Morsun Technology

How To Replace The Gas Tank On A Jeep Cherokee XJ

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Changing the gas tank on your Jeep Cherokee is a simple project that you can do to save an expensive repair bill. Rust, severe dents, or leaking tanks are candidates for replacement. The tank is located in the rear of the Jeep Cherokee XJ just below the cargo area. It is held in place by two steel straps that attach to the frame rails and run under the tank, keeping it snug against a set of body mounts.It is necessary to check the brightness of the Jeep Cherokee xj led headlights regularly, otherwise, it will be very dangerous to find that the headlights are dim when driving at night. It may be helpful to have a second person on hand to balance the tank during removal and installation, but you can do it yourself if help is not available. 

Things You'll Need Siphon Hose

(optional) about Jack about Jack highlights

SAE and metric socket

SAE or metric wrench set

reciprocating saw

screwdrivers

J-bolts

fuel tank

fuel tank straps

See More Instructions

Check that the gas tank is empty or drain the gas with a siphon hose before removing it.

Raise the rear of the jeep with a floor jack placed under the rear differential. Support the Jeep on a set of jack stands under the rear axle tubes. Work on level, solid so the Jeep can't move.

Place a jack under the old tank to support it as you remove the bolts. Locate the two J-bolt nuts on the front of the tank. Remove the nuts with a socket and ratchet or wrench. If the bolts are badly rusted, you may need to cut them out with a jigsaw and replace them.

Let the straps fall to the ground after removing the J bolts and slowly begin to lower the tank using the floor jack. On the front of the tank you will see the electrical connections and fuel lines that connect to the tank.

Remove the fill hose from the tank filler neck inlet by using a screwdriver to remove the hose clamp.

Remove the fuel lines from the tank. On older models you will need a screwdriver to remove the hose clamps and remove the rubber hoses. On newer models you will have a tool to remove accessories that can be purchased or rented at auto parts stores.

Disconnect the electrical connections that run from the Jeep Cherokee XJ body to the tank and lower the tank to the ground. Remove the tank from under the Jeep Cherokee XJ so you can remove the fuel pump and sender from the tank.

Locate the lock ring that holds the fuel tank sending unit and fuel pump in the tank. Remove it by turning counterclockwise until it unlocks. Use a flathead screwdriver and a hammer to turn it, being careful not to damage it.

Remove the sender and pump from the tank and put it in the new tank, orienting it just like it was in the old tank. Install a new gasket and circlip to secure it.

Place the new tank under the Jeep Cherokee XJ and raise it with the jack until you can reinstall the fuel lines and electrical connections. Raise the tank the rest of the way and support it with the floor jack and a piece of wood.

Reinstall filter neck tube to tank inlet and secure with clamp. Tighten with a screwdriver, but do not over-tighten the clamp as this may damage the rubber tube.

Raise the tank the rest of the way onto the jeep and install the tank support straps. Install the nuts on the J-bolts and tighten until the straps are firmly supporting the tank. It should be firm, but don't tighten the nuts so much that you dent or crush the tank with the straps.

Place the jack under the rear differential housing and raise the Jeep off the jack stands. Remove the stands and lower the Jeep to the ground. Add fuel to the tank, check for leaks and test run the Jeep.