Aeromotive fuel system for 4.0L

Rerock · 04-23-2007, 11:57 AM

I picked up a cell, pump, regulator and two inline filters for my '95 XJ. I'm waiting for RCI to finish building the cell, so while I wait, I need to figure out a solution for the return line portion of the plumbing. My plan is to have the pump mounted in the cargo area along with the pump and filters. 100 micron on the inlet side, and 10 micron on the outlet side. The regulator will get mounted on the firewall in the engine compartment. Now, the regulator obviously has a inlet and outlet, but it also has a return line to shed the excess pressure. Now, the fuel rail has the regulator on the rail heading to the return line. My question is what is the best way to plumb this gonna be? I will essentially have two seperate locations that will need to be routed back to the tank. Shall I simply get a "Y" fitting? Also, since the new regulator will be mounted on the inlet side of the fuel rail, do I simply remove the factory regulator and plug the vaccum line? Thanks for some insight!

JEEPRZ · 04-23-2007, 12:01 PM

I am not sure why you wouldnt just use the factory regulator.

If your wanting higher pressure for some reason, you will have to eliminate the rail mounted regulator, plug the return line, or exchange your fuel rail for a newer returnless style.

If you want to go to a returnless, I have one I will do an even trade for. This would be the cleanest setup.

Rerock · 04-23-2007, 12:40 PM

My reasoning for going with an external regulator is because in the future I will be swapping a Ford drivetrain and using a 5.0L.

I had thought about removing the stock regulator and blocking off the return port on the rail, but was curious about the added volume of the aftermarket pump versus the stock pump. Will the added volume not matter, or will the return port on the bottom of the regulator be sufficient for redirecting the excess pressure and volume?

JEEPRZ · 04-23-2007, 01:02 PM

Your aftermarket regulator will allow the excess fuel to return to the tank. You just need to adjust it properly.

Rerock · 04-23-2007, 02:54 PM

That's what I needed to know. Thanks!

04-23-2007, 11:57 AM	#1
Rerock Wheeler Join Date: Mar 2004 Member # 28604 Location: Minneapolis, MN Posts: 223	Aeromotive fuel system for 4.0L I picked up a cell, pump, regulator and two inline filters for my '95 XJ. I'm waiting for RCI to finish building the cell, so while I wait, I need to figure out a solution for the return line portion of the plumbing. My plan is to have the pump mounted in the cargo area along with the pump and filters. 100 micron on the inlet side, and 10 micron on the outlet side. The regulator will get mounted on the firewall in the engine compartment. Now, the regulator obviously has a inlet and outlet, but it also has a return line to shed the excess pressure. Now, the fuel rail has the regulator on the rail heading to the return line. My question is what is the best way to plumb this gonna be? I will essentially have two seperate locations that will need to be routed back to the tank. Shall I simply get a "Y" fitting? Also, since the new regulator will be mounted on the inlet side of the fuel rail, do I simply remove the factory regulator and plug the vaccum line? Thanks for some insight!

04-23-2007, 12:01 PM	#2
JEEPRZ Registered User Join Date: May 2000 Member # 784 Location: Plano, TX Posts: 1,390	I am not sure why you wouldnt just use the factory regulator. If your wanting higher pressure for some reason, you will have to eliminate the rail mounted regulator, plug the return line, or exchange your fuel rail for a newer returnless style. If you want to go to a returnless, I have one I will do an even trade for. This would be the cleanest setup. __________________ Think for yourself

04-23-2007, 01:02 PM	#4
JEEPRZ Registered User Join Date: May 2000 Member # 784 Location: Plano, TX Posts: 1,390	Your aftermarket regulator will allow the excess fuel to return to the tank. You just need to adjust it properly. __________________ Think for yourself

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04-23-2007, 12:40 PM	#3
Rerock Wheeler Join Date: Mar 2004 Member # 28604 Location: Minneapolis, MN Posts: 223	My reasoning for going with an external regulator is because in the future I will be swapping a Ford drivetrain and using a 5.0L. I had thought about removing the stock regulator and blocking off the return port on the rail, but was curious about the added volume of the aftermarket pump versus the stock pump. Will the added volume not matter, or will the return port on the bottom of the regulator be sufficient for redirecting the excess pressure and volume?

04-23-2007, 02:54 PM	#5
Rerock Wheeler Join Date: Mar 2004 Member # 28604 Location: Minneapolis, MN Posts: 223	That's what I needed to know. Thanks!