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Jeep Cherokee
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Fuel system » Fuel delivery system » Removal and installation
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.

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