Sylvie Willis
Replacing a fuel tank on a CJ5 is a complex process. This article will outline the steps to take, from removing the negative battery cable to disconnecting the fuel lines and filler neck. We will also cover the installation of a new fuel tank, including the tightening of the bolts.
How to replace a CJ5 fuel tank
| Characteristics | Values |
|---|---|
| Step 1 | Remove the negative battery cable |
| Step 2 | Jack up the vehicle and support it with jack stands |
| Step 3 | Remove the drain plug and drain any remaining fuel into a suitable container |
| Step 4 | Disconnect the plug from the sending unit |
| Step 5 | Remove the gravel shield (if equipped) |
| Step 6 | Disconnect the three fuel lines |
| Step 7 | Plug the outlet line to prevent fuel from leaking |
| Step 8 | Disconnect the filler neck and vent line |
| Step 9 | Remove the fuel tank protector |
| Step 10 | Remove the bolts from the tank and carefully lower the tank |
| Step 11 | Install the new fuel tank |
| Step 12 | Tighten the tank bolts to 11-16 ft. lbs |
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What You'll Learn
Removing the old fuel tank
To remove the old fuel tank from your CJ5, first, remove the negative battery cable. Jack up the vehicle and support it with jack stands. Remove the drain plug and drain any remaining fuel into a suitable container. It is best to run the tank as low on fuel as possible before removing it. Disconnect the plug from the sending unit. Remove the gravel shield if equipped. Disconnect the three fuel lines. Plug the outlet line to prevent fuel from leaking. Disconnect the filler neck and vent line. Remove the fuel tank protector.
Next, remove the six bolts from the tank and carefully lower the tank. You can use a jack to lower the tank down. Once the tank is lowered, you can lift it out and replace it with a new one.
It is important to follow safety precautions when working with fuel. Make sure the area is well-ventilated and avoid any sources of ignition.
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Draining the fuel
To remove the tank, disconnect the plug from the sending unit and remove the gravel shield if equipped. Disconnect the three fuel lines, plugging the outlet line to prevent fuel from leaking. Disconnect the filler neck and vent line, then remove the fuel tank protector.
Now, remove the six bolts from the tank and carefully lower it. Installation of the new tank is the reverse of this process.
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Disconnecting the fuel lines
Firstly, ensure the vehicle is securely jacked up and supported with jack stands. This will provide a stable platform to work on and ensure your safety. Next, locate the three fuel lines and proceed to disconnect them carefully. It is important to note that you should plug the outlet line to prevent any fuel from leaking, which could create a hazardous situation. Once the fuel lines are disconnected, you will need to address the filler neck and vent line. Carefully disconnect these components, ensuring that you have a suitable container to catch any residual fuel that may leak out.
At this stage, it is also important to remove the fuel tank protector, which will provide access to the tank itself. With these steps completed, you will have successfully disconnected the fuel lines and can proceed to the next stage of the fuel tank replacement process. Remember to work carefully and methodically, ensuring that you follow all safety protocols when working with fuel systems.
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Installing the new fuel tank
To install the new fuel tank, jack up the vehicle and support it with jack stands. Drain any remaining fuel into a suitable container. It is best to run the tank as low on fuel as possible before removing it. Disconnect the plug from the sending unit. Remove the gravel shield if equipped. Disconnect the three fuel lines. Plug the outlet line to prevent fuel from leaking. Disconnect the filler neck and vent line. Remove the fuel tank protector.
Install the new fuel tank. Tighten the six tank bolts to 11-16 ft. lbs. You can go with a stock replacement metal tank, or poly, depending on your preference.
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Tightening the bolts
To tighten the bolts on a CJ5 fuel tank, you will need to follow these steps:
Firstly, make sure the vehicle is jacked up and supported with jack stands. Remove the negative battery cable. Then, drain any remaining fuel into a suitable container by removing the drain plug. It is best to run the tank as low on fuel as possible before beginning this process.
Next, disconnect the plug from the sending unit and remove the gravel shield if your vehicle has one. Disconnect the three fuel lines, making sure to plug the outlet line to prevent fuel from leaking. Disconnect the filler neck and vent line, and then remove the fuel tank protector.
Now you can remove the six bolts from the tank and carefully lower it. Install the new fuel tank and tighten the six tank bolts to 11-16 ft. lbs..
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Frequently asked questions
First, jack up the vehicle and support it with jack stands. Then, drain any remaining fuel into a suitable container. Disconnect the plug from the sending unit and remove the gravel shield if equipped. Disconnect the three fuel lines, plug the outlet line to prevent fuel from leaking, and disconnect the filler neck and vent line. Remove the fuel tank protector and the six bolts from the tank, then carefully lower the tank.
You can go with a stock replacement metal tank or poly, depending on your preference.
You will need a jack, jack stands, a suitable container for draining fuel, and a wrench to remove the bolts.
If your tank is leaking or damaged, it may be time to replace it.
