Removing and installing the fuel pump on your Jeep Wrangler requires careful work to avoid damage to the fuel and vapor lines. Also, a special note should be made of the alignment marks on the fuel/pump assembly during installation for proper operation of the sending unit and pump. The following steps are based on the 2003 to 2006 Jeep Wrangler models.
Park your Jeep Wrangler in a safe place with a level surface and open the hood.
Relieve the fuel system pressure by depressing the small stem inside the Schrader valve located on the fuel supply line just before the first fuel injector. The valve is similar to the air valve on bicycle tires. Place a shop rag on the valve as you relieve the fuel pressure to catch the squirt of fuel. Disconnect the black, negative battery cable and loosen the filler cap.
Drain the fuel tank through the filler hose using a hand siphon pump, if necessary. Loosen the wheel lugs on the rear, right-hand side tire and raise the rear of the vehicle using a floor jack and safely support it on two jack stands.
Remove the tire and the wheel house liner. Remove the evaporative emissions (EVAP) control canister support bracket, behind the right/rear side wheel. Unplug the electrical connector located on the left and front of the fuel tank and the two vapor lines next to the electrical connector by pressing the lock tabs. Disconnect the fuel supply line next to the electrical connector and the two vapor and overfill hoses next to the filler hose.
Place a floor jack underneath the fuel tank for support, then remove the 3 tank mounting nuts located at the front of the tank and the 4 mounting nuts at the rear using a wrench or ratchet and socket; then lower the tank and the protective plate underneath the tank as a single unit. If necessary, disconnect the fuel filler hose at the tank by removing the clamp using a screwdriver or ratchet and socket.
Remove the pump module locknut using tool number 6856, if you have a 2003-2004 model. Lift the fuel pump/sending unit assembly off the tank and install the new pump. Reinstall the assembly in the tank using a new O-ring seal gasket. Install the locknut, making sure the arrow on the module points toward the front of the Jeep. Also, rotate the fuel pressure regulator fitting--the center ring on the pump/sending unit assembly--until its mark is at the 10 o'clock position, facing towards the front of the vehicle.
Make a note of the arrow position on top of the pump/sending unit assembly if you have a 2005-06 model. Remove the locking from the assembly using tool 9340. Lift the fuel pump module from the tank and install the new pump. Install the pump assembly in the tank with a new O-ring seal gasket. Install the locking on the module and rotate the ring by hand until the embossed arrow points to the center aligning mark on top of the assembly--the same position as before disassembly. Tighten the locking using tool 9340.
Connect the filler hose to the tank; then lift the fuel tank into its mounting position and tighten the tank mounting nuts. Remove the floor jack from underneath the Jeep and connect the two vapor lines, fuel supply line and electrical connector at the left and front of the tank. Connect the two vapor and overfill hoses next to the filler hose and install the EVAP control canister bracket and wheel house liner.
Install the tire and lower the vehicle. Finish tightening the wheel lugs. Fill the fuel tank. Connect the black negative battery cable. Start the engine and check for leaks and fuel pump operation.
