Hello everyone,
I own a 1997 XJ and my fuel tank is leaking from the top. I was at 1/4 tank and as soon as I pulled into the gas station the gas light came on. I filled up and and knowing its a 20 gallon tank, it should've taken about 15 gallons but it took 18.5 gallons. I thought that was a little strange, so I drove home just a few miles away and when I got out of the Jeep there was a strong odor of gasoline. I looked under and saw gas dripping and puddle starting to form. I crawled under the Jeep, and upon further inspection the leak was coming from the top of the tank. I also drove back to the gas station I filled up at (in another vehicle) and didn't see any indication of my Jeep leaking there. I know it could be a number of things but has anyone had this problem? Leaky fuel line? Hole at the top? Breached gasket? Over filled? I think it's either a breached gasket or possibly I over filled the tank. Would over filling cause this problem? Not sure exactly how the pump/sending unit work, but my theory is either the float that indicates the capacity broke or the sensor malfunctioned. Also what's the best way to get fuel out of an XJ? Like I said above, I just filled up and I really don't want to waste that gas, and I'd rather not drive it since it's leaking. Is there an access or drain port? Easy to just siphon? Any help would be greatly appreciated.

Thanks, Justin

 

my comment relates to a '96, but a big fat o-ring seals the fuel tank sender, try degreasing and cleaning to verify if thats the cause, as a '97 may require tank dropping,
Others can confirm. Check the '97 FSM

 

Does the 1997 fuel line attach at the top of the tank? If that is the original one it is about time for it to disintegrate.

 

97+ the tank must be dropped to get to the sender and pump. Only one line coming off. Only possibility of leak on 97+ is large o ring, fuel pressure regulator as it sits on top of the sending unit, the one fuel line coming out of the tank or a hole in the top. Might even be a cracked filler tube just spewing enough to puddle up top as its filling

 

Yep.

Yep.

Top of tank, and yes it needs to be dropped. The tank strap J-bolts usually need to be cut off. They are stupidly expensive, but many here have found inexpensive alternatives. A search should turn up a few for you.

 

You should drain the tank before dropping...a full tank is going to very heavy

 

X2 on what BruceB said.

Drain as much as possible out, especially if you will not be able to put it on a lift and support it while removing it. I dropped my gas tank in my driveway with about 5 gallons in it, and it was a pain in the rear end

 

yes my thoughts exactly. And it’s completely full. What’s the best way to drain it? I’ve heard siphoning can be quite difficult.

 

https://www.harborfreight.com/multi-...ump-63144.html

Something Like this?

What is going to suck is that you have a full tank. You will also need at least four 5 gallon gas cans or other cars in the family that need to be topped off.

And a good bunch of elbow grease..

 

Do I pump it through the fill tube?

 

draining by removing the hose at the filter works, although it is slow, a STOPPER for the hose is needed, while you deal with the drained amount

When draining fuel, take extreme precautions against fire (can be started with static electricity)

 

Battery off/out for sure.

I've had issues with the rubber pipe on the top of the tank before, there's a few inches of rubber between the pump and the hard line presumably to stop vibration stressing the metal pipe. Mine was leaking.

Once you've got the tank out and everything is free from vapour it's well worth lifting the carpet in the boot (you just need a cross head screw driver to take out the plastic trim pieces) and cut an access hatch in the boot floor. In future you'll be able to service/replace your fuel pump module without dropping the tank. You can treat it with your choice of anti-rust product at the same time.
I was really annoyed with the PO who did this "hack job" to my XJ until I had fuel pump issues and it saved me a whole ton of time. A lot of vintage cars had fuel pump access panels from the factory....

 

things I learned about doing this job, not just on Jeeps, is to place lots of anti-sieze on the the J-bolts that hold the tank up, (to prevent future rust), and inside the filler pipe to tank junction, this is often troublesome to separate, you will usually need to work lube into this joint initially. Tank removal is a job that needs doing eventually on most vehicles

 

There been plenty of write ups on this. Check out CCKen's post at #27.

https://www.cherokeeforum.com/f2/fue...2/#post3231679

Detailed as hell huh? LOL.
I figured if and when I do this job I am still going to drop the tank.
But also might cut an access hole while it is out.
My thinking is raid the boneyard for a nice section of the cargo pan.
So instead of having to build up the edges of the piece you cut out lay in a bigger piece over it.
Figure some rivnuts and weatherstripping and are good to go.
Also cause of the tie downs being riveted on top of the carpet figure, cause I want to keep them, instead of riveting them back
in use rivnuts there too.
Picked up a brand new Mopar Fuel pump awhile back for $150 just to have in "stock".
Hoping to never have to use it. MLOL.

 

That's a great link - and I wish I'd known about the Pump Spanner before I swapped two pumps with my bare hands! I swear I nearly broke my thumbs....