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Old 11-08-2009, 11:12 AM   #1
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Fuel system continuously leaking

Hey guys, i keep having major problems with my fuel system, and i cant figure out whats wrong!! I have a 97 wrangler sport 4.0l with 5 speed. and original fuel pump.

First symptom was the hard starting. So i installed a check valve right after the fuel pump.

Then my fuel line going to the fuel rail popped off (nylon to metal part), i replace that and it was good for a week.

Then my nylon fuel hose after the check valve sprung a pinhole leak, i changed that, all was good.

Next few days, i smell gas, its in the engine side again, my 2 fuel injectors were leaking, so i replaced all the o-rings, but one injector still leaked. I got a replacement from the junkyard, and replaced it. No problems for 2 days.

Then my rear nylon fuel hose sprung another leak!! The hose just blew out! So i replaced that, again.

Next day, i smelled gas, again. This time up front, another fuel injector leak, but this was the main body leaking. So i replaced another one.

Now, everything is ok, but i have a feeling i will have another leak! Any ideas on what to look for to remedy this problem, or am i just having a string of bad luck!

Frank

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Old 11-08-2009, 11:21 AM   #2
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Sounds like your fuel pressure regulator isn't doing it's job. As much time, money, effort as you have put in it might be a good idea to invest in a pressure guage to see what kind of fuel pressure your getting. You also might have some sort of restriction in the return line.

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Old 11-08-2009, 01:16 PM   #3
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Wow sounds like your fuel pressure is way too high. I would check or have the pressure checked.
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Old 11-08-2009, 01:24 PM   #4
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Originally Posted by coyote_94yj View Post
Sounds like your fuel pressure regulator isn't doing it's job. As much time, money, effort as you have put in it might be a good idea to invest in a pressure guage to see what kind of fuel pressure your getting. You also might have some sort of restriction in the return line.
Where us the fuel pressure regulator on a 97? I don't have a return line on the fuel rail and I don't see any regulator on the fuel rail.

Frank
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Old 11-08-2009, 01:41 PM   #5
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This is from a 99 FSM.

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Old 11-08-2009, 07:37 PM   #6
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Originally Posted by ultravorx View Post
Where us the fuel pressure regulator on a 97? I don't have a return line on the fuel rail and I don't see any regulator on the fuel rail.

Frank
Frank,

You mentioned in your OP that you installed a check valve just after the fuel pump. Was that the original factory check valve that looks like the gadget in Coyote's message? If so that is the check valve/fuel pressure regulator/fuel filter.

What are you lubricating the injector o-rings with? I just installed a new set of Bosch III injectors in my '02 and literature said to use dish soap, even named a brand (maybe Joy?) and cautioned against using motor oil. I used silicon grease and no leaks.

Literature also said you don't have to reinstall the c-clips but I wouldn't advise it. I noticed the injectors positions were not to my liking without the c-clips so I installed them on the Bosch injectors.
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Old 11-08-2009, 07:44 PM   #7
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I was just thinking, the fuel lines would have to be able to handle full fuel pump pressure for safety reasons and if the pressure was much higher than specifations you would notice it in the Jeep's performance, it would run rich or maybe not at all. Did you kink any of the hard plastic lines?
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Old 11-08-2009, 10:40 PM   #8
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I was just thinking, the fuel lines would have to be able to handle full fuel pump pressure for safety reasons and if the pressure was much higher than specifations you would notice it in the Jeep's performance, it would run rich or maybe not at all. Did you kink any of the hard plastic lines?
i've been getting about 200 miles per tank, and since the problems im still getting the same mileage. the jeep was running great but maybe a bit rich. all the lines are kink free as well.

As far as the o ring lube, i just used a small dab of grease which helped them seat really easily.


frank
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Old 11-09-2009, 02:18 PM   #9
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i've been getting about 200 miles per tank, and since the problems im still getting the same mileage. the jeep was running great but maybe a bit rich. all the lines are kink free as well.

As far as the o ring lube, i just used a small dab of grease which helped them seat really easily.


frank
You should purchase a cheap fuel pressure gauge and put that issue to rest, especially if you think it's running rich. 200 miles per tank may be right if you have big tires or high numerical ratio gears.

When my jeep was new (02 bought in 01) I would get 275 miles to the tank, highway driving at 60 - 65 mph. That has fallen off a bit partly because of increased speed limits and maybe (or maybe not) the 10% ethanol in the gasoline.

I decided to give the new Bosch 3 injectors a try after reading some good stuff about them. I think my gas milage is back! Can't wait to take a trip so I can check the mpg. Only cost $125 for all six injectors and no core charge. The main visual different is the 4 injector ports compared to 1 in the OEM injectors. Check 'em out here. Good luck keeping your fuel in the lines.

Jeep Only - Fuel Injector Connection

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