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Unread 09-29-2013, 01:17 PM   #46
Nelliebelle7
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Quote:
Originally Posted by CrawlingForward View Post
Yeah, I forget who said it, but the supply line definitely is 3/8 on the tank side and 5/16 on the hard line side. Trying to use 5/16 to fit on both ends did *not* work, even with a heat gun, lithium grease, and excessive amounts of effort and trying to make an adaptor.

Eventually just ended up using 3/8 for the line and using a lot of overlap and multiple hose clamps on the hard line (the slotted kind, not the FI type that catch on themselves) and that stopped any leaks.

In terms of the rubber block, we had issues with that as well. For the vent line, I just left it and replaced the hose going to the T. The other lines just took a lot of white lithium grease and consistent pressure to get it through. When we removed the 5/16 line and replaced it with the 3/8, though, I just avoided the rubber squeezing all together and just ran it through the hole in the crossmember right next to it.

....man, this whole job was a PITA, though.
For all of you who have trouble with the hoses going through the rubber block... You can pull the block out with the hoses. It's open on one end and you fold it open. You can then place it on the lines where it should be and wrap it with tape. (factory did this) Then you feed the lines and the block back into place.

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Unread 11-08-2013, 07:49 PM   #47
dukeryder
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Originally Posted by Mean Max View Post
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Ok so I'm replying here for future reference for anyone who did a search like I did and came up with 1/4" tubing for the fuel lines.

On the 1995 (late 96 build date), YJ has 5/16 and 7/16" fuel line (well mine does anyway). Just one of those stupid YJ things where different years can have completely different parts.
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Unread 11-08-2013, 07:51 PM   #48
napaguy
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Quote:
Originally Posted by dukeryder View Post
Ok so I'm replying here for future reference for anyone who did a search like I did and came up with 1/4" tubing for the fuel lines.

On the 1995 (late 96 build date), YJ has 5/16 and 7/16" fuel line (well mine does anyway). Just one of those stupid YJ things where different years can have completely different parts.
7/16" fuel line? I have never heard of such a thing?
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Unread 11-09-2013, 05:01 AM   #49
CrawlingForward
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Quote:
Originally Posted by dukeryder View Post

Ok so I'm replying here for future reference for anyone who did a search like I did and came up with 1/4" tubing for the fuel lines.

On the 1995 (late 96 build date), YJ has 5/16 and 7/16" fuel line (well mine does anyway). Just one of those stupid YJ things where different years can have completely different parts.
Mine is a 95 and mine were 5/16 and 3/8 as stated.
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Unread 11-09-2013, 03:31 PM   #50
Nelliebelle7
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Yeah, me too. 5/16 and 3/8. Something else that may help a little, I eliminated that short hard line that goes to the "special" hose before the fuel filter. Ran the hose right from the tank to the filter.
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Unread 11-09-2013, 08:55 PM   #51
Mean Max
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Quote:
Originally Posted by Nelliebelle7 View Post
Yeah, me too. 5/16 and 3/8. Something else that may help a little, I eliminated that short hard line that goes to the "special" hose before the fuel filter. Ran the hose right from the tank to the filter.
This seems like a good idea to me, I like it.

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Unread 11-10-2013, 10:37 PM   #52
dukeryder
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Quote:
Originally Posted by Nelliebelle7 View Post
Yeah, me too. 5/16 and 3/8. Something else that may help a little, I eliminated that short hard line that goes to the "special" hose before the fuel filter. Ran the hose right from the tank to the filter.
I should have done this! I ended up buying the special Mopar 90* line, this option would've been much cheaper and easier too.

Mine most definitely had 7/16" line (I used 3/8 as the replacement). The crazy thing is that the return line hardline is of larger diameter than the main line, which is opposite of what's coming from the fuel pump (3/8" supply, 5/16 return). My guess is that someone once upon a time replaced the fuel pump and used the 7/16" line.

I swear this fuel tank R&R was the biggest pain in the @$$ job I've done to date on the YJ. That includes tearing the transfer case apart TWICE! (once to replace shift fork pads, once for SYE install).
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Unread 11-11-2013, 06:46 AM   #53
Nelliebelle7
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Quote:
Originally Posted by dukeryder View Post
I should have done this! I ended up buying the special Mopar 90* line, this option would've been much cheaper and easier too.

Mine most definitely had 7/16" line (I used 3/8 as the replacement). The crazy thing is that the return line hardline is of larger diameter than the main line, which is opposite of what's coming from the fuel pump (3/8" supply, 5/16 return). My guess is that someone once upon a time replaced the fuel pump and used the 7/16" line.

I swear this fuel tank R&R was the biggest pain in the @$$ job I've done to date on the YJ. That includes tearing the transfer case apart TWICE! (once to replace shift fork pads, once for SYE install).
The good thing is that you won't have to do it again for a long time. Fingers crossed!
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Unread 08-18-2014, 02:11 AM   #54
fantomas
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Thanks for this write up! Just replaced the skid plate over the last week. A few helpful pointers I have for everyone: The fuel line is cheap enough that if you're going to drop the tank for any reason, buy 3' each of 5/16, 3/8 and 1/4" and proper fuel line clamps. Someone else said 2' was enough, but it is NOT (well it is, but the factory hoses were nearly 3'). We used 2' of each on the advice here and it was a tight fit getting everything connected because the tank had to be raised quite a bit.

We dropped the tank to replace the skid plate on Wednesday. Swapped the plate out within 3 hours with no real issues. Finally yesterday I went to drive it for the first time and the fuel hose must have dry rotted to the point that it leaked because we messed around with it. So we had to drop the tank again and replaced all three hoses. I have a late model '95 and got away with using 5/16" for the supply and return. The 3/8" would not fit in the block when we tried to get it back through the cross member. The gas tank connection is definitely 3/8" but we had no problem getting the 5/16" hose on.

Make sure the supply line is rated for fuel injection systems. The vent doesn't need to be, and I don't believe the return is under any sort of pressure either.
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Unread 08-18-2014, 10:45 PM   #55
TomYJ
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When I dropped my tank to change the pump, I took the tank to a local radiator shop to have it cleaned out - nothing like ruining a new pump with debris. I also changed the fuel filter and all the rubber hoses on top of the tank...found a vacuum line that was completely smashed from previous time the tank was installed.
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