Rajan Wilcox
Removing the fuel tank from a Jeep Wrangler TJ is a complex process that requires careful preparation and execution. It is important to note that the fuel tank removal process may vary slightly depending on the make, model, and year of the Jeep Wrangler TJ. Before beginning, it is crucial to gather the necessary tools and ensure a spacious and well-lit work area. The process typically involves removing the skid plate, disconnecting fuel lines, vent lines, and electrical connectors, and carefully lowering the fuel tank. It is recommended to siphon the fuel beforehand to make the task safer and more manageable. Additionally, it is important to be cautious when dealing with rusted parts and to take appropriate measures to prevent fuel leakage.
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What You'll Learn
Disconnect the fuel supply line
Disconnecting the fuel supply line is a crucial step in removing the fuel tank from a Jeep Wrangler TJ. Here is a detailed guide on how to do this safely and effectively:
First, it is important to relieve the pressure in the fuel system. This can be done by disconnecting the relay located in a black box under the hood of the Jeep. There may be a cheat sheet inside the box that shows which relay to disconnect. Pull out the fuel pump relay and place it in the box under the hood for easy access later. Attempt to start the Jeep to ensure the fuel pump relay has been successfully disconnected; the vehicle should start quickly and then lose pressure and die.
Next, locate the fuel lines underneath the Jeep. These lines are typically held together by simple push connectors. Look for the lines that lead to the fuel tank and push them apart by finding and pressing the push button on the connector. This button is often almost flush with the rest of the connector but will usually be a different colour. Pushing the button will release the connector, allowing you to pull the fuel line apart from it. Repeat this step for all fuel lines connected to the fuel tank.
When disconnecting the fuel supply line, it is important to be cautious. There are usually two fuel lines connected to the tank, and gas may leak out when they are disconnected. It is recommended to have a rag handy to catch any leaking gas and to avoid having your head directly under the fitting to prevent gas from getting into your eyes.
For some Jeep Wrangler models, there may be additional steps or variations to disconnecting the fuel supply line. For example, for a 2006 Jeep Wrangler X, there may be a blue tab and a black tab/fuel line. To disconnect the line, squeeze the blue tab and, while continuing to squeeze, pull the black tab/fuel line forward and then pull back.
By carefully following these steps, you can safely disconnect the fuel supply line when removing the fuel tank from a Jeep Wrangler TJ.
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Prepare for removal
To prepare for the removal of the fuel tank in your Jeep Wrangler TJ, you will need to gather the right tools and parts. Make sure you have a suitable workspace with enough light and time to complete the job. It is recommended to work in an area with ample space and good lighting. Ensure you have the correct replacement fuel tank for your Jeep's specific make, model, and year.
Before beginning the removal process, it is essential to remove the pressure from your fuel system. Disconnect the relay located in a black box under the hood of your Jeep. You can identify the correct relay by referring to the cheat sheet inside the box's lid. Pull out the fuel pump relay and place it in the designated spot. To confirm that the fuel pump relay is disconnected, attempt to start your Jeep; it should start quickly and then lose pressure and die.
Next, you will need to address the fuel lines. The fuel lines underneath your Jeep are typically held together by simple push connectors. Look for the lines that lead to your fuel tank and push them apart by locating the side with a push button. This button is often nearly flush with the rest of the connector but will be a different colour. Pushing the button will release the connector, allowing you to pull the fuel line apart. Repeat this step for all the fuel lines connecting to your fuel tank.
Additionally, you will need to remove the breather tube and the electrical connection next to the fuel lines. Simply pull the breather tube off the differential. For the electrical connection, push the red tab down and pull to disconnect it.
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Remove skid and tank
Removing the fuel tank skid plate and tank from a Jeep Wrangler TJ is a straightforward process, but it requires the right tools and some mechanical know-how. Here is a detailed guide on how to remove the skid and tank:
Prepare the Jeep:
Before starting, ensure you have all the necessary tools, including a floor jack, a piece of wood, and various wrenches and sockets. Remove the tires from the Jeep to easily access the fuel line connections. If necessary, also remove the springs and shocks. Apply a penetrating lubricant to all components to loosen rusted or frozen parts and protect against further corrosion.
Disconnect Fuel System:
Release the pressure from the fuel system by disconnecting the relay located in a black box under the hood. Pull out the fuel pump relay and place it back in the box to reconnect later. The Jeep will start and then quickly lose pressure and die, confirming the disconnection. Disconnect the fuel pump by pulling on the red safety tab and squeezing the connector clip. The plug may come loose or break away, which is normal.
Disconnect Fuel Supply Line:
The fuel supply line can be disconnected by squeezing two grey tabs 180 degrees apart and pulling the rubber flex line. Be cautious, as fuel may spill out. Have a rag ready to catch any fuel and ensure your head is not directly under the fitting.
Prepare for Removal:
Place the floor jack with the wood block under the tank and jack it up until it lifts the rear of the Jeep slightly.
Remove the 13mm nuts from the front and back crossmembers (seven nuts in total, with four at the back and three at the front). The skid plate is now detached, and you can slowly lower the tank. Once the tank is lowered a couple of inches, remove the check valve hoses.
Lowering the Tank:
Continue slowly lowering the tank, ensuring you disconnect the remaining components as it drops. These include the two fuel lines, a vent line, filler hose, filler vent hose, and an electrical connector.
It is recommended to siphon the fuel from the tank before starting to make the process easier and safer. Additionally, if your Jeep has significant rust, be cautious when removing components as they may snap and require repairs.
Upgrading to an aluminum skid plate from UCF, GenRight, or Savvy can provide better protection for the tank and resist rust.
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Lower the tank
Lowering the tank is a delicate process. First, place a 4x4 piece of wood on top of a car jack to hold the weight of the tank. Apply pressure to the tank without lifting it. Slowly lower the gas tank. When the tank has dropped down a couple of inches, stop and remove the check valve hoses. Disconnect the fuel lines (usually two), a vent line, filler hose, filler vent hose, and an electrical connector. Siphoning the fuel out beforehand makes the job easier.
Some users have encountered issues with the fuel lines, particularly the main pressure hose, which necks down from 3/8" to 5/16". It is also recommended to disconnect the pressure from your fuel system by disconnecting the relay located in a black box under your Jeep’s hood. This will cause the Jeep to start quickly, then lose pressure and die.
The fuel lines underneath your Jeep are held together by simple push connectors. Look for all the lines that lead to your fuel tank and push them apart by finding the side with a push button. This button is often almost flush with the rest of the connector but will be a different colour. Pushing the button will free the connector, so you can pull the fuel line apart from the connector. Repeat this step with all of the fuel lines connecting to your fuel tank.
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Disconnect the wiring harness
Disconnecting the wiring harness is a crucial step in removing the fuel tank from a Jeep Wrangler TJ. This process involves detaching the electrical connections and fuel lines that supply power and fuel to the tank. Here is a detailed guide on how to disconnect the wiring harness:
Locate the Wiring Harness: The wiring harness is typically located near the fuel tank. It consists of electrical connectors, fuel lines, and other components that facilitate the flow of electricity and fuel to the tank.
Disconnect the Electrical Connector: Before disconnecting the fuel lines, it is essential to first detach the electrical connector. This connector provides power to the fuel pump and other components within the fuel system. To disconnect it, locate the red safety tab on the connector. Pull on the tab gently, squeezing it if necessary, to disengage the locking mechanism. Then, squeeze the connector clip and pull to separate the connector. If the plug is challenging to remove, ensure the safety tab is fully disengaged before trying again.
Unplug the Fuel Pump: The fuel pump, located within the fuel tank assembly, needs to be unplugged. Gently pull on the fuel pump connector to detach it from the fuel pump. Similar to the electrical connector, there may be a red safety tab that needs to be disengaged before the fuel pump connector can be fully removed.
Detach the Fuel Lines: The fuel lines supply fuel to the tank and must be carefully disconnected. There are usually two fuel lines connected to the tank. To detach them, locate the grey tabs on the fuel line connectors. Squeeze these tabs simultaneously while using your other hand to grip the rubber flex line. Then, push your hands together and pull on the flex line to separate it from the tank. Be cautious, as fuel may leak from the line during this step. Have a rag or container ready to catch any spilled fuel.
Address Additional Connections: Depending on your Jeep Wrangler TJ model, there may be additional connections to address, such as vent lines, filler hoses, and vent hoses. These connections should be carefully disconnected or detached as per the specific requirements of your vehicle. Always refer to a qualified mechanic or a Jeep Wrangler TJ-specific forum for detailed instructions on addressing these additional connections.
Disconnecting the wiring harness is a delicate process that requires attention to detail. Ensure you have a comprehensive understanding of your Jeep Wrangler TJ's fuel system and consult reliable sources or professionals for guidance if needed.
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Frequently asked questions
You will need a 1/2″ socket, a 3/16″ allen wrench, a 13 mm socket, a 3/8 drive ratchet, a 3/8 drive 6″+ extension, a Phillips screwdriver, a floor jack, and a piece of wood.
First, remove the screws holding the filler neck and bezel, and install the gas cap on the filler neck. Cut the zip tie holding the diff breather off the fuel filler hose. Then, unplug the fuel pump by pulling on the red safety tab and squeezing the connector clip. Disconnect the fuel supply line, and place your floor jack with the block of wood under the tank and jack it up. Remove the 13mm nuts from the front and back crossmembers, slowly lower the tank, and remove the check valve hoses.
Before starting, take your Jeep’s tires off to easily see all of the fuel line connections. Remove the pressure from your fuel system by disconnecting the relay located in a black box under your Jeep’s hood. Soak everything with penetrating lubricant to loosen rusted or frozen parts and protect your Jeep from further rust and corrosion.
After removing the fuel tank, you can replace the fuel pump, fuel filter, or fuel lines. You can also make repairs to the frame and body under and around the tank. Consider upgrading to an aluminum skid plate to protect the tank and prevent rust.
