Fuel Tank: Service and Repair

CAUTION: Observe all fire hazard precautions detailed in FUEL SYSTEMS / SERVICE PRECAUTIONS, when working on open fuel systems.
Fuel system MUST be depressurized before disconnecting any fueling component.

Jaguar recommends use of a special non-ferrous wrench, tool JD175, for removing fuel hose clamps located inside fuel tank. This is to eliminate the possibility of sparks being created.

1. Depressurize fuel system. Fuel Pressure Release
2. Disconnect battery.
3. Drain fuel tank into suitable container.
4. Lift car on hoist.

Under Body Fuel Hose Connections:

5. Remove clips securing fuel supply and return hoses and disconnect from fuel tank. Fit protective plugs to open hoses and tank.
6. Remove sealing rings from hoses and lower car.
7. Open trunk and remove spare tire.
8. Remove floor carpet, right liner, left liner, and front liner.

Closing Plate:

9. Remove fasteners securing fuel tank closing plate and remove plate.
10. Remove spare wheel securing stud.
11. Remove closing plate lower mounting brackets.
12. Disconnect fuel breather hose from filler neck.
13. Disconnect purge and overflow pipes from evaporative loss flange.
14. Disconnect fuel pump harness from evaporative loss flange connection.

Fuel Tank Sending Unit Connections:

15. Note position of wiring and disconnect from fuel tank sending unit.

NOTE: Top terminal is positive supply, center terminal is ground, bottom terminal is fuel warning light and should be blanked off with insulation cover preventing incorrect connection.

Side Panel:

16. Use suitable prop to support trunk lid. Remove left lower gas strut mounting.
17. Remove left side panel.
18. Remove ABS ECU securing strap and move ECU aside for access.
19. Loosen filler neck hose clamps and disconnect neck drain hose.

Filler Cap:

20. Open filler flap and remove screws securing neck and neck seal.
21. Remove filler neck and seal.
22. Remove filler hose and clamps.
23. Remove tank.
24. Remove insulation pad from tank.
25. Remove fuel pump.
26. Remove tank sending unit and seal.
27. Remove magnetic drain plug and clean plug.
28. Fitting a new tank is reverse procedure.
29. Refit components from old tank.
30. Refit fuel pump.
31. Be sure to use new seals where applicable.
32. Check all connections for leaks before closing up trunk.