Jeep Cherokee (XJ): Fuel gauge sending unit. Fuel injector rail/fuel damper-2.5L engine. Fuel injector rail/fuel damper-4.0L engine

Jeep Cherokee (XJ) 1984 - 2001 Service Manual > Fuel system > Fuel delivery system > Removal and installation > Fuel gauge sending unit. Fuel injector rail/fuel damper-2.5L engine. Fuel injector rail/fuel damper-4.0L engine

Fuel gauge sending unit

The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module (Fig. 27). The fuel pump module is located within the fuel tank.

Fig. 27 Fuel Gauge Sending Unit Location
Fig. 27 Fuel Gauge Sending Unit Location

1 - FUEL GAUGE FLOAT
2 - PICK-UP FILTER
3 - FUEL GAUGE SENDING UNIT
4 - FUEL FILTER/FUEL PRESSURE REGULATOR
5 - ELECTRIC FUEL PUMP
6 - PIGTAIL WIRING HARNESS

REMOVAL

(1) Remove fuel tank. Refer to Fuel Tank Removal/ Installation.

Fig. 28 Fuel Gauge Sending Unit Release Tab
Fig. 28 Fuel Gauge Sending Unit Release Tab

1 - ELECTRICAL CONNECTOR
2 - FUEL GAUGE SENDING UNIT
3 - RELEASE TAB
4 - FUEL PUMP MODULE

(2) Remove fuel pump module. Refer to Fuel Pump Module Removal/Installation.

(3) Remove electrical wire connector at sending unit terminals.

(4) Press on release tab (Fig. 28) to remove sending unit from pump module.

INSTALLATION

(1) Position sending unit to pump module and snap into place.

(2) Connect electrical connector to terminals.

(3) Install fuel pump module. Refer to Fuel Pump Module Removal/Installation.

(4) Install fuel tank. Refer to Fuel Tank Removal/ Installation.

Fuel injector rail/fuel damper-2.5L engine

REMOVAL

The fuel damper is not serviced separately.

WARNING: THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE EVEN WITH ENGINE OFF.

THIS PRESSURE MUST BE RELEASED BEFORE SERVICING FUEL RAIL.

(1) Remove fuel tank filler tube cap.

(2) Perform Fuel System Pressure Release Procedure as described in this Group.

(3) Disconnect negative battery cable from battery.

(4) Remove air tube at top of throttle body. Note: Some engine/vehicles may require removal of air cleaner ducts at throttle body.

(5) Remove injector harness electrical connectors at each injector. Each injector connector should have a numerical tag attached identifying its corresponding cylinder (Fig. 29). If not, identify each connector before removal.

Fig. 29 Fuel Rail Mounting-2.5L Engine
Fig. 29 Fuel Rail Mounting-2.5L Engine

1 - FUEL DAMPER
2 - FUEL INJECTOR
3 - NUMBERED TAG
4 - FUEL RAIL
5 - FUEL RAIL MOUNTING BOLTS/NUTS
6 - TEST PORT
7 - CABLE BRACKET

(6) Disconnect fuel supply line latch clip and fuel line at fuel rail. Refer to Quick-Connect Fittings in this group for procedures.

(7) Disconnect throttle cable at throttle body. Refer to Throttle Cable Removal/Installation in this group for procedures.

(8) Disconnect speed control cable at throttle body (if equipped). Refer to Speed Control Cable in Group 8H, Speed Control System for procedures.

(9) Disconnect automatic transmission cable at throttle body (if equipped).

(10) Remove cable routing bracket (Fig. 29) at intake manifold.

(11) Remove nut securing crankshaft position sensor pigtail harness to fuel rail mounting stud.

Remove clamp and harness from fuel rail mounting stud.

(12) Clean dirt/debris from each fuel injector at intake manifold.

(13) Remove fuel rail mounting nuts/bolts (Fig.

29).

(14) Remove fuel rail by gently rocking until all the fuel injectors are out of intake manifold.

INSTALLATION

(1) Clean each injector bore at intake manifold.

(2) Apply a small amount of clean engine oil to each injector o-ring. This will aid in installation.

(3) Position tips of all fuel injectors into the corresponding injector bore in intake manifold. Seat injectors into manifold.

(4) Install and tighten fuel rail mounting bolts to 11 63 N·m (100 625 in. lbs.) torque.

(5) Position crankshaft position sensor pigtail wire harness clamp and wire harness to fuel rail mounting stud. Install nut securing harness to fuel rail mounting stud.

(6) Connect tagged injector harness connectors to appropriate 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 fitting (if equipped).

(9) Install cable routing bracket to intake manifold.

(10) Connect throttle cable at throttle body.

(11) Connect speed control cable at throttle body (if equipped).

(12) Connect automatic transmission cable at throttle body (if equipped).

(13) Install air tube (or duct) at top of throttle body.

(14) Install fuel tank cap.

(15) Connect negative battery cable to battery.

(16) Start engine and check for fuel leaks.

Fuel injector rail/fuel damper-4.0L engine

REMOVAL

The fuel damper is not serviced separately.

WARNING: THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE EVEN WITH ENGINE OFF.

THIS PRESSURE MUST BE RELEASED BEFORE SERVICING FUEL RAIL.

(1) Remove fuel tank filler tube cap.

(2) Perform Fuel System Pressure Release Procedure.

(3) Disconnect negative battery cable from battery.

(4) Remove air tube at top of throttle body. Note: Some engine/vehicles may require removal of air cleaner ducts at throttle body.

(5) Disconnect electrical connectors at all 6 fuel injectors. To remove connector refer to (Fig. 30). Push red colored slider away from injector (1). While pushing slider, depress tab (2) and remove connector (3) from injector. The factory fuel injection wiring harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. If harness is not tagged, note wiring location before removal.

Fig. 30 Remove/Install Fuel Injector Connector-2.5L/4.0L Engine
Fig. 30 Remove/Install Fuel Injector Connector-2.5L/4.0L Engine

(6) Disconnect fuel supply line latch clip and fuel line at fuel rail. Refer to Quick-Connect Fittings.

(7) Disconnect throttle cable at throttle body. Refer to Throttle Cable Removal/Installation.

(8) Disconnect speed control cable at throttle body (if equipped). Refer to Speed Control Cable in Group 8H, Speed Control System.

(9) Disconnect automatic transmission cable at throttle body (if equipped).

(10) Remove cable routing bracket at intake manifold.

(11) If equipped, remove wiring harnesses at injection rail studs by removing nuts.

(12) Clean dirt/debris from each fuel injector at intake manifold.

(13) Remove fuel rail mounting nuts/bolts (Fig.

31).

(14) Remove fuel rail by gently rocking until all the fuel injectors are out of intake manifold.

Fig. 31 Fuel Rail Mounting-4.0L Engine
Fig. 31 Fuel Rail Mounting-4.0L Engine

1 - INJ. #1
2 - INJ. #2
3 - INJ. #3
4 - INJ. #4
5 - INJ. #5
6 - INJ. #6
7 - FUEL INJECTOR RAIL
8 - FUEL DAMPER
9 - PRESSURE TEST PORT CAP
10 - MOUNTING BOLTS (4)
11 - QUICK-CONNECT FITTING

INSTALLATION

(1) Clean each injector bore at intake manifold.

(2) Apply a small amount of clean engine oil to each injector o-ring. This will aid in installation.

(3) Position tips of all fuel injectors into the corresponding injector bore in intake manifold. Seat injectors into manifold.

(4) Install and tighten fuel rail mounting bolts to 11 63 N·m (100 625 in. lbs.) torque.

(5) If equipped, connect wiring harnesses to injection rail studs.

(6) Connect electrical connectors at all fuel injectors.

To install connector, refer to (Fig. 30). Push connector onto injector (1) and then push and lock red colored slider (2). Verify connector is locked to injector by lightly tugging on connector.

(7) Connect fuel line and fuel line latch clip to fuel rail. Refer Quick-Connect Fittings..

(8) Install protective cap to pressure test port fitting (if equipped).

(9) Install cable routing bracket to intake manifold.

(10) Connect throttle cable at throttle body.

(11) Connect speed control cable at throttle body (if equipped).

(12) Connect automatic transmission cable at throttle body (if equipped).

(13) Install air tube (or duct) at top of throttle body.

(14) Install fuel tank cap.

(15) Connect negative battery cable to battery.

(16) Start engine and check for fuel leaks.

    Previous pageFuel filter/fuel pressure regulator. Fuel pump module. Fuel pump inlet filter

    Fuel filter/fuel pressure regulator The combination Fuel Filter/Fuel Pressure Regulator is located on the fuel pump module. The fuel pump module is located on top of fuel tank. The filter/regulat ...

    Next pageFuel injectors. Fuel tank. Fuel tank filler tube cap

    Fuel injectors REMOVAL (1) Remove fuel rail. Refer to Fuel Injector Rail Removal in this section. (2) Disconnect clip(s) that retain fuel injector(s) to fuel rail (Fig. 32). Fig. 32 Fuel In ...

    Other materials:

    Diagnosis and testing
    Fuel pump pressure test Use this test in conjunction with the Fuel Pump Capacity Test, Fuel Pressure Leak Down Test and Fuel Pump Amperage Test found elsewhere in this group. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into th ...