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Old 08-20-2019, 10:14 AM
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Fuel Pump Help:

Having a hard time finding a fuel pump. I have a '91 2.5 MPFI, but all the pumps from the stores I went to are very different than the one currently installed.

The ones that are listed for my year/model don't have a filter/screen installed and the one currently installed is permanently attached, can't be swapped over. Also I'm concerned about the performance difference between the 2.5 pumps and 4.0 pumps.

I guess my main question is, if my Jeep originally came with a 15 gal tank and I happen to have a 20 gallon tank, would the 15 galllon pump still be viable? Or should I pretend like I have the 4.0 engine / 20 gallon tank?

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1991 YJ / MPFI 2.5L / AX-5 / Non-CAD D-30 / D-35 / 4.10's / 1" MML / 1" BL / 32x11.50R15 BFG MT-KM2 (See Jeep-Profile for Detailed List of Upgrades / Mods)

Past Project: Rear Shackle Frame-Rot Repair
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Old 08-20-2019, 10:31 AM   #2
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2.4 and 4.0 fuel pumps are exactly the same. The difference is there is a tube extending down into the tank so when you fill it, it will stop at 15 gallons and the fuel sending unit is different.

The factory pump is made by Bosch and from reports they are the only pump you should use. If you use a McAuto parts brand pump they will not last. Some bubbas haven't figured this out and started hacking holes in their floor so they dont have to drop the tank when their Duralast fuel pump dies prematurely.

A good quality pump will last 25 years and you wont have to hack big ugly holes in the floor ruining the tub. The Bosch part number is BOSCH 69302 they are $56 on rockauto.com

https://www.rockauto.com/en/moreinfo...185005&jsn=435

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Old 08-20-2019, 10:56 AM
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Quote:
Originally Posted by agalloch07 View Post
2.4 and 4.0 fuel pumps are exactly the same. The difference is there is a tube extending down into the tank so when you fill it, it will stop at 15 gallons and the fuel sending unit is different.

The factory pump is made by Bosch and from reports they are the only pump you should use. If you use a McAuto parts brand pump they will not last. Some bubbas haven't figured this out and started hacking holes in their floor so they dont have to drop the tank when their Duralast fuel pump dies prematurely.

A good quality pump will last 25 years and you wont have to hack big ugly holes in the floor ruining the tub. The Bosch part number is BOSCH 69302 they are $56 on rockauto.com

https://www.rockauto.com/en/moreinfo...185005&jsn=435
Yeah there is nothing like that tube you mentioned inside my tank, it must've been changed before I bought it in 2003 to a 20 gal. The vent tube hose extends a smidge into the tank, but not more that 2".

The part number that is installed now is a Bosch 0-580-453-464, that's what's stamped on the outside of the pump assy, can't find anything about it online.

Advanced Auto Parts has that part number you mentioned, I was there earlier but the pump they had on file for my 2.5 was way different than the current one. Not sure if I just happen to have a alternate part and the ones in stock are actually the right ones.

Do the YJ fuel pumps normall come with filter/socks? All the ones I check out so far didn't.
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Past Project: Rear Shackle Frame-Rot Repair
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Old 08-20-2019, 11:25 AM
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This is my current fuel pump next to the Bosch 69302, no filter/sock:

Gonna swap over the old one, think it should be fine.
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Past Project: Rear Shackle Frame-Rot Repair
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Old 08-20-2019, 11:28 AM   #5
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I think you need to ditch searching for a 2.5 replacement and look at the 4.0 's for a 20 gal. pump and sender combo. One key thing to watch out for would be the round lock ring or rectangle bolted with gasket on the top
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Old 08-20-2019, 12:12 PM
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I was able to swap over the sock/filter from the old pump to the new pump. I think it should be good. Only costs $90 for this project and I was able to fix my sending unit issue. I also adjusted the location of the rheostat slightly to accomadate for the difference in 15 to 20 gallon tanks, so the fuel-float now rises a bit further than it did before to show a true full reading, (instead of beyond "F"). I don't think it's necessary to purchase the 20 gallon sending unit, the gauge will show "E" but I will still have 2-3 gallons in the tank by the time it hits "E", I'm not too worried about it.
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Old 08-20-2019, 01:37 PM   #7
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They sell socks separately i am not sure if all strainers will fit all pumps. There are a lot of different branded fuel pumps for the YJ so there might be different strainers. A strainer for a Denso pump might not fit on a Bosh pump and vise versa. Usually if you want a sock you can buy the complete fuel pump kit with everything in it.

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