Fuel Tank Repair - 2003 KJ

[tesuzuki2002]

I have a 2003 KJ and over the weekend I incurred a gas tank puncture that is at about the 1/2 point of the fuel tank. (I was able to finish out my trip picking up a 2nd Jerry can so could fill up as needed with only about a 140 mile range.

I was looking at replacing the fuel tank since that would give me the confidence in having a good tank. These are out of production so to source a replacement my option would be going to a salvage yard.

The puncture appears to be more of a gouge and a knife like cut into the tank above the horizontal joint between the upper and lower part of the tank. (I will get some pictures where I can get it jacked up and get under it much better.)

My question is about gas tank repair kits and their success rate? This is a plastic tank and I have never used one of these. From my initial look at the damage it seems feasible that I could sand down the area and clean it up and use a plastic gas tank repair epoxy on it.

I do a bit of off-roading in the SW mainly California deserts. This is a stock liberty and I know it definitely has it's limits, however, I'm saying this before it most certainly experiences a fair share of vibration.

Any info and or experience with this type of repair would be appreciated.

I do plan to keep this vehicle for a while despite being 19 years old.. Just passed 155K miles on this trip and all else is very mechanically sound

thanks!!

 

[tesuzuki2002]

Here is an update with pictures of the cut into the gas tank.

After doing a bit more research on this. I know my KJ has the 18.5 gallon tank and I'm now seeing that some trim models or in later years there were some with a 20.5 gallon tank. Perhaps this was more on the KK model? Does anyone know the compatablilty across these models? If I end up doing a tank replacement it looks like I could get an extra 2 gallons on board. Not a lot.. but good for an extra 35 miles on long trips.

Thanks again for looking and any info.

 

[klc]

Here is an update with pictures of the cut into the gas tank.

After doing a bit more research on this. I know my KJ has the 18.5 gallon tank and I'm now seeing that some trim models or in later years there were some with a 20.5 gallon tank. Perhaps this was more on the KK model? Does anyone know the compatablilty across these models? If I end up doing a tank replacement it looks like I could get an extra 2 gallons on board. Not a lot.. but good for an extra 35 miles on long trips.

Thanks again for looking and any info.

I have an 06 Limited, they come with the bigger tank.