GM pump assembly to XJ tank - adapter ring by blistovmhz

Last crawled date: 3 years ago

This is for installing a GM truck (All vortec) fuel pump assembly into a Jeep XJ fuel tank (late model plastic tank). Use this for all my LS swaps.
After screwing with tons of aftermarket pumps, expensive filter regulators and fittings, and having nothing but problems, I gave up and just stuck a stock GM truck pump and assembly into the XJ fuel tank. Works mint.
For those doing LS swaps, this is by far the easiest and probably best solution. You've already got the GM pump and can from the donor right? Why waste money and time with aftermarket parts of questionable quality?
Instructions:
Print adapter ring out of something tough and fuel safe. PETG should be fine. I generally shoot for 3 perimeters, 40% infill, just because I want this thing to be as strong as a full potato.
Remove the XJ pump assembly and throw it away where it won't hurt anyone ever again.
Using both the GM and XJ rubber gaskets, assemble the adapter onto the GM pump assembly. It's a very snug fit. Should go on fine with a little spit (or grease if you've got it). Make sure to put the GM lock ring between the top of the adapter and the XJ tank locking ring.
Remove the GM fuel sending arm if you're not using it.
Stick the assembly into the tank and push down until the assembly bottoms out. Measure the gap between the mating surface of the ring to the top of the tank (where you'll thread things on). You're measuring how much of the pump can assembly legs you want to chop off here.
Disassemble everything, chop off the legs to the correct length, reassemble and then re-flare the ends of the legs (regular flaring tool will do just fine).
Drop it in and run some cheap nylon lines with 3/8 and 5/16 quick connect fittings. You can probably even re-use the lines that came with the donor truck. Stick a cheap filter in-line somewhere.
Going this route costs less than $50, and you get to use an OEM pump that you already know works for your application.
Pro-tip: If you're throwing an LS in anything, find a way to finagle an XJ tank in. They're an awesome tank, indestructible, cheap, easy to find, and they fit almost anywhere. I'm running this setup in my LS swapped, bobbed 95 4runner truggy on Land Cruiser BJ/FJ60 axles :). The GM tank is too big to fit anywhere, the Toyota tank is crappy steel and sits well below the frame. XJ tank fits very nicely just behind the rear axle. You can land on these tanks and they just bend and survive.