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Old 07-06-2014, 08:58 PM   #1
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97 Wrangler (4.0L, Manual) - Won't Start On First Attempt

My '97 Wrangler with a 4.0L engine isn't starting on the 1st attempt and sometimes not on the 2nd attempt. I've figured out that if I turn it on and let the fuel pump run then turn it off and then on again to let it run again.. if I do this 3-4 times it will start on first crank.

So my guess is the fuel pump or the regulator is going bad.

Does anyone have any other ideas on how to determine which one, or if it's something else, before I try and source some parts and figure out how to replace them?

Also, any suggestions on which parts to get? Should I get Mopar for these or will aftermarket from O'Reilly's work?

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Old 07-06-2014, 09:12 PM   #2
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Replace both, most fuel pump kits like the Bosch I recently installed include both. Avoid cheap store brands or Spectra or Airtex. They don't last long enough to be worth the effort to install. My previous Spectra lasted less than three years and that's a better brand than Airtex or store brands. I'd go strictly with Bosch or Mopar. eBay has good inexpensive sources for Bosch and www.wermopar.com is a good source for discounted Mopar parts.

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Old 07-06-2014, 09:16 PM   #3
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Thanks Jerry,

While I was researching I noticed that there are two possible fuel pumps for my year... There's s 15 gallon and a 19 gallon. I've never put in over 14 gallons so I'm not sure which I have. Guess I'll have to let it drain down 1 more time and see what I can put in it.

Also looking it appears Bosch only makes one.. so makes me wonder if I'm going to have problems with the Bosch...
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Old 07-06-2014, 09:22 PM   #4
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Unless your TJ was a very basic stripped down model, odds are good it has the 19 gallon tank. The fuel gauge is notoriously pessimistic, indicating far less fuel than is really present. My tank always still has 3-4 gallons in it well after the low fuel light comes on
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Old 07-06-2014, 09:25 PM   #5
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You'll be fine with the Bosch. There was only one size gas tank, they just left the filler neck sticking down an extra 3-4 inches on the "14 gallon" tank so that the pumps would shut off early... If you actually have one of the fake 14's, cut a few inches off the filler tube and you'll magically have a normal sized tank. The fake 14 sender unit may read "Full" until you burn off the first 4 gallons though.
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Old 07-06-2014, 09:33 PM   #6
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Ahhh, thanks for the feedback... This is the Bosch that I found at a pretty good price.

http://amzn.com/B000BZL922

I'm still trying to figure out if it's a complete unit or if I will have to buy other things. Do you guys happen to know? I never trust Amazon reviewers.
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Old 07-06-2014, 09:48 PM   #7
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So my guess is the fuel pump or the regulator is going bad.

Does anyone have any other ideas on how to determine which one, or if it's something else, before I try and source some parts and figure out how to replace them?
The odds are severely stacked in favor of the fuel pressure regulator. There is a 10-cent rubber seal that gets hard and quits sealing completely.

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Ahhh, thanks for the feedback... This is the Bosch that I found at a pretty good price.

http://amzn.com/B000BZL922

I'm still trying to figure out if it's a complete unit or if I will have to buy other things.
That's not the complete pump assembly.
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Old 07-06-2014, 09:50 PM   #8
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The odds are severely stacked in favor of the fuel pressure regulator. There is a 10-cent rubber seal that gets hard and quits sealing completely.
Well after looking at what I have to do to replace one, I agree with Jerry, I should just replace them both. So now I just have to figure out if that Amazon link is the right part and has everything I need.
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Old 07-06-2014, 10:00 PM   #9
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So now I just have to figure out if that Amazon link is the right part and has everything I need.
I can assure you that it does not. That's not a guess.

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Well after looking at what I have to do to replace one, I agree with Jerry, I should just replace them both.
Keep in mind that the pump you have now is probably going to last longer that most of the pumps offered in the aftermarket. Sometimes fixing what isn't broke just opens up another can of worms.

Here is the Bosch version of the complete assy:

http://www.summitracing.com/parts/BCH-67659/
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Old 07-06-2014, 10:06 PM   #10
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That's just the little replacement pump module you'd have to install into the housing. It doesn't include the fuel pressure regulator. I only paid $120 delivered for my complete ready to install Bosch fuel pump and fuel pressure regulator on eBay. It came from very good company in Florida called Herco, look for them on eBay.

The complete kit I paid $120 for from Herko looks like this...



Your 97 takes a different model fuel pump than my 04 so I don't know if Herko sells one for your 97 but they're worth a look. They came through for me with a rush shipment I needed at no extra charge.
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Old 07-06-2014, 10:19 PM   #11
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I only paid $120 delivered for my complete ready to install Bosch fuel pump and fuel pressure regulator on eBay. It came from very good company in Florida called Herko, look for them on eBay.
Unless you are shopping for gunpowder, looking for a company called Herko would almost certainly be more productive.

http://www.herko.com/herko_fuelpumps.html
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Old 07-06-2014, 10:33 PM   #12
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In the mean time just turn the key on twice before attempting to start it and it will prime the fuel line. its the rubber little check valve ball that wont hold pressure to the fuel rail. me and my 14 yr old changed out the fuel pump in 2 hrs. it was easy be gentle on the electrical plug to unplug it. little tricky, you tube it. and make sure the pump comes with the oem style wiring plug. you dont want chopped wires getting wet under the tank. OMG just saw how old this post was, Less wine!!!
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Old 07-06-2014, 10:39 PM   #13
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In the mean time just turn the key on twice before attempting to start it and it will prime the fuel line. its the rubber little check valve ball that wont hold pressure to the fuel rail.
Fact is, a leaking FPR relief valve will produce the exact same results as a leaking fuel pump check valve. And, if you replace the entire assembly, you really don't know which caused the problem.
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Old 07-07-2014, 10:20 AM   #14
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Looking for the fuel pump kit I found these....

NAPA Part Number: BSH N67659 (15 Gallon)
NAPA Part Number: BSH N67655 (19 Gallon)

So if I have the 19 gallon tank, should I get the 67655? Listed above is the 67659.

After everything posted in this thread, I thought it wouldn't matter.. but every time I search it's not so clear.


Edit: I should also mention found nothing on eBay for cheaper than anywhere else.
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Old 07-07-2014, 11:16 AM   #15
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That Napa p/n includes "BSH" which hopefully means it is made by Bosch. As I said above, unless your TJ is a stripped down model, I'd bet on it having the 19 gallon tank.
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Old 07-07-2014, 12:53 PM   #16
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That Napa p/n includes "BSH" which hopefully means it is made by Bosch. As I said above, unless your TJ is a stripped down model, I'd bet on it having the 19 gallon tank.
Yeah they are both Bosch.. just one is 655 and one is 659. I'm going to go with the 655 and get it from SummitRacing. Seems to be the best price I can find for it.
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Old 07-07-2014, 01:11 PM   #17
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Yeah I can't find it in stock anywhere..

SummitRacing is out...
RockAuto is out...
All local parts stores are out...

Guess I'll try and find someone on eBay I trust... I hate eBay.
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Old 07-07-2014, 03:53 PM   #18
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Yeah I can't find it in stock anywhere..

SummitRacing is out...
RockAuto is out...
All local parts stores are out...
But FPR's are a readily available.

Why? Because that's the part that fails.
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Old 07-07-2014, 04:35 PM   #19
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You'll be fine with the Bosch. There was only one size gas tank, they just left the filler neck sticking down an extra 3-4 inches on the "14 gallon" tank so that the pumps would shut off early... If you actually have one of the fake 14's, cut a few inches off the filler tube and you'll magically have a normal sized tank. The fake 14 sender unit may read "Full" until you burn off the first 4 gallons though.
Actually Vent Tube, not filler tube.

Changed out my 15 gallon pump setup for the 19 and it was a 5 minute deal to cut the tube.
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Old 07-07-2014, 05:44 PM   #20
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But FPR's are a readily available.

Why? Because that's the part that fails.
I used to think that way too. But the last two times this problem happed in my two TJs it was the fuel pump. The first time it happened to my previous TJ it was the FPR. I still have one perfectly good FPR left over from it not fixing the issue and the new fuel pump coming with a new FPR.

Which is why I now recommend replacing them both together... I don't like guessing wrong/playing the odds when it involves having to drop the gas tank.
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Old 07-07-2014, 08:59 PM   #21
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I used to think that way too. But the last two times this problem happed in my two TJs it was the fuel pump. The first time it happened to my previous TJ it was the FPR. I still have one perfectly good FPR left over from it not fixing the issue and the new fuel pump coming with a new FPR. Which is why I now recommend replacing them both together... I don't like guessing wrong/playing the odds when it involves having to drop the gas tank.
This. Still can't find the part anywhere except eBay. :/

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