96 xj ls swal

[silverpearljku]

Okay so some back story. I have a 1996 xj. It currently has a 6.0 ls with a th400 transmission. The fuel tank and pump is from a 97 due to the previous owner of the 96 letting it sit for 12 years and everything rusted through. I currently have the truck intake on my jeep with the built in pressure regulator. I'm needing to replace my fuel pump due to my fuel gauge not working. Is there a way to hollow out or delete the factory 97 pressure regulator or am I just stuck with it pushing out on 43 psi

 

[75SV1]

You might look at Bostwerks. They have a 'kit' to upgrade the fuel pump to a return system and add an adjustable fuel pressure. The early HO's 91-95 had a fuel return system. I forget the part replacement used to bump up the fuel pressure. I'd have to check and see where the one I bought is at.

Edit: the NAPA PN is 2-19681 for the higher Pressure Regulator. That should fit a 91-95 HO. Not sure on the 96. 97 and up the pressure regulator is on the fuel pump.

 

[MJ4BTA]

I would think going back to the pre-97 steel tank, 91-93 sender adapted to the the 96 harness, with a Walboro 255 pump would be the best route. It will work with your 96 cluster, the 91-93 senders are readily available, and the 255 will feed a healthy LS. The biggest part of the swap will be running a return line from rail to the tank.

 

[75SV1]

I did buy a prebent SS tube off of Ebay for a 91-95 XJ. I think it is the return fuel line.

 

[silverpearljku]

I would think going back to the pre-97 steel tank, 91-93 sender adapted to the the 96 harness, with a Walboro 255 pump would be the best route. It will work with your 96 cluster, the 91-93 senders are readily available, and the 255 will feed a healthy LS. The biggest part of the swap will be running a return line from rail to the tank.

That's the route I'm going now. I bought the dorman tank and straps. Picked up a new 91-93 sender and I'm using an ameromotive 11540 fuel pump that I had from my jk hemi swap