[lordhelemt]

I need to figure out what to do for an in-tank pump for a 4.0 conversion. I'm not interested in an externally mounted pump.

Choices are:

1) The Novak pump. Plug and play but expensive.
2) 2.5 YJ sender w/correct sized pump. Even if I reverse the ohms the fuel gauge will still read a little off
3) Modify the CJ sender. Still haven't found a good solution to have a water (gas) tight connection for the wiring.
4) Use a separate fuel hanger. Will need to drill the tank and cap one of the lines on the Jeep sender.

I'm leaning towards option 4. I have an extra fuel hanger/pump from a early 90s Range Rover that fits nicely in the tank. I don't know the rating of the pump but it will run any of the older RV8s (3.9, 4.2, 4.6) so I'm fairly certain it will work on the Jeep 4.0.

I mocked up the set up with an old tank and pump and here is how it would look. I'd just need to add rivnuts to secure the pump hanger and use the Rover cork gasket to seal it up.

Any opinions on set up #4?

 

[Jim1611]

I made my own tank but some of what I did can apply to your idea #4. My fuel pump assembly and sending unit are separate. I bought a pump rated for the requirements of my engine, Ford 5.0 and made the bracket and everything to hold it in place. The aluminum flange that everything bolts to has two studs in it where the wiring hooks to on the outside. They are set in that flange in fiberglass rods that insulate them from the flange. Anyway here is a link to my build thread where that starts Jim's 85 CJ7 rebuild and a few pictures here too. I also have a return line to the tank as well.

 

[Rkuehljr]

Holley makes in in tank fuel pump/sender that replaces the stock CJ sender for the 15 tank, pricy but super simple.

Holley Sniper EFI 12-307 Holley EFI Fuel Tank Modules - 255 LPH - Jeep CJ

• This in-tank fuel pump module is a high-pressure unit that flows 255 liters per hour (LPH) and is capable of supporting electronic fuel injection (EFI) engines producing up to 550 horsepower • A pre-calibrated fuel-level sending unit designed to work with the factory fuel gauge for this...

www.holley.com

 

[houstoniancj]

I need to figure out what to do for an in-tank pump for a 4.0 conversion. I'm not interested in an externally mounted pump.

Choices are:

1) The Novak pump. Plug and play but expensive.
2) 2.5 YJ sender w/correct sized pump. Even if I reverse the ohms the fuel gauge will still read a little off
3) Modify the CJ sender. Still haven't found a good solution to have a water (gas) tight connection for the wiring.
4) Use a separate fuel hanger. Will need to drill the tank and cap one of the lines on the Jeep sender.

I'm leaning towards option 4. I have an extra fuel hanger/pump from a early 90s Range Rover that fits nicely in the tank. I don't know the rating of the pump but it will run any of the older RV8s (3.9, 4.2, 4.6) so I'm fairly certain it will work on the Jeep 4.0.

I mocked up the set up with an old tank and pump and here is how it would look. I'd just need to add rivnuts to secure the pump hanger and use the Rover cork gasket to seal it up.

Any opinions on set up #4?

Holley also makes a nice unit for the 15 gallon tank. We were just talking about it today on this forum where im having some fuel pump sending unit issues with the Novak unit.

Other Jeep Forum Thread

 

[lordhelemt]

I saw the Holley pump but it's more than I need to spend for something simple

 

[houstoniancj]

I saw the Holley pump but it's more than I need to spend for something simple

10-4 on that. Option 3 isn’t bad if you’re handy, its effectively what the Novak unit is. The wiring can be managed in a few ways from bulkhead fittings to insulated studs (thats what Novak has done).


If I had the room I would have used the electrical connectors from Radium Auto, they have a universal one that looks perfect. I don’t have the room though. Option 4 is what I will ultimately do by separating the pump assembly and the sending unit.

 

[StoneTower]

If you read this thread:

Please show me your in tank fuel pump setup

I have a 5.0 Mustang EFI setup with an in tank fuel pump (20 gallon plastic) in my 1985 CJ-7. My fuel gauge sender recently died so I decided to put in a VDO reed switch sender (moves vertically). It is installed in a separate location from the original sender. The install seems to have gone...

www.jeepforum.com

This is how I solved my problem. Those rings could be used for a fuel pump too. You could also make a set of larger aluminum rings to go on the inside and outside of the tank if you needed more room.

 

[rickcdewitt]

Whatever you chose make sure its regulated to the pressure that year 4.0l ecm and injectors want to see

 

[lordhelemt]

Thanks all and I appreciate your feedback and comments. 99% sure I'm going to use the Land Rover pump. It fits nicely and if I never need a replacement they are cheap.