Tip & How-To about 1991 Jeep Wrangler

Wrangler fuel pump problem? Dropping the gas tank made easy.

Fuel pump problems can be a real problem on a Wrangler. They are a Pain to get to.

The fuel pump in a Fuel Injected Wrangler is in the gas tank. The gas tank must be removed to gain access.

This procedure will help you get through it.

You will need a 1/2" socket, ratchet, extensions, flat head, needle nose, floor jack, rag, broomstick,. A creeper will make this easier. Depending on your dimensions and the height of the frame on your particular vehicle, you may be able to use it without jacking the vehicle up.

A word of caution. You're going to be working with a tank of gasoline. Stay aware of that. Wear safety glasses. DON'T SMOKE!! Be safe.

Now, lets get started.

  • Disconnect the negative battery terminal
  • Relieve the pressure in the fuel line.This is done from the injector rack on top of the engine. About the center of the rack you will find what looks like a filler valve on your tire, only thicker. The fuel line can maintain over 40 P.S.I. pressure even with key off. Place a rag over the pressure relief valve. This will prevent gas from shooting out the vent. Use the corner of a screwdriver to poke the center core through the rag. A second or two should do it. Make sure all pressure is relieved.
  • Place a floor jack under the gas tank shield, jack it up until snug.
  • Disconnect the rear exhaust hanger.
  • Loosen and remove the three shield nuts above the rear end
  • Remove the plastic shield from beneath the left rear corner. Two plastic anchors hold it on. Disengage them by pulling the center plug out about 1/2". This will expose the hoses connecting the tank to the body.
  • Loosen the hose clamps
  • If you can get them to twist, try and get them off.
  • Rear nuts next. Loosen and remove all but the center one.
  • Make sure the jack is centered and snug
  • Remove the last nut. The tank isn't going to DROP. It will kind of lean, and jam against the exhaust.
  • Insert the broom stick into the exhaust pipe.
  • Push and hold it to the right, slowly let the jack down. Stop if it hangs up and work it free.
  • When its down far enough to access the top of the tank, disconnect the plug, loosen thew hose clamps, remove the hoses, separate the vent hoses at the 'T' connector.
  • Lower it the rest of the way
  • The tank can now be separated from the shield.
The fuel pump / gauge sender assembly is located top dead center of the tank. Eight bolts hold it on. Remove them and carefully extract the assembly.

Reverse this procedure to to reinstall the tank.

Have fun Jeepsters
Mike

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1991 Jeep Wrangler Logo

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1 Answer

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