2003 Jeep Wrangler X, AutomaticFACTORY OEM SERVICE PROCEDURE

Checking Fuel Delivery

NOTE: For connector identification, see CONNECTOR IDENTIFICATION . For component location, see COMPONENT LOCATIONS . For circuit identification and wiring diagram, see WIRING DIAGRAMS . After each repair procedure has been completed, reconnect all components.
  1. Turn ignition on. With DRBIII®, actuate the ASD Fuel System test. Listen for fuel pump operation at fuel tank. It may be necessary to use a mechanics stethoscope. Does the Fuel Pump operate? If yes, go to next step. If no, go to step  5.
    2. WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released.
  2. Turn the ignition off. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Install a fuel pressure gauge to the fuel rail test port. See Fig 1. With the ignition on and the DRBIII®, actuate the ASD Fuel System test and observe the fuel pressure gauge. Fuel pressure specification should be 44.2-54.2 psi (3.1-3.7 kg/cm2 ). Choose a conclusion that best matches your fuel pressure reading. If fuel pressure is below specification, stop all actuations and go to next step. If fuel pressure is within specification, the test is complete. Stop all actuations. If fuel pressure is above specification, stop all actuations. Fuel pressure regulator is defective. Replace the fuel filter/fuel pressure regulator. See FUEL PUMP MODULE under FUEL SYSTEMS in REMOVAL & INSTALLATION - WRANGLER article. Perform POWERTRAIN VERIFICATION TEST VER-1 under VERIFICATION TESTS in SELF DIAGNOSTICS - WRANGLER article.
  3. Release fuel pressure. Raise and support vehicle. Disconnect fuel pressure line from fuel pump module at fuel tank. Connect Fuel Line Pressure Test Adapter Hose (6539) between disconnected fuel line and fuel pump module. Connect fuel pressure gauge to fuel line adapter hose. Turn ignition on. With DRBIII®, actuate the ASD fuel system test and note fuel pressure. Fuel pressure should be 44.2-54.2 psi (3.23-3.96 kg/cm2 ). If fuel pressure is as specified, stop all actuations. Release fuel pressure, and repair or replace fuel supply line. Perform POWERTRAIN VERIFICATION TEST VER-1 under VERIFICATION TESTS in SELF DIAGNOSTICS - WRANGLER article. If fuel pressure is not as specified, stop all actuations and go to next step.
  4. Release fuel pressure. Remove fuel pump module and inspect fuel inlet strainer. See FUEL PUMP MODULE under FUEL SYSTEMS in REMOVAL & INSTALLATION - WRANGLER article. If fuel inlet strainer is plugged, replace fuel pump inlet strainer. Perform POWERTRAIN VERIFICATION TEST VER-1 under VERIFICATION TESTS in SELF DIAGNOSTICS - WRANGLER article. If fuel inlet strainer is not plugged, replace fuel pump module. Perform POWERTRAIN VERIFICATION TEST VER-1 under VERIFICATION TESTS in SELF DIAGNOSTICS - WRANGLER article.
  5. Turn ignition off. Disconnect the fuel pump module harness connector. Turn the ignition on without the engine running. With the DRBIII®, actuate the ASD Fuel System test. Using a 12-volt test light connected to ground, probe the (A141) Fuel Pump Relay Output circuit at the Fuel Pump Module harness connector. Does the test light illuminate brightly? If yes, stop all actuations and go on to next step. If no, stop all actuations and go to step  8.
  6. Turn ignition off. Disconnect fuel pump module harness connector. Using a test light connected to 12-volts, backprobe the (Z211) Fuel Pump ground circuit at the Fuel Pump Module harness connector. Does the test light illuminate brightly? If yes, go to next step. If no, repair the excessive resistance in the (Z211) Fuel Pump Ground circuit. Perform POWERTRAIN VERIFICATION TEST VER-1 under VERIFICATION TESTS in SELF DIAGNOSTICS - WRANGLER article.
  7. If there are no possible causes remaining, replace the Fuel Pump Module. Perform POWERTRAIN VERIFICATION TEST VER-1 under VERIFICATION TESTS in SELF DIAGNOSTICS - WRANGLER article.
  8. Turn the ignition off. Remove the Fuel Pump Relay from the PDC. Using a 12-volt test light connected to ground, backprobe the Fuel Pump Relay Fused B+ circuit at the PDC. Does the test light illuminate? If yes, go to next step. If no, repair the Fuel Pump Relay Fused B+ circuit for an open. Check for open fuse in the PDC. Perform POWERTRAIN VERIFICATION TEST VER-1 under VERIFICATION TESTS in SELF DIAGNOSTICS - WRANGLER article.
  9. Measure the resistance of the Fuel Pump Relay Output circuit from the relay connector to the fuel pump module connector. Is the resistance below 5.0 ohms? If yes, replace the Fuel Pump Relay. Perform POWERTRAIN VERIFICATION TEST VER-1 under VERIFICATION TESTS in SELF DIAGNOSTICS - WRANGLER article. If no, repair the Fuel Pump Relay Output circuit for an open. Perform POWERTRAIN VERIFICATION TEST VER-1 under VERIFICATION TESTS in SELF DIAGNOSTICS - WRANGLER article.
Fig 1: Identifying Fuel Line Pressure Test Adapter
G00079722Courtesy of DAIMLERCHRYSLER CORPORATION
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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