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Old 09-24-2011, 03:48 PM   #1
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Unhappy New Fuel Pump...Now Won't start!

My fuel level sensor had failed so I replaced the entire fuel pump/sending unit etc on my 1993 Jeep YJ. I have a 20 gallon plastic tank and a 2.5L Engine.

After installing pump, I tested it with 12V signal to make sure gas pump was working properly and to prime the pump. Before bolting the tank back in place, I made all connections and tried to crank the Jeep. It will not start!

I labeled the hoses, so I believe that they are right, however, if anyone has a diagram of hoses routing, I would like to check it. Additionally looking for any other suggestions.

P.S. It was running fine before replacement, just wanted the fuel guage to work and could not get that part by itself.

Help!

The Houston Wrangler

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Old 09-24-2011, 04:01 PM   #2
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Originally Posted by TheHoustonWrangler View Post
My fuel level sensor had failed so I replaced the entire fuel pump/sending unit etc on my 1993 Jeep YJ. I have a 20 gallon plastic tank and a 2.5L Engine.

After installing pump, I tested it with 12V signal to make sure gas pump was working properly and to prime the pump. Before bolting the tank back in place, I made all connections and tried to crank the Jeep. It will not start!

I labeled the hoses, so I believe that they are right, however, if anyone has a diagram of hoses routing, I would like to check it. Additionally looking for any other suggestions.

P.S. It was running fine before replacement, just wanted the fuel guage to work and could not get that part by itself.

Help!

The Houston Wrangler

Does it not turn over? Or what?
Not starting is kind of vague...

I'd say: Make sure you have the proper hoses in (Just follow them. The out hose should run straight to a fuel filter on the inside of the frame on the driver's side. At least that's how it is on my 4.0)
Also, make sure that it's actually plugged in.

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Old 09-24-2011, 04:18 PM   #3
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Thanks IDSKoT for quick reply.. It turns over fine. Was running fine before swap. Just will not fire. Shot some starter fluid in intake and it fired up fine. Not getting fuel. Will verify that the OUT hose goes straight into the Fuel filter and that pump is plugged in. Pretty sure they are both correct, but doesn't hurt to check the simple stuff first. Will advise.
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Old 09-24-2011, 04:43 PM   #4
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Houston, Im working on the same issue on my 95 today. I was going to make my own thread but if you dont mind Id like to tag along on this one. on the 20 gal tank, the return is towards the front of the tank and the feed sits alittle behind it.
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Old 09-24-2011, 05:22 PM   #5
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On our 94 the pickup and return are different size ... But just barely. Kinda suprised you were err able to hook everything up with it on the ground. My lines and stuff are way too short for that. The hot and ground on the pump are different size terminals I think as well. Id just double double check everything. Do you hear the pump prime when you torn the ignition to on
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Old 09-25-2011, 07:32 PM   #6
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DBPapa... checked leads. Pump is priming when ignition turned on. When I spray gas or starting fluid into the intake, the Jeep fires right up and runs until fuel is exhausted. Clearly just not getting fuel. Checked to make sure hose from larger fuel pump outlet is going directly into the fuel filter canister. Recheck vent hoses. Still no success.
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Old 09-25-2011, 09:58 PM   #7
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Make sure nothing is getting pinched
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Old 09-25-2011, 11:28 PM   #8
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well my first question is where did you get the new pump?
some aftermarkets are faulty straight out of the warehouse. seen it many times.
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Old 07-14-2012, 11:52 AM   #9
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I would like to join this thread since we are having the same issue. I have a 93 YJ 4.0L and we just replaced the fuel filter and sending unit all one piece and no fuel is being pushed through the lines at the tank. Someone mentioned about fuel pumps being bad from the factory to begin with so I guess we will assume maybe that is the problem since the Jeep was running fine before and now won't crank but if it does crank won't turn over. Any recommendations to ensure we get a good fuel pump the second time around?
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Old 07-14-2012, 01:26 PM   #10
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Take the line off before it goe into the filter. have someone turn the key on to check that the pump wrks... it will spray a lot if its working right.

if you got gas there move up to where fuel line hooks to fuel rail, take line off and try again.
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Old 07-14-2012, 01:55 PM   #11
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Take the line off before it goe into the filter. have someone turn the key on to check that the pump wrks... it will spray a lot if its working right. if you got gas there move up to where fuel line hooks to fuel rail, take line off and try again.

I had the same problem before. I bought a brand new fuel pump and assembley. The PLUG was bad on the new pump. (the external plug, outside the tank) I had to cut it off and splice on the old plug. You can check it with a meter for continuity, but its confusing because the gas level indicator will also give you a reading. I pulled mine from the tank and hooked it up directly to my battery to finally figure it out.

The other problem you could be having is your hoses are backwards. You might have the feed and return lines mixed up. That would not allow fuel to get to the engine.

Unfortunately, I have experianced both issues...
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Old 07-14-2012, 04:46 PM   #12
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Had same issue with plug. It would dislodge the pins inside the connector and give false readings and no pump. Had to splice and hard wire. Autozone pumps work but connectors are just a hair different in sizes
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Old 07-14-2012, 08:39 PM   #13
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similar problems with pins backing out. Driller

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fuel gauge , fuel pump , fuel sending unit , starting problems

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