80L Replacement Tank

80L Replacement Fuel Tank

  • Comprehensive Fitting Kit and Instructions

  • Includes An Additional Regulation Carbon Canister

  • Fully Baffled For Better Fuel Usage And Stronger Tank Design

  • Pre-Drilled Holes In Mounting Brackets For Fast & Easy Installation

  • Rollover Safety Valve

  • Part Number: TR87

  • Model Fitment: JB64/74 Models

  • Year Fitment: 2018 to Current

  • Fuel Type: Petrol

  • LongRanger Capacity: 80 Litres (replaces the OEM 40lt)

  • Fitting Location: Replaces Original Tank

  • Exhaust Modifications: Required (parts supplied in kit to modify the OEM mid-section)

  • Other Modifications: None

  • Fitting Time: 4 Hours Fitting Time info

  • Shipping Weight: 35KG

  • Shipping Dimensions: 1170mm x 550mm x 1050mm

My fuel gauge went to zero for some distance then started working again, what’s going on here?

If the tank had been over filled or very little fuel has been used from the tank after being filled and driven for a reasonable distance with little to no gauge movement the on-board computer system may think this is a fault as the needle has not moved down as quickly as it thinks it should have and as a result sends the gauge to empty as a warning. This is a temporary experience and has been known to happen to an overfilled OEM tank and could occasionally also happen to The Long Ranger tank, but if you keep driving and use a little more fuel from the top of the tank the gauge simply starts working again.

Where does the tank mount?

The Long Ranger mounts in place of the OEM tank with extra capacity gained from a complex design shape specifically to fit the Jimny.
On the front we utilise new M10 Ubolts for mounting while at the rear we retain the original mounting bolts but to assist with carrying twice as much fuel we have additional Ubolts to take the load, this Ubolt mounting system allows for any movement to assist chassis flexing.

Will this tank fit with my aftermarket exhaust system?

If you have an aftermarket exhaust that follows the same path as the OEM system it will not be compatible, EG: most Cat back systems will need to have a custom mod done to fit with this tank.  An axle back after market system will be compatible as the mid-section is usually unchanged from OEM.  We worked closely with Torqit during the design stage to ensure compatibility with their  63mm Australian made system.

Will this fit with my transfer case bash plate?

Yes, during development we have designed our tank and exhaust modification to be compatible with Rival and Jimny Bits transfer case base plates.  But we believe there will be no issue with any other bash plate on the market, check out our gallery pics to compare with what you have.

The Jimny is a small car, how did you manage to get double the OEM fuel capacity?

With Suzuki having a warrantable weight limit on the roof of only 30KG, carrying fuel on here can have consequences with both insurance and poor handling, inside the car 20 or 40lt of fuel is not the best use of valuable space in such a small car plus in the event of an accident do you really want flammable fuel as your passenger!

So during the development it became obvious that carrying fuel under the vehicle was a high priority for Jimny owners and with available space limited it became apparent early on we had a tough job ahead of us to find some space, removing the OEM tank mounting system and designing some new mounts gained us a few litres but the biggest gain came from a small modification to the OEM exhaust system which allowed us to greatly increase the standard tank size. By relocating the central part of the exhaust system over alongside the LHS chassis rail this opened up a nice area to fit a larger replacement fuel tank.

As with all our tanks they come complete with all the parts required to perform the install and this new Jimny tank is no different, we supply a new 9” Hot Dog to replace the OEM resonator and the correct shape pipes at either end to join back with the OEM exhaust, we supply exhaust clamps and slip joints for ease of fitting, but if you have a welder handy, we recommend welding most of the joints for a better job, alternatively use our exhaust clamps to hold the modified system together and take to your local fabrication shop to have them do a 10 min weld job.

Can I remove the Long Ranger tank and fit to a new Jimny when I trade it in.

This is possible, however, it should be noted we change the sender unit float arm, shorten and change some hoses and cut off some tank supports that would need to be re welded back on. If you intend on doing this you should ask the fitter to retain any parts removed during installation to assist in putting the vehicle back to OEM spec.

Do I need the aftermarket protection plate for the OEM Carbon Canister?

No, we actually relocate the OEM canister a little further forward closer to the transfer case to make room for our tank, our kit includes a 2mm steel relocation bracket that also doubles as a guard to protect the plastic canister from damage, so save your money on this purchase, a good picture of this can be found in our gallery.

Does the Long Ranger fuel tank compromise ground clearance?

At The Long Ranger we want to enhance your adventure by extending the driving range of your vehicle, but we also do our best to create our tanks so you don’t find yourself stuck in a compromised position or even worse a hole in the tank all because the tank hangs to low from a poor design.  This tank has been designed to give the user more fuel capacity and maintain the off road capabilities of the vehicle.  Our 80lt tank hangs approximately 30 mm lower than the OEM tank   however ramp over angle is not affected as the original exhaust resonator in the mid-section of the exhaust system that we remove is actually 5mm lower than the new tank.  In our gallery we have a good cross section view from the digitising in our CAD drawing to show this example. So our design gives maximum capacity while maintaining good off road performance.

Do I need to purchase an additional carbon canister as stated in the Australian LM1 Fuel Systems rule 2.2 from the National Code of Practice Vehicle standards Bulletin (VSB14 NCOP9)?

No, along with the correct plumbing procedure The Long Ranger Jimny fitting kit includes an additional canister to comply with this rule.  This can be seen fitted to the top of our tank in one of the gallery photos, its black plastic about half the size of a shoe box and filled with carbon granules to help capture hydrocarbons (fuel fumes) and prevent them entering the atmosphere, these are later purged by a vacuum line from the engine and burnt in the combustion process.

While we have traditionally never needed these since we started building tanks in the late 70’s, the OEM canister has done the job just fine. This national code of practice now states they are required when adding more fuel capacity to a petrol vehicle, since then we are the only company in Australia to have implemented this change, its an industry first!

How far can I travel when the low fuel light comes on?

Did you know the Jimny has two stages of low fuel warning, the first is a light comes on at same time as one bar is left and the range says zero, there is now approximately 15% of your capacity left in the OEM tank, then there is a second stage when the last bar starts to flash!
After fitting a Longranger to 2019 Australian JB74 Gen4 Jimny when the Low light has been activated (the range will now read zero at this point in time and the on board computer has also advised you of low fuel) you have approximately 11lt left and depending on the economy may be able to drive for approximately 60 to 80km then the last white bar gauge will start to flash as a secondary warning and you will have about 4lt left and can drive for approximately another 50 to 70km before running out of fuel. While this seems like a long way to drive once the range has reached zero and the low warning light coming on it is a proportional increase when compared to the OEM tank.

I fill up just as the low light signal has been activated but don’t get as much fuel in as I should?

As mentioned in previous FAQ at this point there is approximately 15% fuel left in the OEM tank, after the Longranger has been fitted it will be proportionally the same amount of fuel left in the tank, which can be used but you have to drive past the range saying zero!

How will the Range (DTE) work?

Unfortunately the Range function will no longer work as intended, all other functions will continue to work as normal. When our 80L Long Ranger is installed the Range can be doubled to give an estimate of how far you can drive. Note: This “Range” is a calculation based on the average fuel consumption and 85% the OEM tank capacity. The factory tank capacity is built into the OEM computer system and is unable to be modified after the install of a larger capacity tank. (If you have the skills or knowledge to change this we would like to hear from you).

How Will The Gauge Work?

Our compressive fitting kit for The Long Ranger includes a replacement longer float arm, this replacement float arm ensures the gauge works from full to empty to closely mimic the original smaller tank.  However, it should be noted that as the tank is twice as big you can expect the gauge operation to also be magnified by a factor of two, so if you travelled for 50 km before the needle left the full mark with the original tank, you can now expect it to take approximately 100km, likewise if you could travel for 50 km once the needle hit the empty mark, this also will be approximately double the OEM distance you could travel.

Does the tank have anti-surge dam and baffles

Yes, to maximise fuel usage from the new larger tank we have baffles and a built in chamber around the fuel pickup unit to help avoid pickup cavitation sucking in air, these features can be especially useful when accidentally running low on fuel or driving on sloping terrain.
With larger tanks having bigger surface areas baffles also help add strength for those odd knocks and dents you can’t avoid.

Does The Long Ranger have a drain plug

Yes, although some OEM and aftermarket tanks don’t come fitted with a drain plug we believe this is a must have feature when traveling the outback as you never know if you have to drain the tank in the advent of picking up a bad load of fuel.

Does the tank have a rollover valve

Yes, an ADR compliant valve is supplied in the kit and fitted during the installation.
This keep you safe and your car working the way the manufacturer intended it to in the event of a serious accident.


Where are the tanks made

While there is a popular belief that all the big brands are made in a country with a cheap manufacturing base in the same factory with a different badge at The Long Ranger we still design and manufacture our tanks in Australia were it all started way back in the late 70’s.  We are a family run company based in Newcastle employing local people and that’s not about to change anytime soon.

Is the GVM (Gross Vehicle Mass) affected

No, adding a tank is the same as any other accessory and is utilising the vehicles payload capacity IE: anything added to the vehicle from the manufactures specification is using the payload capacity, whether it be driving lights, a set of rubber mats, a LongRanger fuel tank or the kids. As with most vehicles from a manufacturer the standard springs are not designed to cope with a constant full load on an extended trip, we recommend fitting a set of heavier rated springs such as those from Old Man Emu that have been designed to carry the extra weight of a fully loaded vehicle set up for camping.

Do the tanks come complete ready to fit

Yes they do, you may have heard on the grape vine that some aftermarket tank suppliers ship their products with poor fitting instructions and incomplete kits that make a trip to the local auto store a necessity to finish the job. At the LongRanger we supply comprehensive installation instructions with lots of photos to ensure the job is done as efficiently as possible and a complete installation kit ready to install so your local fitter can be rest assured there will be no expensive delays sourcing bits and pieces to finish the job!

Is the LongRanger design compatible with other accessories

There is nothing worse than buying an accessory to find it’s not compatible with something else you have fitted, we might not be first to market, but that’s because we try our best to design our long range tanks to be suitable with all models in the range and most other popular accessories you might want to install either now or in the future. Although we have designed our tanks with maximum compatibility in mind, if you have something specially fitted to your vehicle that is of concern we have provided a good selection of pictures in the gallery showing the installation to give a clear idea where The LongRanger fits under the vehicle.

Where can I purchase a LongRanger fuel tank

If you can’t make it to the Newcastle factory at 65 Northville Drive Barnsley NSW, all our products are distributed by ARB 4×4 accessories. For sales and support around Australia you can find a list of all the ARB stores Here

How long is the warranty period

All LongRanger manufactured products are covered by a 3-year warranty.
Note: There are some third party components not made by The LongRanger such as fuel pumps, sender units and switches etc found in some kits that come with their own 12 month manufacturers warranty.

What are the tanks made from

All LongRanger fuel tanks are made from Aluminised steel. This product is manufactured by the steel mill using 2mm (14gauge) cold rolled steel with a thin aluminium coating applied during the manufacturing process. Aluminised steel offers excellent weight vs. strength and durability when compared to lighter aluminium that just doesn’t have the raw strength to stand up to the hard knocks the underneath of a vehicle can suffer or the heavier Stainless steel that is more prone to fatigue cracks caused by embrittlement in the heat affected zone from the welding process.


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While our tanks have been primarily designed to fit Australian models, car manufacturers have been getting smarter and making their cars on global platforms so they generally fit vehicles of the same model in other countries.
We have seen a picture of the underside of a LHD vehicle from France and it looks the same as our Australian RHD vehicle so other than being LH drive, the European models appear to all be the same underneath which is great if you want to fit our tank.
Your local ARB dealer may be able to assist with any fitment questions as they may have some prior experience with your particular model.
Another good resource is to check our photo gallery for an idea of the shape and location of our tank.  Some common areas to look for possible issues with models in other countries would be: is the filler on the same side, do the chassis look the same around the tank location, If choosing a replacement tank, is the genuine tank the same capacity as with the genuine Australian spec model, Does the exhaust run in the same place, Do you have different genuine or non-genuine accessories fitted that may not be available in Australia for us to verify that may be affected with a new fuel tank.



Cross Break Strengthening. This is a simple and effective feature to aid in the stiffening of large flat panels. This technique reduces the risk of a fuel or water tank suffering from fatigue related stress cracks when travelling on extreme corrugations.



ledaLeading Edge Deflection Angle. Incorporating a leading edge deflection angle on the front lower section of the fuel tank allows road debris to be easily deflected.  This means the tank is marginally smaller in capacity, but in those tricky situations going over mounds of dirt and rocks you are less likely to get hung up than on a tank which hangs to low with a square leading edge.


max-foldMax Fold. Using this feature we maximise the sheet by making the base of the fuel tank from one side to the other in one continuous piece of metal.  This ensures the minimum amount of heat and possible stress from welded joins.



hptHydrostatic Pressure Test. At The LongRanger factory each & every fuel & water tank undergoes a pressure test while being placed under water at a maximum of 5 psi.



The Long Ranger Fuel Hose.FuelHosesml

The LongRanger fuel delivery hose is manufactured to SAE standards. Our fuel hose can be used in applications such as: Automotive fuel lines, emission control hose and commercial usage. Suitable for both diesel, leaded and unleaded fuels. Read More


pac-manPac-Man. You guessed it, we have pacmen inside our tanks working away to help strengthen the high stress areas. While your happily driving along those rough corrugated outback dirt roads listening to your favourite country music in the air-conditioned comfort of your new 4WD, these little guys are busy working away holding things together while the underside of your vehicle is coping a pounding.


shapeShape. Good design practices are what make a fuel tank both usable and functional. Some manufactures build cheap large sheet metal boxes and bolt them under a vehicle and call it a fuel tank. At the LongRanger we take the design a little more serious. Attention to detail and decades of experience building tanks has taught us what it takes to make a great product.


pbsParallel Break Strengthening. Just like CBS this feature aids in the stiffening of large flat panels and reduces the risk of a fuel or water tank suffering from fatigue related stress cracks when travelling on extreme corrugations. We usually incorporate these on the very bottom of a tank.


bafflesBaffles. help add strength to the bottom of a tank, this is especially important for a 4WD when bottoming the tank out on obstacles with the pickup unit sitting on the bottom which could be damaged, if the new tank design is lower than the OEM tank this is even more important with the tank being more vulnerable to accidental obstacle contact. A well designed longrange tank should incorporate baffles for improved offroad performance as baffles also help retain the fuel around the pickup unit.  With longrange tanks generally being longer or wider than the OEM tank when low on fuel it can “run away” from the pickup when driving in undulating terrain and possibly cause the engine to starve for fuel leaving you in an unpredictable situation and potentially unsafe location.


Carbon Canister. When adding additional fuel capacity there is a legal and moral requirement to install a larger or secondary carbon canister.

Carbon canisters contain activated carbon which absorb and store fuel vapour to reliably reduce the emission of hydrocarbons and pollutants into the atmosphere.

Every petrol tank has a pressure balance pipe, which ensures that no vacuum develops as the tank is emptied, and that heating and expansion of the fuel does not create overpressure in the tank. When overpressure is relieved the fuel fumes that escape are routed through the system breather to the activated carbon where they are captured and stored.

When driving the car these hydrocarbons are burned during normal operation as they are purged via a vacuum line from the engine drawing fresh air back through the canister.

Since 2015 LongRanger is the only brand available in Australia to embark on a major initiative which will eventually see all required models shipped with a carbon canister as a standard feature.

This industry first is part of The Long Ranger’s efforts for a more sustainable environment.

3 Year Warranty


Tanks will be free from any manufacturing defects in materials or workmanship for a period of Three Years from the date of purchase.

Manufactured By


It was during the late 70’s that Fred Black, owner of Out of Town 4WD, recognised a need for 4WD travellers to have a greater fuel capacity to travel the vast distances often necessary in Australia.

Distributed By


Today, ARB is Australia’s largest manufacturer and distributor of 4×4 accessories. With an office in the USA and an export network that extends through more than 100 countries around the globe.

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