Q: How to Remove the Fuel Tank from My Jeep Wrangler?
A: The following procedure is much easier to perform if the fuel tank is empty. Run the engine until the tank is empty. Remove the fuel tank filler cap to relieve fuel tank pressure. If the vehicle is fuel-injected, relieve the fuel system pressure. Detach the cable from the negative terminal of the battery. If the tank still has fuel in it, you can drain it at the fuel supply line after raising the vehicle. Raise the vehicle and place it securely on jackstands. Disconnect all hoses and the electrical connector for the fuel gauge sending unit and electric Fuel Pump (if equipped). Carefully label all hoses so you can reinstall them in their original locations. On some models it may be necessary to remove the fuel filler neck shroud from the left rear wheel well in order to access the supply hose. Pull back the stem of the push clips and remove the shroud. Using a mechanical pump (never by mouth), siphon the fuel from the tank at the fuel filler or fuel feed line, not the return line. Ensure all fuel supply and EVAP quick-connect fitting and electrical connectors are disconnected from the fuel tank. If necessary, remove the transfer case skid plate for access and/or removal. Support the fuel tank with a floor jack or jackstands. Position a piece of wood between the jack head and the fuel tank to protect the tank. Remove the nuts or bolts from the flanges of the fuel tank and carefully lower the tank down enough to disconnect any remaining fittings or connectors from the fuel pump module. Do not loosen the nuts from the tank straps. Remove the fuel tank along with the skid plate, if so equipped. Lower and remove the tank from the vehicle. Installation is the reverse of removal.
Q: How Should Fuel Tank or Filler Neck Repairs Be Carried Out?
A: All repairs to the fuel tank or filler neck should be carried out by a professional with experience in this critical and potentially dangerous work. Even after cleaning and flushing the fuel system, explosive fumes can remain and ignite during tank repair. If the fuel tank is removed from the vehicle, it should not be placed in an area where sparks or open flames could ignite the fumes. Extra caution should be taken in garages with gas appliances, as they could cause an explosion.