trunk JAGUAR X308 1998 2.G User Guide

Fuel Tank and Lines - Fuel Tank and Li
nes
Description an
d Operation

Fuel Tank

Parts List
The steel fuel tank is located inside the trunk and mounted across the vehicle behind the passenger compartment bulkhead.
The fuel tank is held in posi tion by two retaining straps fi tted to body-mounted brackets.
The fuel tank has an integral non-adjustable fill er pipe and integral breather and vapor pipework.
A single fuel pump is mounted inside the tank on vehicles with normally aspirated engines. For vehicles with supercharged
engines, two pumps are fitted in the tank. Fuel is drawn by the pump(s) from the fuel tank and supplied via the fuel lines
and 70 micron filter to the fuel rails.
The fuel lines run from front-to-rear down the vehicle's left-hand-side.
Ite
m
Part
Number
Descr
iption
1—Fu

el filler latch box
2—Pressure reli

ef pipe, ORVR
(shown) / tank breather pipe on non-ORVR systems
3—Tank grounding
cable
4—Evaporative flan
ge assembly
(ORVR type shown)
5—Trunk elec
trical harne
ss (part of)
6—Fue
l
level sensor
flange/connector
7—Fu
el tank retaining straps
8—F
u
el tank retaining stra
ps adjustable clamps
9—Fu
el tank retaining straps lower brackets
10—Tank vapor outlet pipe to un
derflo
or pipe quick-fit connector
11—F
u
el filler latch bo
x water drain pipe

Conne
ct the scan tool
1
Have the DTC(s) and fr

eeze
frame data been recorded?
Yes GO to A2
A2
: CHECK FUSE
•

NOTE: See further steps for poss
ible cause of fuse failure.
Chec
k fuse F7 integrity (located in the trunk).
1
OK

?
Yes GO to A3
No Renew fuse and test the syst em for normal operation.
A3:
CHECK SHORT TO SUPPLY

Conne
ct the scan tool
1
Have the DTC(s) and fr

eeze
frame data been recorded?
Yes GO to B2
B2
: CHECK FUSE
•

NOTE: See further steps for poss
ible cause of fuse failure.
Chec
k fuse 15 integrity (located in the trunk)
1
OK

?
Yes GO to B3
No Renew fuse and test the syst em for normal operation.
B3:
CHECK SHORT TO SUPPLY

Fu
el Tank and Lines - Fuel Level Sensor
Remov
a
l and Installation
Removal

Ins
tallation

1.
WA
RNING: BEFORE PROCEEDING, IT IS ESSENTIAL THAT THE
WARNING NOTES GIVEN IN SECTIO N 100-00 (UNDER THE HEADING
'SAFETY PRECAUTIONS') ARE READ AND UNDERSTOOD.
Remove the battery. For additional information, refer to Section 414
-01
Battery, Mounting and Cables
.
2.
Drain
the fuel tank using a suitable suction pump/tanker. If the On-
board Refueling Vapour Recovery (ORVR) system is fitted, refer to
Section 310
-00 Fu
el System
- Gen
e
ral Information
.
3. Remov
e the trunk front liner. For additional information, refer to
Section 501
-05 Interior Trim
and Ornamentation
.

4. D
isconnect the harness co
nnections to the sensor.

5. U
sing special tool 18G 1001, remo
ve the sensor retaining ring.

6.
Remov
e the sensor assembly and discard the seal.
1. Fitting a new level sensor is the reverse of the removal procedure,
noting that a new seal must be fitted.

Fuel Tank and Lines - Fuel Tank

Re
mo
val and Installation
Remov
a
l
•
NO
TE: This removal/installation procedure is applicable to all tank assembly variants.
S
p
ecial Tool(s)

R
e
lease tool 5/16" snap coupling
310-054

F u
el tank retaining strap cam adjuster
310-094
1. Remove the battery. For additi onal information, refer to
Section 414
-01
Battery, Mounting and Cables
.
2. Re
move the trunk floor carpet.
3. Remove the trunk front liner. Fo r additional information, refer
to Section 501
-05
Interior Trim and Ornamentation
.
4. Re
move the rear lamp assembly interior trim finisher. For
additional information, refer to Section 417
-01
Exterior
Ligh
ting.
5. Re
move the trunk seal retainer
. For additional information,
refer to Section 501
-0 5
Interior Trim and Ornamentation
.
6. Re
move the trunk side liner, lefthand. For additional
information, refer to Section 501
-05
Interior Trim and
Or
n
amentation
.
7. WARNING: B E
FORE PROCEEDING, IT IS ESSENTIAL THAT

THE WARNING NOTES GIVEN IN SECTION 100-00 (UNDER THE
HEADING 'SAFETY PRECAUTIONS') ARE READ AND
UNDERSTOOD.
Remove the trunk side liner, righthand. For additional
information, refer to Section 501
-05
Interior Trim and
Or
n
amentation
.
8.
Drain th e fue
l tank using a suitab
le suction pump/tanker. If the
On-board Refueling Vapour Recove ry (ORVR) system is fitted,
refer to Section 310
-00 Fu
el System
- General

Information
.
9. Fr
om under the vehicle, identify the fuel feed and return
tank/pipe connections which are located above and slightly to
the rear of the rear axle assembly.
1. Locate the fuel feed pipe.
2. Locate the fuel return pipe.

10
.
Disconnect the fuel feed and return pipes from the fuel tank
F
it special tool JD-203 around
the pipe as shown. Press
the tool in between the fuel pipe and tank connector to
release the quick-fit tangs. While holding the tool firmly in,
pull out the fuel pipe.
Repeat
for the second pipe.
Plu

g the tank outlet connectors and the fuel pipes.

11
.
From the underside of the vehicl e, release the fuel filler latch
box drain pipe from the clip on the spare wheel well.

12
.
Disconnect and reposition the tr unk harness if it is routed
between the filler tube and the ta nk breather or pressure relief
pipe.
1. Disconnect the lefthand re ar lamp harness connector.
2. Disconnect the fuel flap lock actuator connector.
3. If fitted, disconnect the lefthand side marker lamp
connector and harness fro m the underside of the
vehicle. Withdraw the marker lamp harness and
grommet through the trunk floor access hole.
4. Release the harness securi ng clip from the mounting
bracket.
Wi
thdraw the trunk harness from between the filler tube
and the breather pipe or pressure relief pipe.
13. Disconnect the tank harness connections.

I
nstallation


18
.
On non-ORVR vehicles, disconnect the trunk lid lefthand strut
rear pivot.
Pl
ace a suitable support under
trunk lid or tie to exterior
mirror.
1. Using a screwdriver, release clip at rear end of strut,
withdraw end from trunk lid pivot and lower strut.

19
.
Disconnect the tank ground cable from the vehicle body.
20. Remove the tank from the vehicle.
21. Drain any remaining fuel from the tank.
1. Fit the fuel tank assembly.

2. Re
-connect the tank ground cable to the vehicle.
Tigh

ten to 12 Nm.
3. On non-ORVR fuel tanks, positi on the trunk lid lefthand strut
between the filler tube and the breather pipe.

4. Full
y seat the tank into positi
on, ensuring that no harness
wiring is trapped.

5. On non-
ORVR vehicles, reconnec
t the trunk lid lefthand strut
rear pivot.
1. Fit the retaining clip on to the end of the trunk lid strut and fit the strut to the trunk lid pivot. Re-
position retaining clip to secure the strut.
Re
move any temporary trunk lid supports and check that
the lid operates correctly.

6. NOTE
: Make sure the special tool locating peg is correctly
installed to the cam.
Using the special tool, tighten the fuel tank retaining straps.
1. Rotate the cam clockwise to a torque of 6 Nm.
• NOTE: Using an open ended wrench, maintain the torque
on the special tool.
2. Tighten the fuel tank reta ining strap bolt to 25 Nm.

7. Connect the fi
ller neck to the fuel filler latch box seal.
1. Fit the fuel filler latch box seal over the filler neck.
2. Secure with the spring ring
F i
t the fuel filler cap.

8. Connect the vapour outlet pip
e.
Unplug the v
a
pour pipes.
Reconn
ect th
e tank and underfloor vapour pipes via the
quick-fit coupling .
9. Fit the fuel filler latch box drain pipe.
1. Feed the drain pipe th rough the floor grommet.
2. Connect the drain pipe to the fuel filler latch box stub

pipe.
3
. Tie the drain pipe to th
e filler tube using a ratchet
strap. Trim strap.

10
.
Reconnect the trunk harness connections.
1. If fitted, connect the wi ring to the accelerometer.
2. Connect the wiring to the fuel level sensor harness.
3. Connect the wiring to th e fuel pump connector.
4. If fitted, connect the wiring to the pressure sensor connector.

11
.
Reconnect the lefthand side trunk harness if it has been
necessary to move it for access. Route the harness behind both
the filler tube and breather or pressure relief pipe.
1. Fit the harness securing cl ip to the mounting bracket.
2. Connect the fuel flap lock actuator connector.
3. Connect the lefthand rear lamp harness connector.
4. If applicable, feed the side marker lamp harness through the access hole in the floor and reseat the
sealing grommet.
On
the underside of the vehicl
e, fit the side marker lamp
connector and fix the harness to the securing clips.

12
.
On the underside of the vehicle, fit the drain pipe to the
securing clip.
13. On the underside of the vehicle, reconnect the fuel feed and
return pipes.
R
emove the plugs from the tank
and fuel feed and return

pipes.
1.
Push the fuel feed pipe into the quick-fit tank
connector. Ensu re the pipe is fully home.
2. Push the fuel return pi pe into the quick-fit tank
connector. Ensu re the pipe is fully home.
14. Fit the trunk side liner, lefthand. For additional information,
refer to Section 501
-0 5
Interior Trim and Ornamentation
.
15 . F
it the trunk side liner, righthan
d. For additional information,
refer to Section 501
-0 5
Interior Trim and Ornamentation
.
16 . F
it the trunk seal retainer. For a
dditional information, refer to
Section 501
-05
Interior Trim and Ornamentation
.
17 . F
it the rear lamp assembly
interior trim finisher. For
additional information, refer to Section 417
-01
Exterior
Ligh
ting.
18 . F
it the trunk front liner. For a
dditional information, refer to
Section 501
-05
Interior Trim and Ornamentation
.
19 . F
it the trunk floor carpet.
20. Ensure that the fuel feed pi pes in the engine compartment
are reconnected after tank draining.
21. Re-fit the battery. For additional information, refer to Section
414
-0 1
Battery, Mounting and Cables
.
22 . Carry ou
t a leak test of the evaporative emissions system.