80L Replacement Tank

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.

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.

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.

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.

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.

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.

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.

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.

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!

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.

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!

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).

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.

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.

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.

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.

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.

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.

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!

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.

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

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.

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.