Tools
Maintenance
Forum
About
Links
Contact
Me *
Please find me at the forum if you have any questions!
Website
Last Updated:
5/19/2008
Random
Image
Photo by Jina!
Did
you Know?
Some
portion of the website will not be available until further notice.
DDTJ
has been transmitting 4GBytes+ of data every month to 3000+ unique visitors!
Please join the forum & share your knowlege and
purchase decals
to support the site!!
Problem
with accessing the Forum?
eMail
me at access @ dailydriventj D0T c0m
Michael can
also be found in JeepForum.com and Jeepsunlimited.com under the user name 'Michael_K'.
Warn
Fuel Tank Skid Plate Installation
Protection
for the belly of your Jeep ◆◆◇◇
Medium
Introduction
While
I was trying to tag along a 4 wheeling club ride, I found that
my TJ is not equipped enough to ride safely with them. Since
my jeep only has been a scenic drive vehicle, ;) I haven't
paid much attention underneath the jeep; it was seriously lacking
some protection for vital components under the Jeep.
One
of the components, that needs protection for safe trail ride is
the fuel tank. Even though factory has equipped the plastic
fuel tank with thin sheet metal for skid plate, this is not sufficient
enough to keep the fuel tank safe on a moderate trail.
I
found Quadratec.com selling Warn Fuel Skid Plate for $179.95 plus
shipping. This was the best price I could find anywhere as
it was on their monthly special. Normal price goes for around
$240.
The
older version of Warn skid plate offered 1" gain in ground
clearance. However, it created some problem with the body
lift equipped vehicle that warn revised the design and got rid of
1" gain.
Packaging
The
skid plate did not come with the instruction or any other paper
work, not even a warranty sheet. You can see how the skid
plate looks from the following pictures.
Comparison
From
the following pictures, you can see the different between the OEM
skid plate and the Warn skid plate.
These
pictures show you where the mounting wiring harness can be attached.
It is very nicely done on the Warn product.
From
these two pictures, you can see how Warn has the coverage where
the OEM is left wide open.
You
can see the thickness of Warn skid plate here. The ruller's
smallest denomination is in millimeter.
Tools
& Parts Needed
Warn
Fuel Tank Skid Plate (QuadraTec.com: $200 shipped on Special, weighs
70+ lbs.)
Socket
Assortment
Floor
Jack
Wood
Block
Job
Hours
3 hours
Procedure
Removal
Procedure
1.
First, the fuel line must be depressurized before removing the fuel
tank. You do this by removing the fuel pump relay located inside
of PDC and cranking the Jeep. The engine will start briefly
and die or simply won't start at all. This means there is
no fuel being fed into the engine and this is exactly what we are
trying to do. Remove the negative battery cable.
2.
Remove 8 screws that are holding the fuel hose.
3.
Remove the plastic piece. You will have access to the ground
strap and zip tie holding the axle vent and the fuel hose. Unhook
the ground strap and cut the zip tie.
4.
Place the floor jack with wooden block under the fuel tank assembly
right under the dimple. This will allow you to balance the
gas tank when you are lowering the tank out of the Jeep. **
Try to run the Jeep as empty as you can before you do this step.
5.
Once the floor jack is placed under the fuel tank, remove 7 nuts holding
the gas tank in place. There are 4 nuts in the rear and 3 in the
front of the gas tank.
6.
Disconnect the fuel line, EVAP, and the electrical connector. The
electrical connector has locking tap you need to disengage. The
fuel line also has locking mechanism, press the gray tab, remove
it away from the black line. Gray tab will stay with the metal
line.
7.
Everything is now free from the tank to lower the gas tank away
from the Jeep.
8.
Once freed from the Jeep, it is good idea to move the gas tank away
from the Jeep and out of the garage before doing any more work.
9.
You need to remove two plastic thread protectors before getting
to the bolts for the straps.
10.
Once the plastic pieces are removed, measure the length of the exposed
thread and write it down somewhere.
The
factory service manual specifies that when you replace the plastic
tank, it has to be installed so that the length of exposed thread
is 30mm +/- 2mm. However, mine was already at 27mm, even though
I was puzzled, I decided to keep the reading and use this later.
11.
Remove the straps and remove the tank.
You
can see the debris accumulated underneath the tank. I can
see why they made the tank plastic.
Installation
Procedure
1.
Once the plastic tank is removed, it is a good time for you clean
it up a bit.
2.
Prepare the wooden block on the floor jack and position the skid
plate so it will balance itself on the block.
3.
Place the metal straps and then place the fuel tank.
4.
Strap down the tank using the metal strap. I tightened the
strap so that it will expose 24mm of thread on both sides. The
reasoning is, the increase in thickness of the skid plate has to
be compensated. So I tightened less than original. If
you tighten this down too much, you will be crushing the tank. You
can damage the tank, and the fuel pump assembly. I heard stories
where the fuel tank gauge started reading inaccurately after the
fuel tank install. I figure it happens because people improperly
tighten down the tank.
5.
Make sure your lines are routed as shown and secure the electrical
connector on the tank.
6.
Here is the picture of the finished install of the tank. On
the right you can see the thread protectors installed.
7.
Position the assembly under the Jeep towards the passenger side.
Route the fuel hose in place as you raise the tank in position.
8.
As the tank is positioned where it should be, make sure the bolt
holes line up.
9.
Connect the fuel line, EVAP, and the electrical connector.
10.
Install the ground strap on the body tub as shown and install the
trim piece. You are done working under the Jeep!
11.
Install the fuel pump relay. Put the cap back on the PDC.
Reconnect the battery.
12.
You are done!
If
you have any questions or recommendations, please let me know !!
Disclaimer
I
tried my best to document as much as possible along
with pictures. I hope you find them useful. However,
do use the information provided here "as-is".
DailyDrivenTJ.com or
the author does not warrant or assume any legal liability
or responsibility for the accuracy, completeness, or usefulness of any information,
or process disclosed. Use the information at your own risk.
Written
b y Michael
o n 8.14.2006.
DailyDrivenTJ.com
is best viewed at least 1024px width on FireFox
(FREE)!
DailyDrivenTJ.com
is a graphic intensive site. To best experience this
web site, high speed internet connection is recommended.
