Jaguar Fuel Tank Removal
Before you start a Jaguar fuel tank removal job read this post to prevent extra work and problems you can cause.
This post can be extremely helpful. Because I have done this a few times and know that for which to watch out.
You will find information that will answer question you may have.
While yes, it is a tough job, however you may not have to take all the parts off that are mentioned online.
Not removing unnecessary parts makes the job go quicker.
Do not stress about the gas in the tank. I will tell and show you how to deal with it.
Also provided in this post key facts to know about fuel release tools and how to use them.
How to avoid damaging electrical wires.
Removal procedures to help prevent causing problems for yourself.
You Must Have the Right Release Tool
Most importantly, you must have the right size release tool.
The 2003 Jaguar XJ8 requires a three-eighths” release tool.
Not all fuel release tools will work, not even the correct size.
Some are too short to reach in far enough to push the release open.
Some have long handles that are too long to get in tight spaces.
See Picture.
Blue tool came from an automotive store.
White tool came from Harbor Freight.
Tank Has Fuel No Problem
First, you are working around gas and gas fumes.
CAUTION
NO SMOKING/HEAT OR SPARKS NEAR THE CAR
WARNING
BATTERY MUST BE DISCONNECTED AND COVERED.
YOU MUST COVER BATTERY BECAUSE METAL TANK CAN SHORT THE TWO BATTERY POSTS CAUSING FIRE OR EXPLOSION.
Quick connects should not be damaged if they are not leaking.
Do not bend lines when removing.
Release and pull straight out.
You can pull the lines out without losing fuel.
You should only get a little fuel that is in the line that will drip out.
It is unlikely you will need it but for safety reasons keep a
large wide mouth tote ready to push under the car.
Because if a quick release is damaged and fuel leaks you can catch it.
Regular fuel container will not work as opening is too small and fuel will run in different directions do to vehicle components.
I will show you how to safely remove the fuel after the fuel lines are out. This you will do after you open the tank.
Jaguar Fuel Tank Removal first steps
You must protect the wiring harnesses from damage.
Because the tank is tight coming out and rubs on the wires.
You can cut flat pieces of plastic sheets out of large water bottles to protect the wire harness.
Round edges and make sure they are smooth, slip in between tank and wires.
Place under tank passengers side.
Next Step
Release fuel line disconnect and remove fuel line ends from tank only
You do not have to disconnect the other sections of the line.
To do this follow the next section.
STOP Do not start pulling parts off under the car.
When looking under the car it looks like an impossible job, but it is not.
While this is not an easy job, and everyone may not be able to do it.
However, I recommend you try it first, because it is possible
to remove the fuel lines from under the car.
All without removing any other part under the car.
My son has done it twice already on a 2003 Jaguar XJ8.
Took him less than thirty minutes to release the lines.
Jaguar fuel tank removal
First find the fuel filter above the exhaust on the driver’s side.
Follow the fuel lines up to the tank. It is very tight and mostly room for one hand.
Most importantly, mark one of the lines with tape or white out
and also mark the side of the tank where it enters.
This will help when reinstalling the fuel lines.
With the fuel release tool on the fuel line near the tank, smaller end towards the tank.
When you are ready push release tool against the tank to release fitting.
You should feel it when it goes in to release the line.
Here is the hard part, as you push in to release you must also pull the line out from the tank with one hand.
To make the other hand useful, use a one-inch cable clamp as pictured.
Install clamp on fuel line close to tank, tighten just enough so it will not slip.
DO NOT over tighten clamp, you do not want to dent the fuel line.
Loop thin piece of rope (size of parachute cord) around the clamp.
Run the cord straight back over car components and down.
You can use your free hand to pull the rope when you release the fuel line.
This will help to pull it out from the tank. Repeat on second fuel line.
There are two lines to release.
Once the Fuel Lines are released
Unbolt the two straps in the trunk holding the tank in.
Also remove the little nuts inside the trunk under the fuel cap (their size is seven mm).
Disconnect thick hose off tank on drivers’ side from hose going down.
You must remove overflow hose from fuel cap area in trunk, goes through floor next to tank (clamp underneath car).
Remove drivers’ side taillight, push wire on connector down to release connector.
From under the car on drivers’ side, remove rear side marker light wire and bulb.
You will need to pull rubber cap on wire out from in the trunk floor.
Disconnect wires from CD player and fuel lid opener and remove.
Because CD player will get in the way remove from trunk to allow for room to work with the tank.
Work wires up over trunk door brackets out of the way of the tank when removing.
When ready to move tank carefully push down on outside of fuel refill pipe.
Tip, place a stick or broom handle across trunk door brackets to tie wires up out of the way.
Most wires on top of the tank are removed when the tank is pulled out a little bit.
However, check that it is clear move the tank out a few inches.
Work the tank out slowly one side then the other until you have access to the top of the tank.
Remove all wire connectors attached to the tank.
Not necessary to remove the large wire connector above the tank on passenger’s side.
Loosen or remove all hose clamps on hoses attached to center piece of tank.
Disconnect hoses from center piece of tank with caution.
Use care to not over force plastic tubes at end of hoses ends (Not cheap).
You can tap the ring to the right to release center piece.
TIP, You may have to put a thin screw driver under the hose, very carefully and squirt some oil under hose.
Fuel Pump
Fuel Pump is attached to the center piece.
Once all hoses and wires are clear turn or tap the lock ring counterclockwise to release the center piece.
Lift up center piece slowly, there is a hose that must be disconnected from it.
There is also a bolt at the bottom of the pump that must be removed.
Try not to disturb the fuel sending unit it is also in the tank.
