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Unread 07-09-2013, 07:44 PM   #1
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1997 ZJ 
Join Date: Dec 2012
Location: Plainview, New York
Posts: 6
Change fuel pump

So I just had a mechanic work on my 97 zj And he told me I needed to get the fuel pump changed. There is problems with the jeep that it suddenly loses power and sometimes It won't start and I smell gas fumes . Is changing the fuel pump an easy fix that I can just buy the part and be able to do it with my buddy or will I have to have it professionally done which will end up costing me more?

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Unread 07-09-2013, 08:06 PM   #2
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1997 ZJ 
Join Date: Dec 2008
Location: Sweet Home, Alabama
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it's not too difficult.

run most of the fuel out of it.. spray the strap bolts with penetrating oil a day or two before you start. if you have a hitch spray those too. drop tank, clean it out good with kerosene. be careful with fill tube.
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Unread 07-10-2013, 06:05 AM   #3
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1998 ZJ 
Join Date: Aug 2011
Location: The Abyss, MD
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It's very easy.
Unplug electrical cords, unbolt hose clamps on filler and vent tubes, unbolt tank straps with jack and wood holding it up. Lower it slowly. Unscrew old pump and put the new one in. Be careful when you screw the cap back on making sure the O ring is seated properly. Replace the fuel pressure regulator at the same time.

Like said above, drive it until you think there is no gas left in the tank. Makes it a lot easier.
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Unread 07-10-2013, 06:49 AM   #4
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1996 ZJ 
Join Date: Jan 2012
Location: Central, Ohio
Posts: 3,492
On my 96 4.0 I found it easier to get to the filler tank hoses/clamps off if you remove the driver's side rear plastic wheel well flap which is only held on my 3-4 screws. And spray the filler tube with some PB too and will make the hoses easier to remove.

Couldn't get to the rusted clamps on the hoses on the tank itself so I just pulled the hoses through the frame with rags stuck in the hose ends. Made it easier to remove the metal exhaust shield on passenger side which is held on by three 10mm headed bolts.

Washed my tank out with soap/water but one problem is that it's a bear to get it all out since there's a baffle in front of the hoses inside the tank so it won't just pour out. Also the tank hole is recessed. Finally mopped the rinse water out with a rag and let it dry in the sun before installing.

As others have said it's best to use a floor jack with piece of plywood which fits between the tank straps. My strap bolts were rusted so bad had to use a lot of PB/wire brush and kept going forward/backward so rust wasn't building up on the nut threads. Also hold these bolts at the top with vise grips so you don't twist them out of the body. Only have to loosen them about half way and then lift the curved part of the bolt out of the slot in the body at the top.

Don't believe you're going to find any better price on a new pump assembly than this new Bosch 67649 for $120 with free shipping. The fuel regulator and check valve are built into the assembly while it comes with a new filter on the top. Bosch is the OE replacement on fuel pumps and mine runs real quiet. The vendor (e-herko) is reliable and others here have had real good luck using them. Good luck!
96 4.0 ZJ Laredo, 2004 4.7L WJ Limited, 93 4.0 XJ (spare), 96 4.0 XJ (son's)

-Stalling ZJ? 12 things to check before replacing a sensor; the Dirty Dozen
-Crankshaft position sensor multimeter test. & video of testing.
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Unread 07-10-2013, 08:07 AM   #5
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2000 WJ 
Join Date: Jul 2006
Location: forum/f310/, UT
Posts: 4,508
Also, don't be afraid to tighten down the plastic lock ring. PO on my buddy's ZJ replaced the pump and only tightened it down hand tight, after a little driving around we noticed that any time he parked facing down hill the tank would leak fuel. Thankfully he didn't put the hitch or skid back on, so it was a quick fix dropping the tank and snugging the lock ring back on with a flathead screwdriver and hammer.
His: '00 WJ 4.7 Limited- stock

Hers: '03 WJ 4.7 V8- IRO 3", 245/75/16 Duratracs
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Unread 07-10-2013, 09:43 AM   #6
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1997 ZJ 
Join Date: Dec 2012
Location: Plainview, New York
Posts: 6
Before I get into changing the fuel pump I also believe the problem in my 97 zj might have a bad ignition coil. Jeep while driving or idling suddenly stalls out. Then sometimes it may take while till engine turns overs . The battery is new as well as new spark plugs, new distributor, changed catalytic converter . I would like to know if I should change fuel pump of ignition coil
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Unread 07-10-2013, 10:00 AM   #7
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1994 ZJ 
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Location: Old Town, Maine
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There you go. Complete guide right there. The one in the guide is a '97 too, not that it makes much of a difference.
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Unread 07-10-2013, 11:29 AM   #8
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1997 ZJ 
Join Date: May 2013
Location: Dallas, Georgia
Posts: 43
It is very easy i have it down to being able to do it uninstall to install in less than an hour. make sure that you replace the gasket with a new one.
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