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Jeep Grand Cherokee 1993-2004: How to Replace Fuel Pump

Although this isn't the easiest job in the world, you can change the fuel pump on your Grand Cherokee without breaking the bank.

By Jeffrey Smith - September 4, 2015

This article applies to the Jeep Grand Cherokee ZJ and WJ (1993-2004).

If it's time for you to change out your fuel pump, don't fret about how big of a job this is. You can do it on your own in just a couple of hours. The job isn't too difficult, even if you decide to do it the right way and drop the fuel tank. You will save yourself some pain if you can drain the gas or do the job when your tank is almost empty. There is an alternate method that involves cutting a hole in your cargo bay above the pump, but this is not recommended for both safety concerns as well as the possibility of cutting into fuel lines and having to replace more than just the pump. Fuel pumps themselves are not very expensive, but the labor costs will be considerable, so save yourself a lot of dough by doing this job yourself.

Materials Needed

  • Hydraulic floor jack
  • Jack stands
  • Wheel chocks or blocks
  • Flat head and Phillips head screwdrivers
  • Shop rags
  • Catch pan or container for spilled gasoline
  • Replacement tank straps if applicable
  • Wood blocks
  • Vaseline

Step 1 – Disconnect your battery

Whenever you are working in your engine compartment, or any component of the fuel system, it is always a good idea to disconnect your battery. So go ahead and disconnect the negative (black) battery terminal.

Figure 1. Disconnect negative battery terminal.

Warning

Please do this job in a well-ventilated area, and do not smoke or have any heat as well as flame sources in your working area.

Step 2 – Jack up the rear end of your Jeep

Place wheel chocks in front of the front wheels and jack up the rear of your Jeep. Place jack stands in the approved locations and lower the Jeep onto the jack stands.

Figure 2. Use jack stands to hold up the rear of your Jeep.

Pro Tip

Always use jack stands when working under your Jeep. Never use a hydraulic floor jack alone when working under it.

Step 3 – Remove the inner fender

Use a Phillips head screwdriver to remove the left, or driver's side, rear inner fender cover. This will give you access to the fuel filler neck.

Figure 3. Use a Phillips head screwdriver to remove the inner fender screws.

Step 4 – Disconnect filler neck

Use a flat head screwdriver to disconnect the hose clamp from the filler neck and pull off the fuel hose.

Figure 4. Disconnect hose from filler neck.

Step 5 – Disconnect tank vent hose and fuel pump power supply

Use your flat head screwdriver to remove the clip that holds the vent hose to the gas tank. Pull the hose off the tank and then disconnect the quick disconnect of the power supply for the fuel pump.

Figure 5. Slide up the red locking clip and pull apart the quick connect wiring harness.

Step 6 – Remove the tank straps

Place some wood blocks under the gas tank to prevent it from dropping, or use your hydraulic floor jack with some slight pressure on the tank to keep it from falling to the floor. Use a ratchet with extension to unbolt the strap from the frame.

Figure 6. Remove the tank straps to drop the tank.

Step 7 – Lower the tank and remove fuel line from the pump

You don't have a ton of slack in the fuel line from the tank to the fuel pump. Once those straps are off, use the floor jack to lower the tank only about a foot; lower the thank slightly and just enough to get your hands in there to disconnect the fuel line from the top of the fuel pump. You don't need any tools to disconnect this line, since it snaps off with a slight squeeze and a pull.

Figure 7. Disconnect the fuel hose from the fuel pump.

Step 8 – Remove old fuel pump

Once the fuel line is disconnected from the fuel pump, the tank can be completely removed from under the Jeep. Move the tank to a flat area where you have plenty of room to work. The fuel pump is secured into the tank with a locking ring. Turn the ring counterclockwise to loosen and remove it. Set the ring aside and then pull out the old fuel pump.

Figure 8. Once the locking ring is removed, the old fuel pump lifts right out of the tank.

Step 9 – Install new pump

Use some Vaseline around the base of the top of the new fuel pump, so it makes a nice water tight seal against the tank where it sits in there. Take care, when inserting the new pump, that you do not damage the float and the fuel level gauge. Once you have the pump seated into the tank, apply some pressure to make sure it is in all the way and replace the locking ring. Turn it clockwise to lock it in place. Move the tank back under your Jeep on the floor jack and raise it back up into position, about a foot from where it ultimately will go. You will need a new fuel line retaining clip to connect a fuel line to the new fuel pump. Reach back in and re-attach the fuel line to the fuel pump. Raise the tank back into position and reconnect the tank straps. If they appear worn or questionable at all, use two new tank straps. Secure the straps, then reconnect the fuel pump power supply and the venting hose. Reconnect the fuel line to the filler neck and reattach the inner fender wall. Start your Jeep and check for leaks. If none, drop the Jeep and you are all set.

Figure 9. Take care when inserting the new fuel pump.

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