Auxiliary gas tank in 2011 -
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post #1 of 4 Old 09-28-2015, 11:37 PM Thread Starter
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Location: Baton Rouge, LA
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Auxiliary gas tank in 2011

I am designing a 6 gallon tank to fit in the space under the Jeep opposite the oe tank. It will ride in front of the evap. I will have a skid plate made to cover both the evap and gas tank. I plan on using a switched fuel pump to transfer the gas from the small tank to the oe tank. I'm not sure how to get the fuel into the oe tank. Can I pull a hose off one of the existing ports in the top of the tank? I can't find a diagram explaining what they are. I would like to splice into the filler hose with a fitting allowing the small hose from the auxiliary tank to push the fuel into the tank that way. I am worried that splicing into the system this way will cause sensor issues. How has anyone else accomplished this? I do not want to carry Gerry cans, etc and my solution will cost less than half the cost if the other solutions on the market. I can also install this without relocating any of the stock parts or loss of storage space.

2011 Natural Green Sport Unlimited
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post #2 of 4 Old 09-28-2015, 11:51 PM
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2005 TJ Wrangler 
Join Date: Jul 2011
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Transfer Flow offers an automatic system for diesels but I think the EPA has ruled out the dual/reserve tank system for gas.

Transfer Flows system automatically pumps fuel from the auxilliary bed mounted tank into the main tank when the main tank hits 1/3... and it pumps until the tank is 2/3 full.
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post #3 of 4 Old 09-29-2015, 01:15 AM
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2015 JK Wrangler 
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Location: Maineville,OH
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Not sure it will fit a 2011 but here you go.

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1989 YJ Wrangler
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post #4 of 4 Old 09-29-2015, 06:37 AM
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2013 JK Wrangler 
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Most of the hoses coming off the tank are evap lines. There are two rollover valves, and a large 5/8" vent. There are two lines to the engine, one for fuel and one for vent. There is no return in the JK system. The vent lines are too small and the 5/8" needs to run to the evap. Regardless, if you use one of those lines you either throw a code or make the system less safe.

One option would be to put a T into the fill line. That would serve the second benefit of filling both tanks at once.

I had a custom aluminum fuel cell made to replace my stock tank and went through the process of re routing the whole system. Pretty straight forward once you know what's going on.

Keep in mind that the system requires a certain amount of vacuum. You also need rollover/vent valves on your new tank. YJ valves work well for that. And make sure all those lines are below the evap or you will flood gas back in. Ask me how I know.... Had or re route my lines a third time up into the wheel wells. Pita.
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