fuel filter location JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual

LUBRICATION & MAINTENANCE
TABLE OF CONTENTS
page page
LUBRICATION & MAINTENANCE
SPECIFICATIONS - FLUID CAPACITIES.......1
INTERNATIONAL SYMBOLS
DESCRIPTION..........................2
PARTS & LUBRICANT RECOMMENDATION
STANDARD PROCEDURE - PARTS &
LUBRICANT RECOMMENDATIONS.........2
FLUID TYPES
DESCRIPTION
DESCRIPTION - ENGINE COOLANT........2
DESCRIPTION - ENGINE COOLANT........3
ENGINE OIL..........................4
DESCRIPTION - ENGINE OIL.............4
DESCRIPTION........................5
DESCRIPTION - TRANSFER CASE - NV242 . . 5
DESCRIPTION - TRANSFER CASE - NV247 . . 5
DESCRIPTION - AUTOMATIC
TRANSMISSION FLUID..................5
DESCRIPTION - ENGINE OIL - DIESEL
ENGINES............................6OPERATION - AUTOMATIC TRANSMISSION
FLUID...............................6
FLUID FILL/CHECK LOCATIONS
INSPECTION - FLUID FILL/CHECK
LOCATIONS..........................6
MAINTENANCE SCHEDULES
DESCRIPTION..........................6
LIFT POINTS
STANDARD PROCEDURE - HOISTING AND
JACKING RECOMMENDATIONS...........6
JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING . . 7
EMERGENCY TOW HOOKS
DESCRIPTION..........................8
TOWING
STANDARD PROCEDURE - TOWING
RECOMMENDATIONS...................8
LUBRICATION &
MAINTENANCE
SPECIFICATIONS - FLUID CAPACITIES
DESCRIPTION SPECIFICATION
FUEL TANK 20 U.S. Gallons (76
Liters)****
Engine Oil - with Filter -
2.7L Diesel6.5L (6.9 qts.)
Engine Oil - with Filter -
4.0L5.7 L (6.0 qts.)
Engine Oil - with Filter -
4.7L5.7 L (6.0 qts.)
Cooling System - 2.7L
Diesel14.2L (15 qts.)***
Cooling System - 4.0L 14.1 L (15 qts.)***
Cooling System - 4.7L 13.7 L (14.5 qts.)***
AUTOMATIC TRANSMISSION
Service Fill - 42RE 3.8 L (4.0 qts.)
Service Fill - 545RFE 2WD - 5.2 L (11 pts.)
4WD - 6.2 L (13 pts.)
O-haul Fill - 42RE 9.1-9.5 L (19-20 pts.)
DESCRIPTION SPECIFICATION
O-haul Fill - 545RFE 13.33 L (28.0 pts.)
Dry fill capacity Depending on type and size of internal
cooler, length and inside diameter of cooler lines, or use
of an auxiliary cooler, these figures may vary. (Refer to
appropriate 21 - TRANSMISSION/TRANSAXLE/
AUTOMATIC/FLUID - STANDARD PROCEDURE).
TRANSFER CASE
NV242 1.35L (2.85 pts.)
NV247 1.6L (3.4 pts.)
FRONT AXLE   0.3 L (1 oz.)
186 FBI (Model 30) 1.18 L (2.5 pts.)*
* With Vari-Lok add 0.07 L (2.5 oz.) of Friction Modifier.
REAR AXLE   0.3 L (1 oz.)
198 RBI (Model 35) 1.66 L (3.5 pts.)*
226 RBA (Model 44) 2.24 L (4.75 pts.)**
* With Trac-lok add 0.07 L (2.5 oz.) of Friction Modifier.
** With Trac-lok or Vari-Lok, add 0.07 L (2.5 oz.) of
Friction Modifier.
*** Includes 0.9L (1.0 qts.) for coolant reservoir.
****Nominal refill capacities are shown. A variation may
be observed from vehicle to vehicle due to
manufacturing tolerance and refill procedure.
WJLUBRICATION & MAINTENANCE 0 - 1

The ASD relay will be shut±down, meaning the
12±volt power supply to the ASD relay will be de-ac-
tivated by the PCM if:
²the ignition key is left in the ON position. This
is if the engine has not been running for approxi-
mately 1.8 seconds.
²there is a crankshaft position sensor signal to
the PCM that is lower than pre-determined values.
OPERATION - ASD SENSE - PCM INPUT
A 12 volt signal at this input indicates to the PCM
that the ASD has been activated. The relay is used to
connect the oxygen sensor heater element, ignition
coil and fuel injectors to 12 volt + power supply.
This input is used only to sense that the ASD relay
is energized. If the Powertrain Control Module
(PCM) does not see 12 volts at this input when the
ASD should be activated, it will set a Diagnostic
Trouble Code (DTC).
REMOVAL
The ASD relay is located in the Power Distribution
Center (PDC) (Fig. 1). Refer to label on PDC cover
for relay location.
(1) Remove PDC cover.
(2) Remove relay from PDC.
(3) Check condition of relay terminals and PDC
connector terminals for damage or corrosion. Repair
if necessary before installing relay.
(4) Check for pin height (pin height should be the
same for all terminals within the PDC connector).
Repair if necessary before installing relay.
INSTALLATION
The ASD relay is located in the Power Distribution
Center (PDC) (Fig. 1). Refer to label on PDC cover
for relay location.
(1) Install relay to PDC.
(2) Install cover to PDC.
CAMSHAFT POSITION
SENSOR
DESCRIPTION
DESCRIPTION - 4.0L
The Camshaft Position Sensor (CMP) on the 4.0L
6±cylinder engine is bolted to the top of the oil pump
drive shaft assembly (Fig. 2). The sensor and drive
shaft assembly is located on the right side of the
engine near the oil filter (Fig. 3).
Fig. 1 Power Distribution Center (PDC) Location
1 - PCM
2 - COOLANT TANK
Fig. 2 CMP and Oil Pump Drive ShaftÐ4.0L Engine
1 - CAMSHAFT POSITION SENSOR
2 - MOUNTING BOLTS (2)
3 - PULSE RING
4 - DRIVE GEAR (TO CAMSHAFT)
5 - OIL PUMP DRIVESHAFT
6 - SENSOR BASE (OIL PUMP DRIVESHAFT ASSEMBLY)
8I - 4 IGNITION CONTROLWJ
AUTO SHUT DOWN RELAY (Continued)

DESCRIPTION - 4.7L
The Camshaft Position Sensor (CMP) on the 4.7L
V±8 engine is bolted to the front/top of the right cyl-
inder head (Fig. 4).
OPERATION
OPERATION - 4.0L
The CMP sensor contains a hall effect device called
a sync signal generator to generate a fuel sync sig-
nal. This sync signal generator detects a rotating
pulse ring (shutter) on the oil pump drive shaft (Fig.
2). The pulse ring rotates 180 degrees through the
sync signal generator. Its signal is used in conjunc-
tion with the crankshaft position sensor to differenti-
ate between fuel injection and spark events. It is also
used to synchronize the fuel injectors with their
respective cylinders.
When the leading edge of the pulse ring (shutter)
enters the sync signal generator, the following occurs:
The interruption of magnetic field causes the voltage
to switch high resulting in a sync signal of approxi-
mately 5 volts.When the trailing edge of the pulse ring (shutter)
leaves the sync signal generator, the following occurs:
The change of the magnetic field causes the sync sig-
nal voltage to switch low to 0 volts.
OPERATION - 4.7L
The CMP sensor contains a hall effect device called
a sync signal generator to generate a fuel sync sig-
nal. This sync signal generator detects notches
located on a tonewheel. The tonewheel is located at
the front of the camshaft for the right cylinder head
(Fig. 5). As the tonewheel rotates, the notches pass
through the sync signal generator. The pattern of the
notches (viewed counter-clockwise from front of
engine) is: 1 notch, 2 notches, 3 notches, 3 notches, 2
notches 1 notch, 3 notches and 1 notch. The signal
from the CMP sensor is used in conjunction with the
crankshaft position sensor to differentiate between
fuel injection and spark events. It is also used to syn-
chronize the fuel injectors with their respective cylin-
ders.
Fig. 3 CMP LocationÐ4.0L Engine
1 - OIL FILTER
2 - CAMSHAFT POSITION SENSOR
3 - CLAMP BOLT
4 - HOLD-DOWN CLAMP
5 - MOUNTING BOLTS (2)
6 - ELEC. CONNECTORFig. 4 CMP LocationÐ4.7L Engine
1 - RIGHT CYLINDER HEAD
2 - CAMSHAFT POSITION SENSOR
3 - MOUNTING BOLT
4 - ELEC. CONNECTOR
WJIGNITION CONTROL 8I - 5
CAMSHAFT POSITION SENSOR (Continued)

FORM-IN-PLACE GASKET AND SEALER
APPLICATION
Assembling parts using a form-in-place gasket
requires care but it's easier then using precut gaskets.
MopartGasket Maker material should be applied
sparingly 1 mm (0.040 in.) diameter or less of sealant
to one gasket surface. Be certain the material sur-
rounds each mounting hole. Excess material can eas-
ily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smear-
ing material off the location.
MopartEngine RTV GEN II or ATF RTV gasket
material should be applied in a continuous bead
approximately 3 mm (0.120 in.) in diameter. All
mounting holes must be circled. For corner sealing, a
3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the
center of the gasket contact area. Uncured sealant
may be removed with a shop towel. Components
should be torqued in place while the sealant is still
wet to the touch (within 10 minutes). The usage of a
locating dowel is recommended during assembly to
prevent smearing material off the location.
MopartGasket Sealant in an aerosol can should be
applied using a thin, even coat sprayed completely
over both surfaces to be joined, and both sides of a
gasket. Then proceed with assembly. Material in a
can w/applicator can be brushed on evenly over the
sealing surfaces. Material in an aerosol can should be
used on engines with multi-layer steel gaskets.
STANDARD PROCEDURE - REPAIR DAMAGED
OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain
the original center line.
Damaged or worn threads can be repaired. Essen-
tially, this repair consists of:
²Drilling out worn or damaged threads.
²Tapping the hole with a special Heli-Coil Tap, or
equivalent.
²Installing an insert into the tapped hole to bring
the hole back to its original thread size.
STANDARD PROCEDUREÐHYDROSTATIC LOCK
CAUTION: DO NOT use the starter motor to rotate
the crankshaft. Severe damage could occur.
When an engine is suspected of hydrostatic lock
(regardless of what caused the problem), follow the
steps below.
(1) Perform the Fuel Pressure Release Procedure
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE).(2) Disconnect the negative cable(s) from the bat-
tery.
(3) Inspect air cleaner, induction system, and
intake manifold to ensure system is dry and clear of
foreign material.
(4) Place a shop towel around the spark plugs to
catch any fluid that may possibly be under pressure
in the cylinder head. Remove the spark plugs.
(5) With all spark plugs removed, rotate the crank-
shaft using a breaker bar and socket.
(6) Identify the fluid in the cylinders (coolant, fuel,
oil, etc.).
(7) Be sure all fluid has been removed from the
cylinders.
(8) Repair engine or components as necessary to
prevent this problem from occurring again.
(9) Squirt a small amount of engine oil into the
cylinders to lubricate the walls. This will prevent
damage on restart.
(10) Install new spark plugs. Tighten the spark
plugs to 41 N´m (30 ft. lbs.) torque.
(11) Drain engine oil. Remove and discard the oil
filter.
(12) Install the drain plug. Tighten the plug to 34
N´m (25 ft. lbs.) torque.
(13) Install a new oil filter.
(14) Fill engine crankcase with the specified
amount and grade of oil. (Refer to LUBRICATION &
MAINTENANCE - SPECIFICATIONS).
(15) Connect the negative cable(s) to the battery.
(16) Start the engine and check for any leaks.
STANDARD PROCEDURE - CYLINDER BORE
HONING
Before honing, stuff plenty of clean shop towels
under the bores and over the crankshaft to keep
abrasive materials from entering the crankshaft
area.
(1)
Used carefully, the Cylinder Bore Sizing Hone
C-823, equipped with 220 grit stones, is the best tool
for this job. In addition to deglazing, it will reduce
taper and out-of-round, as well as removing light scuff-
ing, scoring and scratches. Usually, a few strokes will
clean up a bore and maintain the required limits.
CAUTION: DO NOT use rigid type hones to remove
cylinder wall glaze.
(2) Deglazing of the cylinder walls may be done if
the cylinder bore is straight and round. Use a cylin-
der surfacing hone, Honing Tool C-3501, equipped
with 280 grit stones (C-3501-3810). about 20-60
strokes, depending on the bore condition, will be suf-
ficient to provide a satisfactory surface. Using honing
oil C-3501-3880, or a light honing oil, available from
major oil distributors.
9 - 10 ENGINE - 4.0LWJ
ENGINE - 4.0L (Continued)

STANDARD PROCEDURE - FUEL SYSTEM
PRESSURE RELEASE
Use following procedure if the fuel injector
rail is, or is not equipped with a fuel pressure
test port.
(1) Remove fuel fill cap.
(2) Remove fuel pump relay from Power Distribu-
tion Center (PDC). For location of relay, refer to label
on underside of PDC cover.
(3) Start and run engine until it stalls.
(4) Attempt restarting engine until it will no
longer run.
(5) Turn ignition key to OFF position.
CAUTION: Steps 1, 2, 3 and 4 must be performed to
relieve high pressure fuel from within fuel rail. Do
not attempt to use following steps to relieve this
pressure as excessive fuel will be forced into a cyl-
inder chamber.
(6) Unplug connector from any fuel injector.
(7) Attach one end of a jumper wire with alligator
clips (18 gauge or smaller) to either injector terminal.(8) Connect other end of jumper wire to positive
side of battery.
(9) Connect one end of a second jumper wire to
remaining injector terminal.
CAUTION: Powering an injector for more than a few
seconds will permanently damage the injector.
(10) Momentarily touch other end of jumper wire
to negative terminal of battery for no more than a
few seconds.
(11) Place a rag or towel below fuel line quick-con-
nect fitting at fuel rail.
(12) Disconnect quick-connect fitting at fuel rail.
Refer to Quick-Connect Fittings.
(13) Return fuel pump relay to PDC.
(14) One or more Diagnostic Trouble Codes (DTC's)
may have been stored in PCM memory due to fuel
pump relay removal. The DRBtscan tool must be
used to erase a DTC.
SPECIFICATIONS
FUEL SYSTEM PRESSURE
339 kPa   34 kPa (49.2 psi   5 psi).
TORQUE - FUEL DELIVERY
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Accelerator Pedal Bracket Mounting Nuts
(without adjustable pedals)12  2 - 105  20
Fuel Filter/Fuel Press. Reg. Bolts 3 - 26
Fuel Hose Clamps 3 - 26
Fuel Injector Rail Mounting Bolts -4.0L Engine 11 - 100
Fuel Injector Rail Mounting Bolts -4.7L V-8
Engine11 - 100
Fuel Pump Module Locknut 74 55 -
Fuel Tank Filler Tube-to-Body Mounting Bolts 2 - 15
Fuel Tank-to-Body Mounting Bolts 88 65 -
Fuel Tank Support Bracket Bolts (large brackets) 88 65 -
Fuel Tank Support Bracket Bolts (small bracket) 5 - 45
Fuel Tank Support Bracket Nuts (large brackets) 61 45 -
Fuel Tank Heat Shield Nuts (shield-to-tank) 9 - 85
Fuel Tank Heat Shield Nuts (shield-to-body) 3 - 25
14 - 4 FUEL DELIVERYWJ
FUEL DELIVERY (Continued)

The regulator is calibrated to maintain fuel system
operating pressure of approximately 339 kPa   34
kPa (49.2 psi   5 psi) at the fuel injectors. It contains
a diaphragm, calibrated springs and a fuel return
valve. The internal fuel filter is also part of the
assembly.
Fuel is supplied to the filter/regulator by the elec-
tric fuel pump. The regulator acts as a check valve to
maintain some fuel pressure when the engine is not
operating. This will help to start the engine. A second
check valve is located at the outlet end of the electric
fuel pump.
If fuel pressure at the pressure regulator exceeds
approximately 49 psi, an internal diaphragm closes.
Excess fuel is then routed into a separate fuel return
line and returned to the fuel tank through the top of
the fuel pump module.
Both fuel filters (at bottom of fuel pump module
and within fuel pressure regulator) are designed for
extended service. They do not require normal sched-
uled maintenance. Filters should only be replaced if
a diagnostic procedure indicates to do so.
REMOVAL
The combination Fuel Filter/Fuel Pressure Regula-
tor is remotely mounted to the vehicle body, above
the rear axle and near the front of the fuel tank (Fig.
4) or (Fig. 5).
(1) Perform Fuel System Pressure Release Proce-
dure.
(2) Disconnect negative battery cable at battery.
(3) Raise vehicle.
(4) Clean area around 3 filter/regulator fittings.
(5) Disconnect fuel supply, fuel return and fuel
pressure lines at filter/regulator (Fig. 4) . Refer to
Quick-Connect Fittings.
(6) Remove 2 mounting bolts (Fig. 5) and remove
filter/regulator.
INSTALLATION
The combination Fuel Filter/Fuel Pressure Regula-
tor is remotely mounted to the vehicle body, above
the rear axle and near the front of the fuel tank (Fig.
4) or (Fig. 5).
(1) Before installing filter/regulator, be sure all fit-
tings are cleaned of all dirt and contaminants.
(2) Be sure o-ring is positioned into fuel return fit-
ting in filter/regulator.
Fig. 3 Fuel Filter/Fuel Pressure Regulator Location
1 - FUEL SUPPLY LINE (TO FUEL RAIL)
2 - EVAP LINE
3 - FUEL RETURN LINE (MALE)
4 - FUEL PRESSURE LINE (FEMALE)
5 - FUEL FILTER/PRESSURE REGULATOR
6 - FUEL TANK
Fig. 4 Fuel Filter/Fuel Pressure Regulator Location
1 - FUEL SUPPLY LINE (TO FUEL RAIL)
2 - EVAP LINE
3 - FUEL RETURN LINE (MALE)
4 - FUEL PRESSURE LINE (FEMALE)
5 - FUEL FILTER/PRESSURE REGULATOR
6 - FUEL TANK
14 - 6 FUEL DELIVERYWJ
FUEL FILTER/PRESSURE REGULATOR (Continued)

(1) Remove fuel tank. Refer to Fuel Tank Removal/
Installation.(2) Remove fuel pump module. Refer to Fuel Pump
Module Removal/Installation.
(3) Remove electrical wire connector at sending
unit terminals.
(4) Press upward on release tab (Fig. 7) to remove
sending unit from pump module.
INSTALLATION
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.
(1) Position sending unit to pump module and
snap into place.
(2) Connect electrical connector to terminals.
(3) Install fuel pump module. Refer to Fuel Pump
Module Removal/Installation.
(4) Install fuel tank. Refer to Fuel Tank Removal/
Installation.
FUEL LINES
DESCRIPTION
Also refer to Quick-Connect Fittings.
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
SYSTEM PRESSURE RELEASE PROCEDURE IN
THIS GROUP.
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.
If equipped:The hose clamps used to secure rub-
ber hoses on fuel injected vehicles are of a special
rolled edge construction. 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.
FUEL PUMP
DESCRIPTION
The electric fuel pump is located inside of the fuel
pump module. A 12 volt, permanent magnet, electric
motor powers the fuel pump. The electric fuel pump
is not a separate, serviceable component.
Fig. 6 Fuel Gauge Sending Unit Location
1 - FUEL PUMP MODULE
2 - FUEL GAUGE FLOAT
3 - ELECTRIC FUEL PUMP
4 - INLET FILTER
5 - FUEL GAUGE SENDING UNIT
6 - PIGTAIL HARNESS
Fig. 7 Fuel Gauge Sending Unit Release Tab
1 - ELECTRICAL CONNECTOR
2 - FUEL GAUGE SENDING UNIT
3 - RELEASE TAB
4 - FUEL PUMP MODULE
14 - 8 FUEL DELIVERYWJ
FUEL LEVEL SENDING UNIT / SENSOR (Continued)

(19) Disconnect test leads from relay cavities
immediately after testing.
FUEL PUMP PRESSURE TEST
Use this test in conjunction with other fuel system
tests. Refer to the Fuel Pump Capacity Test, Fuel
Pressure Leak Down Test and Fuel Pump Amperage
Test.
Check Valve Operation:The electric fuel pump
outlet contains a one-way check valve to prevent fuel
flow back into the tank and to maintain fuel supply
line pressure (engine warm) when pump is not oper-
ational. It is also used to keep the fuel supply line
full of gasoline when pump is not operational. After
the vehicle has cooled down, fuel pressure may drop
to 0 psi (cold fluid contracts), but liquid gasoline will
remain in fuel supply line between the check valve
and fuel injectors.Fuel pressure that has
dropped to 0 psi on a cooled down vehicle
(engine off) is a normal condition.When the elec-
tric fuel pump is activated, fuel pressure should
immediately(1±2 seconds) rise to specification.
The fuel system is equipped with a combination
fuel filter/fuel pressure regulator. The fuel pressure
regulator is not controlled by engine vacuum.
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT FUEL PRESSURE EVEN WITH THE ENGINE
OFF. BEFORE DISCONNECTING FUEL LINE AT
FUEL RAIL, THIS PRESSURE MUST BE RELEASED.REFER TO THE FUEL SYSTEM PRESSURE
RELEASE PROCEDURE.
(1) Remove pressure test port cap at fuel rail test
port (Fig. 12) or (Fig. 13) . Connect 0±414 kPa (0-60
psi) fuel pressure gauge (from gauge set 5069) to test
port pressure fitting on fuel rail (Fig. 14) .The DRB
III Scan Tool along with the PEP module, the
500 psi pressure transducer, and the transduc-
er-to-test port adapter may also be used in
place of the fuel pressure gauge.
(2) Start and warm engine and note pressure
gauge reading. The DRB scan tool may also be used
to power fuel pump. Fuel pressure should be 339 kPa
  34 kPa (49.2 psi   5 psi) at idle.
(3) If engine runs, but pressure is below 44.2 psi,
determine if fuel pump or filter/regulator is defective.
Proceed to next step:
(a) Check for a kinked fuel supply line some-
where between fuel rail and fuel pump module.
Fig. 11 FUEL PUMP RELAY - TYPE 3
TERMINAL LEGEND
NUMBER IDENTIFICATION
1 COIL BATTERY
2 COIL GROUND
3 COMMON FEED
4 NORMALLY CLOSED
5 NORMALLY OPEN
Fig. 12 Test Port Cap LocationÐ4.0L 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
WJFUEL DELIVERY 14 - 11
FUEL PUMP (Continued)

(b) If line is not kinked and pressure is low,
raise vehicle and disconnect fuel pressure line at
fuel filter/fuel pressure regulator (Fig. 15) . Three
fuel lines are attached to filter/regulator. Thefuel
pressure lineis attached to the right side of fil-
ter/regulator. It is also the most rearward of the
two (Fig. 15) .
(c) Install Special 5/16º Fuel Line Adapter Tool #
6539 between disconnected fuel line and filter/reg-
ulator fitting
(d) Attach 0±60 psi fuel pressure test gauge to
ªTº fitting on tool 6539.
Fig. 13 Test Port Cap LocationÐ4.7L V-8 Engine
1 - MOUNTING BOLTS (4)
2 - INJ.#7
3 - INJ.#5
4 - QUICK-CONNECT FITTING
5 - INJ.#3
6 - FUEL INJECTOR RAIL
7 - INJ.#1
8 - CONNECTOR TUBE
9 - INJ.#2
10 - INJ.#4
11 - INJ.#6
12 - INJ.#8
13 - PRESSURE TEST PORT CAP
Fig. 14 Fuel Pressure Test Gauge (Typical Gauge
Installation at Test Port)
1 - SERVICE (TEST) PORT
2 - FUEL PRESSURE TEST GAUGE
3 - FUEL RAIL
Fig. 15 Fuel Filter/Fuel Pressure Regulator Location
1 - FUEL SUPPLY LINE (TO FUEL RAIL)
2 - EVAP LINE
3 - FUEL RETURN LINE (MALE)
4 - FUEL PRESSURE LINE (FEMALE)
5 - FUEL FILTER/PRESSURE REGULATOR
6 - FUEL TANK
14 - 12 FUEL DELIVERYWJ
FUEL PUMP (Continued)

(23) Inspect for pinched or leaking fuel tubes/lines.
Inspect for pinched, cracked or leaking fuel hoses.
(24) Inspect for exhaust system restrictions such
as pinched exhaust pipes, collapsed muffler or
plugged catalytic convertor.
(25) If equipped with automatic transmission, ver-
ify electrical harness is firmly connected to park/neu-
tral switch and to transmission components.
(26) Verify fuel pump module pigtail harness elec-
trical connector (Fig. 15) is firmly connected to body
harness connector.
(27) Inspect fuel line harness (from fuel pump
module) at fuel filter/fuel pressure regulator (Fig. 15)
for chaffing, cracks or leaks.
(28) Verify battery cable and solenoid feed wire
connections to starter solenoid are tight and clean.
(29) Inspect for chaffed wires or wires rubbing up
against other components.
(30) Inspect for chaffed vacuum lines or lines rub-
bing up against other components.
Fig. 15 Fuel Filter/Fuel Pressure Regulator Location
1 - FUEL RETURN LINE
2 - FUEL SUPPLY LINE (TO FUEL RAIL)
3 - FUEL FILTER/FUEL PRESSURE REGULATOR
4 - FUEL PRESSURE LINE
5 - REAR AXLE
6 - ELEC. CONNECTOR
7 - EVAP LINE
14 - 38 FUEL INJECTIONWJ
FUEL INJECTION (Continued)