After repeatedly banging my head against the wall trying to figure out a way to get a stock '95+ Jeep fuel pump and regulator to work with my stock CJ-7 tank, I've given up. I've decided to use a aftermarket Mallory FI pump, regulator and inline fuel filter from Summit Racing. Could somebody please confirm the following for me:
The '96+ 4.0L needs 32-36psi fuel pressure at the fuel rail.
Fuel system order should be tank-filter-pump-regulator, with the pump mounted as close to the tank as possible, below the top level of the tank, and having the regulator as close to the fuel rail as possible.
I know I need to use EFI compatible fuel lines and hoses/clamps, but do the fuel lines need to be flared?
I've learned alot about FI systems doing this swap, but the learning curve is not as steep as I can wish for. Thanks for any help.

It's kind of complicated ... but the bullet proof setup seems to be ...

1. Coarse see through filter (for gas tank sludge, water, etc.).
2. Pre-pump ... Carter centrifical or other relaible low pressure unit (to draw fuel from tank).
3. F.I. pump ... mounted anywhere you want, even in the engine bay on the front fender well.
4. lastly, the fine F.I. filter ... so if the F.I. pump grenades you won't loose your injectors.

Think about it ...

The stock fuel pressure target is 39 psi ....

Now... wait a minute, are you using a non return fuel rail? The 96 and up units had a "smart" pump that runs on demand. You must be running a JTEC system then ? What year doner system are you running ?

A normal fuel pump won't work I don't think (of course, I reserve the right to be wrong)

If you are using a SBEC fuel rail (with a return line) the pump will work fine.

91 - 95 HO 4.0l = 32 - 39 psi

96 + (OBDII) 4.0 = 49psi rail

-Mike

Originally posted by CU4WHLN
The stock fuel pressure target is 39 psi ....

Now... wait a minute, are you using a non return fuel rail? The 96 and up units had a "smart" pump that runs on demand. You must be running a JTEC system then ? What year doner system are you running ?

A normal fuel pump won't work I don't think (of course, I reserve the right to be wrong)

If you are using a SBEC fuel rail (with a return line) the pump will work fine.

I'm running a stock fuel rail from a '96 XJ, no fuel return line. I'm planning on running a Mallory 4060FI pump, and an adjustable (3-50psi) Mallory fuel pressure regulator. The regulator is set up for a return line. As far as my brain can figure it, that should work fine.

As far as the OBDII motor is concerned, I know some of them ran a O2 sensor before and after the catalytic converter. Is this true? I'm not planning on running a cat, we don't have emissions testing here in Iowa, but if I need to run 2 O2 sensors, I may have to. Anybody know?

BTT
:confused:

I know the solution. You need to get the fuel rail/regulator from a 95 YJ, then your frame rail mounted fuel pump/filter setup will work just fine. I had this problem when I went to a fuel cell on my TJ.

Actually, I can sell you everything you'll need which includes the factory front portion of the feed/return line because of the special fitting on the rail.

I have all that stuff plus the filter/fuel pump I used.

CJ