WJ Fule pump fix TSB:1400201

buttnakedjeepin · Dec 12, 2008

WJ Fuel pump fix TSB:1400201

so this thread is a little "how to" fix your fuel pump in your WJ....i have been plagued with turning the engine over at least 2 times for it start...this is due to a worn o-ring in the fuel pump allowing the fuel to drain back into the tank..im basically going to show what you need to fix this problem..

the first link is basically the fuel pump and it give some good pics of what needs to be taken off to drop the fuel tank
http://www.wjjeeps.com/fuel_filter.htm

this second link is the TSB for fixing the pump..
http://www.wjjeeps.com/tsb/tsb_wj_1400201.pdf

my sending unit was worn out as well with my pump.. so was able to get a used fuel pump out of 01 WJ and i purchased Mopar part number:5019308AB it ran me about $30 bucks good deal and $40 for a used fuel pump even better...

so this is what the kit looks like...it includes: 1 new o-ring, plastic split washer, new pump seal, lite oil, and 3 plastic strips

first off you take the 3 plastic strips and you slide each one under the locking tabs on the side of the pump..make sure you get each one all the under to where the strip is the same height of the pump..

once you got all the plastic slides in place pull up on the top of the assembly and disconnect it..take off the spring and set it aside you'll be using this again.. becarefull not to pull to hard there are 2 wires that are soldered to the sending unit..

next step is to take off the the old o-ring and replace it with the new o-ring and plastic split washer...

as you can see in this pic the space that is in between the o-ring and poppet.

pinch the old o-ring and take it off

buttnakedjeepin · Dec 12, 2008

put the split washer around the poppet like so....

next step is to place the o-ring on...in the kit there is some DT lite oil...use this and only this oil to put the o-ring on...coat the o-ring in the oil and the poppet as well..save alittle bit of oil for the end..

slide the o-ring on and becarful not to stretch it to mush to distort it..as you can see there is no space left with new slpit washer and o-ring.

last step is to place the spring back over the poppet, put some dt lite oil in the cylinder that the poppet will be going into and place the top back on till it locks on the 3 tabs...one the top of the assembly is back on apply pressure to the top of the assembly it should spring up after the pressure is released...

Now in order to get to the fuel tank the bumper cover has to be removed and the hitch has to be taken off as well...dont forget to disconnect the filler tube,vent tube, and fuel filter/regulator lines, and exhaust heat shield..and the battery of course...**tip** take a picture of both side of how the hitch and gas tank carrier are held up once you get the tank mounted then you try the hitch you'll find out that you will have to move bolts around so it all matches up...

to see if your pump falls into the catergory of needing this repair look at the julain date on the pump wires as so and can be coded by the link....
http://www.wjjeeps.com/tsb/tsb_wj_1400201.pdf

as you can see the pump on the right is the one that was in there and the 01 is on the left with a much larger prefilter...

dont be suprised if you see this...under all that mud/sand is the plastic nut that holds and helps seal the fuel pump..i used the air compressor and a screwdriver to break it all away...while you have it out you minus well unstrap the tank and clean it from the brush gaurd. The clips that hold the fuel lines need no special tool to remove or place them...in your kit a new seal is provided for the fuel pump...to remove the plastic nut i just used a big pair of adjust plyers...be prepared to have a little trouble getting the nut started again when you place teh new pump in...

Jeep Boy · Dec 12, 2008

Sweet dude! That's really good info to know, thanks!

WJ Fule pump fix TSB:1400201

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