Dif JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual

free cloth to check that the bore is clean. Oil the
bores after cleaning to prevent rusting.
CLEANING
Thoroughly clean the oil pan and engine block gas-
ket surfaces.
Use compressed air to clean out:
²The galley at the oil filter adaptor hole.
²The front and rear oil galley holes.
²The feed holes for the crankshaft main bearings.
Once the block has been completely cleaned, apply
Loctite PST pipe sealant with Teflon 592 to the
threads of the front and rear oil galley plugs. Tighten
the plugs to 34 N´m (25 ft. lbs.) torque.
INSPECTION
(1) It is mandatory to use a dial bore gauge to
measure each cylinder bore diameter. To correctly
select the proper size piston, a cylinder bore gauge,
capable of reading in 0.003 mm (.0001 in.) INCRE-
MENTS is required. If a bore gauge is not available,
do not use an inside micrometer (Fig. 46).
(2) Measure the inside diameter of the cylinder
bore at three levels below top of bore. Start perpen-
dicular (across or at 90 degrees) to the axis of the
crankshaft and then take two additional reading.(3) Measure the cylinder bore diameter crosswise
to the cylinder block near the top of the bore. Repeat
the measurement near the middle of the bore, then
repeat the measurement near the bottom of the bore.
(4) Determine taper by subtracting the smaller
diameter from the larger diameter.
(5) Rotate measuring device 90É and repeat steps
above.
(6) Determine out-of-roundness by comparing the
difference between each measurement.
(7) If cylinder bore taper does not exceed 0.025
mm (0.001 inch) and out-of-roundness does not
exceed 0.025 mm (0.001 inch), the cylinder bore can
be honed. If the cylinder bore taper or out- of-round
condition exceeds these maximum limits, the cylinder
block must be replaced. A slight amount of taper
always exists in the cylinder bore after the engine
has been in use for a period of time.
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - CONNECTING ROD
BEARING FITTING
Inspect the connecting rod bearings for scoring and
bent alignment tabs (Fig. 47) (Fig. 48). Check the
bearings for normal wear patterns, scoring, grooving,
fatigue and pitting (Fig. 49). Replace any bearing
that shows abnormal wear.
Inspect the connecting rod journals for signs of
scoring, nicks and burrs.
Misaligned or bent connecting rods can cause
abnormal wear on pistons, piston rings, cylinder
walls, connecting rod bearings and crankshaft con-
necting rod journals. If wear patterns or damage to
any of these components indicate the probability of a
misaligned connecting rod, inspect it for correct rod
alignment. Replace misaligned, bent or twisted con-
necting rods.
(1) Wipe the oil from the connecting rod journal.
(2) Lubricate the upper bearing insert and install
in connecting rod.
(3) Use piston ring compressor and Guide Pins
Special Tool 8507 (Fig. 50) to install the rod and pis-
ton assemblies. The oil slinger slots in the rods must
face front of the engine. The ªFº's near the piston
wrist pin bore should point to the front of the engine.
(4) Install the lower bearing insert in the bearing
cap. The lower insert must be dry. Place strip of Plas-
tigage across full width of the lower insert at the cen-
ter of bearing cap. Plastigage must not crumble in
use. If brittle, obtain fresh stock.
(5) Install bearing cap and connecting rod on the
journal and tighten bolts to 27 N´m (20 ft. lbs.) plus a
90É turn. DO NOT rotate crankshaft. Plastigage will
smear, resulting in inaccurate indication.
Fig. 46 Bore GaugeÐTypical
1 - FRONT
2 - BORE GAUGE
3 - CYLINDER BORE
4-38MM
(1.5 in)
WJENGINE - 4.7L 9 - 109
ENGINE BLOCK (Continued)

(7) The No. 1 and No. 2 piston rings have a differ-
ent cross section. Ensure No. 2 ring is installed with
manufacturers I.D. mark (Dot) facing up, towards top
of the piston.
NOTE: Piston rings are installed in the following
order:
²Oil ring expander.
²Upper oil ring side rail.
²Lower oil ring side rail.
²No. 2 Intermediate piston ring.
²No. 1 Upper piston ring.
(8) Install the oil ring expander.
(9) Install upper side rail (Fig. 76) by placing one
end between the piston ring groove and the expander
ring. Hold end firmly and press down the portion to
be installed until side rail is in position. Repeat this
step for the lower side rail.
(10) Install No. 2 intermediate piston ring using a
piston ring installer (Fig. 77).
(11) Install No. 1 upper piston ring using a piston
ring installer (Fig. 77).
(12) Position piston ring end gaps as shown in
(Fig. 78). It is important that expander ring gap is at
least 45É from the side rail gaps, but not on the pis-
ton pin center or on the thrust direction.
VIBRATION DAMPER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
NOTE: Transmission cooler line snaps into shroud
lower right hand corner.
Fig. 76 Side RailÐInstallation
1 - SIDE RAIL END
Fig. 77 Upper and Intermediate RingsÐInstallation
Fig. 78 Piston Ring End Gap Position
1 - SIDE RAIL UPPER
2 - NO. 1 RING GAP
3 - PISTON PIN
4 - SIDE RAIL LOWER
5 - NO. 2 RING GAP AND SPACER EXPANDER GAP
9 - 122 ENGINE - 4.7LWJ
PISTON RINGS (Continued)

ENGINE LUBRICATION FLOW CHARTÐBLOCK: TABLE 1
FROM TO
Oil Pickup Tube Oil Pump
Oil Pump Oil Filter
Oil Filter Block Main Oil Gallery
Block Main Oil Gallery 1. Crankshaft Main Journal
2. Left Cylinder Head*
3. Right Cylinder Head*
Crankshaft Main Journals Crankshaft Rod Journals
Crankshaft Number One Main Journal 1.Front Timing Chain Idler Shaft
2.Both Secondary Chain Tensioners
Left Cylinder Head See Table 2
Right Cylinder Head See Table 2
* The cylinder head
gaskets have an oil restricter to control oil flow to the cylinder heads.
ENGINE LUBRICATION FLOW CHARTÐCYLINDER HEADS: TABLE 2
FROM TO
Cylinder Head Oil Port (in bolt hole) Diagonal Cross Drilling to Main Oil Gallery
Main Oil Gallery (drilled through head from rear to
front)1. Base of Camshaft Towers
2. Lash Adjuster Towers
Base of Camshaft Towers Vertical Drilling Through Tower to Camshaft Bearings**
Lash Adjuster Towers Diagonal Drillings to Hydraulic Lash Adjuster Pockets
** The number three camshaft bearing journal feeds oil into the hollow camshaft tubes. Oil is routed to the intake
lobes, which have oil passages drilled into them to lubricate the rocker arms.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTINGÐENGINE OIL
PRESSURE
(1) Remove oil pressure sending unit (Fig. 89)and
install gauge assembly C-3292.
(2) Run engine until thermostat opens.
(3) Oil Pressure:
²Curb IdleÐ25 Kpa (4 psi) minimum
²3000 rpmÐ170 - 550 KPa (25 - 80 psi)
(4) If oil pressure is 0 at idle, shut off engine.
Check for a clogged oil pick-up screen or a pressure
relief valve stuck open.
DIAGNOSIS AND TESTINGÐREAR SEAL AREA
LEAKS
Since it is sometimes difficult to determine the
source of an oil leak in the rear seal area of the
engine, a more involved inspection is necessary. The
following steps should be followed to help pinpoint
the source of the leak.If the leakage occurs at the crankshaft rear oil seal
area:
(1) Disconnect the battery.
(2) Raise the vehicle.
(3) Remove torque converter or clutch housing
cover and inspect rear of block for evidence of oil.
Use a black light to check for the oil leak:
(a) Circular spray pattern generally indicates
seal leakage or crankshaft damage.
(b) Where leakage tends to run straight down,
possible causes are a porous block, distributor seal,
camshaft bore cup plugs, oil galley pipe plugs, oil
filter runoff, and main bearing cap to cylinder
block mating surfaces. See Engine, for proper
repair procedures of these items.
(4) If no leaks are detected, pressurized the crank-
case as outlined in the section, Inspection (Engine oil
Leaks in general)
CAUTION: Do not exceed 20.6 kPa (3 psi).
9 - 128 ENGINE - 4.7LWJ
LUBRICATION (Continued)

(5) If the leak is not detected, very slowly turn the
crankshaft and watch for leakage. If a leak is
detected between the crankshaft and seal while
slowly turning the crankshaft, it is possible the
crankshaft seal surface is damaged. The seal area on
the crankshaft could have minor nicks or scratches
that can be polished out with emery cloth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks or
scratches. The crankshaft seal flange is specially
machined to complement the function of the rear oil
seal.
(6) For bubbles that remain steady with shaft
rotation, no further inspection can be done until dis-
assembled. (Refer to 9 - ENGINE - DIAGNOSIS AND
TESTING), under the Oil Leak row, for components
inspections on possible causes and corrections.
(7) After the oil leak root cause and appropriate
corrective action have been identified, (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT OIL
SEAL - REAR - REMOVAL).
DIAGNOSIS AND TESTINGÐENGINE OIL LEAK
Begin with a thorough visual inspection of the
engine, particularly at the area of the suspected leak.If an oil leak source is not readily identifiable, the
following steps should be followed:
(1) Do not clean or degrease the engine at this
time because some solvents may cause rubber to
swell, temporarily stopping the leak.
(2) Add an oil soluble dye (use as recommended by
manufacturer). Start the engine and let idle for
approximately 15 minutes. Check the oil dipstick to
make sure the dye is thoroughly mixed as indicated
with a bright yellow color under a black light.
(3) Using a black light, inspect the entire engine
for fluorescent dye, particularly at the suspected area
of oil leak. If the oil leak is found and identified,
repair per service manual instructions.
(4) If dye is not observed, drive the vehicle at var-
ious speeds for approximately 24km (15 miles), and
repeat inspection.If the oil leak source is not pos-
itively identified at this time, proceed with the air
leak detection test method.
Air Leak Detection Test Method
(1) Disconnect the breather cap to air cleaner hose
at the breather cap end. Cap or plug breather cap
nipple.
(2) Remove the PCV valve from the cylinder head
cover. Cap or plug the PCV valve grommet.
(3) Attach an air hose with pressure gauge and
regulator to the dipstick tube.
CAUTION: Do not subject the engine assembly to
more than 20.6 kpa (3 PSI) of test pressure.
(4) Gradually apply air pressure from 1 psi to 2.5
psi maximum while applying soapy water at the sus-
pected source. Adjust the regulator to the suitable
test pressure that provide the best bubbles which
will pinpoint the leak source. If the oil leak is
detected and identified, repair per service manual
procedures.
(5) If the leakage occurs at the rear oil seal area,
refer to the section, Inspection for Rear Seal Area
Leak.
(6) If no leaks are detected, turn off the air supply
and remove the air hose and all plugs and caps.
Install the PCV valve and breather cap hose.
(7) Clean the oil off the suspect oil leak area using
a suitable solvent. Drive the vehicle at various
speeds approximately 24 km (15 miles). Inspect the
engine for signs of an oil leak by using a black light.
INSPECTION FOR REAR SEAL AREA LEAKS
Since it is sometimes difficult to determine the
source of an oil leak in the rear seal area of the
engine, a more involved inspection is necessary. The
following steps should be followed to help pinpoint
the source of the leak.
Fig. 89 Oil Pressure Sending Unit
1 - BELT
2 - OIL PRESSURE SENSOR
3 - OIL FILTER
4 - ELEC. CONNECTOR
WJENGINE - 4.7L 9 - 129
LUBRICATION (Continued)

NOTE: When installing oil pan gasket/windage tray,
start four pan bolts at each corner before tightening
oil pickup tube. This will keep pan gasket in align-
ment.
(3) Install oil pump pick-up tube using a new
O-ring. First tighten bolt at O-ring end of tube to 28
N´m (20 ft. lbs.). Tighten remain tube support fasten-
ers to 28 N´m (20 ft. lbs.).
(4) Install oil pan and tighten fasteners to 15 N´m
(11 ft. lbs.) (Fig. 95).
(5) Reconnect transmission oil cooler lines to oil
pan stud bolt.
(6) Install starter (Refer to 8 - ELECTRICAL/
STARTING/STARTER MOTOR - INSTALLATION).
(7) Install exhaust system Y-pipe.
(8) Install structural cover (Refer to 9 - ENGINE/
ENGINE BLOCK/STRUCTURAL COVER - INSTAL-
LATION).
(9) Lower vehicle.
(10) Fill engine with proper amount of oil (Refer to
LUBRICATION & MAINTENANCE/FLUID TYPES -
SPECIFICATIONS).
(11) Connect negative cable to battery.
OIL PRESSURE SENSOR/
SWITCH
DESCRIPTION
The 3±wire, solid-state engine oil pressure sensor
(sending unit) is located in an engine oil pressure
gallery.
OPERATION
The oil pressure sensor uses three circuits. They are:
²A 5±volt power supply from the Powertrain Con-
trol Module (PCM)
²A sensor ground through the PCM's sensor
return
²
A signal to the PCM relating to engine oil pressure
The oil pressure sensor has a 3±wire electrical
function very much like the Manifold Absolute Pres-
sure (MAP) sensor. Meaning different pressures
relate to different output voltages.
A 5±volt supply is sent to the sensor from the PCM
to power up the sensor. The sensor returns a voltage
signal back to the PCM relating to engine oil pres-
sure. This signal is then transferred (bussed) to the
instrument panel on either a CCD or PCI bus circuit
(depending on vehicle line) to operate the oil pressure
gauge and the check gauges lamp. Ground for the
sensor is provided by the PCM through a low-noise
sensor return.
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Raise vehicle on hoist.
(3) Remove front splash shield.
(4) Disconnect oil pressure sender wire (Fig. 96).
(5) Remove the pressure sender (Fig. 96).
INSTALLATION
(1) Install oil pressure sender.
(2) Connect oil pressure sender wire.
(3) Install front splash shield.
(4) Lower vehicle.
(5) Connect the negative battery cable.
Fig. 95 Oil Pan Tightening Sequence
Fig. 96 Oil Pressure Sending Unit
1 - BELT
2 - OIL PRESSURE SENSOR
3 - OIL FILTER
4 - ELEC. CONNECTOR
WJENGINE - 4.7L 9 - 133
OIL PAN (Continued)

(3) Apply a small amount of clean engine oil to
o-rings.
(4) Position filter/regulator to body and install 2
bolts. Tighten bolts to 3 N´m (30 in. lbs.) torque.
(5) Connect 3 fittings. Refer to Quick-Connect Fit-
tings.
(6) Connect negative battery cable to battery.
(7) Start engine and check for leaks.
FUEL LEVEL SENDING UNIT /
SENSOR
DESCRIPTION
The fuel gauge sending unit (fuel level sensor) is
attached to the side of the fuel pump module. The
sending unit consists of a float, an arm, and a vari-
able resistor track (card).
OPERATION
The fuel pump module has 4 different circuits
(wires). Two of these circuits are used for the fuel
gauge sending unit for fuel gauge operation, and for
certain OBD II emission requirements. The other 2
wires are used for electric fuel pump operation.
For Fuel Gauge Operation:A constant input
voltage source of about 12 volts (battery voltage) is
supplied to the resistor track on the fuel gauge send-
ing unit. This is fed directly from the Powertrain
Control Module (PCM).NOTE: For diagnostic pur-
poses, this 12V power source can only be veri-fied with the circuit opened (fuel pump module
electrical connector unplugged). With the con-
nectors plugged, output voltages will vary from
about 0.6 volts at FULL, to about 8.6 volts at
EMPTY (about 8.6 volts at EMPTY for Jeep
models, and about 7.0 volts at EMPTY for
Dodge Truck models).The resistor track is used to
vary the voltage (resistance) depending on fuel tank
float level. As fuel level increases, the float and arm
move up, which decreases voltage. As fuel level
decreases, the float and arm move down, which
increases voltage. The varied voltage signal is
returned back to the PCM through the sensor return
circuit.
Both of the electrical circuits between the fuel
gauge sending unit and the PCM are hard-wired (not
multi-plexed). After the voltage signal is sent from
the resistor track, and back to the PCM, the PCM
will interpret the resistance (voltage) data and send
a message across the multi-plex bus circuits to the
instrument panel cluster. Here it is translated into
the appropriate fuel gauge level reading. Refer to
Instrument Panel for additional information.
For OBD II Emission Monitor Requirements:
The PCM will monitor the voltage output sent from
the resistor track on the sending unit to indicate fuel
level. The purpose of this feature is to prevent the
OBD II system from recording/setting false misfire
and fuel system monitor diagnostic trouble codes.
The feature is activated if the fuel level in the tank
is less than approximately 15 percent of its rated
capacity. If equipped with a Leak Detection Pump
(EVAP system monitor), this feature will also be acti-
vated if the fuel level in the tank is more than
approximately 85 percent of its rated capacity.
DIAGNOSIS AND TESTING - FUEL LEVEL
SENDING UNIT
The fuel level sending unit contains a variable
resistor (track). As the float moves up or down, elec-
trical resistance will change. Refer to Instrument
Panel and Gauges for Fuel Gauge testing. To test the
gauge sending unit only, it must be removed from
vehicle. The unit is part of the fuel pump module.
Refer to Fuel Pump Module Removal/Installation for
procedures. Measure the resistance across the send-
ing unit terminals. With float in up position, resis-
tance should be 20 ohms (+/- 5%). With float in down
position, resistance should be 270 ohms (+/- 5%).
REMOVAL
The fuel gauge sending unit (fuel level sensor) and
float assembly is located on the side of fuel pump
module (Fig. 6). The fuel pump module is located
within the fuel tank.
Fig. 5 Fuel Filter/Fuel Pressure Regulator Removal/
Installation
1 - FUEL FILTER/FUEL PRESSURE REGULATOR
2 - MOUNTING BOLTS (2)
WJFUEL DELIVERY 14 - 7
FUEL FILTER/PRESSURE REGULATOR (Continued)

(5) Connect (-) and (+) test cable leads into LCS
adapter receptacles. Use10 amp (10A +)receptacle
and common (-) receptacles.
(6) Gain access to MAIN MENU on DRB screen.
(7) Press DVOM button on DRB.
(8) Using left/right arrow keys, highlight CHAN-
NEL 1 function on DRB screen.
(9) Press ENTER three times.
(10) Using up/down arrow keys, highlight RANGE
on DRB screen (screen will default to 2 amp scale).
(11) Press ENTER to change 2 amp scale to 10
amp scale.This step must be done to prevent
damage to DRB scan tool or LCS adapter
(blown fuse).
(12) Remove cover from Power Distribution Center
(PDC).
(13) Remove fuel pump relay from PDC. Refer to
label on PDC cover for relay location.
WARNING: BEFORE PROCEEDING TO NEXT STEP,
NOTE THE FUEL PUMP WILL BE ACTIVATED AND
SYSTEM PRESSURE WILL BE PRESENT. THIS WILL
OCCUR AFTER CONNECTING TEST LEADS FROM
LCS ADAPTER INTO FUEL PUMP RELAY CAVITIES.
THE FUEL PUMP WILL OPERATE EVEN WITH IGNI-
TION KEY IN OFF POSITION. BEFORE ATTACHING
TEST LEADS, BE SURE ALL FUEL LINES AND
FUEL SYSTEM COMPONENTS ARE CONNECTED.
CAUTION: To prevent possible damage to the vehi-
cle electrical system and LCS adapter, the test
leads must be connected into relay cavities exactly
as shown in following steps.
Depending upon vehicle model, year or engine con-
figuration, three different types of relays may be
used: Type-1, type-2 and type±3.
(14) If equipped withtype±1 relay(Fig. 9), attach
test leads from LCS adapter into PDC relay cavities
number 30 and 87. For location of these cavities,
refer to numbers stamped to bottom of relay (Fig. 9).
(15) If equipped withtype±2 relay(Fig. 10),
attach test leads from LCS adapter into PDC relay
cavities number 30 and 87. For location of these cav-
ities, refer to numbers stamped to bottom of relay
(Fig. 10).
(16) If equipped withtype±3 relay(Fig. 11),
attach test leads from LCS adapter into PDC relay
cavities number 3 and 5. For location of these cavi-
ties, refer to numbers stamped to bottom of relay
(Fig. 11).
(17) When LCS adapter test leads are attached
into relay cavities, fuel pumpwill be activated.
Determine fuel pump amperage on DRB screen.
Amperage should be below 10.0 amps. If amperage is
below 10.0 amps, and specifications for the FuelPump Pressure, Fuel Pump Capacity and Fuel Pres-
sure Leak Down tests were met, the fuel pump mod-
ule is OK.
(18) If amperage is more than 10.0 amps, replace
fuel pump module assembly. The electric fuel pump
is not serviced separately.
Fig. 9 FUEL PUMP RELAY - TYPE 1
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
Fig. 10 FUEL PUMP RELAY - TYPE 2
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
14 - 10 FUEL DELIVERYWJ
FUEL PUMP (Continued)

(14) Install air tube (or duct) at top of throttle
body.
(15) Install fuel tank cap.
(16) Connect negative battery cable to battery.
(17) Start engine and check for fuel leaks.
FUEL TANK
DESCRIPTION
The fuel tank is constructed of a plastic material.
Its main functions are for fuel storage and for place-
ment of the fuel pump module and certain ORVR
components.
OPERATION
All models pass a full 360 degree rollover test
without fuel leakage. To accomplish this, fuel and
vapor flow controls are required for all fuel tank con-
nections.
A fuel tank check valve(s) is mounted into the top
of the fuel tank (or pump module). Refer to Fuel
Tank Check Valve for additional information.
An evaporation control system is connected to the
check valve(s) to reduce emissions of fuel vapors into
the atmosphere. When fuel evaporates from the fuel
tank, vapors pass through vent hoses or tubes to a
charcoal canister where they are temporarily held.
When the engine is running, the vapors are drawn
into the intake manifold. Certain models are also
equipped with a self-diagnosing system using a Leak
Detection Pump (LDP). Refer to Emission Control
System for additional information.
Refer to ORVR for On-Board Refueling Vapor
Recovery system information.
REMOVAL
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT FUEL PRESSURE EVEN WITH ENGINE OFF.
PRESSURE MUST BE RELEASED BEFORE SERVIC-
ING FUEL TANK.
Two different procedures may be used to drain fuel
tank (through ORVR control valve opening at top of
fuel tank, or using DRB scan tool). The quickest is
draining through ORVR control valve opening at top
of fuel tank (Fig. 26).
As an alternative procedure, the electric fuel pump
may be activated allowing tank to be drained at fuel
rail connection. Refer to DRB scan tool for fuel pump
activation procedures. Before disconnecting fuel line
at fuel rail, release fuel pressure. Refer to the Fuel
System Pressure Release Procedure for procedures.
Attach end of Special Adapter Hose Tool number
6539 at fuel rail disconnection. Position opposite end
of 6539 to an approved gasoline draining station.Activate fuel pump with DRB and drain tank until
empty.
If electric fuel pump is not operating, tankMUST
be drained through ORVR control valve opening at
top of fuel tank (Fig. 26).
(1) Release fuel system pressure. Refer to Fuel
System Pressure Release Procedure.
(2) Disconnect negative battery cable at battery.
(3) Raise and support vehicle.
(4) Remove left rear wheel/tire.
CAUTION: HANDLE EVAP, LDP AND ORVR VAPOR /
VACUUM LINES VERY CAREFULLY. THESE LINES
AND HOSES MUST BE FIRMLY CONNECTED.
CHECK THE VAPOR/VACUUM LINES AT THE LDP,
LDP FILTER, EVAP CANISTER, EVAP CANISTER
PURGE SOLENOID AND ORVR COMPONENTS FOR
DAMAGE OR LEAKS. IF A LEAK IS PRESENT, A
DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET.
(5) Clean top of fuel tank at ORVR control valve
(Fig. 26) or (Fig. 27).
(6) Press release tab in direction of arrow in (Fig.
27) and remove ORVR control valve lock ring
(counter-clockwise). Lift up ORVR control slightly.
Using an approved gasoline draining station, drain
tank until empty through this opening.
(7) Remove stone shield behind left/rear wheel
(Fig. 28). Drill out plastic rivets for removal.
(8) Remove 3 LDP mounting bolts (Fig. 29).
(9) Remove support bracket brace bolt (Fig. 30).
(10) Loosen, but do not remove 2 support bracket
nuts at frame rail (Fig. 29).
(11) To separate and lower front section of two-
piece support bracket, remove 3 attaching bolts on
bottom of support bracket (Fig. 30). While lowering
support bracket, disconnect LDP wiring clip (Fig. 31).
(12) Remove hose clamp (Fig. 32) and remove fuel
fill hose from fuel fill tube.
(13) Cut and discard tie wrap from axle vent hose
(Fig. 32).
(14) Disconnect fuel vent hose from fuel vent tube
(Fig. 32).
(15) Disconnect ORVR hose elbow (Fig. 33) at top
of EVAP canister.
(16) Place hydraulic jack to bottom of fuel tank.
(17) Remove fuel tank-to-rear bumper fascia clips
(Fig. 34).
(18) Remove fuel tank heat shield mounting bolts
(Fig. 35).
CAUTION: To protect fuel tank from exhaust heat,
shield must re-installed after tank installation.
WARNING: PLACE SHOP TOWEL AROUND FUEL
LINES TO CATCH ANY EXCESS FUEL.
WJFUEL DELIVERY 14 - 19
FUEL RAIL (Continued)

INLET FILTER
REMOVAL
The fuel pump inlet filter (strainer) is located on
the bottom of fuel pump module (Fig. 42). The fuel
pump module is located on top of fuel tank.
The fuel pump inlet filter (strainer) is located on
the bottom of fuel pump module (Fig. 42). The fuel
pump module is located on top of fuel tank.
(1) Remove fuel tank. Refer to Fuel Tank Removal/
Installation.
(2) Remove fuel pump module. Refer to Fuel Pump
Module Removal/Installation.
(3) Remove filter by prying from bottom of module
with 2 screwdrivers. Filter is snapped to module.
(4) Clean bottom of pump module.
INSTALLATION
The fuel pump inlet filter (strainer) is located on
the bottom of fuel pump module (Fig. 42). The fuel
pump module is located on top of fuel tank.
(1) Snap new filter to bottom of module.
(2) Install fuel pump module. Refer to Fuel Pump
Module Removal/Installation.
(3) Install fuel tank. Refer to Fuel Tank Removal/
Installation.
QUICK CONNECT FITTING
DESCRIPTION
Different types of quick-connect fittings are used to
attach various fuel system components, lines and tubes.
These are: a single-tab type, a two-tab type or a plastic
retainer ring type. Some are equipped with safety latch
clips. Some may require the use of a special tool for dis-
connection and removal. Refer to Quick-Connect Fit-
tings Removal/Installation for more information.
CAUTION: The interior components (o-rings, clips)
of quick-connect fittings are not serviced sepa-
rately, but new plastic spacers are available for
some types. If service parts are not available, do
not attempt to repair the damaged fitting or fuel line
(tube). If repair is necessary, replace the complete
fuel line (tube) assembly.
STANDARD PROCEDURE - QUICK-CONNECT
FITTINGS
Also refer to Fuel Tubes/Lines/Hoses and Clamps.
Different types of quick-connect fittings are used to
attach various fuel system components, lines and
tubes. These are: a single-tab type, a two-tab type or
a plastic retainer ring type. Safety latch clips are
used on certain components/lines. Certain fittings
may require use of a special tool for disconnection.
DISCONNECTING
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSE,
FITTING OR LINE, FUEL SYSTEM PRESSURE MUST
BE RELEASED. REFER TO FUEL SYSTEM PRES-
SURE RELEASE PROCEDURE.
CAUTION: The interior components (o-rings, spac-
ers) of some types of quick-connect fitting are not
serviced separately. If service parts are not avail-
able, do not attempt to repair a damaged fitting or
fuel line. If repair is necessary, replace complete
fuel line assembly.
(1) Perform fuel pressure release procedure. Refer
to Fuel Pressure Release Procedure.
(2) Disconnect negative battery cable from battery.
(3) Clean fitting of any foreign material before dis-
assembly.
(4)2±Button Type Fitting:This type of fitting is
equipped with a push-button located on each side of
quick-connect fitting (Fig. 43). Press on both buttons
simultaneously for removal. Special tools are not
required for disconnection.
Fig. 42 Fuel Pump Inlet Filter
1 - FUEL PUMP MODULE
2 - FUEL PUMP INLET FILTER
WJFUEL DELIVERY 14 - 27

depressed, pull fitting from component.The plas-
tic retainer ring must be pressed squarely
into fitting body. If this retainer is cocked
during removal, it may be difficult to discon-
nect fitting. Use an open-end wrench on
shoulder of plastic retainer ring to aid in dis-
connection.
(b) After disconnection, plastic retainer ring will
remain with quick-connect fitting connector body.
(c) Inspect fitting connector body, plastic retainer
ring and fuel system component for damage.
Replace as necessary.(9)Latch Clips:Depending on vehicle model and
engine, 2 different types of safety latch clips are used
(Fig. 50) or (Fig. 51). Type-1 is tethered to fuel line
and type-2 is not. A special tool will be necessary to
disconnect fuel line after latch clip is removed. The
latch clip may be used on certain fuel line/fuel rail
connection, or to join fuel lines together.
Fig. 46 DISCONNECTING SINGLE-TAB TYPE
FITTING
1 - PULL TAB
2 - SCREWDRIVER
3 - QUICK-CONNECT FITTING
Fig. 47 REMOVING PULL TAB
1 - FUEL TUBE OR FUEL SYSTEM COMPONENT
2 - PULL TAB
3 - QUICK-CONNECT FITTING
4 - FUEL TUBE STOP
Fig. 48 TYPICAL 2±TAB TYPE FITTING
1 - TAB(S)
2 - QUICK-CONNECT FITTING
Fig. 49 PLASTIC RETAINER RING TYPE FITTING
1 - FUEL TUBE
2 - QUICK CONNECT FITTING
3 - PUSH
4 - PLASTIC RETAINER
5 - PUSH
6 - PUSH
7 - PUSH
8 - PUSH
WJFUEL DELIVERY 14 - 29
QUICK CONNECT FITTING (Continued)