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Gen III+ Fuel System Kits
for
Jeep YJ Wranglers, 1987–1995
The Jeep conversion industry has seen various evolutions of fuel system modifications to accommodate modern fuel injection engines. None of these methods are as simple, cost effective, or desirable as using the factory Jeep fuel injection pump — which, on 1991–1995 YJ Wranglers, is natively capable of producing ~100 PSI.
Option I: With Pressure Regulator (recommended for most Gen. III+ swaps)
Included in this kit is a pressure regulator and inline filter that will supply ~58 PSI to the fuel injection rails through a return-less supply line. This is for Gen. III+ engines that require a regulator external to the GM fuel rail. The regulator mounts in proximity to the fuel tank so that a long return line is unnecessary.
Option II: Without Pressure Regulator
Identical to the above kit, except the regulator is not included. This kit is for Gen. III engines that already have the factory regulator integrated into the fuel rail, typically many 1997–2002 GM LS / Vortec series engines. You will notice the presence of a diaphragm-style regulator and its associated return line in addition to the always-present supply line. Check your engine for applicability.
Applications & Compatibility
An example of the integral regulator found on earlier LS-style fuel rails. These engines will always have both a supply line and a return line.
About the YJ Fuel System
The 1991–1995 Jeep YJ Wrangler's factory fuel injection pump is natively capable of producing approximately 100 PSI — well in excess of the 45–58 PSI required by GM Gen. III+ engines. The factory Jeep fuel rail on these models featured an integral pressure regulator and used a two-line system: a high-pressure supply line and a low-pressure return line that fed excess fuel back to the tank. Removing the Jeep engine for a GM conversion also removes this regulator, which is why Novak's kit includes an external replacement that mounts near the tank.
Note that earlier Gen. III motors were regulated at the fuel rail. Starting around 2002, GM moved regulation to the tank or elsewhere on the circuit. Select the Without Regulator option if your engine already regulates at the fuel rail.
For a fast connection between the Jeep supply circuit and the GM engine, a Dorman 800-058 fuel line quick connect is supplied in the Novak kit.
Identifying Your Application
The Application dropdown selects the correct pump module (or no pump) for your YJ:
- 1987–1990, Round Sender: The factory fuel module sender is circular in shape. These early YJ models require a complete pump and module replacement for a GM high-pressure engine application. The old factory fuel module can be removed and replaced with this updated version.
- 1991–1995, Rectangular Sender: The factory fuel module uses a newer rectangular sender. These kits replace the module with a high-pressure in-tank assembly along with all integration hardware for connecting to the GM fuel circuit.
- No Pump (Integration Only): If your 1991–1995 YJ's factory fuel pump is serviceable, it may not need to be replaced — the factory pump on these models is already capable of the pressure required by GM Gen. III+ engines. This option supplies the regulator (if selected) and connection hardware only, without replacing the pump module.
Installation Requirements
Installation requires that the fuel tank be lowered (and preferably nearly empty) and that the replacement fuel module or integration hardware be installed as directed in the supplied instructions. General hand tools are required.
Any person or shop working on any factory or conversion vehicle fuel system must consider that any open flame or electrical spark or tool spark in the proximity to fuel and especially fuel vapors can cause massive damage to life, health and property. Improper electrical connections can spark, overheat and ignite fuels and their vapors. If the installer is not qualified to work on a vehicle fuel system, they should seek the consulting and installation services of someone who is competent in this area.