Fuel Tank Replacement

[sugarloafur]

I have a '94 Cherokee sport and started smelling gas while the tank was full. It hasn't been dripping or anything, but the stock tank is still on the Jeep. It used to only smell when it was full, but it's beginning to smell more and more, even when the tank is only half full.

I'm considering replacing the tank, since the top of the tank is likely rusted. On a '94, should I replace more than just the tank (like fill line, vent line, etc.)? I'd like to order up the parts and have them before I begin taking it all apart.

How hard is this fix? I've never attempted it before. Should I replace it with the stock tank?

[Jeep-King]

I dont know about the tank but on my 89 jeep cherokee i started to smell gas whenever the key was in the on position. i found out it was a bad fuel injector and bad fuel injector o rings. check to see if when you turn the key to on and the fuel system pressurizes if any fuel injectors are leaking. if you cant see anything then try starting the car with the hood open. IF it is a bad fuel injectoer or o ring you will see some smoke like mixture coming from the fuel injectors. If this is the case the tank being full might just be a coincedence.

(if you still cant see any leaks are have already ruled this out then just ignore me because i am wrong. )

[sugarloafur]

Originally Posted by Jeep-King

I dont know about the tank but on my 89 jeep cherokee i started to smell gas whenever the key was in the on position. i found out it was a bad fuel injector and bad fuel injector o rings. check to see if when you turn the key to on and the fuel system pressurizes if any fuel injectors are leaking. if you cant see anything then try starting the car with the hood open. IF it is a bad fuel injectoer or o ring you will see some smoke like mixture coming from the fuel injectors. If this is the case the tank being full might just be a coincedence.

(if you still cant see any leaks are have already ruled this out then just ignore me because i am wrong. )

Thanks for the tips, but I'm pretty sure that it's the tank. When it gets full and stays full for a while, and after a drive, you can see parts of the tank are damp... from gas.

[oljeeptek]

Yep, sounds like your tank is rusted on top. It's where crap sits for a long time, especially in salt belt states. You may indeed need a sender or lines, but you'll have to look at them first. It's not a big deal to pull the tanks, just drain it first. Get new straps or strap bolts if they look corroded. I wash everything with gunk cleaner and spray a coat of sealer to slow rust down some.

[thinmints]

this link may help you


http://www.4x4wire.com/jeep/tech/fuel/nwmp04

[sugarloafur]

Thanks for the feedback. I do live in Maine, so salt has definitely been an issue, and living near the ocean doesn't help either. As soon as it warms up a little bit, I'm going to order one of these: http://www.1aauto.com/1A/GasTanks/Je...ee/JP2B/319499 . Hopefully nothing else will need replacing, like the sender or lines, but I'll be ready to order them if need be.

[vamc]

http://www.quadratec.com/cgi-bin/sgi...06031718513646

Its a little cheeper, not by much. every little bit counts.

[sugarloafur]

Thanks, but I think that tank is for a CJ, not an XJ.

[vamc]

Sorry about that.