Jeep Wrangler/YJ 1987-1995 Repair Guide

Tank Assembly

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REMOVAL & INSTALLATION



See Figure 1



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Fig. Fig. 1: Fuel tank mounting nut locations

Before removing the fuel tank, either drain or siphon the majority of fuel to make handling easier. Make sure that any remaining fuel is below the level of the attached hoses.

  1. Disconnect the negative battery cable.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove the fuel filler cap and drain the fuel tank.
  6.  
  7. Raise and support the vehicle safely.
  8.  
  9. Disconnect fuel fill and vent hoses from the filler neck.
  10.  
  11. Label and disconnect all other fuel supply and return hoses attached to the tank.
  12.  
  13. Place a floor jack under the fuel tank.
  14.  

Do not loosen the fuel tank strap nuts. The fuel tank and skid plate are removed as a unit after loosening the skid plate/fuel tank assembly mounting nuts.

  1. Remove the skid plate/fuel tank assembly mounting nuts.
  2.  
  3. Lower the skid plate/fuel tank assembly slightly and detach the gauge sender wire.
  4.  
  5. Lower tank from the vehicle. Unfasten the tank strap nuts to remove the skid plate.
  6.  

To install:
  1. Place tank into skid plate. Wrap straps around fuel tank and tighten mounting nuts to 65 inch lbs. (7 Nm).
  2.  
  3. Partially raise fuel tank and connect gauge sender wire.
  4.  
  5. Raise the tank into position and tighten the mounting nuts to 12 ft. lbs. (16 Nm). Remove the jack.
  6.  
  7. Connect the fuel filler and vent hoses to the filler neck.
  8.  
  9. Connect the fuel supply and return hoses.
  10.  
  11. Lower the vehicle, then fill and cap the fuel tank.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Start the vehicle and check for leaks.
  16.  

 
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