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Installing a fuel cell is a smart upgrade for race cars, hot rods, and off-road vehicles. Not only does it provide increased safety in performance applications, but it also offers greater flexibility in terms of fitment and fuel system routing. Whether you're upgrading from a stock tank or building from the ground up, proper fuel cell installation is essential for safety and performance.
This guide will walk you through the full process of how to install a fuel cell, from removing the old tank to setting up your new system. If you're searching for tips on fuel cell install, installing fuel cell components, or wondering how to install a fuel cell correctly, this step-by-step breakdown covers it all.
Safety Precautions: Ensuring a Safe Installation
Before getting started, it’s important to respect the risks involved with working around fuel. Gasoline vapors are extremely flammable, and a single spark can lead to fire or explosion.
Safety tips to follow:
- Always work in a well-ventilated area
- Keep sparks, flames, and heat sources away from the work area
- Do not smoke during installation
- Open any fuel lids slowly to relieve pressure
- Use fuel-rated containers if draining the old tank
- Wear safety glasses and gloves
Never install or service a fuel cell near an active battery or running engine. Proper planning and safety will make the process more efficient and much safer.
Removing the Old Fuel Tank: Step-by-Step Process
If your vehicle currently has a stock fuel tank, you will need to remove it before proceeding with the fuel cell installation.
Step 1: Disconnect the Battery
Prevent accidental sparks by disconnecting the negative battery terminal before touching the fuel system.
Step 2: Relieve Fuel System Pressure
Loosen the gas cap and, if needed, depressurize the fuel system using the service port or fuel pump fuse method. Drain fuel safely into an approved container.
Step 3: Disconnect Fuel Lines and Wires
Label and remove all fuel lines, filler hoses, and any electrical connectors attached to the sending unit or fuel pump.
Step 4: Remove Mounting Hardware
Support the fuel tank with a jack or straps, then remove the mounting bolts or fuel tank straps and carefully lower the tank out of the vehicle.
Inspect the area where the new fuel cell will be installed. Remove any sharp edges or debris that could damage the cell.
Installing the New Fuel Cell: Detailed Instructions
Installing a fuel cell requires a secure mounting solution and proper fuel system routing. This installation method applies to most common aluminum or plastic fuel cells.
Step 1: Position the Fuel Cell
Select a mounting location that complies with your sanctioning body's rules. Typically, fuel cells are installed in the trunk or rear bed area. The cell should sit flat with enough clearance from the exhaust, suspension, and drivetrain.
Step 2: Mount the Cell Securely
Use steel mounting brackets or straps around the top, bottom, and sides of the cell. Bolt it to the frame or a reinforced floor pan. The tabs on many aluminum fuel cells are for locating only and should not be relied on for structural support.
Step 3: Install the Vent Line
Every fuel cell must be properly vented to prevent vapor buildup. Use a rollover vent valve and route the hose away from heat sources. Ensure that the vent line has a fuel-safe filter and cannot kink or clog.
Step 4: Connect the Fuel Lines
Install AN fittings or hose barbs based on your fuel delivery setup. Route supply and return lines from the cell to the fuel pump or fuel rail. Use high-quality fuel hose rated for gasoline or ethanol.
Step 5: Wire the Sending Unit (If Equipped)
Many fuel cells include a 0–90 OHM sending unit, which works with most GM-style gauges. Connect the center terminal to your fuel gauge and ground the unit using one of the outer bolts, ensuring a solid frame ground.
Step 6: Double-Check Grounding
Grounding is critical for fuel gauge function and to reduce the chance of static discharge. Make sure the fuel cell is properly grounded to the vehicle chassis.
Step 7: Secure the Cap and Check Seals
Install a secure-fitting fuel cell cap. Replace worn or missing gaskets to ensure a proper seal and to prevent vapor leaks.
Final Checks Before First Startup
Once your installation is complete, take a few moments to check everything again:
- Confirm that all fuel lines are tight and routed away from sharp edges and hot components
- Verify the vent system is installed and unobstructed
- Check that all electrical connections are tight and properly grounded
- Confirm that the mounting hardware is secure and that the fuel cell does not shift under light pressure
- Add fuel and check for leaks before reconnecting the battery
Choosing the Right Fuel Cell for Your Vehicle
Fuel cells come in various shapes, capacities, and configurations. When choosing the best fit, consider the following:
- Application type (street, race, off-road)
- Required capacity (measured in gallons)
- Mounting location and dimensions
- Pump compatibility (internal vs. external)
- Sending unit options
- Compliance with race regulations
JEGS offers a wide range of fuel cells to fit nearly any build. From aluminum race-ready cells to polyethylene drag race models, our inventory includes trusted options that meet safety and performance needs.
Still Have Questions? JEGS Can Help
Whether you're planning a full fuel cell install, wondering how to install a fuel cell safely, or replacing a worn-out tank, JEGS has the parts and experience to help you get the job done. Call a JEGS Tech Representative at 1-800-345-4545 for expert assistance with product selection, installation tips, and troubleshooting.
You can also shop for fuel cells, vent fittings, sending units, and installation hardware anytime at JEGS.com.
4 responses to “Fuel Cell Installation: A Step-by-Step Guide”
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Fred, installation instructions for an RCI Aluminum Fuel Cell are going to depend on the exact model and whether it is a standard bottom feed, rear sump, or top feed configuration. RCI typically includes model specific instructions in the box, but if you need another copy the best way to get the correct document is to reference the exact RCI series and capacity you have so the proper mounting, venting, and plumbing guidance can be matched to your unit. In general, these cells are designed to be mounted securely to a flat surface using the supplied mounting tabs or straps, isolated from vibration, and installed with proper vent routing, rollover protection, and fuel rated hose and fittings. They should not be mounted directly against sharp edges and must be properly grounded. Because fuel system layout and safety requirements vary depending on whether the vehicle is street driven or race only, it is important to make sure everything is routed and secured correctly. To make sure you get the exact installation instructions for your specific RCI Aluminum Fuel Cell and to go over any plumbing or safety questions, please give us a call at 1-800-345-4545 and a JEGS Tech Specialist will be glad to help you.
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Hello I was wanting to take out my factory 2021 jeep gas gladiator fuel cell and install something
like 794-18-2171-SU in the back of the motobilt bed I installed. I was wanting to put it against the bed towards the front behind the back windows. It’s a 17 gallon cell but was wondering if you had anything bigger but keeps the same shape. I also need to know what else I would need to purchase as well like hoses fittings or electrical.-
Hi Brian, that’s a great setup you’re working on. For your 2021 Jeep Gladiator, swapping out the factory fuel tank for a rear-mounted fuel cell is doable, but it takes a little planning. The 17-gallon cell you mentioned will work fine in the Motobilt bed setup, but if you want something larger while keeping a similar shape, you’ll want to look at JAZ Products or RJS Racing Equipment fuel cells. They both offer rectangular and wedge-style aluminum or polyethylene fuel cells in the 20-22 gallon range that are close in footprint to what you’re describing, but a few inches taller. That extra depth is usually the tradeoff for more capacity without extending the length.
Since you’re replacing a factory tank, you’ll need to plan for a few supporting parts. You’ll need AN fuel line and fittings, a fuel filter, and depending on whether you’re retaining the factory fuel injection or switching to a return-style setup, you may need a high-pressure external pump or an in-tank pump module designed for EFI. You’ll also need wiring for the pump and sender, which can be handled using a universal fuel cell wiring harness or by adapting the OEM harness with weather-sealed connectors.
If you’re retaining the stock fuel gauge, make sure the sender in the new cell matches your Jeep’s resistance range (Jeep typically uses 220 ohms empty to 20 ohms full, but it’s best to confirm with a multimeter). You’ll also want to mount the cell securely with steel brackets or straps, as required by most safety standards.
Before you finalize the size, it’s worth confirming how much vertical clearance you have under the bed floor to the frame rails and how far forward you plan to mount it. That’ll determine if one of the slightly taller 20+ gallon options will fit without modification.
For exact fitment recommendations and help picking the right hoses, fittings, and electrical setup, you can call us at 1-800-345-4545 and speak to a JEGS tech specialist. They’ll help match all the pieces to your Jeep’s specific configuration so everything works safely and efficiently.
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