cut-out hatch is a cool idea. How in the hell did you know where it was located?

 

Magic.

 

LOL,,,

 

That's pretty. Did you make the cut without dropping the tank? If so what's the spacing on the cut wrt to the rear seat and the sides of the vehicle?

 

I cut it with the tank installed. A very risky job. Held by breath the whole time. The right-forward corner of the cut-out is about 1/8" from the top of the tank.


When I finish these 12 beers I will post the dimensions - you take the risk.

 

I'll go get you another case, Imma gonna take the horny pony car, BRB.

 

I appreciate that. 1/8" is as good as a mile when I'm cutting with the dremel moto tool.

Thanks

 

Holy ****,,what a way to make a two week project out of it..lol get the proper tool geeesh!

 

Then why don't you just buy the regulator?

http://www.rockauto.com/en/moreinfo....373666&jsn=363

 

Actually just went through this. you are right, its the regulator, actually the regulator is called a filter regulator by jeep because it's also the filter. I got one on ebay for $15 and while not exactly the same housing it went in and worked perfect and fixed exactly the problem you describe. 2 weeks before that I changed just the pump with a $15 pump from ebay, worked great just didnt fix the whole problem. So I would recommend the whole assembly, from ebay, these are OE stuff they bought because the factories realize the vehicles are becoming obsolete and they are dumping them to secondary market buyers like the ebay sellers.

 

That would be great if you posted some measurements as to where to cut. Not sure if I would be willing to take the risk but still would like to know. If I did do this then I could justify only replacing my check valve which I know is what my problem is.

 

Here's some jpg images of the fuel pump access mod. The cut out templet here is jpg but you will need a version in Microsoft word so when printed it will be to scale. If you want, I can send it to your home email addy but you'll have to PM me with your addy.


Tools:








Establishing center of pump from cargo bay:

 

Additional pics.


Template. I initially cut my opening with square corners but if I had to do it again I would radius the corners to avoid cutting too close to the top of the tank.





Cut out notes:





Pump center marking:





Filler:

 

Few more pics.


Pump access with cover. The blue stuff you see is some Dip-It I had left over so I painted the surface that the seal with contact.





Cover installed:





Use of the pump spanner. When I removed my old pump I had a 1/2 tank of gas in the tank so when I wiggled the pump out I got gas on the cargo bay floor - recommend putting some rags down around the hole to absorb some of the gas.

 

Piece of cake to replace the regulator/filter, just take that clip off and pull straight up, just soft rubber holding it on the sides. no need to pull the pump assy again. $15 on ebay mine works great.