Krispy10

I just finished installing a GenRight Jeep XJ 30.5-gallon gas tank and skid plate into my 1991 XJ and wanted to share the setup I ended up using. Since this tank requires a 1997+ fuel pump assembly, I had to piece together a solution that would work with my application. I started with a brand-new Delphi FG1076 fuel pump assembly because I needed the aluminum lower housing/sump section. From there, I installed an AEM 50-1220 high-flow in-tank fuel pump along with the Boostwerks Engineering Billet Fuel Pump Module Kit. One of the nice features of the Boostwerks setup is that it supports up to two fuel pumps and provides a return line back to the tank. If you look through the instructions on their website, the design and functionality make a lot more sense. I also purchased the NRT Autosports 91–95 Jeep 4.0 fuel rail, fuel pressure regulator, and various hoses and fittings. The NRT rail gives you the option to run a rail-mounted regulator similar to the OEM setup, but with a much cleaner design and adjustability. It also allows a dedicated return line directly from the regulator back to the tank. To retain accurate fuel level readings without rewiring or converting resistance values, I removed the fuel level sending unit from my original 1991 fuel pump assembly and modified it to mount onto the 1997+ pump housing/sump. This allowed me to keep the factory gauge functioning correctly while avoiding additional wiring changes or extra parts. Hopefully this helps anyone trying to piece together a similar setup.

I have got all the parts together and should have this finished up by June. I’ll report back with my findings!

Hey @Dzimm, I found this post due to being in this situation. I'm a new user on here just to get in touch with you because I noticed you’re an active user still. I’m going to be installing a Genright fuel tank in a 1991 and I’ve been struggling with how I will route the fuel system or make the components work together. Do you know if this was ever tried? I don’t see why I can’t run the 97+ fuel pump with 49PSI, and let the fuel rail mount regulator drop it down to whatever it needs based on vacuum. Let me know your thoughts, I would greatly appreciate it!