Fuel Tank: Service and Repair

WARNING: WORKING ON THE FUEL SYSTEM RESULTS IN FUEL AND FUEL VAPOUR BEING PRESENT IN THE ATMOSPHERE. FUEL VAPOUR IS EXTREMELY FLAMMABLE, HENCE GREAT CARE MUST BE TAKEN WHILST WORKING ON THE FUEL SYSTEM. ADHERE STRICTLY TO THE FOLLOWING PRECAUTIONS:

DO NOT SMOKE IN THE WORK AREA.

DISPLAY 'NO SMOKING' SIGNS AROUND THE AREA.

ENSURE THAT A CO2 FIRE EXTINGUISHER IS CLOSE AT HAND.

ENSURE THAT DRY SAND IS AVAILABLE TO SOAK UP ANY FUEL SPILLAGE.

EMPTY FUEL USING SUITABLE FIRE PROOF EQUIPMENT INTO AN AUTHORIZED EXPLOSION PROOF CONTAINER.

DO NOT EMPTY FUEL WHILE WORKING IN A WORKSHOP A PIT.

ENSURE THAT WORKING AREA IS WELL VENTILATED.

ENSURE THAT ANY WORK ON THE FUEL SYSTEM IS ONLY CARRIED OUT BY EXPERIENCED AND WELL QUALIFIED MAINTENANCE PERSONNEL.

Remove
- Depressurise fuel system. Service and Repair
- Ensure that the radio code is available for resetting the radio after the battery is reconnected.
- Remove battery/fuse cover and disconnect the battery.
- Remove trunk floor carpet board and front liner.
- Remove the rear lamp assembly interior trim finisher.
- Remove the trunk seal retainer and left side liner.
- Drain fuel tank using approved equipment and observing appropriate safety precautions.
- Raise vehicle on "4 Post" ramp.
- Disconnect the fuel feed and return pipes from the fuel tank using Jaguar Service Tool JD-203.
- Fit plugs to the tank and to the hoses.
- Release the clip securing the filler aperture drain pipe and release the pipe from the clip.
- Lower the vehicle on the ramp.
- Move the in-car entertainment package from the evaporative flange area.
- Disconnect the vehicle harness from the evaporative loss flange.
- Disconnect fuel gauge tank unit feed wires.
- Remove the ratchet strap (1), and the spring band clip (2), to release the filler aperture drain pipe from the fuel tank filler tube and the aperture.
- Remove drainpipe from the body grommet.
- Using Jaguar Service Tool JD-203 disconnect the under floor vapour pipe from the fuel tank.
- Open the flap and remove the fuel filler cap.
- Carefully remove the garter spring (3) from the filler neck seal.
- Move the seal to the tank filler neck.
- Slacken the two retaining strap tensioning bolts (4) at the lower brackets.
- Remove the bracket retaining bolts (5), leaving the brackets attached to the straps.
- Remove the retaining clip from the left side support strut and detach the the strut from the trunk lid ball pin.
- Remove the fuel tank from the vehicle.
- Drain the remaining fuel and store the tank using the approved equipment and observing the appropriate safety precautions.

Refit in the reverse order of the removal procedure. Refer to tightening specifications. Specifications

NOTE: After reconnecting the battery reset the radio with the radio code and reset the clock. Transfer the fuel, drained from the displaced fuel tank to the new tank in the vehicle.