Regan Brown
Removing the fuel tank from a 2010 Jeep Wrangler can be a complex process. Before starting, it is important to ensure you have the right tools and enough space to work. It is also recommended to run the fuel as low as possible to reduce weight and make the process easier. The first steps involve relieving the fuel system pressure, disconnecting the negative battery cable, and removing the fuel filler cap. Next, you'll need to disconnect the fuel pump and the fuel supply line. After that, you can place a floor jack under the tank and start to slowly lower it. Once the tank is lowered a few inches, you can remove the check valve hoses and continue lowering it. Finally, you'll need to disconnect the fuel lines, vent lines, filler hose, and electrical connectors. It is important to be cautious and patient throughout the process to avoid any damage to the vehicle or injury to yourself.
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What You'll Learn
Remove skid plate bolts and exhaust hanger
To remove the skid plate bolts and exhaust hanger on a 2010 Jeep Wrangler, you will need to follow a few important steps. Firstly, it is recommended to run your fuel as low as possible before beginning the process to reduce the weight you will be dealing with.
Next, you will need to place a jack underneath the Jeep and remove all seven bolts that secure the skid plate. Depending on the condition of the bolts, you may simply be able to unscrew them. However, if they are rusty or damaged, you may need to cut them using an angle grinder or a similar tool. Be cautious when doing this, as you don't want to damage any other components. Once the bolts are removed, gently pry the skid plate downwards to free it from the bolt studs.
With the skid plate removed, you can now access the exhaust hanger. Check the condition of the hanger and the rubber hanger/isolators. If they appear worn or stretched, they may need to be replaced. Additionally, inspect the heat shield on the crossover pipe for any damage, as this could cause a rattle. If the exhaust hanger is intact but the skid plate is riding higher or lower than it should be, you may need to adjust the alignment or clear any obstructions.
Finally, when reinstalling the skid plate, consider using a new set of nutserts and bolts to ensure a secure fit. You can purchase a replacement kit for the nutserts, such as the 87-06 YJ and TJ Transfer Case Skid Plate Nutsert Replacement Kit mentioned in the forums.
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Disconnect fuel supply line
Disconnecting the fuel supply line is a critical step in removing the fuel tank from a 2010 Jeep Wrangler. It is important to approach this task with caution, as it involves flammable liquids and gases.
Before disconnecting the fuel supply line, it is recommended to run the fuel as low as possible to reduce the amount of fuel in the tank. This can be done by letting the fuel light come on and then driving for another 50 miles. Keep a jerrycan with a couple of gallons of fuel handy in case of emergencies.
To disconnect the fuel supply line, first locate the fuel pump plug and the corresponding tab on the skid plate. Disconnect the fuel pump by pulling on the red safety tab and then squeezing the connector clip and pulling. The plug may come loose or break away from the skid, which is considered normal. If the plug does not come apart easily, ensure the safety tab is disengaged before trying again.
Next, squeeze the two grey tabs on the fuel supply line that are 180 degrees from each other. While squeezing, grab the rubber flex line with your other hand, push your hands together, and then pull on the flex line. It is common for gas to come out of the line, so be prepared to catch the gas with a rag and ensure your head is not directly under the fitting to avoid getting gas in your eyes.
Once the fuel supply line is disconnected, you can continue with the next steps of removing the fuel tank, such as placing a floor jack under the tank and removing the nuts along the front and back crossmembers.
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![A-Premium Fuel Tank Straps W/ 2PCS Compatible with Jeep Wrangler [YJ Series] 1987 1988 1989 1990 1991 1992 1993 1994 1995 [OHV, 6Cyl 2.5L 4.0L 4.2L]](https://m.media-amazon.com/images/I/611qLQDeWoL._AC_UY218_.jpg)
Release fuel system pressure
To release the fuel system pressure on a 2010 Jeep Wrangler, follow these steps:
- Pop the hood and locate the Schrader valve on the fuel rail. It is under a black plastic screw-on cap and looks like a tire valve stem core or an oversized tire inflation valve.
- Place a rag under the valve to catch any fuel spray and use a small screwdriver to release the pressure. Holding the rag in an "L" shape will help stop the horizontal spray.
- Remove the fuel fill cap.
- Place a non-metallic object into the fuel fill tube and press on the flap to relieve any tank pressure.
- Remove the fuel pump relay from the Power Distribution Center (PDC). Refer to the label on the underside of the PDC cover for the exact location.
- Start and run the engine until it stalls.
- Attempt to restart the engine until it will no longer run.
- Turn the ignition key to the OFF position.
- Unplug the connector from any injector.
- Use a jumper wire with alligator clips to connect the injector terminal to the battery. Connect one end to the positive side of the battery and the other end to the negative side, ensuring that you only power the injector for a few seconds to avoid damage.
- Place a rag or towel under the fuel line quick-connect fitting at the fuel rail to catch any remaining fuel.
- Disconnect the quick-connect fitting at the fuel rail.
Note that some sources suggest that releasing the fuel system pressure may not be necessary, but it is recommended as fuel lines can run at high pressure. Additionally, ensure that you run your fuel as low as possible before starting the process, and always be cautious when working with flammable liquids.
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Lower the tank
Lowering the tank is a delicate process. First, you need to remove the bolts and then slowly lower the tank using a jack. Make sure you have loosened all the fuel lines and other connectors before lowering the tank all the way down. It is recommended to place a floor jack with a block of wood underneath the tank and jack it up until it starts to lift the back of the Jeep.
You should then slowly lower the gas tank. When you have lowered it a couple of inches, stop and remove the check valve hoses. You can then lower it a bit more, disconnecting the wiring harness, and then a bit further, disconnecting two vent lines on the rollover valves.
It is also important to disconnect the fuel supply line. There are two grey tabs 180 degrees from each other; squeeze these and grab the rubber flex line with your other hand, then push your hands together and pull on the flex line. Gas will likely come out of the line, so be sure to have a rag handy to catch it.
It is also possible to disconnect the exhaust hanger to allow you to shift the tank to one side and clear the frame on the driver's side.
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Reinstall the tank
To reinstall the fuel tank in a 2010 Jeep Wrangler, follow these steps:
Firstly, ensure the tank is completely empty to make it as light as possible. When reinstalling, lift the driver's side up and get the filler/vent lines up and over the frame rail first, then raise the other end of the tank into place. Make sure the fuel line clamp is tight and the vent hoses are connected.
If you have a body lift, the filler neck hose clamp can be tricky, so flip the clamp over on the hose before you go to put it back on. You will need to undo the strap bolts and then the skid plate bolts to get the tank back up into place. To get the bolts started into their holes, one trick is to weld a piece of wire to the centre of the bolt and thread the wire through the correct holes from the inside before the tank is in the way.
You will also need new tank straps, as it is very rare to be able to get them apart and reuse them. When the tank is back in place, the skid plate bolts can be difficult to get in, so use a pry rod in the bolt holes and some vice grips to make it easier.
Finally, make sure the exhaust pipe is out of the way. It should swing out, as it is suspended by rubber mounts.
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