Back in November, I took the Jeep to Tire Guys in Redlands for a California smog inspection and emissions certificate, required for the title transfer for the DMV. The first time through the inspection, it passed everything except the evaporation test, which is all about finding unwanted vapor emissions. The master tech working on the Jeep, Mike, was very helpful in identifying where the leaks were coming from (a few cracked fuel lines, as well as the round hatch area above the fuel sending unit that sits above the gas tank). In my list of things I don't want to work on I put fuel lines near the top. I let them handle the bad fuel hoses, but the cost for them to replace the O-ring around the unit was a bit high (and it was mostly labor). Since the fuel gauge was inconsistent in its functioning and unreliable in its readings, I figured I could replace the sending unit, fuel lines, and the O-ring 
for less than what the Tire Guys would charge me. So I placed a call to BJ's Off Road for a new sending unit, a new O-ring, and a new plastic hex nut (2 1/4" wide, holds the sending unit in place). Mike had popped the rivets off the sending unit access hatch for me and showed me where the hatch was (underneath the bench seat). The Tire Guys were perfectly happy to let me do the work instead of them. Mike even said that he would do a free evap test first when I brought the Jeep back for a smog retest to make sure I took care of the problem. I was able to replace the unit and put in a new O-ring. I 
also replaced about three feet of fuel hose running to and from the sending unit along the top of the gas tank under the back of the Jeep, all for about sixty bucks, just over a third of the Tire Guys' estimate (which is not a criticism of the Tire Guys shop or pricing). Since they were on top of the gas tank, I didn't have to worry about fuel pouring out when I replaced the lines. All that spilled out was what little had remained in the lines due to surface tension. The only frustrating or time-consuming part of the process was removing the ends of the fuel hoses from the steel hard lines behind the gas tank above the rear axle. This is where several lines, including brake lines, converge and tuck in the left frame rail, making for a crowded area that my big hands don't exactly fit. I was able to do it, but not before giving a few DNA samples from my knuckles.My fuel gauge is now much more reliable, I don't have any of the crusty, cracking fuel hose that is always dangerous, and I have a smog certified Jeep. A good round of work overall.
