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Jeep Wrangler YJ
YJ Build Threads & Member's Rides
My '94 Hunter Green “No Compromises" Build
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<blockquote data-quote="machoheadgames" data-source="post: 428158" data-attributes="member: 18789"><p><strong>Basically All New Fuel System</strong></p><p></p><p>When I started the bumper project, as I stated earlier I needed to remove the gas tank to get to the wiring that runs across the backside of the Jeep, fastened to the underside of the tub. Over the years, my fuel tank level had become less accurate, especially on left turns. Left turns would severely mess with my fuel level reading. The plastic YJ tanks have always had some issues, mainly due to their fuel bowl which is riveted to the bottom of the tank. The purpose of the bowl is to hold fuel for the fuel pump to pull from, so that the pump doesn't starve and the Jeep doesn't sputter when you're off kilter or making turns, accelerating, braking, etc. Believed to be due to the ethanol in modern fuel, virtually all of these bowls warp and end up bending in such a way that they block the fuel sender float. It can hold the sender down (forcing the gauge to read low or E), push it up (forcing it to read full), or it can just interfere barely, but just enough to make the reading sporadic.</p><p></p><p>After dropping the tank, I pulled the fuel sender to see how my fuel bowl looked. Sure enough, it was quite warped. I opted to buy a new fuel tank. Pretty much the only new tank available for YJs is the 20 gallon version from MTS Company. I ordered it from Gas Tank Depot for a killer price. I received it in three days from FedEx. To go with it, I ordered new vent valves and grommets.</p><p></p><p>Here is the tank sitting next to the old one.</p><p></p><p>[ATTACH]117072[/ATTACH]</p><p></p><p>Picture of the bottom of the tank. MTS tanks have the fuel bowl molded into the tank itself, so it isn't a part that can warp. This is a better design that should last for many years.</p><p></p><p>[ATTACH]117066[/ATTACH]</p><p></p><p>Buying the gas tank set me off on a downhill path of buying other parts, as these types of things usually do. To protect my tank, I wanted to go with a nice skid plate so I bought the Warn skid plate. Unfortunately, MTS makes their tank a bit larger than stock. They claim there are Jeeps that came with a tank that matches their own which is what they built the one they sell from. I have no idea, but my tank was definitely too tall for the Warn, and the straps wouldn't reach. I sent back the Warn. I looked at MTS website and they offered a skid plate, so I went to Gas Tank Depot and bought that one. It turned out to be a reboxed Warrior products skid. It wasn't as protective as the Warn, but it is indeed better than the stock skid and it did solve the height issue, so I'm fine with it. I opted for a new fuel tank mat from Detroit Muscle Technologies.</p><p></p><p>This is what the tank looks like inside the Warrior skid with the straps on. I don't have any pictures of mine.</p><p></p><p>[ATTACH]117073[/ATTACH]</p><p></p><p>To go with the new tank/skid, of course I wanted a new sending unit as well. Who wants to put their nasty old sending unit in a nice new tank? No one. I ordered the MTS 20-gallon sending unit from you guessed it, Gas Tank Depot. I also ordered a new Bosch pump off of Amazon to keep as a spare. The MTS pump/sending unit has great reviews so I'm not too worried, but you never know.</p><p></p><p>Here is the sending unit and pump assembly waiting to go into the tank...</p><p></p><p>[ATTACH]117058[/ATTACH]</p><p></p><p>After I finished up with the bumper install, I got the tank up in place. I tried to install the filler hoses but ran into issues. Of course! The fuel filler and vent hoses wouldn't reach the new tank. At first I thought it was due to the body lift, but the body lift had been installed for a while on the old tank, so I figured that's probably not the issue. After some comparing, the issue came down to how the Warrior skid places the tank. It positions it further over to the right side of the Jeep. The tanks are about the same dimensions but with the new tank in the new skid, it was too far away and the hoses couldn't reach.</p><p></p><p>The only options at that point were to try and extend my old hoses, buy some new longer hoses if any were available, or go to a shop and have custom ones molded. I really didn't want to go the custom route because it is extra expensive and you're kinda screwed if you need new ones years later. First, I decided to try cutting and extending the hoses using pieces of 3/4" (for vent hose) and 1" (for filler hose) pipe from Lowe's.</p><p></p><p>Immediately after cutting the hoses, of course the pipes would not go in. They were too big, and the hoses had enough weird bends to them that there was no good straight portion to mate to the couplers anyways. Now, I had no hoses!</p><p></p><p>[ATTACH]117074[/ATTACH]</p><p></p><p>After some back and forth in my head, I decided to try an extended filler hose kit on eBay. These are more geared towards people with super tall body lifts, not so much moderate body lifts, but I figured with my tank placement being further away, and the body lift, they just may work.</p><p></p><p>[ATTACH]117075[/ATTACH] [ATTACH]117062[/ATTACH]</p><p></p><p>The hoses ended up being really long, and of course, too long for me to use as they were shipped. I was able to chop enough off each end of both hoses, and I cut and removed some section of the straight portion on the vent hose, and coupled it back together with the 3/4" extension I had purchased from Lowe's originally.</p><p></p><p>[ATTACH]117063[/ATTACH]</p><p></p><p>After all the doctoring of the hoses, I managed to get them onto the Jeep with no kinking.</p><p></p><p>Vent hose cut and spliced back...</p><p></p><p>[ATTACH]117055[/ATTACH]</p><p></p><p>Both Hoses in place...</p><p></p><p>[ATTACH]117064[/ATTACH]</p><p></p><p>Everything clamped together and rock solid!</p><p></p><p>[ATTACH]117057[/ATTACH]</p></blockquote><p></p>
[QUOTE="machoheadgames, post: 428158, member: 18789"] [B]Basically All New Fuel System[/B] When I started the bumper project, as I stated earlier I needed to remove the gas tank to get to the wiring that runs across the backside of the Jeep, fastened to the underside of the tub. Over the years, my fuel tank level had become less accurate, especially on left turns. Left turns would severely mess with my fuel level reading. The plastic YJ tanks have always had some issues, mainly due to their fuel bowl which is riveted to the bottom of the tank. The purpose of the bowl is to hold fuel for the fuel pump to pull from, so that the pump doesn't starve and the Jeep doesn't sputter when you're off kilter or making turns, accelerating, braking, etc. Believed to be due to the ethanol in modern fuel, virtually all of these bowls warp and end up bending in such a way that they block the fuel sender float. It can hold the sender down (forcing the gauge to read low or E), push it up (forcing it to read full), or it can just interfere barely, but just enough to make the reading sporadic. After dropping the tank, I pulled the fuel sender to see how my fuel bowl looked. Sure enough, it was quite warped. I opted to buy a new fuel tank. Pretty much the only new tank available for YJs is the 20 gallon version from MTS Company. I ordered it from Gas Tank Depot for a killer price. I received it in three days from FedEx. To go with it, I ordered new vent valves and grommets. Here is the tank sitting next to the old one. [ATTACH alt="IMG_0685.PNG"]117072[/ATTACH] Picture of the bottom of the tank. MTS tanks have the fuel bowl molded into the tank itself, so it isn't a part that can warp. This is a better design that should last for many years. [ATTACH alt="IMG_1940.PNG"]117066[/ATTACH] Buying the gas tank set me off on a downhill path of buying other parts, as these types of things usually do. To protect my tank, I wanted to go with a nice skid plate so I bought the Warn skid plate. Unfortunately, MTS makes their tank a bit larger than stock. They claim there are Jeeps that came with a tank that matches their own which is what they built the one they sell from. I have no idea, but my tank was definitely too tall for the Warn, and the straps wouldn't reach. I sent back the Warn. I looked at MTS website and they offered a skid plate, so I went to Gas Tank Depot and bought that one. It turned out to be a reboxed Warrior products skid. It wasn't as protective as the Warn, but it is indeed better than the stock skid and it did solve the height issue, so I'm fine with it. I opted for a new fuel tank mat from Detroit Muscle Technologies. This is what the tank looks like inside the Warrior skid with the straps on. I don't have any pictures of mine. [ATTACH alt="IMG_1946.JPG"]117073[/ATTACH] To go with the new tank/skid, of course I wanted a new sending unit as well. Who wants to put their nasty old sending unit in a nice new tank? No one. I ordered the MTS 20-gallon sending unit from you guessed it, Gas Tank Depot. I also ordered a new Bosch pump off of Amazon to keep as a spare. The MTS pump/sending unit has great reviews so I'm not too worried, but you never know. Here is the sending unit and pump assembly waiting to go into the tank... [ATTACH alt="IMG_0040.JPEG"]117058[/ATTACH] After I finished up with the bumper install, I got the tank up in place. I tried to install the filler hoses but ran into issues. Of course! The fuel filler and vent hoses wouldn't reach the new tank. At first I thought it was due to the body lift, but the body lift had been installed for a while on the old tank, so I figured that's probably not the issue. After some comparing, the issue came down to how the Warrior skid places the tank. It positions it further over to the right side of the Jeep. The tanks are about the same dimensions but with the new tank in the new skid, it was too far away and the hoses couldn't reach. The only options at that point were to try and extend my old hoses, buy some new longer hoses if any were available, or go to a shop and have custom ones molded. I really didn't want to go the custom route because it is extra expensive and you're kinda screwed if you need new ones years later. First, I decided to try cutting and extending the hoses using pieces of 3/4" (for vent hose) and 1" (for filler hose) pipe from Lowe's. Immediately after cutting the hoses, of course the pipes would not go in. They were too big, and the hoses had enough weird bends to them that there was no good straight portion to mate to the couplers anyways. Now, I had no hoses! [ATTACH alt="IMG_1947.jpeg"]117074[/ATTACH] After some back and forth in my head, I decided to try an extended filler hose kit on eBay. These are more geared towards people with super tall body lifts, not so much moderate body lifts, but I figured with my tank placement being further away, and the body lift, they just may work. [ATTACH alt="IMG_0675.PNG"]117075[/ATTACH] [ATTACH alt="IMG_0861.JPEG"]117062[/ATTACH] The hoses ended up being really long, and of course, too long for me to use as they were shipped. I was able to chop enough off each end of both hoses, and I cut and removed some section of the straight portion on the vent hose, and coupled it back together with the 3/4" extension I had purchased from Lowe's originally. [ATTACH alt="IMG_0862.JPEG"]117063[/ATTACH] After all the doctoring of the hoses, I managed to get them onto the Jeep with no kinking. Vent hose cut and spliced back... [ATTACH alt="62950599192__235864CC-7C5C-4849-B1F7-7A1A78D04395.JPEG"]117055[/ATTACH] Both Hoses in place... [ATTACH alt="IMG_0866.JPEG"]117064[/ATTACH] Everything clamped together and rock solid! [ATTACH alt="62950820479__5E35FA37-2381-4FB6-B0BA-F77A154E8694.JPEG"]117057[/ATTACH] [/QUOTE]
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My '94 Hunter Green “No Compromises" Build
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