mhead
NAXJA Forum User
- Location
- Encinitas, CA
Hi All,
Replaced the gas tank and fuel pump on my 1992 XJ 4.0L 4X4 auto trans. This vehicle also has a factory gas tank shield. Installed a Bosch fuel pump.
The pump operates quietly in a nearly empty tank. Replacement tank was a drop-in with no hassles. Bosch pump required simple mods to make it fit. Part numbers below.
If anyone knows the part numbers and supplier for the tank filler hoses please post these. NAPA has general purpose hoses but they seem really stiff and I expected they would be difficult to install. I re-used my 25 year old hoses since they had no cracks and seemed in good condition.
Here is a step by step list of what I did. You could use this as a plan if you are doing the same job.
Safety
Eye protection
Beware of gasoline entering ear canal
Perform this service in well ventilated area
Beware ignition hazards such as sparks, water heater pilot lights, cigarettes.
Use copper hammer and drift to remove securing ring from old tank fuel pump assy.
Shopping List
Gas Tank: Amazon - Spectra Premium JP2B Fuel Tank for Jeep Cherokee/Wagoneer $74.49 with free shipping.
(Tank arrived with new o-ring and locking ring for fuel pump assy .)
Evaporation valve: Amazon - Genuine Chrysler J5360058 Fuel Tank Rollover Safe Valve (2 required) $21.99
Valve seal: Amazon - Crown Automotive 52018823 Vapor Valve Seal (2 required) $7.44
Fuel pump to fuel filter hose: 3/8" ID (3 feet required). Must be certified for fuel injection use.
Fuel return to tank hose: 5/16" ID (2 feet required)
Evaporation valve hose: 3/16" ID (4 feet required)
4" X 10" X 1/16 rubber sheet.
Tank to filler main hose. 1 1/2" ID (need p/n)
Tank to filler vent hose. 5/8" ID (need p/n)
Contact cement
Silicone oil
WD 40
Preparation
Review youtube.com videos
https://www.youtube.com/watch?v=5gm_m1hKtY8&t=318s
Purchase parts
Primer and paint new gas tank
Operate vehicle until gas tank is nearly empty
Measure pressure at fuel rail with vacuum to pressure regulator disconnected. (40 psi)
Wire brush threads of retaining bolts.
Soak retaining bolts with liquid wrench. Coat with anti-sieze.
Removal Procedure
Place vehicle on axle stands. Height should be low enough for floor jack to reach tank.
Remove rear wheels.
Photograph area for reference for re-installation.
Depressurize fuel line using valve on fuel rail.
Remove filter outlet fuel line, connect several feet of new fuel line, pump remaining gas out using vehicle fuel pump.
(Didn't work - need some way of convincing fuel pump to operate.)
If factory tank skid plate
Support skid plate with rachet strap from leaf spring to leaf spring
Remove muffler pipe hanger
Remove 4 X 18 mm bolts
Support skid plate with floor jack
Release strap.
Lower skid plate and remove from area.
Mark fuel pump with pencil noting which line goes to filter and which is return. (larger port is pressure, small is return)
Disconnect hoses and electrical from fuel pump. Catch gas in a cup.
Remove shield covering filler tube at bottom of vehicle.
Remove gas cap.
Remove hose clamps securing 2 rubber hoses to filler cap.
WD 40 hose connections to filler tube.
From gas cap side gently pound long pry upon hoses to press them off.
Disconnect two screws (8mm) on filler tube and remove. Inspect.
Loosen tank strap retainer hanger bolts (9/16) to the point where they can be removed but do not remove.
Remove passenger side hanger bolt and strap.
Support tank with floor jack in middle. Align jack wheels towards passenger side.
Remove driver side hanger bolt.
Lower tank and move towards passenger side until filler hoses clear.
Lower driver side of tank by hand.
Remove tank from under vehicle. Be careful when dragging tank that there are no sparks.
Remove fuel pump assy from tank.
Install new fuel pump on fuel pump assy removed from tank.
The white plastic spacer supplied with new pump must be cut a little.
The factory mount has a small groove that must be widened a little to receive the top fuel pump mount bracket.
The wiring harness supplied with the new pump must be used.
Red pump wire to wire from fuel tank connector.
Black pump wire to ground on factory pump assembly.
Hose clamps supplied with new pump should be replaced with higher quality clamps.
Install new fuel pump into tank using o-ring and metal ring supplied with tank.
Install evap valve rubber seals into new tank.
Silicone oil inside of seal.
Press new evap valve into seal.
Glue on 2" X 10" x 1/16" rubber strips in two recesses in new tank.
Install new filler neck hoses.
Move tank under vehicle
Unscrew nuts on tank retainer straps to nearly off the bolts.
Install tank retainer straps into rear of vehicle.
Lift driver side of tank and pass filler hoses through port in chassis.
Lift tank into position.
Install passenger side retainer strap loosly
Install driver side retainer strap loosly
Coat tube attach points on filler neck with light coating of silicone oil.
Install filler neck into hanger and secrue with two screws.
Install filler hoses from tank onto filler neck. Secure with hose clamps.
Install shield covering filler hoses on underside of vehicle.
Install gas cap.
If factory gas tank shield, install shield loosely
Tighten tank retaining straps
if factory gas tank shield, tighten retainer bolts (18mm)
Install new fuel pump hoses.
Connect electrical.
Cable tie all in place
Start vehicle.
Measure fuel pressure. Should be the same as previously.
Inspect all connections for gasoline leaks while engine running.
Mike
Replaced the gas tank and fuel pump on my 1992 XJ 4.0L 4X4 auto trans. This vehicle also has a factory gas tank shield. Installed a Bosch fuel pump.
The pump operates quietly in a nearly empty tank. Replacement tank was a drop-in with no hassles. Bosch pump required simple mods to make it fit. Part numbers below.
If anyone knows the part numbers and supplier for the tank filler hoses please post these. NAPA has general purpose hoses but they seem really stiff and I expected they would be difficult to install. I re-used my 25 year old hoses since they had no cracks and seemed in good condition.
Here is a step by step list of what I did. You could use this as a plan if you are doing the same job.
Safety
Eye protection
Beware of gasoline entering ear canal
Perform this service in well ventilated area
Beware ignition hazards such as sparks, water heater pilot lights, cigarettes.
Use copper hammer and drift to remove securing ring from old tank fuel pump assy.
Shopping List
Gas Tank: Amazon - Spectra Premium JP2B Fuel Tank for Jeep Cherokee/Wagoneer $74.49 with free shipping.
(Tank arrived with new o-ring and locking ring for fuel pump assy .)
Evaporation valve: Amazon - Genuine Chrysler J5360058 Fuel Tank Rollover Safe Valve (2 required) $21.99
Valve seal: Amazon - Crown Automotive 52018823 Vapor Valve Seal (2 required) $7.44
Fuel pump to fuel filter hose: 3/8" ID (3 feet required). Must be certified for fuel injection use.
Fuel return to tank hose: 5/16" ID (2 feet required)
Evaporation valve hose: 3/16" ID (4 feet required)
4" X 10" X 1/16 rubber sheet.
Tank to filler main hose. 1 1/2" ID (need p/n)
Tank to filler vent hose. 5/8" ID (need p/n)
Contact cement
Silicone oil
WD 40
Preparation
Review youtube.com videos
https://www.youtube.com/watch?v=5gm_m1hKtY8&t=318s
Purchase parts
Primer and paint new gas tank
Operate vehicle until gas tank is nearly empty
Measure pressure at fuel rail with vacuum to pressure regulator disconnected. (40 psi)
Wire brush threads of retaining bolts.
Soak retaining bolts with liquid wrench. Coat with anti-sieze.
Removal Procedure
Place vehicle on axle stands. Height should be low enough for floor jack to reach tank.
Remove rear wheels.
Photograph area for reference for re-installation.
Depressurize fuel line using valve on fuel rail.
Remove filter outlet fuel line, connect several feet of new fuel line, pump remaining gas out using vehicle fuel pump.
(Didn't work - need some way of convincing fuel pump to operate.)
If factory tank skid plate
Support skid plate with rachet strap from leaf spring to leaf spring
Remove muffler pipe hanger
Remove 4 X 18 mm bolts
Support skid plate with floor jack
Release strap.
Lower skid plate and remove from area.
Mark fuel pump with pencil noting which line goes to filter and which is return. (larger port is pressure, small is return)
Disconnect hoses and electrical from fuel pump. Catch gas in a cup.
Remove shield covering filler tube at bottom of vehicle.
Remove gas cap.
Remove hose clamps securing 2 rubber hoses to filler cap.
WD 40 hose connections to filler tube.
From gas cap side gently pound long pry upon hoses to press them off.
Disconnect two screws (8mm) on filler tube and remove. Inspect.
Loosen tank strap retainer hanger bolts (9/16) to the point where they can be removed but do not remove.
Remove passenger side hanger bolt and strap.
Support tank with floor jack in middle. Align jack wheels towards passenger side.
Remove driver side hanger bolt.
Lower tank and move towards passenger side until filler hoses clear.
Lower driver side of tank by hand.
Remove tank from under vehicle. Be careful when dragging tank that there are no sparks.
Remove fuel pump assy from tank.
Install new fuel pump on fuel pump assy removed from tank.
The white plastic spacer supplied with new pump must be cut a little.
The factory mount has a small groove that must be widened a little to receive the top fuel pump mount bracket.
The wiring harness supplied with the new pump must be used.
Red pump wire to wire from fuel tank connector.
Black pump wire to ground on factory pump assembly.
Hose clamps supplied with new pump should be replaced with higher quality clamps.
Install new fuel pump into tank using o-ring and metal ring supplied with tank.
Install evap valve rubber seals into new tank.
Silicone oil inside of seal.
Press new evap valve into seal.
Glue on 2" X 10" x 1/16" rubber strips in two recesses in new tank.
Install new filler neck hoses.
Move tank under vehicle
Unscrew nuts on tank retainer straps to nearly off the bolts.
Install tank retainer straps into rear of vehicle.
Lift driver side of tank and pass filler hoses through port in chassis.
Lift tank into position.
Install passenger side retainer strap loosly
Install driver side retainer strap loosly
Coat tube attach points on filler neck with light coating of silicone oil.
Install filler neck into hanger and secrue with two screws.
Install filler hoses from tank onto filler neck. Secure with hose clamps.
Install shield covering filler hoses on underside of vehicle.
Install gas cap.
If factory gas tank shield, install shield loosely
Tighten tank retaining straps
if factory gas tank shield, tighten retainer bolts (18mm)
Install new fuel pump hoses.
Connect electrical.
Cable tie all in place
Start vehicle.
Measure fuel pressure. Should be the same as previously.
Inspect all connections for gasoline leaks while engine running.
Mike