Replacing The Fuel Tank On Jeep Xj: Step-By-Step Guide

If you're looking to replace the fuel tank on your Jeep XJ, there are a few things you should know. First, the fuel tank on a Jeep XJ is located at the rear underside of the vehicle, and it typically holds around 20 gallons of gas. To replace the fuel tank, you will need to drain the gas, remove the straps and bolts holding the tank in place, and disconnect the fuel lines. You may also need to remove the heat shield or bumper for easier access. When installing the new fuel tank, make sure to use the correct fuel tank for your model year, as there may be differences in the vent and filler locations. Additionally, consider upgrading to an aftermarket fuel tank with a larger capacity if you're looking for increased range.

Drain the gas

To drain the gas from your Jeep XJ, you will need to first locate the gas tank. The gas tank is typically held in place by straps, which you will need to remove. You may also need to unbolt any metal flaps protecting the fuel lines. Once the straps and bolts are removed, you can then remove the clamps and tubes connected to the gas tank.

It is important to place a container underneath the gas tank to catch the draining fuel. Be very cautious during this process, as gasoline is highly flammable and can pose a safety hazard if not handled properly. Ensure that you are wearing appropriate safety gear, such as gloves and eye protection, and that you are working in a well-ventilated area.

If your Jeep XJ is equipped with a fuel pump, you may need to reach into the tank to remove it. Be sure to have a container nearby to catch any residual fuel that may spill out.

Additionally, if your gas tank is equipped with a rollover check valve, you may need to dislodge it by gently tapping on it with a hammer. This valve is designed to prevent gasoline from leaking out in the event that your Jeep rolls over.

Once the gas tank is drained, you can then proceed with the remaining steps to change the fuel tank on your Jeep XJ. Remember to dispose of the drained gasoline in a safe and environmentally friendly manner.

Remove the fuel tank straps

To remove the fuel tank straps from your Jeep XJ, you will need to drain the gas from the tank. Next, use a 9/16 wrench to loosen the nuts holding the straps in place. If they are rusted, you may need to use two wrenches for better leverage, or simply cut the straps off.

Once the nuts are removed, you can then open the flap of metal protecting the fuel lines. Remove the clamps and tubes from the gas tank side, and the tank should drop down.

It is recommended to use a floor jack to hold the tank if you have not drained the fuel. This will make it easier to access the filler neck hose clamps.

Some Jeep XJ models may have stainless steel straps, which can be cut off with metal-cutting tools if they are rusted or seized.

This process should be relatively straightforward and should not require any modifications to your vehicle.

Unbolt the tank

To unbolt the tank, you will need to first drain the gas. Next, remove the straps and bolts holding the tank in place. You may need to cut the bolts if they are rusted. Once the bolts are removed, use a floor jack to lower the tank if you were unable to drain the fuel.

Now, you can access the filler neck hose clamps. Remove both clamps and then the tank itself. If your Jeep is an older model, this process should be relatively quick and easy. However, if it is a newer model, you may encounter more difficulties.

For example, if your Jeep is a 1996 model, you will need to deal with the in-tank pressure regulator. Additionally, the pump, mount, sending unit, fuel pressure regulator, lines, and connectors are all different in the newer models, so you will need to make modifications if you are swapping tanks between different model years.

If your Jeep has a factory receiver hitch, you can still use the GenRight Off Road XJ Enduro Gas Tank & Skid Plate (30.5 Gal). This tank is designed to fit in the stock location and keep the center of gravity low, even with the extra fuel capacity.

Remove the filler hose clamps

To remove the filler hose clamps, you will need to first drain the gas from your Jeep XJ's tank. Next, remove the straps and bolts holding the tank in place. You may need to use a 9/16 wrench to break the nuts loose, and some PB Blaster to help loosen them if they are rusted. Once the tank is lowered, you can access the filler neck hose clamps and remove them.

The filler hose clamps connect the filler hose to the gas tank. The filler hose is the tube through which gas is pumped into the tank when you fill up at the gas station. The clamps ensure a tight connection between the filler hose and the tank, preventing leaks.

To remove the clamps, you will need to locate them first. They are usually found near the filler neck, which is the opening in the gas tank where the filler hose is attached. Once you have located the clamps, you can use a hose clamp plier or a flat-head screwdriver to loosen and remove them. Be careful not to damage the filler hose during this process.

It is important to ensure that the gas tank is stable and securely held in place while you are working on it. You may need an extra pair of hands or a floor jack to help support the tank while you remove the clamps.

Once the clamps are removed, you can carefully detach the filler hose from the tank. Again, be cautious to avoid any spills or leaks. Have some rags or paper towels handy to wipe up any spilled gasoline, and work in a well-ventilated area to avoid inhaling fumes.

If your filler hose is old or damaged, it is a good idea to replace it along with the fuel tank. You can find replacement filler hoses and clamps at most auto parts stores or online.

Lower the tank

To lower the tank, you will need to drain the gas. You can do this by inserting a drain hose through the vent hose stub, which is the smaller of the two hoses.

Once the tank is empty, remove the straps and bolts holding the tank in place. You may need to use a 9/16 wrench to break the nuts loose, or if they are very rusted, you can cut them off.

Now, open up the flap of metal protecting the fill/return fuel lines and remove the clamps and tubes from the gas tank side. Be sure to have a floor jack ready to support the tank as you remove these components.

With the straps, bolts, and tubes removed, you can now carefully lower the tank. Take caution to avoid damaging any surrounding components or causing injury.

If your Jeep is equipped with a skid plate, you may need to modify or remove it to access the fuel tank. Additionally, if your Jeep has a factory receiver hitch, you may need to detach it for better access.

It is important to note that some states have regulations regarding gas tank removal, so be sure to check your local laws before proceeding.

Frequently asked questions