Fuel Cell Options & Compatibility
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15‑gal or 19‑gal? Both sizes fit the TJ/LJ and use pumps from 1997–2006 model years.
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Ideal for LS or Hemi swaps? We recommend using a 2005–2006 fuel pump for higher pressure (~58 psi), although bigger setups may require aftermarket or inline regulators.
Fitment & Mounting
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For inside-the-bed TJ installations, fuel pump trimming is required on 2005‑2006 stock pumps to fit the clamping ring.
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Loop the vent hose all the way around the bottom of the tank before exiting underneath. Tie into your EVAP system if necessary.
Plumbing & Ventilation
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Most early TJs use a returnless fuel system, so the additional -8 AN fitting is capped (later models may require it).
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EVAP and rollover vent integration is supported but varies by setup—many builders DIY a T connection to plumb the EVAP into the brass rollover valve.
Electrical & Connectors
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Use Russell RUS‑640853 for the pump side and RUS‑640863 for the Jeep fuel line—plus two Sum‑220690B (-6AN) fittings.
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If your TJ is 2004 or earlier, you’ll need the pigtail adapter to fit the newer fuel pump.
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Always extend the fuel pump harness during install (most builders add ~2–3 ft) for future access.
Stretch Tank Solutions
Your fuel cell can be mounted underbody to clear an extended wheelbase or aftermarket axle setup. Popular options:
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Stretch 14.5‑gal underbody cell with steel skid plate (up to 6″ stretch)
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Standard 15‑ or 19‑gal in-bed cells if stretching more than 6”.
Best Practices & New Insights
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All Motobilt cells are made from 1/8″ 5052 aluminum, CNC‑cut, press‑braked, and TIG‑welded for superior strength.
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For Stretch installs the stock filler neck and vent may need to be custom relocated.
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Use Permatex Form-a-gasket-#2 on the filler neck for the in the bed fuel cells. On the pump assembly only use the gasket that is supplied.
