1. Preparation is Key:
* Safety First: Disconnect the battery's negative terminal. Work in a well-ventilated area, away from open flames. Fuel is highly flammable.
* Gather Supplies: You'll need jack stands, wrenches (various sizes), sockets, a fuel line disconnect tool, new fuel lines (if needed), new gaskets, possibly a new sending unit (fuel gauge), and possibly new straps or mounting hardware.
* Drain the Old Tank (if applicable): If you're replacing the old tank, siphon out as much fuel as possible to minimize spills.
* Access: You'll likely need to remove the tailgate and possibly some other components for sufficient access to the tank mounting area.
2. Removing the Old Tank (if applicable):
* Disconnect Fuel Lines: Carefully disconnect the fuel lines at the tank. Use a fuel line disconnect tool to avoid damage. Have rags ready to soak up any spilled fuel.
* Disconnect Vent Line: Locate and disconnect the vent line.
* Disconnect the Fuel Sender: Disconnect the electrical connector to the fuel level sending unit.
* Remove Tank Straps/Mounts: The tank is typically secured with straps or brackets. Carefully remove these.
* Lower the Tank: Carefully lower the tank. It might be heavy and awkward. Have a helper if possible.
3. Installing the New Tank:
* Inspect the New Tank: Before installation, carefully inspect the new tank for any damage.
* Install New Gaskets: Install new gaskets on the tank's mounting points as needed.
* Mount the Tank: Position the tank in its correct location. Make sure it sits correctly and doesn't interfere with anything.
* Secure the Tank: Carefully attach the tank straps or brackets, ensuring they are securely fastened and won't put undue stress on the tank. Tighten to the manufacturer's specifications (consult your repair manual).
* Connect the Fuel Sender: Connect the electrical connector to the fuel level sending unit.
* Connect the Fuel Lines: Carefully reconnect the fuel lines, ensuring they are securely attached and there are no leaks. Use new fuel lines if necessary. Double-check all connections.
* Connect the Vent Line: Connect the vent line.
* Reconnect the Battery: Reconnect the battery's negative terminal.
4. Testing:
* Check for Leaks: Carefully inspect all fuel line connections and the tank itself for any leaks. Start the engine and let it run for a few minutes to check for leaks.
* Check the Fuel Gauge: Verify that the fuel gauge is working correctly.
Important Considerations:
* Fuel Tank Strap Condition: Replace rusted or damaged straps.
* Fuel Line Condition: Replace any cracked or deteriorated fuel lines.
* Correct Tank: Ensure you're installing the correct tank for your specific CJ-5 model.
* Repair Manual: A Jeep CJ-5 repair manual is essential for detailed instructions and torque specifications. This outline is a general guide and may not cover all aspects of the installation.
This is a complex task. If you're not comfortable working with fuel systems, seek professional help from a qualified mechanic. Improper installation can lead to a fire hazard. Safety should always be your top priority.
