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Old 03-05-2014, 09:09 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, 09:28 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, 09:48 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, 01:41 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, 05:05 AM   #5
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Quote:
Originally Posted by firefighter8513 View Post
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, 10:03 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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oh, and a 94 YJ! All here in Cary, NC
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Old 03-06-2014, 10:16 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, 10:29 AM   #8
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I may take you up on that, is it a 15 or 20G tank?
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oh, and a 94 YJ! All here in Cary, NC
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Old 03-06-2014, 10:51 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, 05:50 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, 07:05 AM   #11
It's a Jeep thing!

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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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