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THE SWAMPY BYPASS
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So you think you have a bad Fuel pump... Here is what I did to mine instead of the old in tank pump.. 1st thing you do is make sure that your fuel pump is the problem.. That means eliminate all other possibilities . Change the fuel fiter First .. Then go to the fuel rail.. On the drivers side of the engine there is a Shraeder valve.. Get a fuel pressure tester from auto zone.. (Rent it if you want..) You should have 39# of fuel pressure with the key on... If you do not . Locate the vacum hose to the Fuel pressure regulator.. (Round thing on the drivers side of the engine at the rear of the fuel rail ON 93-95 models..) With the engine running pull the line.. The engine should keep running .. The reinstall the line.. IF the engine stumbles . Your Regulator could be bad... )On 96 and Up Models your Regulator is on the canister.. Check is the same.. Just harder to do since you have to drop the tank.. Then If your regulator checks out ok or you couldnt get your engine runnig to check it... Do one more simple test just to make sure.... Take a cup of gasoline... Pour a small amount down the throttle body. Get someone to start the engine... If it starts pour a little bit more if it should keep running then wait.. If it stalls without gas... It is probobly your fuel pump.. Step 2 order a fuel pump.. That is a picture of the pump installed on my ZJ.. got it from Jegs.. It is part # is 121-2225 Here is a link to Jegs.. after ordering the pump I cut a hole in the floor.. You can drop your skid and reciever hitch and tank.. But I am Lazy..  Be very carefull your fuel lines are under there.. Then I removed the stock canister .. Visible in the picture.. This will take a large screw driver.(Put it on the ridge and tap the cap loose..) Go under the Jeep and find the plug for the fuel pump and unplug it..Pull off the fuel lines.. ANd remove the canister..  (If you are going to cut the hole ...Email me for demensions. Address is in my Profile..) With the canister out.. Set it on a work surface.. It will take a while but carefully open the top of the canister.. IT is obvious how to do it but be carefull not to break the clips.. (This may require two people but I did it on my own.)  When the canister is cracked open.. You will see the pump.under this filter..  Cut the thin fuel line that holds the pump in. and pull it out.(Disconnect the wires and take them with you.. IT should look like this..  Test the pump on your battery one more time just to be sure.. Now that you are positive the pump is crap.. Throw it as far as you can... Take your new pump and attatch some short wires to it... Test it on the battery.. (Not for long it hurts the pump to run dry..) Once you are sure the new pump is good proceed.. Piece of feul line from the top of the canister to the bottom...  Put that back together... Crawl under the Jeep.. You will see a fuel filter canister Drivers side ( 93-95) Follow the fuel line to the unit body rail right in front of your control arm. Cut the fuel line.. You want to remove about 7 or so inches.. Put the fuel line on both sides of the pump and slide it over the stock hard line.. Use 4 hose clamps to tighten it up.. Do not crush the stock fuel line.. Mount the pump to the inner unit body rail.. LIke above picture.. While you are at it make a small jumper with a loop on both sides and ground the pump to one of the mounting screws..  Take another piece of wire and run it along the fuel line to the plug that you unplugged earlier. The #1 location on the wire is the fuel pump feed.. (I am not going to tell you a color because it may be different.) Take a test probe and find the one thats hot when the key is on.. ON mine its red with a tracer.. Cut the wire in half.. On the engine side of the wire crimp the lead to your pump..  Note the pump makes a noticably whine.. (Typical to any high performance fuel pump.. ) It can be quieted down .. I will post a picture later on how to do that... If you have any questions drop me an Email.. If you have a 96 or newer ZJ/WJ Drop me an email ... Its a little different for you... Thank you for takeing the time out to read this long ass post.. In case you forgot.. Here is the finished look ... and as always.... Wear shoes in your shop....The alternative sucks......  UPDATE: If you want to do this on a post 96 model you will have to add a fuel pressure regulator as well.. -Carl |
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