15 Gallons To 19 Gallon Tank Conversion- Easy - JeepForum.com
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post #1 of 5 Old 01-02-2003, 07:59 PM Thread Starter
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1997 TJ Wrangler 
Join Date: Feb 2002
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15 Gallons To 19 Gallon Tank Conversion- Easy

I copied this from another site-

It was said that the YJ's all had 20-gallon tanks but they modified them to only hold 15 gallons. That was unless you paid for the 20-gallon option. After hearing the rumors and doing some investigation I decided to give this simple modification a shot. There is a plastic vent tube that runs from the fill vent hose down into the tank. All you have to do is pull out that plastic tube which is 9" long and cut about 7" off. This procedure only took roughly 45 minutes start to finish. You don't need to drain the fuel but the less in the tank the better. Plus if you wait until it is almost empty it is a pretty cool feeling to fill up with over 19 gallons.

First remove the negative terminal from the battery. This may sound menial but you are working near the taillights and don't want any sparks from some lose connection.
Remove the gas cap to release the pressure from the fuel system. Let it set for a few minutes to let the fumes dissipate.
Remove the filler neck shroud that is below the gas filler housing on the underside of the body. This is held in place by 4 push clips. To remove these, pry the head away from the body then after the head pulls away remove the whole clip. If your Jeep is like mine they were brittle so just yank away then head to your favorite parts store and get new ones.
Using a Torx bit, remove the license plate (watch your fingers) and the filler housing.
Looking up from the underside you see the 2 hoses. The fill vent hose is the upper one running to the rear connection in the fuel tank. The fuel filler hose connects at the front most location.
Remove both hoses from the fuel filler housing and set the housing aside.
The only hose you have to loosen and remove from the fuel tank is the fill vent hose. The one closest to the rear of the Jeep.
After removing the fill vent hose use your needle-nose pliers to remove the inner piece of plastic. You may need a thin screwdriver to make room for the pliers to grab the inner hose.
Pull the inner plastic hose out it will be just over 9 " long. All it needs to be is as long as the neck the fill vent hose connects to.

97 TJ
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post #2 of 5 Old 01-02-2003, 08:18 PM
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post #3 of 5 Old 01-02-2003, 09:58 PM
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Using a Torx bit, remove the license plate (watch your fingers) and the filler housing.
That ain't no ****in lie.

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post #4 of 5 Old 01-02-2003, 10:32 PM
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lol, ya I remember when I took off the spring loaded lisence plate bracket. I got that last torx bolt out and SNAP. Half of my finger turned purple from the huge bruise

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post #5 of 5 Old 01-03-2003, 05:41 AM
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It took me a couple of tries to get mine done. The hose clamp screw was facing towards the top side and could not get a tool on it to loosen it. I finally took a screwdriver and put it between the clamp and bolt holder and pried it apart, then replaced the hose clamp.

2006 Silver Rubicon, 4.5" 4wd hardware lift, 1.25" JKS body lift, currier 1" mm lift, currier anit rock sway bar, 35" Goodyear MTR/s, mile marker 8000 winch.
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