Rajan Wilcox
Removing the fuel tank on an XJ can be a complicated process. Before beginning, it is recommended to consult the Factory Service Manual for your specific model year. The first step is to drain the fuel tank to avoid leakage. This can be done by removing the fuel hose from the petcock and connecting it to a gas can or bucket. Next, remove the side bumper pieces, brackets, and bolts securing the bumper brackets to the body. Then, remove the screws where the quarter panel joins the center panel and the bolts and nuts securing the quarter panel to the wing or fender. With the quarter panel removed, you can access the fuel tank and proceed with the removal process as outlined in the service manual.
How to remove the fuel tank on an XJ
| Characteristics | Values |
|---|---|
| Step 1 | Drain the fuel |
| Step 2 | Disconnect the vacuum hose from the petcock |
| Step 3 | Remove the front tank mounting bolt |
| Step 4 | Remove the seat and the rear tank mounting bolt |
| Step 5 | Remove the petcock handle |
| Step 6 | Remove the side bumper pieces, including their brackets |
| Step 7 | Remove the screws where the quarter panel joins the center panel |
| Step 8 | Remove bolts and nuts securing the quarter panel to the wing/fender |
| Step 9 | Remove the quarter panel |
| Step 10 | Remove straps, unbolt and open the flap of metal protecting the fill/return fuel lines |
| Step 11 | Remove clamps and tubes from the gas tank |
| Step 12 | Cut bolts if necessary |
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What You'll Learn
Drain the fuel tank
To drain the fuel tank of an XJ, there are a few methods you can use. One common method is to siphon the fuel out of the tank. Here are the steps to do this:
- Disconnect the filler hose and vent hose from the side of the tank.
- Insert a hose into the vent tube connection, approximately 4 feet long.
- Place the end of the hose in a bucket that is on the ground and lower than the tank.
- Use your thumb to cap the end of the hose, then extract 2 to 3 feet of fuel.
- Remove your thumb to start the siphon and drain the tank.
If this doesn't work, you can try cutting a small slit in the cross-section of the hose and using a blow gun to start the siphon. It is important to note that you should not elevate the hose higher than the fuel tank or you will lose the siphon.
Another method to drain the fuel tank is to drop the tank and pour the fuel out. This can be done by removing the fuel tank straps and bolts, and then flipping the tank over to pour the fuel out. This method can be more challenging, and it is recommended to replace the bolts on the fuel tank straps as they may be bent.
Additionally, if your XJ has been sitting for an extended period, the fuel may have clogged the pump. In this case, you can try to evaporate the fuel by leaving the tank to sit for a day with the hole for the pump open.
When draining the fuel tank, it is important to take safety precautions to prevent static discharge that could start a fire. Always attach a ground cable from the vehicle to the container that you are filling with fuel.
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Remove bumper pieces and brackets
To remove the bumper pieces and brackets, start by getting under the side bumper piece where it makes a 90-degree turn. Remove the bolts securing the bumper brackets to the body, not to the bumper pieces. If someone has attempted to remove them previously, the nuts joining the rear chromed piece to the side piece may already be broken. If not, spray them with rust dissolver for a few days; otherwise, the stud will break in two when you try to loosen the nuts.
Next, remove the side bumper pieces, complete with their brackets. Then, remove the screws where the quarter panel joins the centre panel. After that, remove the bolts and nuts securing the quarter panel to the wing/fender. Finally, remove the quarter panel. Now you should be able to see the fuel tank.
Note: It is recommended to refer to the Factory Service Manual for your specific car model, as the process can be quite complicated. Additionally, some sources suggest that it may be necessary to drain the gas and remove straps and clamps before attempting to remove the fuel tank.
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Disconnect the vacuum hose
Disconnecting the vacuum hose is a crucial step in removing the fuel tank on an XJ. Here is a detailed guide on how to do this:
First, ensure that you have drained the fuel tank. This is important to avoid any fuel leakage during the process. To drain the tank, remove the fuel hose from the petcock and connect a length of 1/4" fuel hose. Place the other end of this hose into a gas can or large bucket to catch the fuel. Turn the petcock to the "prime" position, allowing the fuel to drain. Wait until most of the fuel has drained from the tank. Finally, place the petcock in the "on" or "reserve" position.
Now, you can proceed to disconnect the vacuum hose. Locate the vacuum hose connected to the petcock. It is usually attached to the fuel tank system. Grasp the hose firmly and carefully pull it away from the petcock. It may require some force to detach it, but be careful not to damage any nearby components.
In some XJ models, there might be additional clamps or fasteners securing the vacuum hose in place. If this is the case, you will need to loosen or remove these fasteners before you can completely disconnect the hose. Make sure to note the type and location of these fasteners so that you can properly secure the new hose or reattach the old one correctly later.
Once the vacuum hose is disconnected, set it aside safely. Be cautious not to kink or damage the hose, as it may still contain residual fuel. If there are any fuel leaks from the hose, carefully absorb them with a suitable absorbent material.
At this point, you have successfully disconnected the vacuum hose from the fuel tank system of your XJ. Remember to refer to your specific XJ model's service manual for additional instructions or variations that may be unique to your vehicle. Always exercise caution when working with fuel systems to avoid any safety hazards.
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Remove mounting bolts
To remove the mounting bolts, first drain the fuel tank to prevent fuel from leaking out. Disconnect the vacuum hose from the petcock and remove the front tank mounting bolt. Next, remove the seat and the rear tank mounting bolt.
Now, remove the side bumper pieces, including their brackets. This involves removing the bolts that secure the bumper brackets to the body, not the bumper pieces themselves.
With the bumper brackets removed, you can access the screws where the quarter panel joins the center panel. Remove these screws, and then proceed to remove the bolts and nuts securing the quarter panel to the wing/fender.
At this stage, you should be able to see the fuel tank. Depending on your specific XJ model, you may need to refer to the Factory Service Manual for further instructions as the process can become quite complicated.
Note: Some forum users have mentioned that their bolts were rusted or difficult to remove, requiring cutting or replacement. Inspect your bolts and brackets for any signs of rust or damage, and have replacements ready if needed.
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Clean the tank
To clean the fuel tank of your XJ, you will first need to drain the tank. Then, fill it with a couple of gallons of fresh gas mixed with a couple of cans of Berryman's. Let the mixture soak for a couple of weeks before draining it again. If your tank is rusty, you can try removing the small nut at the bottom of the tank and using a thin screwdriver to get some gas flowing. Then, remove the large nut and clean out the rust with a plumber's turn brush. Rinse the tank by rocking the car back and forth with about a gallon of gas inside, then drain the tank again. Repeat this process until the rinse runs out clean.
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