1995 JEEP XJ engine

²To remove an original equipment exhaust tailpipe/
muffler combination, cut the exhaust tailpipe close to
the muffler. Collapse the part remaining in the muf-
fler and remove.
²To remove a service exhaust tailpipe/muffler com-
bination, apply heat until the metal becomes cherry
red. Remove the exhaust tailpipe/muffler clamp and
twist the exhaust tailpipe out of the muffler.
INSTALLATION
(1) Install the muffler onto the catalytic converter.
Install the clamp and tighten the nuts finger tight.
(2) Install the exhaust tailpipe into the rear of the
muffler.
(3) Install the exhaust tailpipe/muffler assembly on
the rear exhaust tailpipe hanger. Make sure that the
exhaust tailpipe has sufficient clearance from the
floor pan.
(4) Install the remaining clamps and the front ex-
haust tailpipe hanger.
(5) Tighten the nuts on the muffler-to-catalytic
converter clamp to 61 Nzm (45 ft. lbs.) torque (Fig. 6).
Tighten the nuts on the rear exhaust tailpipe clamp
to 14 Nzm (10 ft. lbs.) torque (Fig. 7).
(6) Lower the vehicle.
(7) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels.
Adjust the alignment, if needed.
MUFFLER AND EXHAUST TAILPIPEÐYJ VEHICLES
All original equipment exhaust systems are manu-
factured with the exhaust tailpipe welded to the muf-
fler. Service replacement mufflers and exhaust
tailpipes are clamped together.
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
REMOVAL
(1) Raise the vehicle and support the rear of the
vehicle by the side rails and allow the axle to hang
free.
(2) Remove the front muffler clamp from the cata-
lytic converter and muffler connection (Fig. 6).
(3) Remove the exhaust tailpipe hanger/bracket
(Fig. 9).
(4) Remove the exhaust tailpipe from the front ex-
haust tailpipe hanger (Fig. 10).
(5) Heat the converter-to-muffler connection with
an oxyacetylene torch until the metal becomes cherry
red.
(6) While the metal is still cherry red, place a
block of wood against the front of the muffler and
drive the muffler rearward to disengage.
(7) Remove the exhaust tailpipe/muffler assembly.
(8) Remove the exhaust tailpipe from the muffler:²To remove an original equipment exhaust tailpipe/
muffler combination, cut the exhaust tailpipe close to
the muffler. Collapse the part remaining in the muf-
fler and remove.
²To remove a service exhaust tailpipe/muffler com-
bination, remove the exhaust tailpipe/muffler clamp.
Heat the exhaust tailpipe-to-muffler connection with
an oxyacetylene torch until the metal becomes cherry
red. While the metal is still cherry red, twist the ex-
haust tailpipe out of the muffler.
Fig. 9 Rear Exhaust Tailpipe Hanger/Bracket
Fig. 10 Front Exhaust Tailpipe Hanger
11 - 6 EXHAUST SYSTEM AND INTAKE MANIFOLDJ

INSTALLATION
(1) Install the muffler onto the catalytic converter
outlet. Ensure that the locator on the converter
aligns with the notch on the muffler, if so equipped.
Install the clamp and tighten the nuts finger tight.
(2) Install the exhaust tailpipe into the muffler
outlet. Ensure that the locator on the exhaust
tailpipe aligns with the notch on the muffler, if so
equipped. Install the clamp and tighten the nuts fin-
ger tight.
(3) Install the front exhaust tailpipe supports and
the rear exhaust tailpipe hanger. Ensure that the ex-
haust tailpipe has sufficient clearance from the floor
pan and shields.
(4) Tighten the nuts on the muffler-to-catalytic
converter and the muffler-to-exhaust tailpipe clamps
to 61 Nzm (45 ft. lbs.) torque.
(5) Lower the vehicle.
(6) Start the engine and inspect for exhaust leaks
and contact with the body panels and shields.
ENGINE EXHAUST MANIFOLDÐ2.5L ENGINE
REMOVAL
(1) Disconnect the battery negative cable.
(2) Remove all components attached to the intake
manifold.
(3) Raise the vehicle.
(4) Disconnect the exhaust pipe from the engine
exhaust manifold.
(5) Lower the vehicle.
(6) Remove fasteners 2 through 5 and remove the
intake manifold (Fig. 11).
(7) Remove fasteners 1, 6 and 7 and remove the
engine exhaust manifold (Fig. 11).
CLEANING
Clean the intake and engine exhaust manifolds and
cylinder head mating surfaces.DO NOT allow for-eign material to enter either the intake mani-
fold or the ports in the cylinder head.
INSTALLATION
(1) Install a new intake manifold gasket over the
alignment dowels on the cylinder head.
(2) Install the engine exhaust manifold assembly.
Exhaust manifold must be centrally located
over the end studs and spacer (Fig. 11).
(3) Tighten bolt No.1 to 41 Nzm (30 ft. lbs.) torque
(Fig. 11).
(4) Install the intake manifold on the cylinder
head dowels (Fig. 11).
(5) Install bolts 2 through 5 (Fig. 11). Tighten
these bolts to 31 Nzm (23 ft. lbs.) torque.
(6) Install new engine exhaust manifold spacers
over the engine exhaust manifold mounting studs in
the cylinder head (Fig. 11).
(7) Tighten nuts 6 and 7 to 31 Nzm (23 ft. lbs.)
torque (Fig. 11).
(8) Install all components to the intake manifold.
(9) Raise the vehicle.
(10) Connect the exhaust pipe to the engine ex-
haust manifold. Tighten the bolts to 31 Nzm (23 ft.
lbs.) torque.
(11) Lower the vehicle.
(12) Connect the battery negative cable.
(13) Start the engine and check for leaks.
ENGINE EXHAUST MANIFOLDÐ4.0L ENGINE
The intake and engine exhaust manifolds on the
4.0L engine must be removed and installed together.
The manifolds use a common gasket at the cylinder
head.
Refer to Intake ManifoldÐ4.0L Engine in this sec-
tion for the proper removal and installation proce-
dures.
INTAKE MANIFOLDÐ2.5L ENGINE
REMOVAL
(1) Disconnect the battery negative cable.
(2) Remove the air inlet hose from the throttle
body and air cleaner.
(3) Loosen the accessory drive belt tension and re-
move the belt from the power steering pump.
(4) Remove the power steering pump and brackets
from the water pump and intake manifold. Support
power steering pump and bracket with mechanics
wire attached to the radiator upper crossmember.
(5) Remove the fuel tank filler cap to relieve the
fuel tank pressure.
(6) Install the fuel tank filler cap.
(7) Disconnect fuel supply and return tube from
the fuel rail (refer to Group 14, Fuel System - Quick
Connect Fittings).
(8) Disconnect the accelerator cable from the throt-
tle body and the holddown bracket.
Fig. 11 Intake/Engine Exhaust Manifold Installation
(2.5L Engine)
JEXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 7

CAUTION: When disconnecting the cruise control
connector at the throttle body, DO NOT pry the con-
nector off with pliers or screwdriver. Use finger
pressure only. Prying the connector off could break
it.
(9) Disconnect the electrical connectors. Pull the
harnesses away from the manifold.
²The throttle position sensor.
²The idle speed control motor.
²The coolant temperature sensor at the thermostat.
²The manifold air temperature sensor at the intake
manifold.
²The fuel injectors.
²The oxygen sensor.
(10) Disconnect the crankcase ventilation (CCV)
vacuum hose and manifold absolute pressure (MAP)
sensor vacuum hose connector at the intake mani-
fold.
(11) Disconnect vacuum hose from vacuum port on
the intake manifold.
(12) Disconnect CCV hose at the cylinder head
cover (Fig. 12).
(13) Remove the molded vacuum harness.
(14) Disconnect the vacuum brake booster hose at
the intake manifold.
(15) Remove bolts 2 through 5 securing the intake
manifold to the cylinder head (Fig. 11). Slightly
loosen bolt No.1 and nuts 6 and 7.
(16) Remove the intake manifold and gaskets.
Drain the coolant from the manifold.
CLEANING
Clean the intake manifold and cylinder head mat-
ing surfaces.DO NOT allow foreign material to
enter either the intake manifold or the ports in
the cylinder head.
INSTALLATION
(1) Install the new intake manifold gasket over the
locating dowels.
(2) Position the manifold in place and finger
tighten the mounting bolts.
(3) Tighten the fasteners in sequence and to the
specified torque (Fig. 11).
²Fastener No.1ÐTighten to 41 Nzm (30 ft. lbs.)
torque.
²Fasteners Nos.2 through 7ÐTighten to 31 Nzm (23
ft. lbs.) torque.
(4) Connect the fuel return and supply tube to the
connector next to the fuel rail. Push them into the
fitting until a click is heard. Verify that the connec-
tions are complete.
²First, ensure only the retainer tabs protrude from
the connectors.
²Second, pull out on the fuel tubes to ensure they
are locked in place.
(5) Connect the molded vacuum hoses to the vac-
uum port on the intake manifold and the cylinder
head cover.
(6) Connect the electrical connectors.
²The throttle position sensor.
²The automatic idle speed control motor.
²The coolant temperature sensor at the thermostat
housing.
²The fuel injectors.
²The air manifold temperature sensor.
²The oxygen sensor.
(7) Connect the CCV vacuum hose and MAP sen-
sor vacuum hose connectors to the throttle body.
(8) Install the power steering pump and bracket
assembly to the water pump and intake manifold.
(9) Connect the accelerator cable and cruise control
cable to the holddown bracket and the throttle arm.
CAUTION: Ensure that the accessory drive belt is
routed correctly. Failure to do so can cause the wa-
ter pump to turn in the opposite direction resulting
in engine overheating. Refer to Group 7, Cooling
System for the proper procedure.
(10) Tension the accessory drive belt. Refer to
Group 7, Cooling System for the proper procedure.
(11) Connect the air inlet hose to the throttle body
and the air cleaner.
(12) Connect the battery negative cable.
(13) Start the engine and check for leaks.
INTAKE MANIFOLDÐ4.0L ENGINE
The intake and engine exhaust manifolds on the
4.0L engine must be removed and installed together.
The two manifolds use a common gasket at the cyl-
inder head.
REMOVAL
(1) Disconnect the battery negative cable.
Fig. 12 Crankcase Ventilation (CCV) Hose (2.5L
Engine)
11 - 8 EXHAUST SYSTEM AND INTAKE MANIFOLDJ

(2) Remove air cleaner inlet hose from throttle
plate assembly.
(3) Remove the air cleaner assembly.
(4) Remove the throttle cable, cruise control cable
(if equipped) and the transmission line pressure ca-
ble.
(5) Disconnect all electrical connectors on the in-
take manifold.
(6) Disconnect and remove the fuel supply and re-
turn lines from the fuel rail assembly (refer to Group
14, Fuel System).
(7) Loosen the accessory drive belt (refer to Group
7, Cooling System). Loosen the tensioner.
(8) Remove the power steering pump and bracket
from the intake manifold and set aside.
(9) Remove the fuel rail and injectors (refer to
Group 14, Fuel System).
(10) Raise the vehicle.
(11) Disconnect the exhaust pipe from the engine
exhaust manifold. Discard the seal.
(12) Lower the vehicle.
(13) Remove the intake manifold and engine ex-
haust manifold.
CLEANING
Clean the mating surfaces of the cylinder head and
the manifold if the original manifold is to be in-
stalled.
If the manifold is being replaced, ensure all the fit-
ting, etc. are transferred to the replacement mani-
fold.
INSTALLATION
(1) Install a new exhaust/intake manifold gasket
over the alignment dowels on the cylinder head.
(2) Position the engine exhaust manifold to the cyl-
inder head. Install fastener No.3 and finger tighten
at this time (Fig. 13).
(3) Install intake manifold on the cylinder head
dowels.
(4) Install washers and fasteners Nos.1, 2, 4, 5, 8,
9, 10 and 11 (Fig. 13).
(5) Install washers and fasteners Nos.6 and 7 (Fig.
13).
(6) Tighten the fasteners in sequence and to the
specified torque (Fig. 13).
²Fasteners Nos.1 through 5ÐTighten to 33 Nzm (24
ft. lbs.) torque.
²Fasteners Nos.6 and 7ÐTighten to 31 Nzm (23 ft.
lbs.) torque.²Fasteners Nos.8 through 11ÐTighten to 33 Nzm
(24 ft. lbs.) torque.
(7) Install the fuel rail and injectors.
(8) Install the power steering pump and bracket to
the intake manifold. Tighten the belt to specification.
Refer to Group 7, Cooling System for the proper pro-
cedures.
(9) Install the fuel supply and return lines to the
fuel rail assembly.Before connecting the fuel
lines to the fuel rail replace the O-rings in the
quick-connect fuel line couplings.Refer to Group
14, Fuel System for the proper procedure.
(10) Connect all electrical connections on the in-
take manifold.
(11) Connect the vacuum connector on the intake
manifold and install it in the bracket.
(12) Install throttle cable, cruise control cable (if
equipped).
(13) Install the transmission line pressure cable (if
equipped). Refer to Group 21, Transmission for the
adjustment procedures.
(14) Install air cleaner assembly.
(15) Connect air inlet hose to the throttle plate as-
sembly.
(16) Raise the vehicle on a side mounted hoist.
(17) Using a new seal, connect the exhaust pipe to
the engine exhaust manifold. Tighten the bolts to 31
Nzm (23 ft. lbs.) torque.
(18) Lower the vehicle.
(19) Connect the battery negative cable.
(20) Start the engine and check for leaks.
Fig. 13 Intake/Engine Exhaust Manifold Installation
(4.0L Engine)
JEXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 9

FRAME
INDEX
page page
Frame Dimensions........................ 13
Frame Repairs........................... 13
Frame Straightening....................... 13
Fuel Tank Skid Plate....................... 15
General Information....................... 10Generator Splash Shield.................... 13
Safety Precautions and Warnings............. 10
Tow Hooks.............................. 13
Transfer Case Skid Plate.................... 15
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE EYE PROTECTION WHEN GRIND-
ING OR WELDING METAL, SERIOUS EYE INJURY
CAN RESULT.
BEFORE PROCEEDING WITH FRAME REPAIR IN-
VOLVING GRINDING OR WELDING, VERIFY THAT
VEHICLE FUEL SYSTEM IS NOT LEAKING OR IN
CONTACT WITH REPAIR AREA, PERSONAL INJURY
CAN RESULT.
DO NOT ALLOW OPEN FLAME TO CONTACT
PLASTIC BODY PANELS. FIRE OR EXPLOSION CAN
RESULT.
WHEN WELDED FRAME COMPONENTS ARE RE-
PLACED, 100% PENETRATION WELD MUST BE
ACHIEVED DURING INSTALLATION. IF NOT, DAN-
GEROUS OPERATING CONDITIONS CAN RESULT.
STAND CLEAR OF CABLES OR CHAINS ON
PULLING EQUIPMENT DURING FRAME STRAIGHT-
ENING OPERATIONS, PERSONAL INJURY CAN RE-
SULT.
DO NOT VENTURE UNDER A HOISTED VEHICLE
THAT IS NOT SUPPORTED ON SAFETY STANDS,
PERSONAL INJURY CAN RESULT.
CAUTION: Do not reuse damaged fasteners, quality
of repair would be suspect.
Do not drill holes in top or bottom frame rail
flanges, frame rail failure can result.
Do Not use softer than Grade 3 bolts to replace
production fasteners, loosening or failure can re-
sult.When using heat to straighten frame components
do not exceed 566ÉC (1050ÉF), metal fatigue can re-
sult.
Welding the joints around riveted cross members
and frame side rails can weaken frame
GENERAL INFORMATION
The Jeep YJ (Fig. 1) frame is the structural center
of the vehicle. In addition to supporting the body and
payload, the frame provides a station for the engine.
The vehicle body is attached to the frame with hold-
downs (Fig. 2 and 3).
Fig. 1 JeepÐYJ
13 - 10 YJÐFRAMEJ

The frame is constructed of high-strength channel
steel siderails and crossmembers. The crossmembers
join the siderails and retain them in alignment in re-
lation to each other. This provides resistance to
frame twists and strains.
FRAME STRAIGHTENING
When necessary, a conventional frame that is bent
or twisted can be straightened by application of heat.
The temperature must not exceed 566ÉC (1050ÉF).
The use of a specially designed heat crayon can de-
termine the desired temperature. Excessive heat will
decrease the strength of the metal and result in a
weakened frame.
Welding the joints around riveted cross members
and frame side rails is not recommended.
A straightening repair process should be limited to
frame members that are not severely damaged.
FRAME REPAIRS
DRILLING HOLES
Do not drill holes in frame side rail top and bottom
flanges, metal fatigue can result causing frame fail-
ure. Holes drilled in the side of the frame rail must
be at least 38 mm (1.5 in.) from the top and bottom
flanges.
Additional drill holes should be located away from
existing holes.
WELDING
Use MIG, TIG or arc welding equipment to repair
welded frame components.
Frame components that have been damaged should
be inspected for cracks before returning the vehicle
to use. If cracks are found in accessible frame com-
ponents perform the following procedures.
(1) Drill a hole at each end of the crack with a 3
mm (O.125 in.) diameter drill bit.
(2) Using a suitable die grinder with 3 inch cut off
wheel, V-groove the crack to allow 100% weld pene-
tration.
(3) Weld the crack.
(4) If necessary when a side rail is repaired, grind
the weld smooth and install a reinforcement channel
(Fig. 4) over the repaired area.
If a reinforcement channel is required, the
top and bottom flanges should be 0.250 inches
narrower than the side rail flanges. Weld only
in the areas indicated (Fig. 4).
FRAME FASTENERS
Bolts, nuts and rivets can be used to repair frames
or to install a reinforcement section on the frame.
Bolts can be used in place of rivets. When replacing
rivets with bolts, install the next larger size diameter
bolt to assure proper fit. If necessary, drill the hole
out just enough to receive the bolt.Conical-type washers are preferred over the split-
ring type lock washers. Normally, grade-5 bolts are
adequate for frame repair.Grade-3 bolts or softer
should not be used.Tightening bolts/nuts with the
correct torque, refer to the Introduction Group at the
front of this manual for tightening information.
FRAME DIMENSIONS
Frame dimensions are listed in millimeter scale.
All dimensions are from center to center of Principal
Locating Point (PLP), or from center to center of PLP
and fastener location (Fig. 5).
TOW HOOKS
REMOVAL
(1) Remove the two bolts that attach the tow hook
to the bumper rail and to the frame rail.
(2) Remove the tow hook.
INSTALLATION
(1) Position the tow hook on the bumper rail and
frame rail.
(2) Install the attaching bolts. Tighten the bolts to
102 Nzm (75 ft. lbs.) torque.
GENERATOR SPLASH SHIELD
REMOVAL
(1) Remove the shield retaining nut and washer
(Fig. 6) from the engine oil pan stud (2.5L engines
only).
(2) Pry the serrated retainers from the frame rail
holes at each side of the vehicle.
(3) Pry the serrated retainers from the fan shroud
holes (Fig. 6).
(4) Remove the shield from the vehicle.
Fig. 4 Frame Reinforcement
JYJÐFRAME 13 - 13

FUEL SYSTEM
CONTENTS
page page
ACCELERATOR PEDAL AND THROTTLE CABLE.17
FUEL DELIVERY SYSTEM.................. 3
FUEL TANKS........................... 13
GENERAL INFORMATION.................. 1
MULTI-PORT FUEL INJECTION (MFI)Ð
COMPONENT DESCRIPTION/SYSTEMOPERATION.......................... 19
MULTI-PORT FUEL INJECTION (MFI)Ð
COMPONENT REMOVAL/INSTALLATION.... 58
MULTI-PORT FUEL INJECTION (MFI)Ð
GENERAL DIAGNOSIS.................. 35
SPECIFICATIONS........................ 67
GENERAL INFORMATION
Throughout this group, references are made to par-
ticular vehicle models by alphabetical designation
(XJ or YJ) or by the particular vehicle nameplate. A
chart showing a breakdown of the alphabetical desig-
nations is included in the Introduction section at the
beginning of this manual.
TheFuel Systemconsists of: the fuel tank, an
electric (fuel tank mounted) fuel pump and a fuel fil-
ter. It also consists of fuel tubes/lines/hoses, vacuum
hoses, throttle body and fuel injectors.
TheFuel Delivery Systemconsists of: the electric
fuel pump, fuel filter, fuel tubes/lines/hoses, fuel rail,
fuel injectors and fuel pressure regulator.
AFuel Return Systemis used on all vehicles.
The system consists of: the fuel tubes/lines/hoses that
route fuel back to the fuel tank.
TheFuel Tank Assemblyconsists of: the fuel
tank, filler tube, fuel fill and vent hoses, fuel gauge
sending unit/electric fuel pump module, a pressure
relief/rollover valve and a pressure-vacuum filler cap.
Also to be considered part of the fuel system is the
Evaporation Control System.This is designed to
reduce the emission of fuel vapors into the atmo-
sphere. The description and function of the Evapora-
tive Control System is found in Group 25, Emission
Control Systems.
FUEL USAGE STATEMENT
Your vehicle was designed to meet all emission reg-
ulations and provide excellent fuel economy using
high quality unleaded gasoline. Only use unleaded
gasolines having a minimum posted octane of 87.
If your vehicle develops occasional light spark
knock (ping) at low engine speeds, this is not harm-
ful. However,continued heavy knock at high
speeds can cause damage and should be re-
ported to your dealer immediately.Engine dam-
age as a result of heavy knock operation may not becovered by the new vehicle warranty.
In addition to using unleaded gasoline with the
proper octane rating,those that contain deter-
gents, corrosion and stability additives are rec-
ommended.Using gasolines that have these
additives will help improve fuel economy, reduce
emissions and maintain vehicle performance.
Poor quality gasolinecan cause problems such
as hard starting, stalling and stumble. If you experi-
ence these problems, use another brand of gasoline
before considering service for the vehicle.
GASOLINE/OXYGENATE BLENDS
Some fuel suppliers blend unleaded gasoline with
materials that contain oxygen such as alcohol, MTBE
and ETBE. The type and amount of oxygenate used
in the blend is important. The following are generally
used in gasoline blends:
ETHANOL
Ethanol (Ethyl or Grain Alcohol) properly blended,
is used as a mixture of 10 percent ethanol and 90
percent gasoline.Gasoline with ethanol may be
used in your vehicle.
METHANOL
CAUTION: DO NOT USE GASOLINES CONTAINING
METHANOL.Use of methanol/gasoline blends may re-
sult in starting and driveability problems. In addition,
damage may be done to critical fuel system compo-
nents.
Methanol (Methyl or Wood Alcohol) is used in a va-
riety of concentrations blended with unleaded gaso-
JFUEL SYSTEM 14 - 1

FUEL DELIVERY SYSTEM
INDEX
page page
Fuel Filter................................ 9
Fuel Pressure Leak Down Test................ 8
Fuel Pressure Release Procedure.............. 6
Fuel Pump Capacity Test.................... 7
Fuel Pump Electrical Control.................. 5Fuel Pump Module......................... 3
Fuel System Pressure Test................... 6
Fuel Tubes/Lines/Hoses and Clamps............ 9
Quick-Connect Fittings..................... 10
FUEL PUMP MODULE
The fuel pump module is installed in the top of the
fuel tank. The fuel pump module contains the follow-
ing components:
²Electric fuel pump
²Fuel pump reservoir
²In-tank fuel filter
²Fuel gauge sending unit
²Fuel supply and return tube connections
The fuel pump used on all vehicles is a turbine
type pump. It is driven by a permanent magnet 12
volt electric motor that is immersed in the fuel tank.
The electrical pump is integral with the fuel sender
unit. The pump/sender assembly is installed inside
the fuel tank.
The fuel pump has a check valve at the outlet end
that consists of a ball held against a seat by force ap-
plied from a spring. When the pump is operating,
fuel pressure overcomes spring pressure and forces
the ball off its seat, allowing fuel to flow. When the
pump is not operating, spring pressure forces the ball
back against the seat preventing fuel backflow
through the pump.
Fuel system pressure is maintained at approxi-
mately 214 kPa (31 psi). This is when the pump is
operating and vacuum is supplied to the fuel pres-
sure regulator. If vacuum is not supplied to the pres-
sure regulator, fuel pressure will be approximately
55-69 kPa (8-10 psi) higher. This may be due to a
broken or clogged vacuum line. When the fuel pump
is not operating, fuel system pressure of 131-269 kPa
(19-39 psi) is maintained for approximately 2 to 6
hours. This is done by the fuel pump outlet check
valve and the vacuum assisted fuel pressure regula-
tor.
REMOVALÐXJ MODELS
The fuel pump/gauge sender unit assembly can be
removed from the fuel tank without removing the
tank from the vehicle.
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING THE FUEL PUMP MODULE,
THE FUEL SYSTEM PRESSURE MUST BE RE-LEASED. REFER TO THE FUEL PRESSURE RE-
LEASE PROCEDURE IN THIS GROUP.
WARNING: EXTINGUISH ALL TOBACCO SMOKING
PRODUCTS BEFORE SERVICING THE FUEL SYS-
TEM. KEEP OPEN FLAME AWAY FROM FUEL SYS-
TEM COMPONENTS.
(1) Remove fuel filler cap. Perform the Fuel Pres-
sure Release Procedure as outlined in this group.
(2) Disconnect negative battery cable.
(3) Using an approved portable gasoline siphon/
storage tank, drain fuel tank until fuel level is below
one quarter (1/4) full.
(4) Raise and support vehicle.
WARNING: WRAP SHOP TOWELS AROUND FUEL
HOSES TO ABSORB ANY FUEL SPILLAGE DURING
FUEL TANK REMOVAL.
(5) Disconnect fuel vent supply and return tubes
from fittings on fuel pump module.
(6) Disconnect fuel pump module electrical harness
connector from main harness.
(7) Using a brass punch and hammer, remove fuel
pump module lock ring by carefully tapping it coun-
terclockwise (Fig. 1).
Fig. 1 Removing Lock RingÐXJ ModelsÐTypical
JFUEL DELIVERY SYSTEM 14 - 3