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Old 10-04-2011, 05:02 PM   #1
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Help with a '94 YJ

Hello all. I recently purchased a '94 Wrangler. It's a 4.0 I6 automatic. It has the KC light kit, 10,000lbs wench, a 4" lift, 31x10.50R15LT size tires and quite a bit more.It's a beast! A couple things are troubling me. I believe it has a 22-25 gal fuel tank on it. I fill it at 1/4 and it takes 17-19 gallons-ish to fill. I'm averaging about 210 mile when I drive it back down to 1/4 of a tank and every once in a while we're getting the smell of fuel vapors in the cab. It's not constant, but kind of happens all of the sudden sometimes. I felt all around the fuel tank and it was dry, but yet when I stick my nose as close to the top of the fuel tank I can, I can faintly smell fuel. I assume ventilation? Should I be averaging about 240 miles per tank of fuel or should I get the fuel system checked? The ruber seal on the fuel cap was dry rotted so I replaced it and the air filter. I know they're not known for great fuel mileage. I guess I'm just looking for confirmation that this is about right. Thanks much in advance.

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Old 10-04-2011, 07:52 PM   #2
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I have pretty much the same setup as you, except I have a 2.5 hampster. What I can tell you is 94 have a 20 gallon tank. The main issues with fuel tank are, vent valve( I've heard it called rollover valve) goes bad and you cant fit 20 gallons in the tank, you have to drop the tank and can get away with cleaning it and putting it back on the hose. It hides behind the fuel filler neck area of the YJ. Second is the fuel shutoff hose. Theyre inside the tank and were setup on the 4bangers to stop the pump at 15 gallons, sometimes if I pump really slow I can get 19 gallons in. Third is hoses get dryrotted. I have a friend whos yj did this. Its not enought to leave a drip or a puddle but it is enough to make a very fine mist when the pump is running and you then smell it when you idle or shut it down. Now to touch on your mileage, 210 isnt that bad for a 4.0, 240 to 260 is more of the norm from what Ive heard but I'm getting about 200 with my YJ 2,5 but I can only fit 10 to 12 gallons in 95% of the time...and did I mention mine runs out at 1/4 tank. Needless to say my tank will be dropped soon because I have the same issues as you plus a few more of my own for good measure. Good luck and If I can help more PM me.

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Old 10-04-2011, 09:15 PM   #3
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Chech out the 20 gal mod for free.
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Old 10-05-2011, 10:13 AM   #4
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check under it by the back leftside tire and be sure you do not have a leak. (with it running) sometimes they'll start spitting out gas right where the lines come together by the left rear tire. Mine would smell but did not drip? It wasn't until a friend looked at it while I reved up the engine that he saw it spray with the higher pressure.

Aside from that, if your tailgate seal is bad, rear window seal, or you have some rust back there it will suck in exhaust when the windows are cracked open. Even if you use duct tape, you'd need to get any holes in the back covered for your safety.
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Old 10-05-2011, 11:24 AM   #5
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Thanks guys, I'll check that out. I'm new to Wranglers but they seem to be put together easy enough to get into. I love the thing regardless. The 240-260 seems pretty standard across the board for a tank of fuel so I'm good with that. The only thing stumping me now is the fuel smell I get once or twice a week. If there are no leaks, I'll have the vent looked at.
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Old 10-05-2011, 01:39 PM   #6
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Quote:
Originally Posted by shaunhall View Post
Thanks guys, I'll check that out. I'm new to Wranglers but they seem to be put together easy enough to get into. I love the thing regardless. The 240-260 seems pretty standard across the board for a tank of fuel so I'm good with that. The only thing stumping me now is the fuel smell I get once or twice a week. If there are no leaks, I'll have the vent looked at.
Mine by the left rear tire tripped me out for a couple weeks. I could smell gas when I got out but no leaks anywhere? You have to rev it to 2700 or 3000 and then she'll start spraying if there is a leak underneith. Good luck with the hunt!

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