Fuel Delivery, Diesel - 2012 Jeep Wrangler JK Factory Service Manual

WARNING

WARNING:

High-pressure fuel lines deliver fuel under extreme pressure from the injection pump to the injectors. This may be as high as 1800 bar (26,106 psi). Use extreme caution when inspecting for high-pressure fuel leaks. Fuel under this amount of pressure can penetrate skin causing personal injury or death. Inspect high-pressure fuel leaks with a sheet of cardboard. Wear safety goggles and adequate protective clothing when servicing fuel system.

HIGH PRESSURE FUEL LEAKS

WARNING:

High-pressure lines deliver diesel fuel under extreme pressure from the injection pump to the fuel injectors. This may be as high as 1800 bar (26,106 psi). Use extreme caution when inspecting for high-pressure fuel leaks. Fuel under this amount of pressure can penetrate skin causing personal injury or death. Inspect for high-pressure fuel leaks with a sheet of cardboard. Wear safety goggles and adequate protective clothing when servicing fuel system.

High-pressure fuel leaks can cause starting problems and poor engine performance.

Carefully place a piece of cardboard (2) over the high-pressure fuel lines or suspected area. Move your body and hands away from the area. Start the engine and run till warm. TURN THE ENGINE OFF. Inspect the piece of cardboard for witness marks. If a high-pressure line connection is leaking, replace damaged, restricted or leaking high-pressure fuel lines with the correct replacement line.

CAUTION:

The high-pressure fuel lines cannot contact each other or other components. Do not attempt to weld high-pressure fuel lines or to repair lines that are damaged. Only use the recommended lines when replacement of high-pressure fuel line is necessary.

FUEL SUPPLY RESTRICTIONS

LOW-PRESSURE LINES

Fuel supply line restrictions or a restricted fuel filter can cause starting problems and prevent engine from accelerating. The starting problems include; no start, longer cranking times, low power and/or white fog like exhaust.

Inspect all fuel supply lines for restrictions or blockage, including the fuel filter. Flush or replace as necessary.

HIGH-PRESSURE LINES

CAUTION:

High-pressure lines cannot contact each other or other components. Do not attempt to weld high-pressure fuel lines or to repair lines that are damaged. High-pressure lines can be reused only after close inspection for cracks or deformation around the sealing cone. Corroded pipes must be replaced. Use only recommended lines when replacement of high-pressure fuel line is necessary.

NOTE:
High-pressure fuel lines must be replaced at each disassembly.

Restricted (kinked or bent) high-pressure lines can cause starting problems, poor engine performance, engine mis-fire and white smoke from exhaust.

DRAINING FUEL TANK

Special Tools: Click to display a list of tools used in this procedure

Conventional Procedure

NOTE:
Due to a one-way check valve installed into the fuel fill fitting at the tank, the tank cannot be drained at the fuel fill cap.

Disconnect the fuel feed line (2) quick-connect fitting (Refer to 14 - Fuel System/Fuel Delivery/FITTING, Quick Connect - Standard Procedure) .

Install the appropriate Fuel Line Adapters / Fitting from the Decay Tool, Fuel 8978A . Route the opposite end of this hose to an diesel fuel draining station.

NOTE:
Activation of the fuel pump module may time out and need to be restarted several times to completely drain the fuel tank.

Using a diagnostic scan tool, activate the fuel pump until the fuel tank is empty.

Alternative Procedure

Disconnect the negative battery cable.

Raise and support vehicle (Refer to 04 - Vehicle Quick Reference/Hoisting - Standard Procedure) .

Remove the fuel pump module (Refer to 14 - Fuel System/Fuel Delivery/MODULE, Fuel Pump - Removal) .

Drain fuel tank using an approved diesel fuel draining station.

CLEANING FUEL SYSTEM COMPONENTS

CAUTION:

Cleanliness cannot be overemphasized when handling or replacing diesel fuel system components. This especially includes the fuel injectors, high-pressure fuel lines, fuel rail, and fuel injection pump. Very tight tolerances are used with these parts. Dirt contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This in turn could lead to possible engine misfire. Always wash/clean any fuel system component thoroughly before disassembly and then air dry. DO NOT wire brush injector nozzles when cleaning. Cap or cover any open part after disassembly. Before assembly, examine each part for dirt, grease or other contaminants and clean if necessary. When installing new parts, lubricate them with clean engine oil or clean diesel fuel only.

SPECIFICATIONS

DESCRIPTION	N·m	Ft. Lbs.	In. Lbs.
Fuel Filler Tube Clamp	4	—	35
Fuel Injectors Retaining Bolts	33	24	—
Fuel Injector Tubes at Fuel Injectors	28	21	—
Fuel Injector Fuel Tubes at Fuel Rail	5	—	44
Fuel Injector Fuel Tubes at Fuel Rail	PLUS 75° TURN
Fuel Line Fittings at Filter Housing	35	25	—
Fuel Fittings at Pump	24	17	—
Fuel Line Clamp Bolt	15	—	133
Fuel Quantity Solenoid	7	—	62
Fuel Rail Nuts	25	18	—
Fuel Tank Bolts	61	45	—
Fuel Water/Separator Mounting Nuts	25	18	—
High Pressure Fuel Feed Tube at Fuel Rail	5	—	44
High Pressure Fuel Feed Tube at Fuel Rail	PLUS 75° TURN
High Pressure Fuel Tubes at High Pressure Pump	28	21	—
High Pressure Injection Pump Blocker Nuts	25	18	—
High Pressure Injection Pump Nuts	25	18	—
High Pressure Injection Pump Sprocket Nut	88	65	—

SPECIAL TOOLS

	1023 - Puller Originally Shipped In Kit Number(s) 8678.
	8534B - Fixture, Driveline Support Originally Shipped In Kit Number(s) 8534, 8534B, 8849, 9565.
	8978A - Decay Tool, Fuel
	9340 - SAE Fuel Pump Lock Ring Wrench Originally Shipped In Kit Number(s) 9327, 9327CC, 9397, 9575.
	VM.1055 - Locking Tool Originally Shipped In Kit Number(s) 9599.