Jeep Wrangler 20-Gallon Fuel Tank Conversion

From 1991-1995, Chrysler available two various sized gasoline tanks for the Jeep Wrangler: 15-gallon and 20-gallon. In reality, these two tanks have been not unique in measurement at all. The change in some was a smaller plastic vent hose that extended down into the tank which injected a lot more than 15 gallons of gasoline currently being loaded into them. By shortening this hose, the tank can keep the 20 gallons of gas it was at first designed to carry. The complete conversion system is about a 60-90 minute task.

  1. Increase the motor vehicle on jack stands.
  2. Take away the plastic panel in the rear proper corner close to the gas filler.
    This is held in area by 4 plastic rivets. Eliminate the rivets by securing the outer portion in place whilst prying the heart outward .25 “-.5” with a compact screwdriver. The rivets will clear away as whole parts. Do not hurt them due to the fact you&#39ll need them for reassembly.
  3. Disconnect the fill vent hose from the tank.
    This is completed by removing the hose clamp and pulling the hose off the fill vent neck. You may well have to have to pry it, but it&#39s only held on with a hose clamp.
  4. Take out the interior plastic fuel vent neck liner.
    Inside the neck of the gasoline vent hose, you can see a tube which traces the within. This liner tube is created of tricky plastic. Itýs about 9.75 “long and reaches about 7” into the tank. Gasoline can not be filled over and above the bottom of this tube. Shortening it will enhance the quantity of gasoline that will match into the tank. To take away it, you will need to pry it absent from the sides with a compact screwdriver and get it with any smaller instrument that provides a Powerful grip. I recommend a needle-nose vise grip since this tube is crammed in there Restricted. In simple fact, taking away this tube was the toughest undertaking on this undertaking. Some persons removed this tube in sections by pulling out 3 “, then chopping it off, and pulling one more 3” right up until the tube was totally taken off.
  5. Slash a 2.5 “portion from the liner tube.
    The fuel vent neck on the tank will have to have a part of the liner tube push back within to keep tension applied when tightening the hose clamp (in the course of re-assembly). I have no thought why this is, but considering that a person encouraged to do so, I did not argument. Slice a 2.25 “-2.5” portion and suit it again into the fill vent neck. You&#39ll require a hammer or a little something major to pound it in. Make confident not to use a steel hammer must you be unlucky more than enough to strike something that results in sparks this shut to the gas tank.
  6. Reassemble every little thing in the reverse order.
    Use the hose clamp to attach the fill vent hose to the fill vent neck, 4 rivets to reattach the plastic deal with on the rear panel, and five lug nuts to mount the taken off wheel.

Until you&#39ve set up a sending unit for a 20-gallon tank, the gasoline gauge in the dashboard will be inaccurate. Others who have finished this conversion claimed the gauge will not start to exhibit movement until eventually there is 15 gallons in the tank. This was not the case for me. My gauge does not display motion until 10-12 gallons continue to be in the tank and when the gauge reads 1/2, the tank is in close proximity to empty. It utilised to be vacant when the gauge read through 1/4, but I ran the tank in the vicinity of dry just to make absolutely sure and it is vacant at the 1/2 mark. I do not know if the sending arm received bent by this or what went improper, but it&#39s now vacant at 1/2.

Source by Dorian Jepsen

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