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Unread 10-27-2013, 09:44 PM   #1
crackedcornish
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fuel tank dimensional differences?

Savvy is making another run of their aluminum fuel tank skids, and this time they want to make them fit more models.

at the moment, Savvy is making them to fit the 20gal poly tanks, but I want one to fit my steel 15 gal tank.

anybody know the difference between the two tanks as far as the external dimensions go

I know the 15 gal. tank only uses one hold down strap across the middle..are there any other differences that would matter as far as fitting in a skid plate would be concerned?

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Unread 10-27-2013, 09:53 PM   #2
1shotwonder
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They're the same tank, i believe.. Just a longer filler hose for the 15gal tanks
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Unread 10-27-2013, 10:24 PM   #3
crackedcornish
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the early steel 15 gallon tanks were truly 15 gallons not just 20's that couldn't use their full capacity... I think they were shorter side to side but the same dimensions front to back and top to bottom as the 20's...I think
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Unread 10-28-2013, 10:30 AM   #4
Que89YJ
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The dimension for the frame rails is the same. In the pre 91 the steel tanks were 15 gallons, after they went to the 20 gallon tank. The 20 gallon will bolt right in to the same spot. The difference is the skid plate that mounts the tank and the tank itself are the only differences as far as fitting it into place.
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Unread 10-28-2013, 10:45 AM   #5
crackedcornish
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Quote:
Originally Posted by Que89YJ View Post
The dimension for the frame rails is the same. In the pre 91 the steel tanks were 15 gallons, after they went to the 20 gallon tank. The 20 gallon will bolt right in to the same spot. The difference is the skid plate that mounts the tank and the tank itself are the only differences as far as fitting it into place.
thanks Que for confirming what I thought I knew about the tank dimensions

if I was to swap out my 15gal steel tank for a 20gal. poly tank would it just be a matter of swapping tanks, skids, and sending units? is the wiring between the two tanks sending units the same? does the fuel gauge work the same with either size tank/sending unit?
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Unread 10-28-2013, 11:10 AM   #6
Que89YJ
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I did the swap.
The connector is different but you can solder the wires from one to the other, both are 3 wires.

No need to swap sending units, the regulator is on the fuel rail and the unregulated output from both pumps are similar in volume.

The vent line and fill hose need to be changed too. Remember that the vent line for the tank limits the amount of fuel you can put in. It needs to be shallow to get the 20 gallon capacity from the poly tank.

The fuel guage will function but full will be off by 5 gallons.
Empty is what we mostly worry about so before putting it in:
Pull the sending unit, clean the tank, and the sending unit contact
Hook up the new wires to the connector
Remove the white baffle in the bottom of the tank
Adjust the float to set zero by bending it and setting it in the bottom of the tank until it is set
Replace the seal for the sending unit and install the sending unit.

Just to make sure that you have everything correct before you attach the vent and fill, attach the the hoses to the fuel pump assembly (Big line 5/8 supplt and 1/2 return) and put a gallon of gas into it. See if it starts and runs.

When it does (Note that I say when not if, LOL) button it back up.
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Unread 10-28-2013, 01:23 PM   #7
crackedcornish
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Quote:
Originally Posted by Que89YJ View Post
I did the swap.
The connector is different but you can solder the wires from one to the other, both are 3 wires.

No need to swap sending units, the regulator is on the fuel rail and the unregulated output from both pumps are similar in volume.

The vent line and fill hose need to be changed too. Remember that the vent line for the tank limits the amount of fuel you can put in. It needs to be shallow to get the 20 gallon capacity from the poly tank.

The fuel guage will function but full will be off by 5 gallons.
Empty is what we mostly worry about so before putting it in:
Pull the sending unit, clean the tank, and the sending unit contact
Hook up the new wires to the connector
Remove the white baffle in the bottom of the tank
Adjust the float to set zero by bending it and setting it in the bottom of the tank until it is set
Replace the seal for the sending unit and install the sending unit.

Just to make sure that you have everything correct before you attach the vent and fill, attach the the hoses to the fuel pump assembly (Big line 5/8 supplt and 1/2 return) and put a gallon of gas into it. See if it starts and runs.

When it does (Note that I say when not if, LOL) button it back up.
I don't have a fuel rail..my regulator is in the throttle body (I wish I had the multi port injection)

is there a 20gal poly tank that uses the round sending unit from my 15gal steel tank? I've only seen the 20gal tanks with the rectangular sending units
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Unread 10-28-2013, 01:39 PM   #8
Que89YJ
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Same thing. I have an 89 2.5. The tj and later have the regulator in the tank.
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Unread 10-28-2013, 03:04 PM   #9
crackedcornish
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Quote:
Originally Posted by Que89YJ View Post
Same thing. I have an 89 2.5. The tj and later have the regulator in the tank.
Que, I think you misunderstood my question...

do you (or anybody else for that matter,) know if there is a 20gal tank that uses the sending unit with the round, lock ring style of mounting like my 15gal tank uses?...see the pics please

15gal with round mounting hole for the sending unit


20gal with rectangular mounting for sending unit


or do all of the 20gal. tanks have the rectangular mounting hole, forcing me to get the rectangular sending unit to replace my current round one?

I have heard of fuel leakage problems with the bolt in rectangular style of mounting due to the gaskets going bad.
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Unread 10-28-2013, 03:49 PM   #10
Que89YJ
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All the 91/95 have the the square. The leak was a recall and fixed. No problem after. You can find the square ones easy cheap and ready to bolt in from anyone scrapping a 91/95 yj.
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Unread 10-29-2013, 09:47 AM   #11
Randonexplosion
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(Some?) early carbed models have the 20 gal. poly with rectangular sender as well. My 88 has one as well as my friends 87. Hope that helps.
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Unread 10-30-2013, 10:21 AM   #12
crackedcornish
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Quote:
Originally Posted by Randonexplosion View Post
(Some?) early carbed models have the 20 gal. poly with rectangular sender as well. My 88 has one as well as my friends 87. Hope that helps.
hmmmm, so I would guess there are no 20gal. tanks that used the round sender then if the rectangular sender was used on even the early models with a 20gal tank


thanks for the info.
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Unread 10-30-2013, 10:24 AM   #13
Que89YJ
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There were round ones. Just don't know why or how. They are definitely out there, but not as a main production run. You have a YJ, its hip to be square!
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Unread 10-30-2013, 10:36 AM   #14
crackedcornish
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Quote:
Originally Posted by Que89YJ View Post
There were round ones. Just don't know why or how. They are definitely out there, but not as a main production run. You have a YJ, its hip to be square!
well Que you know how frugal us YJ owners can be at times

I was trying to avoid buying a square sending unit since my current round one works, but if I have to I have to.
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Unread 10-30-2013, 10:44 AM   #15
Que89YJ
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You can get a pump and sending unit used for $100.00. If you need the parts try contacting
http://www.cfoffroad.com/

Tell him I sent you and he will take of you.
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