1995 JEEP YJ fuel cap

FUEL RAIL ASSEMBLY
REMOVAL
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT FUEL PRESSURE (EVEN WITH THE ENGINE
OFF) OF APPROXIMATELY 131-269 KPA (19-39 PSI).
THIS PRESSURE MUST BE RELEASED BEFORE
SERVICING THE FUEL RAIL.
(1) Remove fuel tank filler tube cap.
(2) Disconnect the negative battery cable from bat-
tery.
(3) Perform the Fuel System Pressure Release Pro-
cedure as described in the Fuel Delivery System sec-
tion of this Group.
(4) Remove and numerically attach a tag (if fuel
injector is not already tagged), the injector harness
connectors. Do this at each injector (Fig. 12).
(5) Disconnect vacuum line from fuel pressure reg-
ulator (Fig. 12).
(6) Disconnect fuel supply line from fuel rail and
the fuel return line from fuel pressure regulator (Fig.
12). Refer to Fuel Tubes/Lines/Hoses and Clamps, or
Quick-Connect Fittings. These can both be found in
the Fuel Delivery section of this group.
(7) Remove fuel rail mounting bolts.
On models with automatic transmissions, it may be
necessary to remove automatic transmission throttle
line pressure cable and bracket. This will aid in fuel
rail assembly removal.
(8) Remove fuel rail by gently rocking until all the
fuel injectors are out of the intake manifold.
INSTALLATION
(1) Position tips of all fuel injectors into the corre-
sponding injector bore in the intake manifold. Seat
injectors into manifold.
(2) Tighten fuel rail mounting bolts to 27 Nzm (20
ft. lbs.) torque.
(3) Connect injector harness connectors to appro-
priate (tagged) injector.
(4) Connect both fuel lines to fuel rail. Refer to the
Fuel Delivery section of this group for procedures.
(5) Connect vacuum supply line to fuel pressure
regulator.
(6) Install protective cap to pressure test port fit-
ting.
(7) Install fuel tank cap.
(8) Connect negative battery cable to battery.
(9) Start engine and check for fuel leaks.
FUEL SYSTEM PRESSURE RELEASE PROCEDURE
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF)
OF APPROXIMATELY 100 KPA (14.5 PSI). BEFORE
SERVICING THE FUEL PUMP, FUEL RAIL, FUELLINES, FUEL FILTER OR FUEL INJECTOR, THE
FUEL SYSTEM PRESSURE MUST BE RELEASED.
Refer to the Fuel Delivery System section of this
group. See Fuel Pressure Release procedure.
FUEL TANKS
Refer to the Fuel Tank section of this group for re-
moval/installation procedures.
FUEL TANK PRESSURE RELIEF/ROLLOVER VALVE
Refer to the Fuel Tank section of this group for re-
moval/installation procedures.
FUEL TUBES/LINES/HOSES AND CLAMPS
Refer to the Fuel Delivery System section of this
group for removal/installation procedures. Also refer
to Quick-Connect Fittings in the Fuel Delivery sec-
tion of this group.
IDLE AIR CONTROL (IAC) MOTOR
The IAC motor is mounted to the throttle body ad-
jacent to the throttle position sensor (Fig. 14).
REMOVAL
(1) Disconnect the electrical connector from the
IAC motor.
(2) Remove IAC motor torx head mounting bolts.
(3) Remove IAC motor.
INSTALLATION
(1) Install IAC motor into throttle body and
tighten retaining bolts.
(2) Connect electrical connector to IAC motor.
IGNITION COIL
Refer to Group 8D, Ignition Systems for removal/
installation procedures.
Fig. 14 Idle Air Control MotorÐRemoval/
InstallationÐTypical
14 - 62 FUEL SYSTEM COMPONENT REMOVAL/INSTALLATIONJ

speedometer pinion gear adapter (Fig. 29). Do not re-
move the gear adapter from the transmission.
INSTALLATION
(1) Clean the inside of speedometer pinion gear
adapter before installing speed sensor.
(2) Install sensor into speedometer gear adapter
and install mounting bolt.Before tightening bolt,verify speed sensor is fully seated (mounted
flush) to speedometer pinion gear adapter.
(3) Tighten sensor mounting bolt to 2.2 Nzm (20 in.
lbs.) torque.
(4) Connect electrical connector to sensor.
SPECIFICATIONS
GENERAL INFORMATION
The following specifications are published from the
latest information available at the time of publica-
tion.If anything differs between the specifica-
tions found on the Vehicle Emission Control
Information (VECI) label and the following
specifications, use specifications on VECI label.
The VECI label is located in the engine compart-
ment.
FUEL TANK CAPACITIES
FUEL SYSTEM
TORQUE
JFUEL SYSTEM SPECIFICATIONS 14 - 67

TIRE CHAINS
Tire snow chains may be used on certain models.
Refer to Owner's Manual for more information.
CLEANING OF TIRES
Steam cleaning may be used for cleaning.
DO NOT use gasoline or wire brush for cleaning.
DO NOT use mineral oil or an oil-based solvent.
PRESSURE GAUGES
High-quality, dial-type, air-pressure gauges are rec-
ommended. After checking with the gauge, replace
valve cap and finger tight.
TIRE INFLATION PRESSURES
Under inflation (Fig. 2) causes rapid shoulder wear
and tire flexing.
Over inflation (Fig. 3) causes rapid center wear and
loss of the tire's ability to cushion shocks.
Improper inflation can cause;
²Uneven wear patterns
²Reduced tread life
²Reduced fuel economy
²Unsatisfactory ride
²Cause the vehicle to drift
Refer to the Owner's Manual for information re-
garding proper tire inflation pressure.
This pressure has been carefully selected to provide
for safe vehicle operation. Tire pressure should becheckedcoldonce per month. Tire pressure de-
creases when the outside temperature drops.
Inflation pressures specified on the placards are al-
wayscold inflation pressure. Cold inflation pres-
sure is obtained after the vehicle has not been
operated for at least 3 hours. Tire inflation pressures
may increase from 2 to 6 pounds per square inch
(psi) during operation.Do notreduce this normal
pressure build-up.
Vehicles loaded to the maximum capacity should
not be driven at continuous speeds above 75 mph
(120 km/h).
WARNING: OVER OR UNDER INFLATED TIRES CAN
AFFECT VEHICLE HANDLING AND CAN FAIL SUD-
DENLY, RESULTING IN LOSS OF VEHICLE CON-
TROL.
REPLACEMENT TIRES
OEM tires provide a proper balance of many fea-
tures such as;
²Ride
Fig. 1 Tire Size Identification
Fig. 2 Under Inflation Wear
Fig. 3 Over Inflation Wear
22 - 2 WHEELS AND TIRESJ

(3) Pull downward and remove the grille from ex-
haust port in the door opening panel.
INSTALLATION
(1) Position the slot located in the upper end of re-
placement grille at the exhaust port and insert edge
in the slot.
(2) Push inward and seat the grille in the exhaust
port.
(3) Install the screw to attach the grille to the door
opening panel.
EXTERIOR NAMEPLATESÐXJ
SERVICE INFORMATION
All of nameplates, with the exception of the JEEP
nameplate located on the grille are attached with ad-
hesive (Fig. 18).
GRILLE OPENING PANEL NAMEPLATE
REMOVAL
(1) Remove the grille opening panel (GOP) support
bracket.
(2) As applicable, remove the nut(s) from the let-
ter(s) that must be replaced.
(3) Remove the nameplate letter(s) from GOP.
INSTALLATION
(1) Clean the panel surface.
(2) Position the replacement letter(s) on the GOP.
(3) Install the nut(s) and tighten.
ADHESIVE-BACKED NAMEPLATES
REMOVAL/INSTALLATION
(1) Pry the nameplate from vehicle panel.
(2) Clean the panel surface.
(3) Position the replacement nameplate on the
panel push inward to seat it.
FUEL FILLER NOZZLE/TUBEÐXJ
REMOVAL
(1) Remove the fuel filler door from the quarter
panel (Fig. 19).
(2) For XJ vehicles, remove the fuel filler hose
splash shield from the quarter inner panel and frame
rail (Fig. 20).
(3) Remove the cap from the nozzle (Fig. 21).
(3) Loosen the clamps and separate the hoses from
the tubes.
(4) Remove the screws that attach the nozzle to
the housing.
(5) Remove the nozzle/tube from the fuel filler
housing (Fig. 22).
INSTALLATION
(1) Insert the fuel filler nozzle/tube into the hous-
ing.
(2) Install the screws to attach the nozzle/tube to
the housing. Tighten screws to 2 Nzm (20 in-lbs)
torque.
Fig. 18 XJ Exterior Nameplates
Fig. 19 Fuel Filler DoorÐTypical
Fig. 20 Fuel Filler Hose Splash ShieldÐXJ Vehicles
23 - 26 EXTERIOR COMPONENTSÐXJJ

(3) Attach the hoses to the tubes with clamps.
Tighten the clamp screws to 4 Nzm (35 in-lbs) torque.
(4) Install the cap on nozzle.
(5) Install the fuel filler hose splash shield on the
quarter inner panel and frame rail.
(6) Install the fuel filler door on the quarter panel.
FUEL FILLER DOOR BUMPERSÐXJ
REPLACEMENT
(1) Grasp the bumper (Fig. 23) with pliers and pull
outward to remove it from the hole.
²It may be necessary to remove the door (Fig. 24) to
replace the door-stop bumper.
(2) Insert bumpers in the holes and force them in-
ward until they are seated in the holes.
EXTERNAL MIRRORSÐXJ
SERVICE INFORMATION
Service procedures for all external rear view mir-
rors are below.
REMOTE AND POWER/MANUAL MIRRORS
REMOVAL
(1) Remove the door trim panel.
(2) Remove the mirror inside trim cover screw (Fig.
1).
Fig. 21 Fuel Filler Nozzle/TubeÐXJ Vehicles
Fig. 22 Fuel Filler Nozzle/Tube Removal/
InstallationÐXJ Vehicles
Fig. 23 Fuel Filler Door Bumpers
Fig. 24 Fuel Filler Door-Stop Bumper
Fig. 1 Remote MirrorsÐPower/Manual
JEXTERIOR COMPONENTSÐXJ 23 - 27

(3) Position the replacement nameplate on the
panel and apply inward force to seat it.
FUEL FILLER PROTECTOR/NOZZLEÐYJ
REMOVAL
(1) Either remove it or support the license plate
bracket away from the fuel filler protector and nozzle
(Fig. 1).
(2) Remove the cap from the nozzle.
(3) Loosen the clamps at the nozzle and separate
the hoses from the nozzle.
(4) Remove the screws that attach the protector to
the body panel.
(5) Remove the protector and nozzle from the open-
ing in the body.
(6) Remove the screws and separate the nozzle
from the protector (Fig. 1).
INSTALLATION
(1) Position the fuel filler nozzle on the protector
and install screws. Tighten the screws to 2 Nzm (20
in-lbs) torque.
(2) Position the protector and the nozzle in body
panel opening, and install. Tighten the screws to 3
Nzm (25 in-lbs) torque.
(3) Attach the hoses to the tubes and tighten the
clamp screws to 3 Nzm (30 in-lbs) torque.
(4) Install the cap on the nozzle.
(5) If removed, install the license plate bracket.
HALF METAL DOOR MIRROR (EXTERNAL)ÐYJ
REMOVAL
(1) Remove the mirror base attaching screws from
the door hinge (Fig. 2).
(2) Remove the mirror from the door hinge (Fig. 2).
INSTALLATION
(1) Clean the door hinge-mirror base contact sur-
face.
(2) Position the mirror base at the door hinge.
(3) Install the mirror base attaching screws in the
door hinge. Tighten the attaching screws to 11 Nzm
(96 in-lbs) torque.
TAILGATEÐYJ
REMOVAL
(1) Remove the tailgate hinge screws with a Torx
bit (Fig. 3).
(3) Disengage the latch and remove the tailgate
from the vehicle.
INSTALLATION
(1) Position and align the tailgate in the body
opening and engage the latch.
(2) Install the hinge retaining screws. Tighten the
screws to 18 Nzm (156 in-lbs) torque.
TAILGATE HINGEÐYJ
REPLACEMENT
(1) Remove the hinge retaining screws and remove
the hinge (Fig. 3).
(2) Prepare and paint the replacement hinge to
match the body paint color.
(3) Lubricate the hinge with spray lubricant.
(4) Position the hinge on the body and install the
retaining screws (Fig. 3). Tighten the screws to 18
Nzm (156 in-lbs) torque.
(5) Align the tailgate with the hinge and install
the hinge-to-tailgate screws. Tighten the screws to 18
Nzm (156 in-lbs) torque.
TAILGATE ADJUSTMENTÐYJ
(1) Loosen the tailgate hinge-to-body screws (Fig.
3).
Fig. 1 Fuel Filler Cap, Protector, Nozzle and Hoses
Fig. 2 Half Metal Door Mirror
JEXTERIOR COMPONENTSÐYJ 23 - 121

EMISSION CONTROLS
INDEX
page page
Crankcase Ventilation System................. 5
EVAP (Evaporation) Control System............ 4
EVAP Canister............................ 4Fuel Tank Filler Tube Cap.................... 4
Oxygen (O2S) Sensor....................... 6
Pressure Relief/Rollover Valve................. 6
EVAP (EVAPORATION) CONTROL SYSTEM
GENERAL INFORMATION
The function of the EVAP control system is to pre-
vent the emissions of gasoline vapors from the fuel
tank into the atmosphere. When fuel evaporates in
the fuel tank, the vapors pass through vent hoses or
tubes to a carbon filled EVAP canister. They are tem-
porarily held in the canister until they can be drawn
into the intake manifold when the engine is running.
The EVAP canister is a feature on all models for
the storage of fuel vapors from the fuel tank.
The hoses used in this system are specially
manufactured. If replacement becomes neces-
sary, it is important to use only fuel resistant
hose.
EVAP CANISTER
A sealed, maintenance free, EVAP canister is used
on all vehicles. On XJ models, the EVAP canister is
located in the engine compartment on the passenger
side frame rail (Fig. 4). On YJ models, the EVAP can-
ister is located in the engine compartment on the
dash panel and below the brake master cylinder (Fig.
5). The EVAP canister is filled with granules of an
activated carbon mixture. Fuel vapors entering the
EVAP canister are absorbed by the charcoal granules.
CANISTER OPERATION
Vacuum is used to control and operate the
EVAP canister. No electrical circuitry is used to
control or operate the EVAP system.
The EVAP canister is equipped with a vacuum con-
trolled purge shutoff switch (orifice) (Figs. 4 or 5)
that controls canister purge operation. The switch is
open when manifold vacuum is applied to it. When
the engine is operating, the EVAP canister purge
function draws fresh air through the top of the can-
ister. This causes the stored vapors to be drawn out
of the canister and into the airstream in the air
cleaner snorkel (Fig. 6).
The air cleaner contains a venturi in the air
cleaner cover used as a purge line vacuum source
(Fig. 6). The venturi effect increases the speed of the
intake air flowing by the slots in the venturi wall.
This creates a low pressure area around the slots.
When the purge shutoff switch is open, vapors from
the canister are drawn through slots and into the air-
stream flowing through the venturi (Fig. 7). The va-
pors pass through the intake manifold into the
engine combustion chambers where they are con-
sumed during engine combustion.
FUEL TANK FILLER TUBE CAP
The fuel tank filler tube cap (fuel tank cap) incor-
porates a two-way pressure/relief valve that is closed
to atmosphere during normal operating conditions.Fig. 4 EVAP Canister LocationÐXJ Models
Fig. 5 EVAP Canister LocationÐYJ Models
25 - 4 EMISSION CONTROL SYSTEMSJ

The relief valve used in fuel filler caps of all models
is calibrated at a pressure of 10 kPa (1.5 psi) or a
vacuum of 6 kPa (1.8 in. Hg). When the pressure or
vacuum is relieved, the valve returns to the normally
closed position.
CAUTION: The fuel filler cap must be removed prior
to disconnecting any fuel system component.
CRANKCASE VENTILATION SYSTEM
All 2.5L 4 cylinder and 4.0L 6 cylinder engines are
equipped with a Crankcase Ventilation (CCV) system(Figs. 8 or 9). The CCV system performs the same
function as a conventional PCV system, but does not
use a vacuum controlled valve.
On 4.0L 6 cylinder engines, a molded vacuum tube
connects manifold vacuum to top of cylinder head
(valve) cover at dash panel end. The vacuum tube
contains a fixed orifice of a calibrated size. It meters
the amount of crankcase vapors drawn out of the en-
gine.
On 2.5L 4 cylinder engines, a fitting on drivers side
of cylinder head (valve) cover contains the metered
orifice. It is connected to manifold vacuum.
A fresh air supply hose from the air cleaner is con-
nected to front of cylinder head cover on 4.0L en-
gines. It is connected to rear of cover on 2.5L
engines.
When the engine is operating, fresh air enters the
engine and mixes with crankcase vapors. Manifold
vacuum draws the vapor/air mixture through the
fixed orifice and into the intake manifold. The vapors
are then consumed during combustion.
Fig. 6 EVAP SystemÐTypical
Fig. 7 Air Cleaner VenturiÐTypical
Fig. 8 CCV SystemÐ2.5L EngineÐTypical
Fig. 9 CCV SystemÐ4.0L EngineÐTypical
JEMISSION CONTROL SYSTEMS 25 - 5