1995 JEEP YJ group 23 body

BUMPERS
INDEX
page page
Front Bumper............................. 5
Front Tow Hooks........................... 7Rear Bumper............................. 8
Rear Tow Hook............................ 9
FRONT BUMPER
REMOVAL/DISASSEMBLY
(1) The bumper guards, end caps and tow hooks can
be removed from XJ front bumpers with the bumper at-
tached to the vehicle. Do not remove the bumper from
the vehicle if only these components require service.
If equipped with a brush guard, refer to the Brush
Guard Removal within Group 23, Body Components.(2) Disconnect the fog lamp wire harness connec-
tors, if equipped (Fig. 1).
(3) Disconnect the vacuum reservoir tube harness
connectors (Fig. 2 and 3).
(4) Remove the locknuts and Torx-head bolts that
attach the tow hook straps (Fig. 4) to the underbody
sillmember.
Fig. 1 Fog Lamp Wire Harness Connector
Fig. 2 Vacuum ReservoirÐLeft Side
Fig. 3 Vacuum ReservoirÐRight Side With Speed
Control Only
Fig. 4 Tow Hook & StrapÐXJ Vehicles
JXJÐBUMPERS 13 - 5

(12) Remove the fog lamps (Fig. 10) from the
bumper rail.
(13) If necessary, remove the vacuum reservoir(s)
from the bumper rail.
(14) If necessary, remove the sill crossmember re-
inforcement brackets from the sillmembers.
ASSEMBLY/INSTALLATION
(1) If removed, install the sill crossmember rein-
forcement brackets on the sillmembers (Fig. 11).
Tighten bolts to 56 Nzm (41 ft. lbs.) torque.
(2) If equipped, install the bumper support brack-
ets and bumper guards on the bumper rail. Tighten
hardware in the sequence indicated in (Fig. 6).
Tighten the locknuts with 20 Nzm (15 ft. lbs.) torque.
Tighten bolts to 56 Nzm (41 ft. lbs.) torque.
(3) If not equipped with bumper guards, install the
bumper support brackets on the bumper rail. Tighten
bolts to 56 Nzm (41 ft. lbs.) torque.
(4) Install tow hooks. Tighten nuts with 100 Nzm
(74 ft. lbs.) torque.
(5) Install the bumper end caps on the bumper
rail. Tighten nuts with 8 Nzm (72 in. lbs.) torque.(6) Install the license plate bracket on the bumper
rail. Tighten the nuts securely.
(7) Install the fog lamps on the bumper rail.
Tighten the nuts to 20 Nzm (15 ft. lbs.) torque.
(8) If removed, install the vacuum reservoir(s) on
the bumper rail. Tighten the retaining screws and
bolts to 8 Nzm (72 in. lbs.) torque.
(9) Position and support the bumper at the front of
the vehicle.
(10) Attach the bumper support brackets to the
right and left sillmembers and reinforcement brack-
ets. Tighten screws and bolts to 56 Nzm (41 ft. lbs.)
torque.
(11) Install the Torx-head bolts and locknuts that
attach the tow hook straps to the underbody sillmem-
ber. Tighten locknuts with 30 Nzm (22 ft. lbs.) torque.
Install the steering gear skid plate and screws
after the left tow hook strap has been installed.
(12) Connect the fog lamp wire harness connectors.
(13) Connect the vacuum reservoir tube harness
connectors.
(14) Remove the bumper support.
FRONT TOW HOOKS
If a tow hook must be replaced or removed only for
service access, remove the nuts and bolts that attach
it to the bumper support bracket. When installing a
tow hook, tighten nuts with 100 Nzm (74 ft. lbs.)
torque.
If a tow hook/bumper support bracket must be re-
placed, refer to the following removal and installation
procedures.
REMOVAL
If equipped with a brush guard, refer to the Brush
Guard Removal within Group 23, Body Components.
(1) Disconnect the fog lamp wire harness connec-
tors, if equipped.
(2) Disconnect the vacuum reservoir tube harness
connectors.
(3) Support the bumper.
(4) Remove the bolts that attach the bumper sup-
port brackets to the right and left sillmembers.
(5) Remove the locknuts and Torx-head bolts that
attach the tow hook straps to the underbody sillmem-
ber.
The retaining screws and the steering gear
skid plate must be removed before the left
strap can be removed from the sillmember.
(6) Detach the tow hook straps from the sillmem-
ber.
(7) Remove the support and the bumper from the
vehicle.
(8) Remove the nuts and bolts that attach the tow
hooks to the bumper support brackets.
(9) Remove the tow hook from the bumper support
bracket.
Fig. 10 Fog Lamp
Fig. 11 Reinforcement Brackets
JXJÐBUMPERS 13 - 7

(10) Remove the support bracket from the bumper
rail.
INSTALLATION
(1) Install the bumper guard and bumper support
bracket on the bumper rail. Tighten the retaining
hardware in the sequence indicated in Figure 7.
Tighten locknuts to 20 Nzm (15 ft. lbs.) torque.
Tighten bolts to 56 Nzm (41 ft. lbs.) torque.
(2) If not equipped with bumper guards, install the
bumper support bracket on the bumper rail. Tighten
bolts to 56 Nzm (41 ft. lbs.) torque.
(3) Position the tow hook at the support bracket.
Install the bolts and nuts that attach tow hook to the
bumper support bracket. Tighten nuts to 100 Nzm (74
ft. lbs.) torque.
(4) Position and support the bumper at the front of
the vehicle.
(5) Attach the bumper support brackets to the
right and left sillmembers and reinforcement brack-
ets. Tighten screws and bolts to 56 Nzm (41 ft. lbs.)
torque.
(6) Install the Torx-head bolts and locknuts that
attach the tow hook straps to the underbody sillmem-
ber. Tighten locknuts to 30 Nzm (22 ft. lbs.) torque.
Install the steering gear skid plate and screws
after the left tow hook strap has been installed.
(7) Connect the fog lamp wire harness connectors.
Connect the vacuum reservoir tube harness connec-
tors.
(8) Remove the bumper support.
REAR BUMPER
REMOVAL
(1) For vehicles equipped with a trailer hitch, re-
move the hitch before removing the bumper. If neces-
sary, refer to the removal procedure within Group 23,
Body Components.
(2) Raise and support the rear of the vehicle.
(3) Support the bumper.
(4) Remove the bolts that attach the bumper sup-
port brackets to the sill crossmember (Fig. 12).
(5) Remove the support and the rear bumper from
the vehicle.
(6) Remove the bumper support brackets and
splash shield the bumper, if necessary (Fig. 13).
(7) Remove the bumper end caps (Fig. 14) and
bumper guards from the bumper (Fig. 15), if neces-
sary.
INSTALLATION
(1) As applicable, install the splash shield and
bumper support brackets, the bumper end caps and
the bumper guards.
(2) Tighten the bumper support bolts to 56 Nzm (41
ft. lbs.).(3) Tighten the nuts in the sequence depicted in
Figure 14. Tighten the bumper end cap plate bolt
Fig. 12 Rear Bumper Removal/InstallationÐXJ
Vehicles
Fig. 13 Bumper Bracket & Splash Shield Removal/
InstallationÐXJ Vehicles
Fig. 14 Bumper End Cap Removal/InstallationÐXJ
Vehicles
13 - 8 XJÐBUMPERSJ

nuts to 22 Nzm (16 ft. lbs.) torque. Tighten the lower
bolt nuts to 8 Nzm (6 ft. lbs.) torque.
(4) If applicable, tighten the bumper guard bolts/
nuts to 56 Nzm (41 ft. lbs.).
(5) Position and support the bumper with the
bracket holes aligned with the sill crossmember
holes. Install the bracket-to-crossmember bolts.
Tighten the bolts to 42 Nzm (31 ft. lbs.) torque.
(6) If removed, install the trailer hitch. If neces-
sary, refer to the installation procedure within Group
23, Body Components.
REAR TOW HOOK
REMOVAL
(1) Remove the bolts that attach tow hook bracket
to the frame rail and reinforcement bracket (Fig. 16).
The reinforcement bracket is held on the
frame rail with two blind rivets.
(2) Remove the bracket and tow hook from frame
rail.
INSTALLATION
(1) Position bracket and tow hook on the frame
rail.
(2) Install bolts that attach tow hook bracket to
frame rail and reinforcement bracket. Tighten bolts
to 75 Nzm (55 ft. lbs.) torque.
Fig. 15 Bumper Guard Removal/InstallationÐXJ
VehiclesFig. 16 Rear Tow HookÐXJ Vehicles
JXJÐBUMPERS 13 - 9

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

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 FUEL
PRESSURE RELEASE PROCEDURE IN THIS
GROUP.
Inspect all hose connections such as clamps, cou-
plings and fittings to make sure they are secure and
leaks are not present. The component should be re-
placed immediately if there is any evidence of degra-
dation that could result in failure.
Never attempt to repair a plastic fuel line/tube. Re-
place as necessary.
Avoid contact of any fuel tubes/hoses with other ve-
hicle components that could cause abrasions or scuff-
ing. Be sure that the plastic fuel lines/tubes are
properly routed to prevent pinching and to avoid heat
sources.
The lines/tubes/hoses used on fuel injected vehicles
are of a special construction. This is due to the
higher fuel pressures and the possibility of contami-
nated fuel in this system. If it is necessary to replace
these lines/tubes/hoses, only those marked EFM/EFI
may be used.
The hose clamps used to secure rubber hoses on
fuel injected vehicles are of a special rolled edge con-
struction. This construction is used to prevent the
edge of the clamp from cutting into the hose. Only
these rolled edge type clamps may be used in this
system. All other types of clamps may cut into the
hoses and cause high-pressure fuel leaks.
Use new original equipment type hose clamps.
Tighten hose clamps to 1 Nzm (15 in. lbs.) torque.
QUICK-CONNECT FITTINGS
Also refer to the previous Fuel Tubes/Lines/Hoses
and Clamps section.
Different types of quick-connect fittings are used to
attach various fuel system components. These are: a
single-tab type, a two-tab type or a plastic retainer
ring type.
SINGLE-TAB TYPE
This type of fitting is equipped with a single pull
tab (Fig. 15). The tab is removable. After the tab is
removed, the quick-connect fitting can be separated
from the fuel system component.
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. Do
not attempt to repair damaged fittings or fuel lines/
tubes. If repair is necessary, replace the complete
fuel 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 FUEL
PRESSURE RELEASE PROCEDURE IN THIS
GROUP.
DISCONNECTION/CONNECTION
(1) Disconnect negative battery cable from battery.
(2) Perform the fuel pressure release procedure.
Refer to the Fuel Pressure Release Procedure in this
section.
(3) Clean the fitting of any foreign material before
disassembly.
(4) Press the release tab on the side of fitting to re-
lease pull tab (Fig. 15).
CAUTION: If this release tab is not pressed prior to
releasing the pull tab, the pull tab will be damaged.
(5) While pressing the release tab on the side of
the fitting, use a screwdriver to pry up the pull tab
(Fig. 16).
(6) Raise the pull tab until it separates from the
quick-connect fitting (Fig. 17). Discard the old pull
tab.
(7) Disconnect the quick-connect fitting from the
fuel system component being serviced.
(8) Inspect the quick-connect fitting body and fuel
system component for damage. Replace as necessary.
(9) 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.
(10) Insert the quick-connect fitting into the fuel
tube or fuel system component until the built-on stop
on the fuel tube or component rests against back of
fitting.
Fig. 15 Single-Tab Type Fitting
14 - 10 FUEL DELIVERY SYSTEMJ

(11) Obtain a new pull tab. Push the new tab down
until it locks into place in the quick-connect fitting.
(12) Verify a locked condition by firmly pulling on
fuel tube and fitting (15-30 lbs.).
(13) Connect negative cable to battery.
(14) Start engine and check for leaks.
TWO-TAB TYPE FITTING
This type of fitting is equipped with tabs located on
both sides of the fitting (Fig. 18). These tabs are sup-
plied for disconnecting the quick-connect fitting from
component being serviced.
CAUTION: The interior components (O-rings, spac-
ers) of this type of quick-connect fitting are not ser-
viced separately, but new plastic retainers are
available. Do not attempt to repair damaged fittings
or fuel lines/tubes. If repair is necessary, replace
the complete fuel 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 FUEL
PRESSURE RELEASE PROCEDURE IN THIS
GROUP.
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 this
section.
(3) Clean the fitting of any foreign material before
disassembly.
(4) To disconnect the quick-connect fitting, squeeze
the plastic retainer tabs against the sides of the
quick-connect fitting with your fingers. Tool use is
not required for removal and may damage plastic re-
tainer. Pull the fitting from the fuel system compo-
nent being serviced. The plastic retainer will remain
on the component being serviced after fitting is dis-
connected. The O-rings and spacer will remain in the
quick-connect fitting connector body.
(5) Inspect the quick-connect fitting body and com-
ponent for damage. Replace as necessary.
CAUTION: When the quick-connect fitting was dis-
connected, the plastic retainer will remain on the
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.
Fig. 16 Disconnecting Single-Tab Type Fitting
Fig. 17 Removing Pull Tab
Fig. 18 Typical Two-Tab Type Quick-Connect Fitting
JFUEL DELIVERY SYSTEM 14 - 11

(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.
PLASTIC RETAINER RING TYPE FITTING
This type of fitting can be identified by the use of a
full-round plastic retainer ring (Fig. 19) usually black
in color.
CAUTION: The interior components (O-rings, spac-
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-
essary, replace the complete fuel 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 FUEL
PRESSURE RELEASE PROCEDURE IN THIS
GROUP.
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 this
section.
(3) Clean the fitting of any foreign material before
disassembly.
(4) To release the fuel system component from the
quick-connect fitting, firmly push the fitting towards
the component being serviced while firmly pushing
the plastic retainer ring into the fitting (Fig. 19).
With the plastic ring depressed, pull the fitting from
the component.The plastic retainer ring must be
pressed squarely into the fitting body. If this re-
tainer is cocked during removal, it may be dif-
ficult to disconnect fitting. Use an open-end
wrench on the shoulder of the plastic retainer
ring to aid in disconnection.
After disconnection, the plastic retainer ring will
remain with the quick-connect fitting connector body.
(5) Inspect fitting connector body, plastic retainer
ring and fuel system component for damage. Replace
as necessary.
(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 into the compo-
nent being serviced until a click is felt.
(8) Verify a locked condition by firmly pulling on
fuel tube and fitting (15-30 lbs.).
(9) Connect negative battery cable to battery.
(10) Start engine and check for leaks.
Fig. 19 Plastic Retainer Ring Type Fitting
14 - 12 FUEL DELIVERY SYSTEMJ