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Old 08-25-2017, 05:33 PM
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JK Owner PSA. Everyone Please read!

I've had a check engine light for a while now. The code was for a large leak in the evaporative emissions system. Since my Jeep is less than 10 years old, I couldn't have a check engine light on and pass emissions. With my plates expiring soon I needed to solve the issue.

I replaced the gas cap, leak detector and gasket on the evap canister and the purge valve with no luck. Tracing the hoses for the system didn't reveal any problems.

I did find the problem when I found a YouTube video titled something like "The Dreaded Check Engine Light" showing a 4 door JK on a lift. In the video, the mechanic found that the stock routing position for the hose that runs from the top of the fuel tank over to the fuel filler hose has it running under the emergency brake cables. When a JK is lifted, the suspension flex pulls on this hose and breaks off the nipple it attaches to on the top of the fuel tank.

Here is a picture of where the nipple broke off on the top of the fuel tank.


Here is a picture of the broken off nipple once the hose had been removed.


In Jeep's wisdom, this part cannot be purchased alone. You need to buy the whole fuel tank.

Another video showed a mechanic sleeving the nipple and where it attaches on the top of the fuel tank with a piece of copper tube and using JB Weld to epoxy it in place.

Here's my attempt.


The epoxy is drying now. Wish me luck!

My Jeep is a 2010. 2011 models and up could be different. Check the routing of this hose on your Jeep before it's too late! Mine had a couple zip ties holding the hose in the middle. These will need to be cut. There is a connector on each end of the hose. Find the white section at the connector. Push the white section in while pulling out and the hose will separate from the nipples. Disconnect both ends and route the hose over the emergency brake lines.

Here is a picture of the hose over the e brake lines. It is just sitting there for the sake of the picture. My picture showing the stock routing came out too blurry.


I'll post this in the JK Tech forum as well and follow up with the results of my patch.

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Old 08-25-2017, 06:09 PM   #2
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Good to know.
Thanks for posting!

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Old 08-25-2017, 07:12 PM   #3
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Thanks for the heads-up, I will look at this when I am under the Jeep this weekend.
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Old 08-26-2017, 07:17 PM
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Update:

This fix has worked so far. No more gas cap warning and no check engine light. I passed the Colorado emissions test and have two years to see if it holds or if I need to replace the tank.
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Old 08-26-2017, 10:40 PM   #5
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I had this exact same problem and repaired it exactly the same way. It has been a year and no checked engine light. Jeep quoted over $800 for a new plastic tank!
Mine was a small crack and it took a smoke machine to find the leak. When I tugged on the line the plastic fitting broke off. I used a small piece of stainless steel tubing and JB Weld. Of courses this all requires dropping the skid plate and tank to get access.
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Old 08-27-2017, 02:06 AM   #6
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Thanks again for the post. I did the 5m job of rerouting the line above the parking break lines. It's really incredible all these plastic pieces in critical areas on vehicles these days. It might cut costs and improve gas mileage to meet federal regulations, but the cost burden is just shifted over to the consumer in the form of repairs.
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Old 08-27-2017, 12:02 PM
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Quote:
Originally Posted by Pushrod View Post
Of courses this all requires dropping the skid plate and tank to get access.
I was able to access mine without dropping the tank. There was even room to get a drill into the area to enlarge the hole for the copper tube.

ETA: I have a 2010 2 door.
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Old 08-27-2017, 12:10 PM   #8
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great fix.

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