Jeep 200 Cherokee, Service Manual

Page: 1354 / 2119

(8) Install protective cap to pressure test port fit-
ting (if equipped).
(9) Install cable routing bracket to intake mani-
fold.
(10) Connect throttle cable at throttle body.
(11) Connect speed control cable at throttle body (if
equipped).
(12) Connect automatic transmission cable at
throttle body (if equipped).
(13) Install air tube (or duct) at top of throttle
body.
(14) Install fuel tank cap.
(15) Connect negative battery cable to battery.
(16) Start engine and check for fuel leaks.
FUEL INJECTORS
REMOVAL
(1) Remove fuel rail. Refer to Fuel Injector Rail
Removal in this section.
(2) Disconnect clip(s) that retain fuel injector(s) to
fuel rail (Fig. 32).
INSTALLATION
(1) Install fuel injector(s) into fuel rail assembly
and install retaining clip(s).
(2) If same injector(s) is being reinstalled, install
new o-ring(s).
(3) Apply a small amount of clean engine oil to
each injector o-ring. This will aid in installation.
(4) Install fuel rail. Refer to Fuel Rail Installation.
(5) Start engine and check for fuel leaks.
FUEL TANK
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT FUEL PRESSURE EVEN WITH THE ENGINE
OFF.
THIS PRESSURE MUST BE RELEASED
BEFORE SERVICING FUEL TANK.
Two different procedures may be used to drain fuel
tank (lowering tank or using DRB scan tool).
The quickest draining procedure involves lowering
the fuel tank.
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 in this group for
procedures. Attach end of special test hose tool num-
ber 6541, 6539, 6631 or 6923 at fuel rail disconnec-
tion (tool number will depend on model and/or engine
application). Position opposite end of this hose tool to
an approved gasoline draining station. Activate fuel
pump and drain tank until empty.
If electric fuel pump is not operating, tank must be
lowered for fuel draining. Refer to following proce-
dures.
REMOVAL
(1) Disconnect negative battery cable at battery.
(2) Release fuel system pressure. Refer to the Fuel
System Pressure Release Procedure in this group.
(3) Raise and support vehicle.
(4) If Equipped: Remove fuel tank skid plate. Refer
to Group 23, Body for procedures.
(5) Remove 4 fuel hose shield mounting bolts and
remove fuel hose shield (Fig. 33) from body.
(6) Remove fuel tank fill hose and vent hose
clamps at fuel tank filler tube (Fig. 34). Remove both
hoses at fuel filler tube (Fig. 34).
(7) Remove exhaust tailpipe heat shield mounting
bolts and remove shield.
CAUTION: To protect fuel tank from exhaust heat,
this shield must reinstalled after tank installation.
(8) Place a hydraulic jack to bottom of fuel tank.
WARNING: PLACE A SHOP TOWEL AROUND FUEL
LINES TO CATCH ANY EXCESS FUEL.
(9) Disconnect fuel supply line from fuel extension
line near front of fuel tank (Fig. 35). Refer to Fuel
Tubes/Lines/Hoses and Clamps in this group. Also
refer to Quick-Connect Fittings for procedures.
(10) Disconnect EVAP canister vent line near front
of tank (Fig. 35).
Fig. 32 Fuel Injector Mounting
1 – INLET FITTING
2 – FUEL INJECTOR RAIL
3 – CLIP
4 – FUEL INJECTOR
XJ
FUEL SYSTEM 14 - 19
REMOVAL AND INSTALLATION (Continued)