Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2004 Jeep Wrangler Sahara, AutomaticFACTORY OEM SERVICE PROCEDURE
Fuel Pump Module: Installation
Fuel tank removal will be necessary for fuel pump module removal.
CAUTION:
Whenever the fuel pump module is serviced, the module gasket must be replaced.
- Thoroughly clean locknut threads and mating fuel tank threads. Use a soap/water solution. Do not use carburetor cleaner to clean threads.
- Using new gasket, position fuel pump module into opening in fuel tank.
- Apply clean water to locknut threads.
- Position locknut over top of fuel pump module.
- Rotate module until arrow is pointed toward front of vehicle (12 o'clock position). This step must be done to prevent float/float rod assembly from contacting sides of fuel tank.
- Install Special Tool 6856 to locknut.
- Tighten locknut to 74 N.m (55 ft. lbs.) torque.
- Rotate fuel filter/fuel pressure regulator until its fitting is pointed to 10 o'clock position.
- Install fuel tank. See FUEL TANK .
Factory Service Tools
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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.