Fuel System: Removal & Installation Jeep Compass I рестайлинг 2

REMOVAL

Scheme 64

Note. Wrap shop towels around hose to catch any gasoline spillage.

Scheme 65

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Scheme 70

1. Release the fuel system pressure.
2. Disconnect the negative battery cable.
3. Disconnect the fuel line from the fuel rail. Refer to «FITTING, QUICK CONNECT»(ref-612715-S40934319052014043000000) .
4. Fuel line removed from the fuel rail.
5. Unlock and disconnect the electrical connectors from the fuel injectors.
6. Remove the wiring harness from the fuel rail studs.
7. Remove the 2 bolts from the fuel rail.
8. Remove the fuel rail and injectors from the intake manifold.
9. Fuel rail removed from intake manifold.
10. Remove fuel injectors from fuel rail.

INSTALLATION

1. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector.
2. Install the fuel injectors to the fuel rail.
3. Install injector into cup of fuel rail.
4. Install retaining clip and check to ensure fuel injector is properly seated. Fuel rail assembly.
5. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place.
6. Install the 2 bolts to the fuel rail. Tighten fuel rail bolts to 27 N.m (20 ft. lbs.).
7. Install the wiring harness to the fuel rail.
8. Connect and lock the electrical connectors to the fuel injectors.
9. Connect the fuel line to the fuel rail. Refer to «FITTING, QUICK CONNECT»(ref-612715-S40934319052014043000000)
10. Connect the negative battery cable.
11. Use the Scan Tool Fuel System Test to pressurize the fuel system. Check for leaks.

Scheme 71

Scheme 72

1. Remove the fuel pump module. Refer to «MODULE, FUEL PUMP, REMOVAL»(ref-612715-S04992928672014043000000) .
2. Disconnect the fuel level sending unit electrical connector (1). CAUTION: Do not touch the terminals or the resistor card. CAUTION: Do not pull the fuel level sending unit by the wires or the float arm.
3. Using your finger, press the fuel level sending unit snap tab to the left while gently pushing up on the bottom of the fuel level sending unit and remove.

Scheme 73

Scheme 74

1. Position the new fuel level sending unit to the fuel pump module reservoir.
2. Gently push the fuel level sending unit down until the snap tab (2) engages. CAUTION: Ensure the fuel level sending unit wires are routed so they do not get pinched between the coils of the spring when the module is completely compressed.
3. Connect the fuel level sending unit electrical connector.
4. Install the fuel pump module. Refer to «MODULE, FUEL PUMP, INSTALLATION»(ref-612715-S18662309542014043000000) .

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Scheme 87

1. Release fuel system pressure (refer to «FUEL SYSTEM PRESSURE RELEASE PROCEDURE»(ref-612715-S11840219172014043000000) ).
2. Remove the air cleaner lid, disconnect the inlet air temperature sensor and makeup air hose.
3. Disconnect and isolate the negative battery cable.
4. Remove the rear seat cushion.
5. Remove plastic cover.
6. Clean top of tank to remove loose dirt and debris.
7. Use Fuel Pump Lock Ring Wrench (special tool #9340, SAE Fuel Pump Lock Ring Wrench) or equivalent to remove left side fuel pump module lock ring. NOTE: wrap shop towels around hoses to catch any gasoline spillage.
8. Disconnect electrical and fuel lines from module.
9. Drain fuel from tank.
10. Raise and support the vehicle.
11. Remove the fuel tank skid plates, if equipped.
12. Remove exhaust system.
13. For All Wheel Drive vehicles, remove drive shaft.
14. Remove stay bars. NOTE: For All Wheel Drive vehicles the rear driveline module must be lowered to remove fuel tank assembly.
15. Tie rear driveline module to suspension crossmember.
16. Support rear driveline module.
17. Remove 3 mounting bolts and lower rear drive line module from suspension crossmember.
18. Module lowered.
19. Remove splash shield.
20. Remove splash shield.
21. Disconnect vapor canister line.
22. Disconnect filler tube recirculation vent line and purge line. CAUTION: There may be fuel in the fill tube. Remove hose carefully to reduce fuel splash.
23. Disconnect fuel tank from rubber fill hose.
24. Remove parking brake cable mounting from fuel tank strap.
25. Remove parking brake cable mounting from fuel tank strap.
26. Support fuel tank.
27. Remove bolts from the fuel tank straps.
28. Remove fuel tank from vehicle.

Scheme 88

1. Install fuel tank straps.
2. Raise fuel tank into position.
3. Position fuel tank straps. Tighten fuel tank strap bolts to 47 N.m (34.5 ft. lbs.). Remove transmission jack. Ensure straps are not twisted or bent.
4. Install parking brake cable.
5. Install parking brake cable.
6. Connect filler tube recirculation vent line and purge line.
7. Connect fuel fill tube to tank inlet. Tighten hose clamp to 4 N.m (35 in. lbs.).
8. Connect vapor canister line.
9. Install rear driveline module. Refer to «INSTALLATION»(ref-612704-S06567409382014043000000) .
10. Install stay bars. Refer to «INSTALLATION»(ref-612704-S06567409382014043000000) .
11. Install splash shield.
12. Install splash shield.
13. Install exhaust system (1).
14. Install drive shaft (2). Refer to «INSTALLATION»(ref-612702-S26511483572014043000000) .
15. Install the fuel tank skid plates, if equipped.
16. While holding the pump module in position, install lock ring and use Fuel Pump Lock Ring Wrench (special tool #9340, SAE Fuel Pump Lock Ring Wrench) or equivalent to tighten lock ring.
17. Connect electrical connector and lock the connector.
18. Connect the fuel line (refer to «FITTING, QUICK CONNECT»(ref-612715-S40934319052014043000000) ).
19. Install plastic cover.
20. Install rear seat cushion.
21. Reconnect the negative battery cable.
22. Install the air cleaner lid, connect the inlet air temperature sensor and makeup air hose.
23. Fill fuel tank with clean fuel. Use a scan tool to pressurize the system and check for leaks.

1. Install fuel filler tube. Connect fuel filler tube hose to fuel tank neck and tighten clamp to 4 N.m (35 in. lbs.).
2. Install fuel filler tube mounting screw and tighten to 9 N.m (79.5 in. lbs.).
3. Connect filler tube vent line.
4. Install the inner splash shield.
5. Install rear tire.
6. Lower vehicle.
7. Install fuel filler tube cap.
8. Install the negative battery cable.
9. Install the air cleaner lid and makeup air hose.

Note. It is necessary to remove the primary and secondary pumps to remove and install the pump transfer tube.

1. Remove the Primary Fuel Pump Module Refer to «MODULE, FUEL PUMP, REMOVAL»(ref-612715-S04992928672014043000000) .
2. Remove the Secondary Fuel Pump Module Refer to «MODULE, FUEL PUMP, REMOVAL»(ref-612715-S04992928672014043000000) .
3. Remove the fuel pump transfer tube (2) from the fuel tank.

Note. It is necessary to remove the primary and secondary pumps to remove and install the pump transfer tube.

1. Position the fuel pump transfer tube (2) into the fuel tank. NOTE: Make sure the tube is not twisted while aligning the fittings (1) to the tank openings.
2. Install the Primary Fuel Pump Module Refer to «MODULE, FUEL PUMP, INSTALLATION»(ref-612715-S18662309542014043000000) .
3. Install the Secondary Fuel Pump Module Refer to «MODULE, FUEL PUMP, INSTALLATION»(ref-612715-S18662309542014043000000) .

1. Release the fuel pressure. Refer to «FUEL SYSTEM PRESSURE RELEASE PROCEDURE»(ref-612715-S11840219172014043000000) .
2. Disconnect the negative battery cable.
3. Disconnect the electrical connectors from the fuel injectors.
4. Fuel line connection at fuel rail.
5. Remove the fuel line from the fuel rail.
6. Remove wire harness from fuel rail mounting studs.
7. Remove the 2 bolts to the fuel rail at the lower manifold.
8. Remove the fuel rail.
9. Remove clip holding fuel injector to fuel rail.
10. Remove fuel injector clip and fuel injector from fuel rail.

1. Apply a light coating of clean engine oil to the upper O-ring.
2. Install injector in cup on fuel rail.
3. Install retaining clip.
4. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector.
5. Insert fuel injector nozzles into openings in lower intake manifold. Seat the injectors in place.
6. Tighten fuel rail mounting screws to 27 N.m (20 ft. lbs.).
7. Install wiring harness clips to the fuel rail mounting studs.
8. Attach electrical connectors to fuel injectors, refer to «STANDARD PROCEDURE - INJECTOR CONNECTOR»(ref-612715-S19190054052014043000000) for electrical connector installation.
9. Connect fuel supply tube to fuel rail.
10. Connect the negative battery cable.
11. Use the scan tool to pressurize the fuel system. Check for leaks.

Scheme 89

1. Disconnect and isolate negative battery cable at battery.
2. Disconnect the electrical connector from accelerator pedal.
3. Remove mounting nuts and remove accelerator pedal from the mounting studs.

Scheme 90

1. Install the accelerator pedal and mounting nuts to the mounting studs. Tighten the nuts in a mandatory torque sequence to 29 N.m (21 ft. lbs.).
2. Connect the electrical connector from accelerator pedal.
3. Connect negative battery cable, tighten nut to 5 N.m (45 in. lbs.).
4. Use a scan tool and perform the APPS RELEARN function.

1. Install manifold absolute pressure (MAP) sensor to intake manifold.
2. Tighten screw to 8 N.m (71 in. lbs.).
3. Connect electrical connector to sensor.
4. Connect the negative battery cable.

Scheme 91

The upstream oxygen sensor threads into the outlet flange of the exhaust manifold.

The downstream heated oxygen sensor threads into the system depending on emission package.

Note. Pre-fill the fuel filter with clean diesel fuel.

1. Install the fuel filter and securely tighten.
2. Install the fuel filter shield (3). Tighten bolts (1) to 6 N.m (53 in. lbs.).
3. Connect the fuel heater harness connector (2).
4. Install air cleaner housing.
5. Connect the negative battery cable.
6. Start engine and inspect for leaks.

1. Install the fuel rail (1). Tighten bolts (2) to 9 N.m (80 in. lbs.).
2. Connect the fuel rail pressure sensor wire harness connector (1).
3. Connect the fuel rail pressure regulator wire harness connector (2). NOTE: Any time a high pressure fuel tube has been loosened or disconnected, that high pressure fuel tube must be replaced.
4. Install the new high pressure feed tube (4) to fuel rail. Tighten fuel tube (4) to 33 N.m (24 ft. lbs.).
5. Install the new high pressure fuel tubes (2) at fuel injectors (1) and fuel rail (3).
6. Tighten the high pressure fuel tubes (2) at fuel injectors (1) and fuel rail (3) to 7 N.m (62 in. lbs.).
7. Tighten the high pressure fuel tubes (2) at fuel injectors (1) and fuel rail (3) to 33 N.m (24 ft. lbs.).
8. Install bolt (1) securing the high pressure feed tube. Tighten bolt (1) to 9 N.m (80 in. lbs.).
9. Using new sealing washers, position fuel rail return line to the rail (2). Tighten banjo bolt (1) to 32 N.m (24 ft. lbs.).
10. Position fuel injector wire harness and push down to lock in place.
11. Connect the fuel injector wire harness connector (2).
12. Connect the Camshaft Position Sensor (CMP) sensor (1) wire harness connector.
13. Install the engine cover (1).
14. Connect the negative battery cable.

Note. The fuel rail pressure regulator is not serviceable component. If diagnosis has lead you to replace the fuel rail pressure regulator, then the fuel rail has to be replaced.

1. To remove the fuel rail. Refer to «RAIL, FUEL, REMOVAL»(ref-612715-S32118528922014043000000) .

1. Install the fuel rail pressure sensor (2) onto fuel rail (3). Tighten to 35 N.m (26 ft. lbs.).
2. Connect the fuel rail pressure sensor harness connector (1).
3. Connect the negative battery cable.

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Scheme 98

1. Remove fuel pump module. Refer to «MODULE, FUEL PUMP, REMOVAL»(ref-612715-S13519943522014043000000) .
2. Depress retaining tab and remove the fuel pump/level sensor connector from the BOTTOM of the fuel pump module wire harness connector. NOTE: The pump module harness on TOP of flange is not serviceable or removable.
3. Remove the wedge lock from the wire harness connector. 1 - TERMINAL REMOVAL TOOL 2 - FUEL LEVEL SENSOR CONNECTOR
4. Using the (special tool #C-4334, Extractor) tool (1) terminal remover or equivalent, remove terminals from level sensor harness connector (2). 1 - FUEL LEVER SENSOR
5. Remove wire from wire retainer.
6. Depress the tab and unlock the sender card.
7. Slide level sensor out of channel in module.

Scheme 99

Scheme 100

1. Wrap wires into groove in back of level sensor.
2. While feeding wires into guide grooves (1). 1 - FUEL LEVER SENSOR
3. Slide level sensor up into channel until it snaps into place. Ensure tab at bottom of sensor locks in place.
4. Install wire into wire retainer.
5. Install level sensor wires in connector. Push the wires up through the connector and then pull them down until they lock in place. Ensure signal and ground wires are installed in the correct position refer to the appropriate Wiring information.
6. Install locking wedge on connector. 1 - ELECTRICAL CONNECTOR
7. Push connector up into bottom of fuel pump module electrical connector (1).
8. Install fuel pump module. Refer to «MODULE, FUEL PUMP, INSTALLATION»(ref-612715-S39318905692014043000000) .

Scheme 101

1. Disconnect the negative battery cable.
2. Remove the engine cover (1).
3. Disconnect the fuel rail pressure sensor wire harness connector (2).
4. Release the four lock tabs (1) lift up and position aside engine wire harness (2).
5. Remove the fuel rail pressure sensor (2) from fuel rail (1).

1. Install the fuel rail pressure sensor (2) onto fuel rail (1). Tighten sensor (2) to 35 N.m (26 ft. lbs.).
2. Position the wire harness (2) and push down to lock tabs (1).
3. Connect the fuel rail pressure sensor wire harness connector (2).
4. Install the engine cover (1).
5. Connect the negative battery cable.

1. Disconnect the negative battery cable.
2. Remove the engine cover (1).
3. Disconnect the Camshaft Position Sensor (CMP) (1) wire harness connector.
4. Disconnect the fuel injector wire harness connector (2).
5. Lift up on fuel injector wire harness and position aside.
6. Disconnect the turbocharger actuator (1) wire harness connector.
7. Disconnect the turbocharger exhaust temperature sensor (1) wire harness connector.
8. Disconnect the turbocharger exhaust temperature sensor wire harness connector (2) from bracket.
9. Remove the two bolts (3) and position aside the ground wires.
10. Disconnect the glow plug module wire harness connector (1).
11. Release the four lock tabs (1) lift up and position aside engine wire harness NOTE: After removing high pressure fuel tubes, seal off fuel injectors and fuel rail with protective caps to ensure cleanliness.
12. Remove high pressure fuel tubes (2) at fuel injectors (1) and fuel rail (3) and discard high pressure fuel tubes.
13. Install protective caps onto the fuel injector and fuel rail.

Note. Any time a high pressure fuel tube has been loosened or disconnected, that high pressure fuel tube must be replaced.

1. Remove the protective caps from the fuel rail and fuel injectors.
2. Install a new high pressure fuel tubes (2) at fuel injectors (1) and fuel rail (3).
3. Tighten the high pressure fuel tubes (2) at fuel injectors (1) to 7 N.m (62 in. lbs.).
4. Tighten the high pressure fuel tubes (2) and fuel rail (3) to 7 N.m (62 in. lbs.).
5. Tighten the high pressure fuel tubes (2) at fuel injectors (1) to 33 N.m (24 ft. lbs.).
6. Tighten the high pressure fuel tubes (2) and fuel rail (3) to 33 N.m (24 ft. lbs.).
7. Reposition the engine wire harness and push down to lock tabs.
8. Connect the glow plug module wire harness connector (1).
9. Reposition ground wires and tighten bolts (3) to 9 N.m (80 in. lbs.).
10. Connect the turbocharger exhaust temperature sensor wire harness connector (2) to bracket.
11. Connect the turbocharger exhaust temperature sensor (1) wire harness connector.
12. Connect the turbocharger actuator (1) wire harness connector.
13. Position the fuel injector wire harness and push down to lock in place.
14. Connect the fuel injector (2) wire harness connector.
15. Connect the Camshaft Position Sensor (CMP) (1) wire harness connector.
16. Connect the negative battery cable.
17. Start engine and inspect for leaks.
18. Install the engine cover (1).

Scheme 102

1. The fuel drain tubes (1) connect to the back of all four injectors (2). These tubes are used to return unused fuel from the fuel injectors (2) to the tank.

Scheme 103

1. Disconnect the negative battery cable.
2. Remove the engine cover (1).
3. Release the lock tab (1) and disconnect the fuel injector return line from each fuel injector and position aside.

Scheme 104

Scheme 105

1. Replace the O-ring (2) on the fuel injector return lines (1).
2. Reposition and install the fuel injector return line and set the lock tab (1).
3. Connect the negative battery cable.
4. Start the engine and check for leaks.
5. Install the engine cover (1).

1. Disconnect the negative battery cable.
2. Disconnect the accelerator pedal harness connector (1).
3. Remove mounting nuts (3) band the accelerator pedal (2).

1. Install the accelerator pedal. Using the tightening sequence shown in illustration. Tighten nuts to 16 N.m (142 in. lbs.).
2. Connect the accelerator pedal harness connector (1).
3. Connect negative battery cable.

1. Install the boost pressure sensor (3) into mixing chamber (1). Tighten bolts (4) to 8 N.m (71 in. lbs.).
2. Connect the boost pressure sensor wire harness connector (2).
3. Install the engine cover (1).
4. Connect the negative battery cable.

1. Install the camshaft position sensor (1). Tighten bolt (2) to 6 N.m (53 in. lbs.).
2. Connect the cam position sensor wire harness connector (1).
3. Install the engine cover (1).
4. Connect the negative battery cable.

1. Install the crankshaft position sensor (1). Tighten bolt (2) to 8 N.m (71 in. lbs).
2. Connect the crankshaft position sensor wire harness connector (1).
3. Connect the lower charge air tube (3) from the charge air cooler (CAC) inlet (5) and securely tighten clamp (4).
4. Install the lower charge air tube (3) to the upper charge air tube (1) to turbocharger and lock the lock ring in place.
5. Install the negative battery cable.

Scheme 106

1. Remove the engine cover (1).
2. Remove air inlet duct (2).
3. Disconnect the negative battery cable.
4. Remove cooling fan assembly. Refer to «FAN, COOLING, REMOVAL»(ref-612716-S32355363712014043000000) .
5. Remove bolts (1) and the heat shield (2).
6. Disconnect the fuel temperature sensor wire harness connector (2).
7. Remove the fuel temperature sensor (1).
8. Remove and discard sealing washer and O-ring.

Scheme 107

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Scheme 109

1. Replace the O-ring seal (1) and sealing washer (2).
2. Install the fuel temperature sensor (1). Tighten to 15 N.m (133 in. lbs.).
3. Connect the fuel temperature sensor wire harness connector (2).
4. Install the heat shield (2). Tighten bolts (1) to 9 N.m (80 in. lbs.).
5. Install coolant fan assembly. Refer to «FAN, COOLING, INSTALLATION»(ref-612716-S03927958782014043000000) .
6. Install the power steering reservoir (2). Tighten bolt (1) to 12 N.m (106 in. lbs.).
7. Install the radiator closure panel (2) and securely tighten the bolts (1), screws (3).
8. Install the air inlet duct (1).
9. Connect the negative battery cable.
10. Install the engine cover (1).

1. Install the Mass Air Flow (MAF) sensor (2) to the air cleaner housing (1). Tighten nuts (3) to 6 N.m (53 in. lbs.).
2. Connect the turbocharger inlet tube (2) to the MAF sensor (4) and securely tighten clamp (1).
3. Connect the MAF sensor wire harness connector (3).
4. Connect the negative battery cable.
5. With the scan tool, navigate to Miscellaneous Functions and perform the MAF Sensor Replacement Initialization routine.