Jeep Wagoneer/Commando/Cherokee 1984-1998

Tank Assembly

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Removal & Installation



Except 1996-98 Grand Cherokee

See Figures 1 and 2


CAUTION
If the vehicle is equipped with the Multi-Point Fuel Injection, perform the fuel system pressure release sequence described earlier in this section.

  1. Disconnect the negative battery cable.
  2.  
  3. If equipped with a fuel injection system, relieve fuel system pressure as outlined in this section.
  4.  
  5. Remove the fuel filler cap.
  6.  
  7. Drain the fuel tank.
  8.  
  9. Raise and support the vehicle safely.
  10.  
  11. On 1986-91 Comanche models, remove the rear driveshaft.
  12.  
  13. Tag and disengage all hoses and wires connected to the tank.
  14.  


CAUTION
Wrap heavy shop towels around disconnected fuel lines to absorb spilled fuel. Be prepared to catch any fuel that is not absorbed!

  1. Remove the skid plate, if equipped.
  2.  
  3. Remove the fuel tank shield.
  4.  
  5. Support the tank with a floor jack and remove the strap nuts.
  6.  
  7. Partially lower the tank and disconnect the tank vapor vent hoses.
  8.  
  9. Remove the tank.
  10.  
  11. Inspect for rotted or leaking fuel lines.
  12.  

To install:
  1. Raise the fuel tank into position and connect the vent hose to the filler neck and tighten the clamp.
  2.  
  3. Wrap the support straps around the fuel tank, tighten them to 100 inch Ibs. (11 Nm). If 3 straps are used, tighten the center strap to 43 inch Ibs. (4 Nm) and the outer straps to 65 inch lbs. (7 Nm).
  4.  



Click image to see an enlarged view

Fig. Fig. 1: Some models use skid plates which must be removed to access the tank

  1. Install the tank shield and skid plate.
  2.  
  3. Engage all wires and hoses and lower the vehicle.
  4.  
  5. Fill the tank and install the filler cap.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Start the vehicle and check for leaks.
  10.  



Click image to see an enlarged view

Fig. Fig. 2: Common fuel tank and shield mounting

1996-98 Grand Cherokee

See Figure 3

  1. Disconnect the negative battery cable and relieve the fuel system pressure.
  2.  
  3. Raise and support the vehicle with jackstands.
  4.  
  5. Remove the fuel tank filler hose and vent hose clamps.
  6.  
  7. Remove both tubes at the filler tube.
  8.  
  9. If equipped remove the tow hooks and trailer hitch.
  10.  
  11. Remove the fuel tank skid plate retaining nuts/bolts, if equipped.
  12.  
  13. Unfasten the exhaust tailpipe heat shield retaining bolts and remove the shield.
  14.  
  15. Place a hydraulic jack under the tank.
  16.  


CAUTION
Place a shop towel around fuel lines to catch any fuel spillage.

  1. Tag and disengage the fuel supply line, fuel vent line and fuel pump module electrical connection.
  2.  
  3. Remove the tank strap nuts and position the straps away from the tank.
  4.  
  5. Lower the right side of the tank while feeding the fuel hoses through the hole in the body until the filler hose clamps can be removed.
  6.  

Before removing the filler hoses mark their rotational position in relation to the tank

  1. Remove the hoses and clamps.
  2.  
  3. Insert a drain hose (from an approved draining station) into one of the hose openings and drain the tank.
  4.  
  5. Slowly lower the jack and remove the tank. To prevent any remaining fuel loss through the hoses, keep the left side of the tank higher than the right side while lowering. Do not allow the hose openings to fall below the top of the tank.
  6.  

To install:
  1. Connect the fuel filter-to-fuel pump module supply line to the module.
  2.  
  3. Install the filler hoses and clamps to the tank noting their previously marked position.
  4.  
  5. Position the tank on the jack and raise the tank into position while guiding the fuel filler hoses through the access hole in the body.
  6.  
  7. Continue to raise the tank until it is in position and install the mounting straps.
  8.  
  9. Tighten the two mounting nuts until 3.149-3.268 in. (80-83mm) is attained between the end of the mounting bolt and the bottom of the strap. Do not overtighten.
  10.  
  11. Engage the pump module electrical connection and install the exhaust pipe heat shield.
  12.  
  13. Connect the fuel filter-to-fuel pump module supply line to the fuel filter.
  14.  
  15. Install the skid plate, trailer hitch and tow hooks, if equipped.
  16.  
  17. Install the fuel tank filler hose and vent hose. Tighten both clamps.
  18.  
  19. Lower the vehicle and connect the negative battery cable.
  20.  
  21. Fill the tank, start the vehicle and check for leaks.
  22.  



Click image to see an enlarged view

Fig. Fig. 3: Exploded view of the Grand Cherokee fuel tank and related components-1996 model shown

 
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