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Unread 10-08-2006, 10:19 PM   #1
RTst
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Join Date: Mar 2004
Posts: 16
LONG STARTING PROBLEM - SOLUTION<<Sticky it please>>

I would ask if you can sticky this so other can read it. I don't visit the board often as jeep is my wifes ride so I don't get to play around with it too much. Since I visited last I got a bunch of pm's regarding this problem.

As I stated a while back chysler has a cheap kit to resolve the issue of long/hard starting as outlined in their TSB 14-002-01.
Cost of parts is LESS THEN $20 but it requires around 2hrs of charged labour making it pricey to repair, but it's something you can easily do if you are somewhat skilled.

This issue appears on a lot of 1999-2001 jeeps and the problem is a o-ring located in the fuel pump module. To remove it you have to remove the gas tank in order to access the fuel pump module and remove it from the tank.

It took me about 3hrs to do the job, but next time it would take me 1hr probably.

Tools needed:
- 18mm (1/2" drive w/ longer extension impact gun welcome but not a must).
- 13mm for negative battery terminal
- 12mm socket for heatshield nuts
- 7mm socket and ratchet/screwdriver type handle for hose clamps
- Pliers and flat head screwdriver for rear valance clips
- hammer and flat head screwdriver or pry bar so you don't have to use special tool to unscrew the plastic ring around the fuel pump module, you can tap it gently around until you can unscrew it by hand.
- Rags/towels for small fuel spills

I used ramps to drive the rear wheels onto them, but hoist or jackstands will work too.

PLAN AHEAD, RUN YOUR GAS TANK NEAR EMPTY BEFORE DOING THE WORK TO AVOID HAVING TO DRAIN IT


RIGHT HERE AND CLICK SAVE AS
In the zip file, included
- TSB with repair instructions (.pdf file)
- Fuel tank removal/install instructions (.doc Microsoft Word document)
- Fuel Pump Module removal/install instructions (same .doc Microsoft Word document as above)
- Part number for the kit 05019308AA everything you need is included in that kit! - LIST PRICE IS LESS THEN $15US

TSB TEXT BELOW:
SUBJECT:
Longer Than Normal Engine Crank Time Prior To Engine Start
OVERVIEW:
This bulletin involves the repair of the fuel pump module.
MODELS:
1999 - 2001 (WJ) Grand Cherokee
2001 (WG) Grand Cherokee
NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH
A GASOLINE ENGINE.
SYMPTOM/CONDITION:
The customer may experience a longer than normal engine cranking time prior
to engine start. This condition may be caused by fuel pressure loss due to
a worn sealing ring within the fuel module.
NOTE: QUALITY ANALYSIS HAS REVEALED THAT A WORN SEALING RING IS THE
PRIMARY REASON WHY THE FUEL MODULE IS REPLACED FOR FUEL PRESSURE
LEAK DOWN. IT IS RECOMMENDED THAT THE SEALING RING BE REPLACED
BEFORE A FUEL MODULE ASSEMBLY REPLACEMENT IS ATTEMPTED.
DIAGNOSIS:
1. Start and run the engine. Verify normal fuel system pressure of 339
kPa +/- 34 kPa (49.2 psi +/- 5 psi).
2. Stop the engine. Verify that the fuel system pressure does not fall below
207 kPa (30 psi) in less than five (5) minutes.
3. If the fuel pressure does not fall below 207 kPa (30 psi) in less than five (5)
minutes, then the long crank time may not be due to the fuel system. Further
diagnosis must be made to the entire engine system.
4. If fuel pressure does fall below 207 kPa (30 psi) in less than five (5) minutes, then
refer to TSB 14-05-99 for additional fuel system diagnostic assistance.
5. If diagnosis determines that the cause of the fuel system pressure loss is due to the fuel
pump module, then inspect the fuel pump module part number label for its assembly
14-002-01 -2-
build date code (Julian date). The part number label is affixed to the fuel pump module
wire harness (pigtail), near the electrical connector to the body wire harness.
6. Inspect the bottom row of numbers on the fuel module label and locate the module
build date code. Determine the date of build (Julian date) for the fuel module
assembly. The first two numbers in the date code indicate the calendar year (1998
= 98, 1999 = 99, 2000 = 00, 2001 = 01), and the remaining three numbers in the
code (1 to 365) represent the day of the calendar year (Fig. 1).
Fig. 1
7. If the module part label indicates that the fuel module assembly was built on or before
November 04, 1999 (Julian date of 99308), then a spacer must be used with the sealing
ring. The split washer in the repair kit is used as the sealing ring spacer.
NOTE: FAILURE TO USE THE SPLIT WASHER, AS A SPACER FOR THE
SEALING RING (WHEN REQUIRED), MAY CAUSE EXCESSIVE MOVEMENT
AND DAMAGE TO THE SEALING RING.
8. If the module part label indicates that the fuel module assembly was built after
November 04, 1999 (Julian date of 99308), then a spacer must NOT be used with
the sealing ring. The split washer in the repair kit can be discarded.
NOTE: SOME REPLACEMENT FUEL PUMP MODULES, BUILT AFTER NOVEMBER
04, 1999 (DATE CODE 99308), HAVE BEEN USED TO REPLACE FUEL MODULES
BUILT PRIOR TO NOV. 04, 1999. IT IS IMPORTANT THAT PRIOR TO EACH REPAIR
THE MODULE DATE CODE BE PROPERLY DETERMINED.
9. An ALTERNATE METHOD to determine whether a spacer is required is to
measure the width of the sealing ring gland (Fig. 2).
a. Apply sufficient pressure to hold the poppet firmly in place on top of the fuel outlet
port. To prevent an incorrect measurement, the applied pressure must be on-center.
The poppet can easily tip up if an off-center force is applied to it.
b. Carefully measure the width of the sealing ring gland.
c. If the gland width is between 3.0 and 3.5 mm (0.118 to 0.138 in.), then
a spacer is not required to be installed.
d. If the gland width is 4.0 mm (0.157 in.) or greater, then a spacer is required
to be installed prior to the installation of the new sealing ring. The sealing
ring spacer is 1 mm (0.394 in.) in thickness and is used to prevent excessive
movement (wear) of the sealing ring in the gland.

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Unread 10-08-2006, 10:43 PM   #2
LEDFoot
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1999 WJ 
 
Join Date: Sep 2004
Location: DFW area, Texas
Posts: 762
Awesome... Thanks for sharing that.

I have an _intermittent_ long start, seems to only happen when fuel level in tank is low, I suppose it might be the same thing. Sure wish jeep had put an access hole for the fuel pump module in the trunk...
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Unread 10-08-2006, 11:11 PM   #3
RTst
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Join Date: Mar 2004
Posts: 16
no problem, that kit sat at home for about a month due to other obligations, and wife forgetting to not fill the tank before the weekend.. 70L of fuel is kinda hard syphon

access hole would be nice, it sure would save some time.

I can post the picture of the worn ring, it's really more stretched but it does have some damage. I waited 6hrs (it's pretty cool out tonight), and it started right up. Before it would barely start on the 2nd try and it would sputter for few seconds.

Also, it's not outlined as much as it should be how important it is that when you're done the installation of the ring and once you put the fuel pump together, that you press down on it to see if it springs back freely without snugging on anything. They provide lubricating oil and make sure that you apply it generously over the o ring and all over the shaft (w/o sounding ghey ). It's plastic on plastic contact thats wearing the ring out.
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Unread 10-09-2006, 12:55 AM   #4
10achik
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1999 WJ 
 
Join Date: Sep 2003
Location: STL (IL side)
Posts: 8,341
Good thread...I added your solution to the bottom of the FAQ for this section.
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