel injector, the check valve within thefuel pump module, or a fuel tube/line is leaking. (9) Again, start engine and bring to normal oper-ating temperature. (10) Shut engine off. (11) Testing for fuel injector or fuel rail leak-age: Clamp off the rubber hose portion of AdaptorTool between the fuel rail and the test port “T” onAdapter Tool. If pressure now holds at or above 30psi, a fuel injector or the fuel rail is leaking. (12) Testing for fuel pump check valve, filter/regulator check valve or fuel tube/line leakage:Clamp off the rubber hose portion of Adaptor Toolbetween the vehicle fuel line and test port “T” onAdapter Tool. If pressure now holds at or above 30 Fig. 11 Fuel Injector Internal Components—Typicalpsi, a leak may be found at a fuel tube/line. If no SERVICE PROCEDURESleaks are found at fuel tubes or lines, one of thecheck valves in either the electric fuel pump or filter/ FUEL SYSTEM PRESSURE RELEASEregulator may be leaking. Note: A quick loss of pressure usually indicates a PROCEDURE–WITH PRESSURE TEST PORTdefective check valve in the filter/regulator. A slow NOTE: The fuel pressure test port is used on cer-loss of pressure usually indicates a defective check tain engines only. If equipped, the test port will bevalve in the electric fuel pump. located on fuel rail. A sealing cap is screwed onto The electric fuel pump is not serviced separately. test port.Replace the fuel pump module assembly. The filter/regulator may be replaced separately on certain The fuel system is under constant fuel pressureapplications. Refer to Fuel Filter/Fuel Pressure Reg- (even with engine off).
  10. 10. 14 - 10 FUEL SYSTEM XJSERVICE PROCEDURES (Continued)WARNING: BECAUSE THE FUEL SYSTEM IS (8) Connect one end of a second jumper wire to theUNDER CONSTANT FUEL PRESSURE, IT MUST BE remaining injector terminal.RELEASED BEFORE SERVICING ANY FUEL SYS-TEM COMPONENT. THIS DOES NOT APPLY TO CAUTION: Supplying power to an injector for moreTHROTTLE BODY REMOVAL. than 4 seconds will permanently damage the injec- tor. Do not leave the injector connected to power (1) Disconnect negative battery cable. for more than 4 seconds. (2) Remove fuel tank filler tube cap to release fueltank pressure. (9) Momentarily touch the other end of this (3) Remove protective cap from pressure test port jumper wire to the negative terminal of the batteryon fuel rail. This is located on top of fuel rail. for no more than 4 seconds. (10) Place a rag or towel below the fuel line at theWARNING: DO NOT ALLOW FUEL TO SPILL ONTO quick connect to the rail.ENGINE INTAKE OR EXHAUST MANIFOLDS. PLACE (11) Disconnect the quick connect fitting to theSHOP TOWELS UNDER AND AROUND PRESSURE rail. Refer to Quick-Connect Fittings in this section.PORT TO ABSORB FUEL WHEN PRESSURE IS (12) Return the fuel pump relay to the PDC.RELEASED FROM FUEL RAIL. (13) One or more Diagnostic Trouble Codes (DTC’s) may have been stored in the PCM memory due to fuel pump relay removal. The DRB scan tool must beWARNING: WEAR PROPER EYE PROTECTION used to erase a DTC. Refer to Group 25, EmissionWHEN RELEASING FUEL SYSTEM PRESSURE. Control System. See On-Board Diagnostics. (4) Obtain fuel pressure gauge/hose assembly from FUEL TUBES/LINES/HOSES AND CLAMPSfuel pressure gauge tool set 5069. Remove gauge Also refer to the section on Quick-Connect Fittings.from hose. (5) Place one end of hose (gauge end) into an WARNING: THE FUEL SYSTEM IS UNDER A CON-approved gasoline container. STANT PRESSURE (EVEN WITH THE ENGINE OFF). (6) Place a shop towel under test port. BEFORE SERVICING ANY FUEL SYSTEM HOSES, (7) To release fuel pressure, screw other end of FITTINGS OR LINES, THE FUEL SYSTEM PRES-hose onto fuel pressure test port. SURE MUST BE RELEASED. REFER TO THE FUEL (8) After fuel pressure has been released, remove SYSTEM PRESSURE RELEASE PROCEDURE INhose from test port. THIS GROUP. (9) Install protective cap to fuel test port. Inspect all hose connections such as clamps, cou-FUEL SYSTEM PRESSURE RELEASE plings and fittings to make sure they are secure andPROCEDURE—WITHOUT PRESSURE TEST PORT leaks are not present. The component should be Use the following procedure if the fuel rail is replaced immediately if there is any evidence of deg-not equipped with a fuel pressure test port. radation that could result in failure. (1) Remove the Fuel Pump relay from the Power Never attempt to repair a plastic fuel line/tube.Distribution Center (PDC). For location of the relay, Replace as necessary.refer to the label on the underside of the PDC cover. Avoid contact of any fuel tubes/hoses with other (2) Start and run engine until it stalls. vehicle components that could cause abrasions or (3) Attempt restarting engine until it will no scuffing. Be sure that the plastic fuel lines/tubes arelonger run. properly routed to prevent pinching and to avoid heat (4) Turn ignition key to OFF position. sources. The lines/tubes/hoses used on fuel injected vehiclesCAUTION: Steps 1, 2, 3 and 4 must be performed to are of a special construction. This is due to therelieve high pressure fuel from within the fuel rail. higher fuel pressures and the possibility of contami-Do not attempt to use the following steps to relieve nated fuel in this system. If it is necessary to replacethis pressure as excessive fuel will be forced into a these lines/tubes/hoses, only those marked EFM/EFIcylinder chamber. may be used. If equipped: The hose clamps used to secure rub- (5) Unplug connector from any injector. ber hoses on fuel injected vehicles are of a special (6) Attach one end of a jumper wire with alligator rolled edge construction. This construction is used toclips (18 gauge or smaller) to either injector terminal. prevent the edge of the clamp from cutting into the (7) Connect the other end of the jumper wire to hose. Only these rolled edge type clamps may bethe positive side of the battery.
  11. 11. INSERTED TUBE END TAB PULL PRESS REMOVE PULL TAB HERE TOQUICK-CONNECT FITTING FUEL TUBE OR FUEL SYSTEM STOP FUEL PULL TAB TUBE COMPONENT QUICK-CONNECT FITTING PULL TAB SCREWDRIVER QUICK-CON- NECT FITTINGXJ FUEL SYSTEM 14 - 11SERVICE PROCEDURES (Continued)used in this system. All other types of clamps may (2) Perform the fuel pressure release procedure.cut into the hoses and cause high-pressure fuel leaks. Refer to the Fuel Pressure Release Procedure in this Use new original equipment type hose clamps. section.Tighten hose clamps to 1 N·m (15 in. lbs.) torque. (3) Clean the fitting of any foreign material before disassembly.QUICK-CONNECT FITTINGS (4) Press the release tab on the side of fitting to Also refer to the Fuel Tubes/Lines/Hoses and release pull tab (Fig. 13).Clamps section. Different types of quick-connect fittings are used to CAUTION: If this release tab is not pressed priorattach various fuel system components. These are: a to releasing the pull tab, the pull tab will be dam-single-tab type, a two-tab type, a plastic retainer ring aged.type or a latch clip type. (5) While pressing the release tab on the side ofSINGLE-TAB TYPE the fitting, use a screwdriver to pry up the pull tab This type of fitting is equipped with a single pull (Fig. 13).tab (Fig. 12). The tab is removable. After the tab isremoved, the quick-connect fitting can be separatedfrom the fuel system component. Fig. 13 Disconnecting Single-Tab Type Fitting (6) Raise the pull tab until it separates from the quick-connect fitting (Fig. 14). Discard the old pull Fig. 12 Single-Tab Type Fitting tab.CAUTION: The interior components (o-rings, spac-ers) of this type of quick-connect fitting are not ser-viced separately, but new pull tabs are available. Donot attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the completefuel tube assembly.WARNING: THE FUEL SYSTEM IS UNDER A CON-STANT PRESSURE EVEN WITH THE ENGINE OFF.BEFORE SERVICING ANY FUEL SYSTEM HOSES,FITTINGS OR LINES, THE FUEL SYSTEM PRES-SURE MUST BE RELEASED. REFER TO THE FUELSYSTEM PRESSURE RELEASE PROCEDURE INTHIS GROUP.DISCONNECTION/CONNECTION Fig. 14 Removing Pull Tab (1) Disconnect negative battery cable from battery. (7) Disconnect the quick-connect fitting from the fuel system component being serviced.
  12. 12. TAB(S) QUICK-CON- NECT FITTING14 - 12 FUEL SYSTEM XJSERVICE PROCEDURES (Continued) (8) Inspect the quick-connect fitting body and fuel DISCONNECTION/CONNECTIONsystem component for damage. Replace as necessary. (1) Disconnect negative battery cable from the bat- (9) Prior to connecting the quick-connect fitting to tery.component being serviced, check condition of fitting (2) Perform the fuel pressure release procedure.and component. Clean the parts with a lint-free Refer to the Fuel Pressure Release Procedure in thiscloth. Lubricate them with clean engine oil. section. (10) Insert the quick-connect fitting into the fuel (3) Clean the fitting of any foreign material beforetube or fuel system component until the built-on stop disassembly.on the fuel tube or component rests against back of (4) To disconnect the quick-connect fitting, squeezefitting. the plastic retainer tabs (Fig. 15) against the sides of (11) Obtain a new pull tab. Push the new tab the quick-connect fitting with your fingers. Tool usedown until it locks into place in the quick-connect fit- is not required for removal and may damage plasticting. retainer. Pull the fitting from the fuel system compo- (12) Verify a locked condition by firmly pulling on nent being serviced. The plastic retainer will remainfuel tube and fitting (15-30 lbs.). on the component being serviced after fitting is dis- (13) Connect negative cable to battery. connected. The o-rings and spacer will remain in the (14) Start engine and check for leaks. quick- connect fitting connector body. (5) Inspect the quick-connect fitting body and com-TWO-TAB TYPE FITTING ponent for damage. Replace as necessary. This type of fitting is equipped with tabs located onboth sides of the fitting (Fig. 15). These tabs are sup- CAUTION: When the quick-connect fitting was dis-plied for disconnecting the quick-connect fitting from connected, the plastic retainer will remain on thecomponent being serviced. component being serviced. If this retainer must be removed, very carefully release the retainer from the component with two small screwdrivers. After removal, inspect the retainer for cracks or any dam- age. (6) Prior to connecting the quick-connect fitting to component being serviced, check condition of fitting and component. Clean the parts with a lint-free cloth. Lubricate them with clean engine oil. (7) Insert the quick-connect fitting to the compo- nent being serviced and into the plastic retainer. When a connection is made, a click will be heard. (8) Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.). (9) Connect negative cable to battery. (10) Start engine and check for leaks.Fig. 15 Typical Two-Tab Type Quick-Connect Fitting PLASTIC RETAINER RING TYPE FITTINGCAUTION: The interior components (o-rings, spac- This type of fitting can be identified by the use of aers) of this type of quick-connect fitting are not ser- full-round plastic retainer ring (Fig. 16) usually blackviced separately, but new plastic retainers are in color.available. Do not attempt to repair damaged fittingsor fuel lines/tubes. If repair is necessary, replace CAUTION: The interior components (o-rings, spac-the complete fuel tube assembly. ers, retainers) of this type of quick-connect fitting are not serviced separately. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is nec-WARNING: THE FUEL SYSTEM IS UNDER A CON- essary, replace the complete fuel tube assembly.STANT PRESSURE EVEN WITH THE ENGINE OFF.BEFORE SERVICING ANY FUEL SYSTEM HOSES,FITTINGS OR LINES, THE FUEL SYSTEM PRES-SURE MUST BE RELEASED. REFER TO THE FUELPRESSURE RELEASE PROCEDURE IN THISGROUP.
  13. 13. FUELRETAINER PLASTIC INSTALLATION PUSH TUBE REMOVAL PUSH PUSH QUICK CONNECT FITTING PUSH PUSHXJ FUEL SYSTEM 14 - 13SERVICE PROCEDURES (Continued) (6) Inspect fitting connector body, plastic retainer ring and fuel system component for damage. Replace as necessary. (7) Prior to connecting the quick-connect fitting to component being serviced, check condition of fitting and component. Clean the parts with a lint-free cloth. Lubricate them with clean engine oil. (8) Insert the quick-connect fitting into the compo- nent being serviced until a click is felt. (9) Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.). (10) Connect negative battery cable to battery. (11) Start engine and check for leaks. FUEL LINE AT FUEL RAIL A latch clip is used to secure the fuel line to the fuel rail on certain engines (Fig. 17). This type of quick-connect fitting may also be used at various other fuel system components. A special tool will be necessary to separate the fuel line from the fuel rail after the latch clip is removed. Fig. 16 Plastic Retainer Ring Type Fitting DISCONNECTION/CONNECTION AT FUEL RAIL (1) Disconnect the negative battery cable from bat-WARNING: THE FUEL SYSTEM IS UNDER A CON- tery.STANT PRESSURE EVEN WITH THE ENGINE OFF. (2) Perform the fuel pressure release procedure.BEFORE SERVICING ANY FUEL SYSTEM HOSES, Refer to the Fuel Pressure Release Procedure in thisFITTINGS OR LINES, THE FUEL SYSTEM PRES- section.SURE MUST BE RELEASED. REFER TO THE FUEL (3) Clean the fitting of any foreign material beforeSYSTEM PRESSURE RELEASE PROCEDURE IN disassembly.THIS GROUP. (4) Pry up on the latch clip with a screwdriver (Fig. 17).DISCONNECTION/CONNECTION (1) Disconnect negative battery cable from the bat-tery. (2) Perform the fuel pressure release procedure.Refer to the Fuel Pressure Release Procedure in thissection. (3) Clean the fitting of any foreign material beforedisassembly. (4) To release the fuel system component from thequick-connect fitting, firmly push the fitting towardsthe component being serviced while firmly pushingthe plastic retainer ring into the fitting (Fig. 16).With the plastic ring depressed, pull the fitting fromthe component. The plastic retainer ring must bepressed squarely into the fitting body. If thisretainer is cocked during removal, it may bedifficult to disconnect fitting. Use an open-end Fig. 17 Latch Clip Removal—Typicalwrench on the shoulder of the plastic retainer (5) Slide the latch clip toward the fuel rail whilering to aid in disconnection. lifting with the screwdriver. (5) After disconnection, the plastic retainer ring (6) Insert special fuel line removal tool (Snap-Onwill remain with the quick-connect fitting connector number FIH 9055- 1 or equivalent) into the fuel linebody. (Fig. 18). Use this tool to release the locking fingers in the end of the line.
  14. 14. SPECIAL LINE TOOL FUEL FUEL RAIL FUEL LINE14 - 14 FUEL SYSTEM XJSERVICE PROCEDURES (Continued) (4) Remove retainer clamp from top of filter/regu- lator (Fig. 19). Clamp snaps to tabs on pump module. Discard old clamp. (5) Pry filter/regulator from top of pump module with 2 screwdrivers. Unit is snapped into module. (6) Discard gasket below filter/regulator (Fig. 20). (7) Before discarding filter/regulator assembly, inspect assembly to verify that o-rings (Fig. 21) are intact. If the smallest of the two o-rings can not be found on bottom of filter/regulator, it may be neces- sary to remove it from the fuel inlet passage in fuel pump module. Fig. 18 Fuel Line Disconnection—Typical (7) With the special tool still inserted, pull thefuel line from the fuel rail. (8) After disconnection, the locking fingers willremain within the quick-connect fitting at the end ofthe fuel line. (9) Inspect fuel line fitting, locking fingers andfuel rail fitting for damage. Replace as necessary. (10) Prior to connecting the fuel line to the fuelrail, check condition of both fittings. Clean the partswith a lint-free cloth. Lubricate them with cleanengine oil. (11) Insert the fuel line onto the fuel rail until aclick is felt. (12) Verify a locked condition by firmly pulling onfuel line and fitting (15-30 lbs.). Fig. 19 Fuel Filter/Fuel Pressure Regulator (13) Install latch clip (snaps into position). If thelatch clip will not fit, this indicates the fuel lineis not properly installed to the fuel rail.Recheck the fuel line connection. (14) Connect negative battery cable to battery. (15) Start engine and check for leaks.REMOVAL AND INSTALLATIONFUEL FILTER/FUEL PRESSURE REGULATOR The combination Fuel Filter/Fuel Pressure Regula-tor is located on the fuel pump module. The fuelpump module is located on top of fuel tank. The filter/regulator may be removed withoutremoving fuel pump module although fuel tank mustbe removed.REMOVAL (1) Remove fuel tank. Refer to Fuel Tank Removal/Installation. Fig. 20 Fuel Filter/Fuel Pressure Regulator Gasket (2) Clean area around filter/regulator. INSTALLATION (3) Disconnect fuel line at filter/regulator. Refer to (1) Clean recessed area in pump module where fil-Quick-Connect Fittings in this group for procedures. ter/regulator is to be installed.
  15. 15. FUEL FILTER/FUEL PRES- FUEL SUPPLY TUBE SURE REGULATOR O-RINGS FUEL TO TANK RETURN LOCKNUT SPECIAL TOOL 6856 TO FUEL INJECTORSXJ FUEL SYSTEM 14 - 15REMOVAL AND INSTALLATION (Continued) (1) Drain fuel tank and remove tank. Refer to the Fuel Tank Removal/Installation section of this group. (2) Thoroughly wash and clean area around pump module to prevent contaminants from entering tank. (3) Disconnect fuel line at filter/regulator. Refer to Quick-Connect Fittings in this group for procedures. (4) The plastic fuel pump module locknut is threaded onto fuel tank (Fig. 22). Install Special Tool 6856 to fuel pump module locknut and remove lock- nut (Fig. 23). The fuel pump module will spring up when locknut is removed. (5) Remove module from fuel tank.Fig. 21 Fuel Filter/Fuel Pressure Regulator O-Rings (2) Obtain new filter/regulator (two new o-ringsshould already be installed). (3) Apply a small amount of clean engine oil too-rings. Do not install o-rings separately intofuel pump module. They will be damaged wheninstalling filter/regulator. (4) Install new gasket to top of fuel pump module. (5) Press new filter/regulator into top of pumpmodule until it snaps into position (a positive clickmust be heard or felt). (6) The arrow (Fig. 19) molded into top of fuelpump module should be pointed towards front of Fig. 22 Top View of Fuel Tank and Fuel Pumpvehicle (12 o’clock position). Module (7) Rotate filter/regulator until fuel supply tube(fitting) is pointed towards front of vehicle (12 o’clockposition). (8) Install new retainer clamp (clamp snaps overtop of filter/regulator and locks to flanges on pumpmodule). (9) Connect fuel line at filter/regulator. Refer toQuick-Connect Fittings in this group for procedures. (10) Install fuel tank. Refer to Fuel Tank Removal/Installation.FUEL PUMP MODULE Fuel tank removal will be necessary for fuel pumpmodule removal.REMOVALWARNING: THE FUEL SYSTEM IS UNDER A CON- Fig. 23 Locknut Removal/Installation—TypicalSTANT PRESSURE EVEN WITH ENGINE OFF. INSTALLATIONBEFORE SERVICING THE FUEL PUMP MODULE,FUEL SYSTEM PRESSURE MUST BE RELEASED. CAUTION: Whenever the fuel pump module is ser- viced, the module gasket must be replaced.
  16. 16. FUEL PUMP INLET FILTER FUEL PUMP MODULE14 - 16 FUEL SYSTEM XJREMOVAL AND INSTALLATION (Continued) (1) Using a new gasket, position fuel pump module FUEL GAUGE SENDING UNITinto opening in fuel tank. The fuel gauge sending unit (fuel level sensor) and (2) Position locknut over top of fuel pump module. float assembly is located on the side of fuel pump (3) Rotate module until molded arrow (Fig. 22) is module (Fig. 25). The fuel pump module is located onpointed toward front of vehicle (12 o’clock position). top of fuel tank.This step must be done to prevent float/float rodassembly from contacting sides of fuel tank. (4) Install Special Tool 6856 to locknut. (5) Tighten locknut to 34 N·m (25 ft. lbs.) torque. (6) Rotate fuel filter/fuel pressure regulator untilits fitting is pointed toward front of vehicle (12o’clock position). (7) Connect fuel line at filter/regulator. Refer toQuick-Connect Fittings in this group for procedures. (8) Install fuel tank. Refer to Fuel Tank Installa-tion in this section.FUEL PUMP INLET FILTER The fuel pump inlet filter (strainer) is located onthe bottom of fuel pump module (Fig. 24). The fuelpump module is located on top of fuel tank. Fig. 25 Fuel Gauge Sending Unit Location Fig. 24 Fuel Pump Inlet FilterREMOVAL Fig. 26 Fuel Gauge Sending Unit Release Tab (1) Remove fuel tank. Refer to Fuel Tank Removal/Installation. REMOVAL (2) Remove fuel pump module. Refer to Fuel Pump (1) Remove fuel tank. Refer to Fuel Tank Removal/Module Removal/Installation. Installation. (3) Remove filter by prying from bottom of module (2) Remove fuel pump module. Refer to Fuel Pumpwith 2 screwdrivers. Filter is snapped to module. Module Removal/Installation. (4) Clean bottom of pump module. (3) Remove electrical wire connector at sending unit terminals.INSTALLATION (4) Press on release tab (Fig. 26) to remove send- (1) Snap new filter to bottom of module. ing unit from pump module. (2) Install fuel pump module. Refer to Fuel PumpModule Removal/Installation. INSTALLATION (3) Install fuel tank. Refer to Fuel Tank Removal/ (1) Position sending unit to pump module andInstallation. snap into place.
  17. 17. FUEL RAIL PORT TEST FUEL MOUNTING EQUIPPED) PRESSURE BOLTS (IF FUEL INJECTOR NUMBEREDAG FUEL RAIL TXJ FUEL SYSTEM 14 - 17REMOVAL AND INSTALLATION (Continued) (2) Connect electrical connector to terminals. (8) Disconnect speed control cable at throttle body (3) Install fuel pump module. Refer to Fuel Pump (if equipped). Refer to Speed Control Cable in GroupModule Removal/Installation. 8H, Speed Control System for procedures. (4) Install fuel tank. Refer to Fuel Tank Removal/ (9) Disconnect automatic transmission cable atInstallation. throttle body (if equipped). (10) Remove cable routing bracket at intake man-FUEL INJECTOR RAIL ifold (three bolts). (11) Remove nut securing crankshaft position sen-REMOVAL sor pigtail harness to fuel rail mounting stud. Remove clamp and harness from fuel rail mountingWARNING: THE FUEL SYSTEM IS UNDER CON- stud.STANT FUEL PRESSURE EVEN WITH ENGINE OFF. (12) Clean dirt/debris from each fuel injector atTHIS PRESSURE MUST BE RELEASED BEFORE intake manifold.SERVICING FUEL RAIL. (13) Remove fuel rail mounting bolts (Fig. 27). 4.0L engines use 4 mounting bolts. 2.5L engine use 2 (1) Remove fuel tank filler tube cap. mounting bolts. (2) Disconnect negative battery cable from battery. (14) Remove fuel rail by gently rocking until all (3) Perform Fuel System Pressure Release Proce- the fuel injectors are out of intake manifold.dure as described in this Group. (4) Remove air tube at top of throttle body. Note: INSTALLATIONSome engine/vehicles may require removal of air (1) Clean each injector bore at intake manifold.cleaner ducts at throttle body. (2) Apply a small amount of clean engine oil to (5) Remove and numerically attach a tag (if fuel each injector o-ring. This will aid in installation.injector is not already tagged), the injector harness (3) Position tips of all fuel injectors into the corre-connectors. Do this at each injector (Fig. 27). sponding injector bore in intake manifold. Seat injec- tors into manifold. (4) Install and tighten fuel rail mounting bolts to 11 Ϯ3 N·m (100 Ϯ25 in. lbs.) torque. (5) Position crankshaft position sensor pigtail wire harness clamp and wire harness to fuel rail mount- ing stud. Install nut securing harness to fuel rail mounting stud. (6) Connect injector harness connectors to appro- priate (tagged) injector. (7) Connect fuel line and fuel line latch clip to fuel rail. Refer Quick-Connect Fittings in this group for procedures. (8) Install protective cap to pressure test port fit- ting (if equipped). (9) Install cable routing bracket to intake manifold (three bolts). (10) Connect throttle cable at throttle body. (11) Connect speed control cable at throttle body (if Fig. 27 Fuel Rail Mounting (4.0L Shown) equipped). (6) Disconnect fuel supply line latch clip and fuel (12) Connect automatic transmission cable atline at fuel rail. Refer to Quick-Connect Fittings in throttle body (if equipped).this group for procedures. (13) Install air tube (or duct) at top of throttle (7) Disconnect throttle cable at throttle body. Refer body.to Throttle Cable Removal/Installation in this group (14) Install fuel tank cap.for procedures. (15) Connect negative battery cable to battery. (16) Start engine and check for fuel leaks.
  18. 18. FUEL RAIL FUEL RAIL PLIERS INJECTOR FUEL INJEC- INJECTORTOR CLIP CLIP14 - 18 FUEL SYSTEM XJREMOVAL AND INSTALLATION (Continued)FUEL INJECTORS (5) Start engine and check for fuel leaks.REMOVAL FUEL TANK (1) Remove fuel rail. Refer to Fuel Injector RailRemoval in this section. WARNING: THE FUEL SYSTEM IS UNDER CON- (2) Remove clip(s) that retain fuel injector(s) to STANT FUEL PRESSURE EVEN WITH THE ENGINEfuel rail (Fig. 28) or (Fig. 29). OFF. THIS PRESSURE MUST BE RELEASED BEFORE SERVICING FUEL TANK. The electric fuel pump may be activated allowing fuel tank to be drained. This is done at fuel rail con- nection using DRB scan tool. Refer to scan tool for fuel pump activation procedures. Before disconnect- ing fuel line at fuel rail, release fuel pressure. Refer to the Fuel System Pressure Release Procedure in this group for procedures. Attach end of special test hose tool number 6541, 6539, 6631 or 6923 at fuel rail disconnection (tool number will depend on model and/or engine application). Position opposite end of this hose tool to an approved gasoline draining sta- tion. Activate fuel pump and drain tank until empty. If electric fuel pump is not operating, tank will have to be lowered for fuel draining. Refer to following Fig. 28 Injector Mounting procedures. REMOVAL (1) Disconnect negative battery cable at battery. (2) Release fuel system pressure. Refer to the Fuel System Pressure Release Procedure in this group. (3) Raise and support vehicle. (4) If Equipped: Remove fuel tank skid plate. Refer to Group 23, Body for procedures. (5) Remove 4 fuel hose shield mounting bolts and remove fuel hose shield (Fig. 30) from body. Fig. 29 Injector Retaining Clips—Typical InjectorINSTALLATION (1) Install fuel injector(s) into fuel rail assemblyand install retaining clip(s). (2) If same injector(s) is being reinstalled, installnew o-ring(s). (3) Apply a small amount of clean engine oil toeach injector o-ring. This will aid in installation. Fig. 30 Fuel Hose Shield (4) Install fuel rail. Refer to Fuel Rail Installationin this section.
  19. 19. XJ FUEL SYSTEM 14 - 19REMOVAL AND INSTALLATION (Continued) (6) Remove fuel tank fill hose and vent hoseclamps at fuel tank filler tube (Fig. 31). Remove bothhoses at fuel filler tube (Fig. 31). Fig. 33 Fuel Tank Mounting Straps/Nuts Fig. 31 Fuel Fill and Vent Hoses Fig. 34 Fuel Fill/Vent Hose Index Marks Tubes/Lines/Hoses and Clamps in this group. Also refer to Quick-Connect Fittings for procedures.Fig. 32 Fuel Tank Connections at Front of Fuel Tank (10) Disconnect EVAP canister vent line near (7) Remove exhaust tailpipe heat shield mounting front of tank (Fig. 32).bolts and remove shield. (11) Disconnect fuel pump module electrical con- nector (pigtail harness) near front of tank (Fig. 32).CAUTION: To protect fuel tank from exhaust heat, Harness connector is clipped to body.this shield must reinstalled after tank installation. (12) Remove two fuel tank strap nuts (Fig. 33). Position both tank support straps away from tank. (8) Place a hydraulic jack to bottom of fuel tank. (13) Carefully lower right side of tank while feed- ing both fuel hoses through access hole in body. FuelWARNING: PLACE A SHOP TOWEL AROUND FUEL Tank Full And Not Drained Using DRB ScanLINES TO CATCH ANY EXCESS FUEL. Tool: To prevent fuel loss through hoses, keep left side of tank higher than right side while lowering. (9) Disconnect fuel supply line from fuel extension Do not allow hose openings to drop lower than top ofline near front of fuel tank (Fig. 32). Refer to Fuel tank.
  20. 20. CABLE CLIP MOUNTING NUTS RETAINER TABS14 - 20 FUEL SYSTEM XJREMOVAL AND INSTALLATION (Continued) (14) Continue lowering tank until clear of vehicle. tected by a plastic sheathing and is connected to thePlace tank on floor with left side (hose side) higher throttle body linkage by a ball socket. It is connectedthan right side. to the upper part of the accelerator pedal arm by a (15) Drain tank by removing fuel fill hose at tank. plastic retainer (clip) (Fig. 35). This retainer (clip)Fuel fill hose is largest of 2 hoses (Fig. 34). Insert the snaps into the top of the accelerator pedal arm.drain hose (from an approved gasoline draining sta- Retainer tabs (built into the cable sheathing) (Fig.tion) into hose opening. Drain tank until empty. 35) fasten the cable to the dash panel. (16) If fuel pump module removal is necessary,refer to Fuel Pump Module Removal/Installation inthis group for procedures.INSTALLATION (1) If fuel pump module is being installed, refer toFuel Pump Module Removal/Installation in thisgroup for procedures. (2) Install fuel fill/vent hoses to tank fittings. Toprevent hose from kinking, rotate each hose untilindex mark on hose is aligned to index tang on fueltank (Fig. 34). (3) Install hose clamps to hoses. Position clampsbetween index marks on each hose (Fig. 34). (4) Position fuel tank to hydraulic jack. (5) Raise tank into position while guiding fuel filland vent hoses into and through access hole in body. (6) Continue raising tank until positioned to body. (7) Attach two fuel tank mounting straps andmounting nuts. Tighten nuts to 9 N·m (80 in. lbs.)torque. Do not over tighten nuts. (8) Install both fuel hoses to fuel fill tube. Tightenboth retaining clamps. Fig. 35 Accelerator Pedal Mounting—Typical (9) Position fuel hose shield to body. Install andtighten 4 mounting bolts. Dual throttle return springs (attached to the throt- (10) Connect fuel pump module pigtail harness tle shaft) are used to close the throttle.electrical connector near front of tank. (11) Connect fuel pump module supply line near CAUTION: Never attempt to remove or alter thesefront of tank. Refer to Quick-Connect Fittings for springs.procedures. (12) Connect EVAP hose near front of tank. CAUTION: Be careful not to damage or kink the (13) Install exhaust tailpipe heat shield. cable core wire (within the cable sheathing) while (14) Install fuel tank skid plate (if equipped). servicing the accelerator pedal or throttle cable. (15) Lower vehicle and connect battery cable tobattery. REMOVALFUEL TANK FILLER TUBE CAP (1) From inside the vehicle, hold up accelerator If replacement of the fuel tank filler tube cap is pedal. Remove plastic cable retainer (clip) and throt-necessary, it must be replaced with an identical cap tle cable core wire from upper end of acceleratorto be sure of correct system operation. pedal arm (Fig. 35). Plastic cable retainer (clip) snaps into pedal arm.CAUTION: Remove the fuel tank filler tube cap to (2) Remove accelerator pedal mounting bracketrelieve fuel tank pressure. The cap must be nuts. Remove accelerator pedal assembly.removed prior to disconnecting any fuel systemcomponent or before draining the fuel tank. INSTALLATION (1) Place accelerator pedal assembly over studs protruding from floor pan. Tighten mounting nuts toACCELERATOR PEDAL 5 N·m (36 in. lbs.) torque. The accelerator pedal is connected to the throttlebody linkage by the throttle cable. The cable is pro-
  21. 21. XJ FUEL SYSTEM 14 - 21REMOVAL AND INSTALLATION (Continued) (2) Slide throttle cable into opening in top of pedalarm. Push plastic cable retainer (clip) into accelera-tor pedal arm opening until it snaps into place. (3) Before starting engine, operate acceleratorpedal to check for any binding.THROTTLE CABLEREMOVAL (1) From inside vehicle, hold up accelerator pedal.Remove plastic cable retainer (clip) and throttle cablecore wire from upper end of accelerator pedal arm(Fig. 35). Plastic cable retainer (clip) snaps into pedalarm. (2) Remove cable core wire at pedal arm. (3) From inside vehicle, pinch both sides of cablehousing retainer tabs (Fig. 35) at dash panel.Remove cable housing from dash panel and pull intoengine compartment. THROTTLE CABLE OFF (4) Remove cable from cable guide on engine cylin-der head (valve) cover (Fig. 36). (5) Remove throttle cable ball end socket at throt-tle body linkage (snaps off) (Fig. 37). Fig. 36 Cable Guide and Squeeze Tabs—Typical (6) Remove throttle cable from throttle bodymounting bracket by compressing squeeze tabs (Fig.36) and pushing cable through hole in bracket. (7) Remove throttle cable from vehicle.INSTALLATION (1) Slide throttle cable through hole in throttlebody bracket until retainer tabs lock into bracket. (2) Connect cable ball end to throttle body linkageball (snaps on). (3) Snap cable into cable guide on engine cylinderhead (valve) cover. (4) Push other end of cable through opening indash panel until retaining tabs lock into panel. (5) From inside drivers compartment, slide throttlecable core wire into opening in top of acceleratorpedal arm. Push cable retainer (clip) into pedal armopening until it snaps in place. Fig. 37 Throttle (Accelerator) Cable at Throttle (6) Before starting engine, operate accelerator Body—Typicalpedal to check for any binding.
  22. 22. 14 - 22 FUEL SYSTEM XJSPECIFICATIONS FUEL TANK CAPACITYVECI LABEL Models Liters U.S. Gallons If anything differs between the specifications found All 76 20on the Vehicle Emission Control Information (VECI) Nominal refill capacities are shown. A variation may belabel and the following specifications, use specifica- observed from vehicle to vehicle due to manufacturingtions on VECI label. The VECI label is located in the tolerance and refill procedure.engine compartment. FUEL SYSTEM PRESSURE 339 kPa Ϯ 34 kPa (49.2 psi Ϯ 5 psi). TORQUE CHART DESCRIPTION TORQUE Accelerator Pedal Bracket Mounting Nuts . . . . . . . . . . . . 5 N·m (36 in. lbs.) Fuel Hose Clamps . . . . . . . . . . . . 1 N·m (15 in. lbs.) Fuel Rail Mounting Bolts . . . . . 11 N·m (100 in. lbs.) Fuel Tank Mounting Strap Nuts . 9 N·m (80 in. lbs.) Fuel Pump Module Locknut . . . . 34 N·m (25 ft. lbs.)

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