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  #16  
Old April 7th, 2015, 20:22
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1996 XJ fuel pump and pressure regulator repair details

Yesterday I swapped in a 97+ plastic tank since the baffle/tray in my 96's tank was loose(also wanted to lose weight). I had already upgraded the pump to a 255lph Walbro, so that along with the sender is available if someone is looking for a working used 96 setup.

Last edited by gradon; April 7th, 2015 at 20:27.
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  #17  
Old April 9th, 2015, 03:10
Dragonslayer Dragonslayer is offline
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Re: 1996 XJ fuel pump and pressure regulator repair details

gradon - I had been thinking about swapping in a later model plastic tank into my '96, too,
but I didn't know how much work was needed to do this. Were there any special mods needed to do this? What were they? Thanks.
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  #18  
Old April 9th, 2015, 03:11
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Question Re: 1996 XJ fuel pump and pressure regulator repair details

gradon - I had been thinking about swapping in a later model plastic tank into my '96, too,
but I didn't know how much work was needed to do this. Were there any special mods needed to do this? What were they? Thanks.
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  #19  
Old April 9th, 2015, 20:10
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Re: 1996 XJ fuel pump and pressure regulator repair details

You need the two filler hoses from the 97+ XJ(smaller hose necks up at tank and bigger hose is smaller than 96's). You need a smaller hose from external fuel filter to fuel pump nipple/barb(I had 2' of 5/16" fuel hose left over from a $3 pack in AA's help aisle). You need to to move pins around on the 97+ pump harness to match the 96's wiring(I'll post them tomorrow) and pull 6" of the 96's harness closer to the tank(my interior is stripped, so was easy--it's under the passenger rear left seat's carpet).
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  #20  
Old April 9th, 2015, 22:20
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Re: 1996 XJ fuel pump and pressure regulator repair details

Sounds like some good information. Count me as interested too.

I have given serious thought to a GenRight 30 gallon (or whatever it works out to be) tank. They list the tank as only being for 1997+, but I would think a '96 could be accomplished too. The details you ran into would probably be the same ones to come up with the GenRight.
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  #21  
Old April 10th, 2015, 12:33
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Re: 1996 XJ fuel pump and pressure regulator repair details

Wiring:
On our 96:
1: Dark Green/Red = Fuel Pump Relay Output(+12V)
2: Black/Light Blue = Sensor Ground
3: Dark Blue = Fuel Level Sensor Signal
4: ----------
5: Dark Blue/White = Low Fuel Sense
6: Black = Ground

On 97+:
1: Dark Green/White = Fuel Pump Relay Output
2: ---------
3: Dark Blue/Light Green = Fuel Level Sensor
4: Brown/Yellow = Sensor Ground
5: ---------
6: Black = Ground

You have to move pin 4 from 97+ fuel pump tail to pin 2 and I haven't done anything with the Low Fuel Sense yet(don't really care about the low-fuel light on the dash).
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  #22  
Old April 11th, 2015, 02:01
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Re: 1996 XJ fuel pump and pressure regulator repair details

Except for moving some of the wire pins, it sounds like it's almost a straight swap, yes?
No cutting of sheet metal? No welding? If so, then this is on my "To Do" list. I am
always a bit nervous about having the fuel pump on my '96 to go south on me while out
in the boonies - and then having to hunt for another rare and expensive fuel pump.
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  #23  
Old April 11th, 2015, 19:33
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Re: 1996 XJ fuel pump and pressure regulator repair details

The pump is common
It's the sending unit and pressure regulator that are special
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  #24  
Old April 11th, 2015, 23:15
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1996 XJ fuel pump and pressure regulator repair details

I replaced my 96's bad pump with a $70 walbro and it worked fine(but whined more than the stock one). I put 6+ gallons in yesterday and the needle hasn't moved, so don't follow me down this path yet. . .
Oh yeah, the colors I mentioned above for the 99 are the body harness colors and not the actual fuel pump tail colors. Besides the +12v and Black ground that get the pump going, there is a pink with black wire and a black with green wire. I swapped them between pins 2&3 and no change in gauge. At least I know the stroker is consistent with its 15mpg city. . .

Last edited by gradon; April 11th, 2015 at 23:24.
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  #25  
Old April 12th, 2015, 08:26
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Re: 1996 XJ fuel pump and pressure regulator repair details

Sorting through the details is the fun part.

A working fuel gauge is a priority if I ever decide to go down that route. Let us know if you find a solution.
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  #26  
Old April 19th, 2015, 16:38
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1996 XJ fuel pump and pressure regulator repair details

So the gauge goes from 1/4@full tank to 1/4 below the empty. Maybe I'll measure the resistance of the old float full swing and compare to new float.
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  #27  
Old April 19th, 2015, 17:34
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Re: 1996 XJ fuel pump and pressure regulator repair details

Sounds like the sender got bumped. The older style use a strip with contacts, and as the arm moves it sweeps across the contacts. The jeep senders are pretty robust so it usually has to physically dislodge (unlike my old Cadillac which uses thin strand wire (folicles) that simply corrode and break.)
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  #28  
Old April 19th, 2015, 22:03
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1996 XJ fuel pump and pressure regulator repair details

The prob is that the '96 and under senders are different than the newer dash '97 and newers, so don't know yet if it's a resistance difference or has to do with the dif protocol.
On a side note, my Jeep kicked @$$ yesterday in autocross and weighs 2700# wet and didn't have a metal tank with a loose baffle in it.

Last edited by gradon; April 19th, 2015 at 22:13.
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  #29  
Old August 31st, 2015, 14:37
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Re: 1996 XJ fuel pump and pressure regulator repair details

Great thread. I'm posting in it to make sure it comes up for me in case I ever need to go through it. Thank you Anak!
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  #30  
Old September 2nd, 2015, 16:14
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Re: 1996 XJ fuel pump and pressure regulator repair details

Adding to old thread, when I bumped mine, it was a bad connection. I cleaned all connections, checked unit to gauge plugged in, outside of tank, and then reassembled.

I was pretty irked to find it didn't work the first time. No reason not to pull the slip terminals and clean the tabs while you're in there. Mine were crusty and obviously needed to be cleaned.
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