BrokenXJ
NAXJA Forum User
- Location
- Massachusetts
I just finished installing a 94' YJ poly gas tank into my 88' XJ. This is my 4th tank gas so I decided to go poly. My previous tanks were rusting inside the skidplate.
The donor vehicle was a 94' YJ 4 banger. The fuel pumps ended up being the same.
The YJ tank is like 1" deeper, and 3-4" wider.
Here are some side by side pictures:
The XJ has a tank saddle built into the unibody underneath the rear deck. I cut slots into it, and hammered it flat to get the tank to fit. The following is picture of the flatten saddle.
The wide YJ tank just barely squeezed between the frame rails of the XJ. This was so close that the filler neck and vent neck are protruding through the frame rail to get it in. This is what prevented me from moving the tank backwards to get more rear axle room.
The hole in the unibody frame rail could be enlarged and strengthened to move the tank back farther, because there is about 4 1/2" more space behind the tank.
Even with the wider tank the YJ tank is notched for the exhaust and the clearance looks good.
The sizes of the filler neck and vent tube were different sizes, so I had to adapt generic hoses to get them to fit. I also had to splice my harness on, because the connectors were different.
The YJ tank I used had a return fuel line, and the same gas vapor lines. I didn't do a late model XJ poly tank because I was told there was no return fuel line.
After I got it installed, I added two gallons of gas and it started right up. Gas gauge works, and it seems to be about 16-17 gallon tank.
The donor vehicle was a 94' YJ 4 banger. The fuel pumps ended up being the same.
The YJ tank is like 1" deeper, and 3-4" wider.
Here are some side by side pictures:
The XJ has a tank saddle built into the unibody underneath the rear deck. I cut slots into it, and hammered it flat to get the tank to fit. The following is picture of the flatten saddle.
The wide YJ tank just barely squeezed between the frame rails of the XJ. This was so close that the filler neck and vent neck are protruding through the frame rail to get it in. This is what prevented me from moving the tank backwards to get more rear axle room.
The hole in the unibody frame rail could be enlarged and strengthened to move the tank back farther, because there is about 4 1/2" more space behind the tank.
Even with the wider tank the YJ tank is notched for the exhaust and the clearance looks good.
The sizes of the filler neck and vent tube were different sizes, so I had to adapt generic hoses to get them to fit. I also had to splice my harness on, because the connectors were different.
The YJ tank I used had a return fuel line, and the same gas vapor lines. I didn't do a late model XJ poly tank because I was told there was no return fuel line.
After I got it installed, I added two gallons of gas and it started right up. Gas gauge works, and it seems to be about 16-17 gallon tank.