Injector swap, 00', P0203 code
Thread Starter
CF Veteran

Joined: Jul 2009
Posts: 1,005
Likes: 3
Year: 1992
Model: Cherokee
Engine: Inline 6 4.0L
My 00' has heat soak issues. I just put a hood scoop on, and it's venting the heat well. Today my CEL came on and it read the P0203 code.
Cylinder 3 fail open code. All of the wiring looks good. It happened after driving 1 hour, parking for 15, then restarting it. I know the heat soak sputter... This was not it. While I was driving, the throttle was not very responsive at all. I let her cool down and she's idling much better. I'm going to limp home.
So. I've already searched everything on the web, and I can't find a good write up for replacing fuel injectors on a 2000. Do they just pull out? I'm fully aware of the O ring importance, and of the opinions of different injectors.
**** what important steps are there
-disconnect battery!
-remove fuel cap?
-what else?
Cylinder 3 fail open code. All of the wiring looks good. It happened after driving 1 hour, parking for 15, then restarting it. I know the heat soak sputter... This was not it. While I was driving, the throttle was not very responsive at all. I let her cool down and she's idling much better. I'm going to limp home.
So. I've already searched everything on the web, and I can't find a good write up for replacing fuel injectors on a 2000. Do they just pull out? I'm fully aware of the O ring importance, and of the opinions of different injectors.
**** what important steps are there
-disconnect battery!
-remove fuel cap?
-what else?
Thread Starter
CF Veteran

Joined: Jul 2009
Posts: 1,005
Likes: 3
Year: 1992
Model: Cherokee
Engine: Inline 6 4.0L
http://www.jeepforum.com/forum/f9/fu...55-1-a-867654/
Great video on this forum about the fuel/ac quick link disconnect tool in use
Great video on this forum about the fuel/ac quick link disconnect tool in use
http://www.jeepforum.com/forum/f9/fu...55-1-a-867654/
Great video on this forum about the fuel/ac quick link disconnect tool in use
Great video on this forum about the fuel/ac quick link disconnect tool in use
Thread Starter
CF Veteran

Joined: Jul 2009
Posts: 1,005
Likes: 3
Year: 1992
Model: Cherokee
Engine: Inline 6 4.0L
And don't know if you saw, but there's a write-up by Dukie564 in the XJ write-up section (although I think that was done on a 96). I'll check back when I finally pull the trigger (prob tomorrow eve, if rain holds off here). If you beat me to the punch, I would also be grateful for any observations or hints that pop up
Also FWIW, my own dumb question post from a couple weeks ago sparked an interesting conversation about injectors between "the pros." (that thread was called "replacing fuel injector").
Thread Starter
CF Veteran

Joined: Jul 2009
Posts: 1,005
Likes: 3
Year: 1992
Model: Cherokee
Engine: Inline 6 4.0L
So I got my injectors in today. I've been crawling all over this site, and reading the user manual to make sure i don't f anything up!
2000 4.0l I6
6 refurbished BOSCH 3rd gen. 4 hole injectors (6 for $129.99) from Precision Auto Injectors
1: remove negative battery terminal and secure
2: unscrew gas cap
3: tape cylinder #'s on the injector wires
4: remove air intake
5: for my year, I had to remove the throttle cable bracket and cables that straddle #3 injector. 13/32 bolts
6: unscrew cap on fuel pressure let off port on the fuel rail. place a rag below. (I had no pressure in my fuel line. My #3 was failing/ leaking pressure?
7: disconnect fuel line: you need a quick connect remover "universal a/c and fuel line remover tool ($5). you remove the fuel line clip and insert the tool into the quick connect and pull. I lost just a few drops (still a fair amount in the rail itself.
8: disconnect injector wires
9: unscrew the 4 13/32 bolts securing the fuel rail
10: rock n pull the fuel rail straight out carefully
Then I took some time to clean the fuel injector ports. I could see that there was "gunk" all up in there, and it didn't look like the O ring would seat well. I carefully used q-tips to remove build up. Once fairly clean, I used some triflow on a q-tip to remove the rest of the gunk on the O ring seat. that worked very well.
Then I went in the shop and removed all of the fuel injector clips and injectors. I replaced all of the injectors (push in) in the correct orientation and replaced clips
then I went out and replaced the fuel rail with injectors, taking my time.
I did the reverse order to complete the project. To re-prime the fuel rail with fuel, I turned my key to AUX power to activate the fuel pump. I then released pressure on the fuel rail port. I did this 3 times until it vented liquid gas. Then I cranked it for 3 seconds until it fired.
It was pretty straight forward. 1 hour for 6 injectors!
I noticed that my idle is very very smooth!
2000 4.0l I6
6 refurbished BOSCH 3rd gen. 4 hole injectors (6 for $129.99) from Precision Auto Injectors
1: remove negative battery terminal and secure
2: unscrew gas cap
3: tape cylinder #'s on the injector wires
4: remove air intake
5: for my year, I had to remove the throttle cable bracket and cables that straddle #3 injector. 13/32 bolts
6: unscrew cap on fuel pressure let off port on the fuel rail. place a rag below. (I had no pressure in my fuel line. My #3 was failing/ leaking pressure?
7: disconnect fuel line: you need a quick connect remover "universal a/c and fuel line remover tool ($5). you remove the fuel line clip and insert the tool into the quick connect and pull. I lost just a few drops (still a fair amount in the rail itself.
8: disconnect injector wires
9: unscrew the 4 13/32 bolts securing the fuel rail
10: rock n pull the fuel rail straight out carefully
Then I took some time to clean the fuel injector ports. I could see that there was "gunk" all up in there, and it didn't look like the O ring would seat well. I carefully used q-tips to remove build up. Once fairly clean, I used some triflow on a q-tip to remove the rest of the gunk on the O ring seat. that worked very well.
Then I went in the shop and removed all of the fuel injector clips and injectors. I replaced all of the injectors (push in) in the correct orientation and replaced clips
then I went out and replaced the fuel rail with injectors, taking my time.
I did the reverse order to complete the project. To re-prime the fuel rail with fuel, I turned my key to AUX power to activate the fuel pump. I then released pressure on the fuel rail port. I did this 3 times until it vented liquid gas. Then I cranked it for 3 seconds until it fired.
It was pretty straight forward. 1 hour for 6 injectors!
I noticed that my idle is very very smooth!
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Great instructions. Despite my own research to date, I hadn't heard about priming the fuel rail after completion so I glad you laid it all out. Was it really hard to seat the rail after you replaced them? (I'll allot myself 3 hrs for the project haha)
Thread Starter
CF Veteran

Joined: Jul 2009
Posts: 1,005
Likes: 3
Year: 1992
Model: Cherokee
Engine: Inline 6 4.0L
It wasn't hard to seat them. I was very careful. They don't go in very far, ~1/2" if that. So the injector holes are small. Take your time cleaning the ports when the injectors are out. 1, to clean the I ring seats. 2, to make sure you don't bump some grease on the O ring, tip of injector, or in chamber. Don't rock it in. Straight push in. Same for installing in fuel rail. Once finally seated and bolted, I gave each a slight twist back and fourth to feel the seals. They were smooth.
Thread Starter
CF Veteran

Joined: Jul 2009
Posts: 1,005
Likes: 3
Year: 1992
Model: Cherokee
Engine: Inline 6 4.0L
You could probably just crank on the key to prune it, but I did the priming on my own intuition. Not sure if it's the best way. Worked well for me. The manual didn't give that info.
And I drained the fuel rain into my gas tank :-)
And I drained the fuel rain into my gas tank :-)
Seasoned Member
Joined: Sep 2018
Posts: 337
Likes: 33
From: Latonia,Kentucky
Year: 2000
Model: Cherokee (XJ)
Engine: 4.0 fresh rebuild
I have stock injectors (1 hole) I'll send them to you if you want I only have 5 (got 6but one is cracked ) you pay shipping. Ah hell I'll pay shipping.Merry February.....
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