I’m having an issue with the Gen2 fuel head when using an in-tank electric fuel pump. Now for a little backstory. The in-tank fuel pump was installed ~10k miles ago and the Gen2 fuel head was installed -55k miles ago. Also just finished completely rebuilding the engine after spinning the #3 journal bearing and am just now starting it for the first time.

So shortly after starting the Jeep I sprung a small leak on the backside of CP3 pump as I had removed the hard fuel lines from the pump when the engine was disassembled. So fixed that leak and restarted the engine and ran for maybe 30 seconds and then heard a loud pffft sound which sprayed fuel everywhere. The pffft sound was the gasket between the fuel filter and the fuel filter head popping out from between them. So disassembled the filter and filter head, fixed the gasket position and reassembled it making sure the filter was good and tight. Reinstalled the filter assembly and fired it back up and almost immediately fuel started spraying everywhere, including onto the ceiling of the garage. The gasket between the filter and filter head is fine this time. So took the whole filter assembly off again and found that the rubber seal between the filter pump section and the heater element section had blown a hole in it.

So couldn’t find a filter head assembly locally, so ordered a complete fuel filter head assembly from ID Parts and paid for overnight air shipping. Installed it earlier this evening and now a repeat of two nights ago with the gasket popping out and fuel spraying everywhere. So getting ready to fix the gasket and try starting it again, but this time pulling the fuse that powers the fuel pump, fuse #17 prior to trying it again. My suspicion is that my in-tank Carter fuel pump is not shutting off when reaching its cutoff pressure.

Need to figure out how to post pictures so I can show gasket and fuel head issues.
Has anyone experienced such an issue or have any thoughts about what I’ve got going on.

Same issue with the gasket popping out even after removing the fuse that feeds the in-tank fuel pump. Needless to say I’m a bit perplexed.

Are you sure you have the "correct lift pump" for our engine? Should be no more than 6-8psi if I remember correctly. What happens if you you disable the pump completely (remove power) and then try to start the jeep?

WW I believe has a way to install a fuel pressure gauge at the filter head and he may be able to chime in and tell you how to do it to double check the fuel pressure.

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05 CRD; Rebuilt top end w/ARP studs, EGR delete, SEGR, 3.7L HD cooling fan, Samco hoses, in tank pump, JBA coil overs & control arms, KK clevis fork, 1/2" cradle drop, 1/4" motor mount lift, WJ rear upper trilink w/WW mount, WJ lower control arms, 4:10 gear, front/rear air lockers, ARB bumper, Rock Lizard sliders/roof rack, Mod T-stat

Carter pumps use an internal regulator. It's essentially a check valve. The weight of the spring is what determines the output regulated pressure. If it's stuck closed it could build up pressure until something fails (as you've found). You will need to replace the pump or try to free up the internal regulator, both of which requires removing the old pump. Things that sit idle for long periods of time can cause issues.

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GDE FT Ecotune, EHM, Weeks kit stage 1 & 2, Carter 4600 lift pump, Upgraded tranny, Fishing boat hauler!
New at 164K: head gasket, rockers, exhaust valves, ARP head studs, Injectors, 5v Bosch glow plugs, water pump, timing everything, serpentine everything,
New at 225k: new head, timing belt