4.0 swap: fuel line connections - JeepForum.com

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post #1 of 19 Old 03-20-2013, 09:27 PM Thread Starter
Gigemags05
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4.0 swap: fuel line connections

Im swapping a 1992 4.0 into my cj.
Is there any special connector I need to Attach the fuel lines to the rail? Can I just use fuel injection rated clamps? If I need special connectors, can I get them at a local parts store?

Also, which one is the incoming fuel and which line is the return fuel line?

Dumb questions, I know. But any help is greatly appreciated.

Bonus question:
What is the connection closest to the firewall on the intake manifold? Right next to the MAT sensor.

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post #2 of 19 Old 03-21-2013, 07:08 AM Thread Starter
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Any ideas?
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post #3 of 19 Old 03-21-2013, 08:36 AM
markso125
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I assume you are going to use the 4.0 MPI if you are going to do that you need to change your lines out with EFI rated lines all the way down and put an fuel injection rated pump in the system.
I used the stock wrangler nylon lines with mine down to the inline fuel filter and pump I installed on the frame rail and then ran replacement nylon lines into the tank with EFI rated hose as a flex point.

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post #4 of 19 Old 03-21-2013, 08:50 AM Thread Starter
Gigemags05
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I've got fuel injection rated hoses to go from the new pump to the rail and then from the rail to the fuel injection rail.

What I'm confused on is how to connect the lines to the fuel injection rail.
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post #5 of 19 Old 03-21-2013, 08:59 AM
CSP
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Yes they do use quick connect fittings. You can get them at NAPA with the quick connect at one end and a barbed fitting at the other end to attach your hose to. I don't know the sized of the rail, otherwise I could find part numbers pretty easily. This will give you an idea what they look like:


The outlet of the regulator is the return line, so that should help differentiate between supply and return.

You might try looking at Google images on a search of "Jeep 4.0 fuel rail" for more info. XJ forums have a wealth of knowledge that you should tap into if you haven't already.
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post #6 of 19 Old 03-21-2013, 09:13 AM Thread Starter
Gigemags05
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Thanks for the info. I'll stop by napa at lunch.


I've been looking at the xj boards and cross posted this there as well. But I am more comfortable with this place for some reason
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post #7 of 19 Old 03-21-2013, 09:23 AM
CSP
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NAPA probably won't be much help to determine what size of fittings you need. I bought these type of fittings when I converted my 7.3 Powerstroke to use a fuel conditioner from a 6.0 Powerstroke. I had to know what size fittings for them to look them up as they aren't a stock part used in a configuration they have in their books/computers.
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post #8 of 19 Old 03-21-2013, 09:26 AM Thread Starter
Gigemags05
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Ok I'll see if I can find the sizes.
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post #9 of 19 Old 03-21-2013, 09:33 AM
SLO_Ken
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Quote:
Originally Posted by Gigemags05 View Post
Ok I'll see if I can find the sizes.
Please share when you do. I'm getting ready to do this same swap in a month or so. Thanks.
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post #10 of 19 Old 03-21-2013, 09:44 AM Thread Starter
Gigemags05
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Striking out so far.
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post #11 of 19 Old 03-21-2013, 10:25 AM Thread Starter
Gigemags05
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Best I can tell, I think they're 5/16 connectors.


Am I good using fuel injection rated hose and clamping it to the fuel line along the frame and also to the fuel pump? I've not seen anyone mention any different but I don't want to do anything unsafe.
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post #12 of 19 Old 03-21-2013, 10:36 AM
CSP
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Personally I wouldn't take that chance, but I"m sure it has been done.
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post #13 of 19 Old 03-21-2013, 10:50 AM Thread Starter
Gigemags05
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What is the alternative?
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post #14 of 19 Old 03-21-2013, 11:23 AM
SLO_Ken
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Quote:
Originally Posted by CSP View Post
Yes they do use quick connect fittings. You can get them at NAPA with the quick connect at one end and a barbed fitting at the other end to attach your hose to. I don't know the sized of the rail, otherwise I could find part numbers pretty easily. This will give you an idea what they look like:


The outlet of the regulator is the return line, so that should help differentiate between supply and return.

You might try looking at Google images on a search of "Jeep 4.0 fuel rail" for more info. XJ forums have a wealth of knowledge that you should tap into if you haven't already.
The photo you posted is from Summit. On their website, they only show these connectors available in 5/16" or 3/8". Is it safe to infer that one of those two sizes should fit?



The next question would be, does the fuel rail require "quick connect" or "double bead" connectors?
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post #15 of 19 Old 03-21-2013, 11:37 AM
jeepwhore
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Quote:
Originally Posted by Gigemags05
What is the alternative?
Oem uses hard line from near the rail down along the frame to a point back near the tank. I pulled a set of lines from an XJ in the junkyard with the hopes I can cut/bend them to get back near the tank.

'84 CJ-7: Yota axles (spartan locked front, e-locked rear) 4" BDS, 1" Daystar & 3/8" shackle lifts, 35" X-Terrains on steelies, YJ Tub & family roll bar, heater blower upgrade, 4.2L w/MC2100 & Team Rush, Warn 8274. Rebuilt 4.2/4.0 hybrid, AX15 and twin sticks/clocking ring waiting to go in.

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