Jeep Tech Bulletin - Fuel Pump/Gas Tank - no. 14-06-97

[Groundhog]

It seems I never get to post anything on this forum unless it has to do with Jeep trouble, but I'm really stumped with this one guys...

Has anyone experienced fuel pump/gas tank issues with their 97 TJ, 96ZJ, or 94 -96 XJ's that has to do with multiple fuel pump failures?

I have a bulletin from Jeep outlining this condition (which they are fully aware of) and it states:

"that in 'rare' cases where multiple fuel pump failures have occurred on the same vehicle, a build up of residue may have accumulated on the inside of the fuel tank. The presence of this residue is not easily identifiable. The residue can pass through the in-tank filter and contaminate the pump rotor. Consideration should be made to replace the fuel tank to avoid future problems."

This will be my third gas tank and fourth or fifth fuel pump in this ZJ. This time I got stuck in Mystic Seaport. $300.00 to get towed home!

My question is, is there an alternative fuel delivery system for Jeeps that anyone here is aware of such as aftermarket tanks, moving the fuel pump out of the gas tank, a high performance pump that you have had luck with , etc. ? Every time this happens it costs $600.00 to fix and I only get a year or two out of the repair.

I have never experienced anything like this before on any type of vehicle.

Any suggestions? (please don't say sell the ZJ, there's no turning back now.)

Thanks in advance.

Groundhog :furious:
860-621-8413
nejeep@ardvrk.com

 

[CJKarl]

get AAA

 

[Groundhog]

That WAS with AAA!, Just the basic coverage though. That's changing today.

My concern is that once she hits the trails, I'm dead in the water if this happens again. Last time I was out in the wild we were 8 miles off road in Pittsburg, New Hampshire, up a fire trail that leads to one of the forestry's fire towers. Not a place to be stuck. 18 moose and 1 black bear that day.

As far as gas goes, I normally buy at HESS, this time I fueled up at two different gas stations.

I'm on my way to the shop where I had her towed, so I'll keep you posted. Removing the tank should be a charm with a full tank of gas!


Groundhog
860-621-8413
nejeep@ardvrk.com

 

[CrzyFrlssJeep]

As a mechanic I have seen all of those problems with quite a few "chrysler" made product with a plastic gas tank.

Yes....the only real fix is to replace the gas tank.

I've even had to change a few pumps in ZJ's with full tanks of gas, it's easy with a tranny jack.

From what I've heard in the grapevine is, they (chrysler) has a class action lawsuit pending on this problem.

 

[Groundhog]

Well,
Normally I wouldn't want money from anyone. My wife and I just aren't "sue" people, but boy, would I like to get reimbursed for what this has cost me so far!

Do you know where I can find out more about this class action suit? Even getting my tow expenses recouped would be a help. This is money that was ear-marked for suspension and tires.

I haven't heard anything from the mechanic, so I'm not going to jump the gun. Maybe it's something else altogether.

The tech manual I have also says the crank position sensor and distributor can look like a fuel problem. I'm hoping it's one of those, a whole lot cheaper and they were on my list of things to replace anyway.

Groundhog
860-621-8413
nejeep@ardvrk.com

 

[CrzyFrlssJeep]

CPS and distibutor would mean "no spark"....

As for finding the info you need, I've heard that Chrysler is being very tight lipped about it (I wonder why) :roll:

In any case good luck on getting that ZJ fixed and running again

 

[beaker]

Would a steel gas tank from an older ZJ / WJ fit? The steel ones seem to last much better. Maybe an aftermarket larger tank. Once the std fuel pump is in a steel tank it would probably last just fine.

 

[Groundhog]

As of right now, I don't have spark or fuel, but that is exactly what happened last time.

Apparantly it's something to do with the ASD relay. My Haynes manual says it cuts out the power to the fuel pump, injectors, ignition coil, and heated oxygen sensor. I guess it's activated by loss of ignition(distributor) signal, cam or crank reference sensor signal. I'm not sure how it's all tied together. Sounds like one feeds the other and vise versa.



So far, the checking I've done hasn't turned up any steel aftermarket tanks. I will make some calls tomorrow on that. I've emailed quite a few fuel cell manufacturers, but none have gotten back to me.

I spoke to my mechanic after my last post and tomorrow we're replacing the Crank Position Sensor and the Cam Position Sensor, then we'll go from there. At least we'll eliminated those items.

I really appreciate the input, thank you all.

Stay tuned... :!:

 

[kevinc]

here is a link to a www.mallcrawlin.com/forum writeup on bypassing the stock pump. This site is like NAGCA, but more tech heavy and advanced. They are pretty harsh to newbie questioners, so make sure you search before asking.

linky http://www.mallcrawlin.com/forum/viewtopic.php?t=199

Kevin C.

 

[Groundhog]

Thanks.

I'll look around.

 

[Groundhog]

Well, it's official. A bad cam position sensor can look like a fuel pump problem, at least on a 96 ZJ.

I had the guys change the cam pos. sensor and bang, she started right up. The codes in the PCM were pointing to fuel, crank and cam position. I'm glad we didn't drop that tank again for nothing.

So let's see, that's $300.00 for the tow and $277.00 for labor - all for a $68.00 part. Gotta love your Jeep! Why do we do this? :?

Thanks to all who posted, very much appreciated.

Groundhog

 

[Groundhog]

Another update.

For anyone found in this predicament - fuel pump/tank issues, I have found a site that makes an external pump & filter combination.

Go to: www.hesco.biz/cgi-bin/ez-catalog/cat_display.cgi?4X364946#s

That supercharger kit is lookin pretty good too!