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TJ Wrangler - remote fuel pump?

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geberhard

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Discussion starter · #1 · (Edited)
I am searching but having a hard time finding the best approach here. The Wrangler TJ's have a PITA setup and ring to replace a fuel pump on the trail, and the design is crappy to start with, plus the internal support plastic piece is known to brake easily.

I want to make things simple and have an external pump, what could be a 15 minute fix as opposed to an hour fix.

What have you gusy been using and what worked? I believe the most used setup is the Ford and ES2000? What has to be done to teh pump, rail, pickup, etc?

This will be on a TJ with a 4.0L engine.

Thanks!
 
#3 · (Edited)
I used an E2000 with a Mallory 4305M regulator. It is a 97 TJ with a 4.0L.
I mounted the regulator on the firewall and ran a return line along the frame right next to the stock supply line. I have the fuel pump mounted on the frame toward the rear, under the bed.
Are you using a fuel cell or the stock tank? This was for a fuel cell setup, but it shouldn't be any different for the stock tank.
 
#4 ·
I am currently running a fuel cell with a sump, E2000 fuel pump, a Puralator F43178 for a prefilter and a regular YJ fuel filter after the pump. Pump and filters are mounted under the jeep. This is in a 2000 TJ that was oringally a returnless fuel rail so I swapped it out for a YJ fuel rail with a built in regulator and return port. I ran a second fuel line down the frame next to the supply line for the new return. Its all off the shelf and should be available at pretty much any parts store.

Its worked well for the couple of trips I have had it on. That being said I am switching it all up

I plan to run the E2000 in the tank until or if it dies and then swap in an E8248. I picked up four Walbro fuel pickups to run intank as well. http://www.autoperformanceengineering.com/html/pickups.html I plan to run that out to a 2000 Jeep Grand Cherokee fuel filter/regulator combo that puts out the the TJ 49+/- PSI needed. The return line will run right back into the tank. I might run it all in tank if I can find a fully metal version of the fuel filter/regulator combo with the return plumbed into the supply. The filter/regulator combo is under $30. G8414 is a rockauto.com part number for a Fram filter.

I think this setup will help the fuel pump live longer. It will put it in the tank where it wont have to pull fuel which is what seems to kill these pumps. Also it will stay cooled by the fuel which address another pump killer, heat.

The second setup will not address your need to have an easy to change pump though. Just know that while these pumps can and do work in a pull setup they are not designed to pull fuel and should be put as close to the tank as possible and preferably used with sump tank that can sort of gravity feed them.
 
Discussion starter · #5 · (Edited)
Thx guys, I am running a fuel cell behind the rear seat. The pump is easily accessible from the top. I had issues with a TJ fuel pump before and really woudl like to have a better than stock setup in place. The old pump was in the stock tank location, and pretty much had to drop teh tank, deal with the PITA plastic ring, etc. The pump failed because the plastic tube cracked.

I remember reading someplace that Dustin (redBulljeep) did a trick setup on their TJ for KOH, using two external pumps (one for redundancy) that could be switched almost on the fly. I am not looking to go that bling, but basically want to make this an easier trail repair job. I bought a spare pump yesterday, but was thinking at $120 bucks there should be a better approach out there?

Cool info, will look into the E2000 option, I remember seeing something about using the YJ rail, or making one. AT, do you have any pics showing your setup and pump location? How noisy is it? heat?
 
#6 ·
I used a Aeromotive pump and filter. I ran stainless line from a Aeromotive regulator up to the rail. I got a barbed mail quick disconnect to plug into the factory rail. It's over kill but maybe there will be a LS in the future.:D
 
#7 · (Edited)
geberhard said:
AT, do you have any pics showing your setup and pump location? How noisy is it? heat?
Click to expand...
This looks pretty ghetto, I just finished a winter build and did this in about 10 minutes. I intend to do something a little more solid, but in this same location. It is easy to get to and I keep a spare E2000 with me. It is not too noisy but I can definitely hear it.
Image

This is the regulator set up. The supply and return go straight down to the frame rail. The supply ties into the stock hard line and I ran another hard line right along side it for the return. I had an extra port on the regulator so I put a small pressure gauge on it. I had a lot of help from frostytj setting this up.
Image
 
#8 ·
So digging up an old thread. I am not sold on using the stock tj pump in a fuel cell quite yet so been looking at external fuel pumps. The e2000 and grand cherokee regulator/filter have peaked my interest. Anyone using this combo in a tj fuel cell and got pics and more info. Kinda confusing myself with everything I have read LOL
 
#9 ·
offroadman83 said:
So digging up an old thread. I am not sold on using the stock tj pump in a fuel cell quite yet so been looking at external fuel pumps. The e2000 and grand cherokee regulator/filter have peaked my interest. Anyone using this combo in a tj fuel cell and got pics and more info. Kinda confusing myself with everything I have read LOL
Click to expand...
So you are searching. :flipoff2:

I am runing that setup now. I posted a little about it on page 3 of http://www.pirate4x4.com/forum/jeep-non-hardcore/779926-rci-fuel-cell-install-jeep-3.html

Fuel cell is in the back of a Jeep right by the tailgate. Fuel pump and filter are attached to the side of the fuel cell and have a cover to keep them from getting hit. Only pics I could find right now.

Note that the fuel pump is upside down in these pics. :shaking:

Seems to be working fine from the few rides I've been on with it so far. I do think I need some more heat management for the fuel line running along the fame rail. Exhaust is on the drivers side and not far from the fuel line but thats another story.

At some point I'd like to move the fuel pump in the tank but I should probably leave well enough alone.





I posted this pic somewhere and its probably in a thread here, maybe not. Anyway its of the fittings I used.

Fuel filter/regulator.
 
#10 ·
I used Walbro pickups in the tank. I used a compression tee fitting to hook it up to the pickup tube in the tank.

Some 3/8" steel line
2 - Dorman 800-193 3/8" fuel line connectors
Some Dorman 800-075 fuel line
2 - Walbro pickups
1 - compression tee

Only pics I think I have of it all together. When connected to the in tank pickup the Walbros touch the bottom of the tank and so far do not bang or clang around. Heat the nylon line up a little with a hair dryer and slide it on the Walbro pickup.

I ran across this idea from Timmay from LLI on the board and I'm pretty sure he sells all the pieces you need to connect everything in tank like this.









I used Permatex 80019 Aviation Form-A-Gasket No. 3 Sealant and some cork gasket material to seal the filler neck and sending unit seeing how the rubber gasket that came with the tank was shot. (used tank) Just the Permatex alone didnt seem to seal but I blame that on the fact that the filler neck surface was not flat and there were a couple gaps that were too much for the sealant.
 
#12 ·
Dont forget about shutoff valves. I didnt have any when I put the cell in and wanted to get it installed for a ride. I need to add them though.

Also the capped port is the vent line. You can connect it to the charcoal canister factory stuff if you want, I think yours has all that under the hood. You'd just hook it up to the other line running on the fuel rail.

If you are ditching that, which I did, then you need to run a vent line. I ran mine three sides and downish, well more than 3 sides but it should work just the same. I ran it into a Fram G6567 filter.

Rough drawing of what my vent line looks like. Once it comes back around the long side, which faces the tailgate, it drops down to the bottom of the tank and is run out the wheel well to the filter which is about inline with the bottom of the tank. The vent line actually has a couple of small loops/coils in it after it drops to the bottom of the tank. Left over from my previous setup and I left it seeing how it shouldnt hurt anything.

 
#13 ·
I"m switching to a fuel cell and running a Walbro fuel pump. I'm planning to use a male fuel rail fitting to tie into the stock fuel line. In this thread I see a lot of people saying that they ran a new return line. Is there any reason not to use the factory return line?

thanks everyone.
 
#18 ·
What is the vapor line made of? Are you trying to keep the evap stuff? What regulator do you plan on running?

I pulled mine ages ago with the evap stuff and cant remember offhand if its a hard line or what. I don't think there was enough slack to get it to the fuel rail but that's an easy fix I suppose. It doesn't need to be run back to the tank.
 
#20 ·
frostytj said:
I used Walbro pickups in the tank. I used a compression tee fitting to hook it up to the pickup tube in the tank.

Some 3/8" steel line
2 - Dorman 800-193 3/8" fuel line connectors
Some Dorman 800-075 fuel line
2 - Walbro pickups
1 - compression tee

Only pics I think I have of it all together. When connected to the in tank pickup the Walbros touch the bottom of the tank and so far do not bang or clang around. Heat the nylon line up a little with a hair dryer and slide it on the Walbro pickup.

I ran across this idea from Timmay from LLI on the board and I'm pretty sure he sells all the pieces you need to connect everything in tank like this.

View attachment 955393

View attachment 955401

View attachment 955409

View attachment 955417

View attachment 955425

I used Permatex 80019 Aviation Form-A-Gasket No. 3 Sealant and some cork gasket material to seal the filler neck and sending unit seeing how the rubber gasket that came with the tank was shot. (used tank) Just the Permatex alone didnt seem to seal but I blame that on the fact that the filler neck surface was not flat and there were a couple gaps that were too much for the sealant.
Click to expand...
is this stainless line? I have a cell that I would guess is 18"x20" 12"H and i have a walbro in each corner, but it looks like most people are running just 2. I assume you can just use normal 3/8 steel/alum line and compression fittings?
 
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