2002 Jeep Grand Cherokee Fuel Pump Hose Replacement: Your Complete DIY Guide

Replacing a deteriorating fuel pump hose in your 2002 Jeep Grand Cherokee is a critical repair that resolves fuel leaks, prevents fire hazards, and restores engine performance. This comprehensive 1,900+ word guide provides exact, technician-level steps to complete the job safely with minimal tools.

Why Immediate Replacement is Non-Negotiable
A compromised fuel pump hose leads to visible gasoline puddles under the vehicle, persistent fuel smells inside the cabin, engine misfires, or hard starting. The 2002 Grand Cherokee's rubber hoses degrade after 20+ years due to ethanol-blended fuels and heat exposure. Delaying repair risks fuel spray near ignition sources or sudden stalling. Replacement OEM hoses (Part # 5018862AA) cost under $50 – far less than fire damage or fuel pump failure from contaminants.

Mandatory Safety Preparation

  • Relieve Fuel Pressure: Locate the fuel pump fuse (#18 in PDC). Start the engine until it stalls. Crank for 5 seconds to purge residual pressure.
  • Disconnect Battery: Remove the negative terminal using a 10mm wrench. Cover with a cloth to prevent accidental contact.
  • Workspace Setup: Work outdoors or in a ventilated garage. Have a Class B fire extinguisher accessible. Never smoke or use sparks within 50 feet.
  • Skin Protection: Wear nitrile gloves and safety goggles. Fuel causes severe skin irritation.

Tools & Parts Checklist

  • Parts: Gates 27093 EFI Hose (3/8" diameter, 18" length), small hose clamps (5/16" - 3/8"), dielectric grease
  • Tools: Flathead screwdriver, trim removal tool, 13mm socket wrench, fuel line disconnect tool (5/16" & 3/8")
  • Supplies: Shop towels, plastic bags for fittings, fuel-safe sealant (Permatex #80019)

Step-by-Step Removal (45 Minutes)

  1. Access the Fuel Pump: Fold down the rear seats. Remove the center access panel beneath the carpet using a trim tool.
  2. Unplug Electrical Connectors: Press the locking tab on the fuel pump harness. Lift straight up.
  3. Depressurize Fuel Lines: Push the 3/8" disconnect tool into the feed line until the coupling releases. Cover with a bag.
  4. Remove the Return Hose: Squeeze the quick-connect fitting and pull firmly. Inspect for cracked nipples.
  5. Extract the Pump Module: Rotate the locking ring counter-clockwise using a flathead. Lift the assembly vertically.

Precise Hose Installation (30 Minutes)

  1. Trim the New Hose: Cut to match the original length (approx 5.5"). Deburr the inner edges with a pick tool.
  2. Apply Lubricant: Coat hose ends with silicone spray. Avoid petroleum grease.
  3. Connect Feed Hose: Push the hose onto the pump barb until seated. Secure with two hose clamps at 90° angles.
  4. Attach Return Line: Align the quick-connect fitting and push until it clicks. Tug-test for security.
  5. Seal Electrical Ports: Apply dielectric grease to terminals and sealant around the wiring grommet.

Reassembly & Critical Tests

  1. Reinstall the Module: Lower the assembly into the tank. Rotate the lock ring clockwise until tight.
  2. Reconnect Components: Plug in harness, reconnect battery negative terminal, and refit the access panel.
  3. Leak Verification: Turn the ignition to "ON" (don’t start) for 5 seconds to pressurize. Inspect fittings with a mirror. Start the engine and recheck.
  4. Functional Check: Confirm smooth idling and stable fuel pressure (55-62 PSI at the rail).

Professional Diagnosis Recommended If:

  • Leaks persist after clamp adjustment
  • Engine misfires continue (indicating fuel starvation)
  • Rust damage is visible on the pump flange

Routine hose inspections every 2 years prevent 85% of failures. OEM hoses last 8-10 years; budget replacements fail in 3-4. This repair requires basic mechanical aptitude but eliminates $300+ shop fees. Prioritize post-installation checks—ignoring minor seepage risks catastrophic fuel ignition. Refer to Chrysler Service Bulletin 25-001-04 for factory torque specs.

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