Repair Procedure

This repair involves selectively erasing and reprogramming the Powertrain Control Module (PCM) on TJ vehicles with new software (calibration changes) and installing a revised fuel rail on all listed vehicles.

NOTE:
THE PCM REPROGRAMMING PROCEDURE APPLIES TO TJ VEHICLES. PROCEED TO STEP 11 FOR XJ & AN VEHICLES.

1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up.

2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.

3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.

4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU.

5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU.

6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM.

7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming.

If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair.

8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process.

NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.





9. Type the necessary information on the "Authorized Software Update Label" P/N 4669020. Attach the label to the PCM and cover the label with the clear plastic overlay.





10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label.

11. Remove the fuel tank filler cap.

12. Disconnect the battery negative cable.

13. Perform the fuel pressure release procedure to relieve any fuel system pressure that may be present on the inject rail. If you are not familiar with this procedure, refer to group 14 in the appropriate service manual.

14. Remove the air cleaner crossover tube.

15. Remove and tag each injector harness connector to identify them to the correct cylinder.

16. Remove the fuel supply line from the fuel rail.

17. Remove the automatic transmission throttle cable, if equipped, to gain access to the fuel rail.

18. Remove the fuel rail mounting bolts and remove the fuel rail.

19. Transfer the injectors from the original fuel rail to the new rail.

20. Lubricate the injector O-rings with clean engine oil and insert the new fuel rail into the manifold.

21. Install the fuel rail and tighten the mounting bolts to 11 Nm (100 in. lbs.).

22. Connect the injector harness connectors to the injectors making sure to install them to correct injector tagged earlier.

23. Connect the fuel line to the fuel rail.





24. Remove the plug from the intake manifold in the location shown.

25. Install the vacuum fitting provide in the kit in the location of the removed plug.

26. Install the vacuum tube and connect it to the pressure regulator and the fitting on the manifold.

27. Connect the battery negative cable.

28. Install the fuel tank filler cap.

29. Select and install the appropriate VECI label over the original label with the revised label indicated on the conversion sheet supplied in the fuel rail kit.