Hole In Gas Tank??

DanMan2k06

DanMan2k06

NAXJA Forum User
Location
Damascus, MD
So after a run last night, I went and topped off with gas. I was on mega empty so the tank filled up with 18 gallons no sweat. But when I woke up in the morning I noticed a puddle underneath the gas tank. I thought it was from where my exahust hanger was previously rubbing on the tank. However, after a closer look it seems to be coming form the top of the gas tank, dripping down the side, and then falling off onto the ground. So my question is, is there anywhere the tank can spew out gas other than the filler tube? Otherwise it would SUCK to lose a whole tank of gas onto the dirt.
 
what year? If 97+, it could be the large o-ring that goes between the pump assembly and the tank or a loose hose clamp.

Good Luck dropping a full tank!.......actually dropping is not the hard part---puting it back up is the hard part.
 
There's usually vents on the top for evap. sys. and filler, or is it the seal around fuel pump mounting assy. that are leaking?
I'd inspect it real close, did you puncture tank?
 
i'll bet it's the vents up top. mine leak after i put a differnt tank that i modded so i can fill it to about 25.5 gallons. i'm planning to put some rollover vents in . i think jcw sells some.
just think of every imaginable trip you can make till you're at about 1/2 tank and see if it still leaks.
oh, and the reason i had to put a differnt tank in is because my old one was leaking out of the seam. though it was a 90, just something to watch for.
 
I've started having this problem too:( I'm gonna run it dry and chuck in a new tank, is it a ton of work to drop it out? What's involved?
 
Mine (diesel, but same as 2.5l petrol) leaked when over half full.

I jet-washed the underside to try and pinpoint the source and it started leaking all the time.

Took it off and found it was perforated by corrosion in many, many places.

New tank is on order.

I think the plastic "shield" fitted to my XJ did more harm than good, not much protection against knocks, but very good at trapping dirt between the shield and the tank.


Getting it off should have been easy, only two bolts and some hoses... but on those two bolts (tank retaining straps), I was fighting against the "star" washers all the way down. Quarter turn - locks up - apply loads of pressure - crack - skinned knuckles - repeat.


Don't know about refitting yet, I'm still waiting for the new tank to arrive.
 
When I bought my 91 the tank had holes in it, but it was only at 1/4 tank so you couldn't tell. I went and filled up and whaddya know, I smelled gas and there was gas dripping slowly but surely from the tank. I had no choice but to drive off the gas and keep it at 3/8 or less until the new tank was finally delivered. That is one job I did not do myself, I got a great deal from a friend of my brother who owned a repair shop. All I can say is get the new straps and bolts before you think you need them- which are the rules of engagement for my XJ :roll:
 
The plastic shield is stupid, especially for the metal tanks. It pops out and hides dents to your tank. It's only really there for pebbles and road debris.

Newer XJ's use plastic tanks, although I think they still use a plastic shield, am I right? Unless you have a metal skid for "upcountry" or an aftermarket skid..
 
I have a plastic tank, and no plastic shield. It's a 97. It stopped leaking after it went down to about 7/8 tank, so i think it just can't be topped off. And no, no dents. I was on mega empty when I topped it off, which is why i think I fit so much fuel in. Next time I fill up I'll monitor it again.
 
buy new tank strap bolts (the ones that hook into the framerail) it suks trying to bend up threaded rod to tye you over. thay like to snap
 
Strap bolts

bcmaxx said:
buy new tank strap bolts (the ones that hook into the framerail) it suks trying to bend up threaded rod to tye you over. thay like to snap
Click to expand...

Yeah...

Had order 2 from stealership for about $42 when I snap one of them in half.

be careful and good luck

Ron - :05of5:
 
My vote would be for a leaking fuel pump gasket. I have replaced mine twice in the years I have owned my 90 but never on the 92. You can replace the fuel pump and gasket on a 90 without dropping the tank but is is easier with the vehicle on a lift.
 
Its pretty easy to replace the gasket, just try to have an empty tank when you drop it, or else its really heavy. There are also 2 smaller vent lines on top that could be leaking as well. Best bet is to drop it and see whats leaking, its only 2 nuts to undo, just be sure to not break the j-bolts, they are expensive to replace from the dealer.
 
Ok well I finally got the tank down to mega-empty, hopefully just enough fumes to make it to the buddy's shop. Tomorrow I'll drop the tank and see what all this commotion is about.
 
Hand pump and a jerrycan (or several jerrycans) can be useful if the tank isn't empty.

I used a pump sold for filling heaters, cost all of 2 euros, plus a bit of tubing I had lying around to extend it into the tank.

Pumping out half a tank of diesel took a while though.
 
Well I didn't want to start another thread so I'll add the progress onto here. I finally took down the tank after 1/4 of a full tank leaked out while I was on a hill. And with gas being $3.65 a gallon I just can't have that. So I took it out and can see around the fuel pump where the gas was puddling, and then dripping over the ridge in front. There were no punctures/cracks/bad seals, so I'm kinda stumped. The only other thing I could think of is a bad high pressure flex tube fitting. If that makes sense. There's a flexible line between the pump and the hardlines that has little o-rings inside it where it connects on each ends. I think this might be what's leaking under pressure. Keep in mind it only leaks out when the tank is full. Here's a few pics I snapped.


Here's the tank, the dirt around the pump is where the fuel leaked and then collected dust etc...
DSC01956.jpg


Heres the end of the connector on the flexible hose
DSC01957.jpg


And here's a close-up of one of the or-rings inside (there's two)
DSC01958.jpg
 
I'd help you out if I knew but my Junk is too old cause mine has a metal tank and a different fuelpump hook-up too. Sorry my experience is of a different tank and pump setup. Good Luck.
 
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