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Old 03-05-2014, 10:09 PM   #1
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Question My 1994 Yj is Leaking Gas!!!

I'm looking for a little help here. I've got a 1994 YJ with the 2.5 engine. I'm about at my wits end! It's leaking gas from the tank. It's coming from the fuel lines going into the pump. It did this when I got the jeep and I dropped the tank and replaced all of the rubber fuel lines and vacuum lines going to the tank. I've replaced the gas cap as well.
It quit leaking for awhile but has started again. It seems like there might be excess pressure on the system. I'm not sure though. I have thought about replacing the charcoal canister but not sure if that would help. The seal around the fuel pump is good it's leaking out of the lines. Any ideas?? I'm not sure what else would be causing the leak and I'm running out of ideas!!!!

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Old 03-05-2014, 10:28 PM   #2
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Hmm, I don't believe there are any vacuum lines going to the fuel tank on the 2.5. There should only be 2 lines to deal with. A main fuel line, and return line. The fuel pump sends pressure through the main fuel line to the filter and then to the engine. Excess pressure is bled off at the fuel rail via the fuel pressure regulator, and then that fuel returns to the tank through the return line.

If you think you have abnormal pressure, you can borrow a fuel-pressure gauge from autozone and check the pressure at the rail while the engine is running. This will also tell you if you have a bad pressure-regulator. You'll need to confirm psi requirements for your '94. You can also drop the tank with everything hooked up and then run the engine. I had to do this last month and it works. Then you'll be able to see excactly where the leak is coming from.

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Old 03-05-2014, 10:48 PM   #3
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There are two vacuum lines that go to the rollover valves on either side of the tank. these run up the frame with the fuel lines and go into the vapor canister. I thought maybe one of the roll over valves is bad but I don't know. The leak is coming from the rubber fuel lines that go into the tank. I know it's not the rubber because I've replaced all the lines and I've made sure the clamps were tight. I'm going to try the fuel pressure test tomorrow! Thanks for the info! Hopefully that will give me an answer!! I've gotta get this thing going because it's almost spring weather and it's time to take the top off!!!
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Old 03-06-2014, 02:41 AM   #4
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Make sure that the grommets of the roll over valves are not leaking. I had to replace both of them on my 95.
Doug J.
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Old 03-06-2014, 06:05 AM   #5
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There are two vacuum lines that go to the rollover valves on either side of the tank. these run up the frame with the fuel lines and go into the vapor canister. I thought maybe one of the roll over valves is bad but I don't know. The leak is coming from the rubber fuel lines that go into the tank. I know it's not the rubber because I've replaced all the lines and I've made sure the clamps were tight. I'm going to try the fuel pressure test tomorrow! Thanks for the info! Hopefully that will give me an answer!! I've gotta get this thing going because it's almost spring weather and it's time to take the top off!!!
My bad I meant to say "no vacuum lines to the fuel pump", fuel tank yes. I know how you feel I can't wait for Spring. I actually removed the tank completely because I found a lot of corrosion I wanted to deal with before I put the tank back in, also considering a skid-plate upgrade while I have everything apart. But yeah you can defintely run the engine while the tank is on the ground and everything is hooked up, let us know what you find out.
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Old 03-06-2014, 11:03 AM   #6
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Subscribed, because my 94 yj 2.5L is leaking somewhere on top of the tank, and i'm getting ready to drop it.I also replaced all the fuel lines when i replaced the fuel pump a while back.
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Old 03-06-2014, 11:16 AM   #7
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just an FYI... If anyone needs a fuel tank I have one out of a 95 that I will sell for 50 dollars plus shipping with a good pump assembly in it. I can post pics tonight when I get home.
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Old 03-06-2014, 11:29 AM   #8
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I may take you up on that, is it a 15 or 20G tank?
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Old 03-06-2014, 11:51 AM   #9
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I want to say it is a 15 gallon tank but I will check tonight when I get home from work.
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Old 03-06-2014, 06:50 PM   #10
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Well I dropped the tank this afternoon. Apparently one of the hose clamps holding one of the fuel lines on broke! The line was still connected but under pressure it was just spraying out. Not sure why it broke might have been when I installed the tank the last time. So I got some better clamps and reinstalled them and the tank... I drove it about 25 miles and let it run for a while and so far no leaks or smell of gas! Hopefully this will fix it as this is the third time I've dropped the tank and to be honest I don't wanna do it again lol! Thanks for the help I will let y'all know if I encounter any problems.
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Old 03-07-2014, 08:05 AM   #11
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F.Y.I. the plastic tank in a 95 should be a 20 gallon tank. you just need to pull or remove the large vent tube to be able to put the extra gallons in it.
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Old 08-12-2014, 10:11 PM   #12
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Ok guys..... The jeep is leaking again! Basically now it's leaking after I don't start the jeep for a while. If it sits for a day or so when I crank it, it leaks from the lines. I can let it sit after that and go to crank it again and it's fine. No leaks! I replaced the cap thinking maybe it was developing pressure while sitting. No luck. Still leaks after not being cranked for a day or so. I'm out of ideas and losing my mind lol! Anyone got a suggestion?
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Old 08-13-2014, 02:44 AM   #13
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Did you use new hose that was specificly marked as being for fuel injection use

Did you use clamps? Did you put the clamps on the proper side of, and distance from, the bulge on the pipe?

Did you cross fuel lines? With the supply and returns switched?

Check the vapor line for obstructions. Seal the fuel filler with a a rag around an air nozzle and a quick light blast of compressed air should vent out the hose disconnected from the charcoal canister.

The high ethanol content of fuel these days can melt fuel lines and corrode and crack the fuel pipes on top of the tank
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Old 08-13-2014, 10:11 AM   #14
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Yep replaced all new hoses and clamps. Everything was good to go. It ran fine for a while. What is strange to me is that it's only when I don't crank the jeep up for a day or so. Then I crank it it leaks gas. If I wait a couple of hours and crank it again no gas leak. I've never seen anything like it. Kinda frustrating lol
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Old 08-13-2014, 02:53 PM   #15
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My guess is that the auto parts store sold you regular gas line instead of fuel injection gas line. And you used standard hose clamps instead of fuel injection hose clamps.

The regular gas line is standard neoprene line. Works on the older vehicles and things like a lawn mower or motorcycle. Not made for the pressures of a fuel injection pump, and not designed to limit expansion and contraction of the line.

If you have the proper sized fuel injection line, it should be tough to fit it onto the pipe fitting that it is being placed onto.

The fuel injection clamps are made totally different than a standard hose clamp. They grip the hose and "crimp" it onto the steel pipe. Makes a complete seal because they give equal pressure the entire way around the clamp instead of just where the screw is, like a standard hose clamp does.
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Old 08-13-2014, 02:59 PM   #16
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Gas leak

Just for grins, loosen the gas lank cap and run the vehicle. If the leak stops the cap may be wrong or blocked. It seems like a pressure is building up and the cap or the evaporator system is not relieving. So my 2 cents are the cap or evaporation (charcoal) system.
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Old 08-15-2014, 09:47 AM   #17
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I cleaned out the vapor lines and replaced the canister with one i had lying around. So far so good!!
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Old 10-06-2014, 10:44 PM   #18
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Quote:
Originally Posted by firefighter8513 View Post
What is strange to me is that it's only when I don't crank the jeep up for a day or so. Then I crank it it leaks gas. If I wait a couple of hours and crank it again no gas leak. I've never seen anything like it. Kinda frustrating lol
My '93 is doing the SAME THING!! Did you fix yours??

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