fuel tank removal JAGUAR X308 1998 2.G Workshop Manual

                    Coolant E x
pansion
 Tank  (26.15.01)  
                    
Coolant Outlet  Pipe  (26.31.08)  
                    
                     Cooling Fan  Motor  (26.25.24)  
                     Cooling Fan  Motor  and  Shroud  (26.25.25)  
                     Cooling Fan  Motors  (26.25.25)  
                     Cooling Fan  Shroud  (26.25.30)  
                     Engine Coolant  Level  Switch  (26.40.11)  
                     Radiator (26.40.01)  ‐ 3.2L  NA  V8  ‐ AJ26/4.0L  NA V8  ‐ AJ27  
                     Radiator (26.40.01)  ‐ 4.0L  SC  V8 ‐ AJ26  
                     Radiator Lower Hose  (26.30.07)  ‐ 3.2L  NA  V8  ‐ AJ26/4.0L  NA  V8  ‐ AJ27  
                     Radiator Lower Hose  (26.30.07)  ‐ 4.0L  SC  V8 ‐ AJ26  
                     Radiator Upper Ho
se (26.30.01)  ‐ 3.2L  NA  V8  ‐ AJ26/4.0L  NA  V8  ‐ AJ27  
                     Radiator Upper Hose  (26.30.01)  ‐ 4.0L  SC  V8 ‐ AJ26  
                     Thermostat  (26.45.07)  ‐ 3.2L  NA  V8  ‐ AJ26/4.0L  NA  V8  ‐ AJ27  
                     Thermostat  (26.45.07)  ‐ 4.0L  SC  V8 ‐ AJ26  
                     Thermostat  Housing  Cover  (26.
45.22)  ‐ 3.2L  NA  V8  ‐ AJ26/4.0L  NA  V8  ‐ AJ27  
                     Thermostat  Housing  Cover  (26.45.22)  ‐ 4.0L  SC  V8 ‐ AJ26  
                     Thermostat  Housing  Cover  Seal  (26.45.20)  ‐ 3.2L  NA  V8  ‐ AJ26/4.0L  NA V8  ‐ AJ27  
                     Thermostat  Housing  Cover  Seal  (26.45.20)  ‐ 4.0L  SC  V8 ‐ AJ26  
                     Water Pump  (26.50.
01) ‐ 3.2L  NA  V8  ‐ AJ26/4.0L  NA V8  ‐ AJ27  
                     Water Pump  (26.50.01)  ‐ 4.0L  SC  V8 ‐ AJ26  
                     Water Pump  Pulley  (26.50.05)  ‐ 3.2L  NA  V8  ‐ AJ26/4.0L  NA  V8  ‐ AJ27  
                     Water Pump  Pulley  (26.50.05)  ‐ 4.0L  SC  V8 ‐ AJ26  
 
             303‐03B : Supercharger  Cooling 
                 Removal and  Installation  
                     Water Pump  
 
             303‐04:  Fu
el Charging  and Controls  
                 Diagnosis  and  Testing  
                     Fuel Charging  and Controls  
                 Inspection  and Verification  
                     Driver Information  Chart  
                     Default mode Definitions  
                     Diagnostic Trouble  Code  (DTC)  index  
                     Pinpoint Tests  

                    Superchar
ger
 Outlet  Pipe (18.50.16)  
                     Supercharger  Outlet  Pipe Gasket  (18.50.17)  
                     Throttle Body  Elbow  (19.70.28)  
                     Throttle Body  Elbow  Gasket  (19.70.29)  
 
             303‐13:  Evaporative  Emissions  
                 Diagnosis  and  Testing  
                     Evaporative  Emissions 
                                       
Preliminary
 Inspection
 
                     Diagnostic
 Drive  Cycles  
                     Diagnostic
 Trouble  Code  (DTC)  index/Symptom  Chart  
                     Pinpoint
 Tests  
                 Removal
 and  Installation  
                     Evaporative 
Emission Canister  (17.15.13)  
                     Evaporative 
Emission Canister  Purge  Valve (17.15.30)  
                     Fuel
 Tank  Press
ure Sensor  (19.55.31)  
                     Fuel
 Vapor  Vent  Valve  Housing  (19.55.24)  
                     Fuel
 Vapor  Vent  Valve  Housing  Seal  (19.55.25)  
 
             303
‐14:  Electronic  Engine  Controls  
                 Description
 and
 
                                      Diagnosis
 and  Testing  
                     Electronic
 Engine  Con
trols  
                     Inspection
 and  Verification  
                     Driver
 Information  Chart  
                     Default 
mode Definitions  
                     Diagnostic
 Trouble  Code  (DTC)  Index  
                     Pinpoint
 Tests  
                 Removal
 and  Installation  
                     Catalyst 
Monitor  Sensor LH  (18.30.81)  
                     Catalyst 
Monitor  Sensor RH  (18.30.80)  
                     Heated Oxygen  Sensor  (HO2S)  LH  (18.30.79)  
                    
Heated Oxygen  Sensor  (HO2S)  RH  (18.30.78)  
                    
                    
Camshaft  
Position  
Sen s
or
 
ECM  
Position  
Sensor  
Crankshaft
Removal
Engine  
Coolant Temperature
Sensor 
Operation
Intake  Air  Temperature  (IAT)  Sensor  (18.
30.52)  

        309: Exhaust  Syst
em
 
 
             309‐00:  Exhaust  System 
                 Specification  
                 Description  and  Operation  
                     Exhaust System  
                 Diagnosis  and  Testing  
                     Exhaust System  
                 Removal and  Installation  
                     Catalytic Converter  LH  (17.50.15)  ‐ 3.2L  NA  V8  ‐ AJ26/4.0L  NA V8  ‐ AJ27  
                     Catalytic Converter  LH  (17.50.15)  ‐ 4.0L  SC  V8 ‐ AJ26,  Vehicles  With:  
            Supercharger  
                     Catalytic Converter  RH  (17.50.16)  ‐ 3.2L  NA  V8  ‐ AJ26/4.0L  NA V8  ‐ AJ27  
                     Catalyt
ic Converter  RH  (17.50.16)  ‐ 4.0L  SC  V8 ‐ AJ26,  Vehicles  With:  
            Supercharger  
                     Catalytic Converter  Gasket  LH  (17.50.06)  ‐ 3.2L  NA  V8  ‐ AJ26/4.0L  NA  V8  ‐ AJ27  
                     Catalytic Converter  Gasket  LH  (17.50.06)  ‐ 4.0L  SC  V8 ‐ AJ26  
                     Catalytic Converter  Gasket  RH  (17.50.07)  ‐ 3.2L  NA V8  ‐ AJ26/4.0L  NA  V8  ‐ AJ27  
                     Catalyt
ic Converter  Gasket  RH  (17.50.07)  ‐ 4.0L  SC  V8 ‐ AJ26  
                     Front Muffler  (30.10.18)  ‐ 3.2L  NA  V8  ‐ AJ26/4.0L  NA V8  ‐ AJ27  
                     Front Muffler  (30.10.18)  ‐ 4.0L  SC  V8 ‐ AJ26  
                     Intermediate  Muffler LH  (30.10.15)  ‐ 3.2L  NA  V8  ‐ AJ26/4.0L  NA  V8  ‐ AJ27  
                     Intermediate  Muffler LH  (30.10.15)  ‐ 4.0L  SC  V8 ‐ AJ
26  
                     Intermediate  Muffler RH  (30.10.16)  ‐ 3.2L  NA  V8  ‐ AJ26/4.0L  NA  V8  ‐ AJ27  
                     Intermediate  Muffler RH  (30.10.16)  ‐ 4.0L  SC  V8 ‐ AJ26  
                     Muffler and Tailpipe  LH (30.10.22)  
                     Muffler and Tailpipe  RH (30.10.52)  
 
        310:  Fuel  System  
 
             310‐00:  Fuel  System  ‐ General  Information  
                 General Procedures  
                     Fuel System  Pressure  Check  
                     Fuel Tank  Draining  
 
  
Fuel  Sy stem  Pres
sure
 Release  

            310‐01:  Fu el Tank  and  Lines  
                 Removal and  Installation  
                     Fuel Level  Sensor  (88.25.32)  
                     Fuel Pump  (19.45.08)  
                     Fuel Tank  (19.55.01)  
 
             310‐02
:
 Acceleration  Control  
                 General Procedures  
                     Accelerator  Cable  Adjustment  (12.20.05)  
                 Removal and  Installation  
                     Accelerator  Cable  (19.20.06)  
 
             310‐03:  Speed  Control  
                 Diagnosis  and  Testing  
                     Speed Con
trol 
 
    4:  Electrical  
 
        412:  Climate  Control  System  
 
             412‐00:  Climate  Control  System  ‐ General  Information 
                 Specification  
                 Description  and  Operation  
                     Climate Control System  
                 Diagnosis  and  Testing  
                     Climate Control System  
                 General Procedures  
                     Air Conditioning  (A/C)  System  Check ‐  Retail Procedure  
                     Air Conditioning  (A/C)  System  Recovery,  Evacuation  and  Charging  (82.30.30)  
                     Contaminated  Refrigerant  Ha
ndling  
                     Manifold Gauge  Set Connection  
                     Refrigerant  Adding (82.30.02)  
                     Refrigerant  Oil Adding  
                     Refrigerant  System Tests  
 
             412‐01:  Air  Distribution  and  Filtering  
                 Description  and  Operation  

The fuel fil
ler cap is the same as
that used on non-ORVR systems.
The check valve assembly is a push fit into the end of the fuel filler tube and is accessible with the evaporative flange
removed. The valve has a light spring load ing and opens under the inflow of fuel.
ORVR Evaporative Loss Flange Assembly

The evaporative loss flange assembly is fitted to the top of the tank via a seal and locking ring arrangement identical to that
used for non-ORVR systems. The assembly is re moveable complete with the fitted components.
The fuel level vent valve (FLVV) is mounted in the ELF assembly via a bayonet fitting : it is turned approximately 90 °
clockwise to release. The grade vent valve and pressure sensor are push in fits via sealing gromme ts : note that, due to the
tight fit, removal of these components may require cutting the grommets. The fuel pump connector is push fitted and
crimped into a location tube on the underside of the flange.
It e
m
Par
t
Number
De
scr
iption
1—An
ti-s
urge valve
2—Pressure rel
i
ef pipe
3—Check v
a
lve
It
e
m
Par
t
Number
De
scr
iption
1—Fi
ll
level vent valve (FLVV) /
pressure relief valve assembly
2—Pres
sure
sensor
3—Grade vent
valve
4—Fue
l
pump connector
5—Lockin
g rin
g
6—Evaporative loss flange (ELF)
7—Seal
8—F
u
el pump link lead

Evapor
ative Emissions - Fuel Va
por Vent Valve Housing Seal
Remov
al and Installation
Re

moval
• NO
TE: The Removal and Installation procedur
es below show one type of flange but are applicable to the other evaporative loss systems
described.
Special To
ol(s)

Lock

Ring Wrench - Fuel Tank Flange
412-070 (JD 174)
1. Remove battery. Refer to 86.15.01.
2. WARNING: 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 fuel tank assembly for access. Refer to operation 19.55.01.

3. Discon
nect vapor hose(s) from flange assembly.

4. Remov
e locking ring using special tool 412-070 (JD 174).
Insta

ll special tool to locking ring.
Usi

ng a suitable bar, turn special tool anti-clockwise to release
locking ring from the five tank tabs.

5. Lift
flange assembly slightly and disconnect fuel pump link lead from the
underside of flange connector. Secure connector to tank aperture.
6. Discard sealing ring.

Filler Cap and P
ipe
The fuel
filler cap with bayonet-type fixi
ng is located beneath a remote-release sp ring-latched lid on the rear saddle panel
on the left-hand-side of the vehicle.
Fuel Pum
p
The fu
el pump(s) is energized by an ECM co
ntrolled relay. Fuel is drawn by this pu mp and supplied to the fuel injectors via
the fuel line, filter and fuel rails.
Servicing of the fuel pump re quires fuel tank removal.
Ev
aporative Loss Flange Assembly
The evaporative-loss flan
ge asse
mbly is mounted centrally on top of the tank. The flange assembly consists of a removeable
steel cap which mounts the evaporative emissions system vapor outlet valves and, if applicable, a pressure sensor. The
external electrical supply to th e fuel pump(s) is also made via a connector on the flange.
The flange assembly is fixed to the tank by a locking ring which is turned usin g special tool JD-174. A seal is fitted between
the flange assembly and the tank. Three di fferent flange assemblies are applicable according to the evaporative emission
system fitted to the vehicle. The fl ange size and fixing are identical fo r the three systems, as described.
Removal of the evaporative flange assembly is necessary to gain access to th e fuel pump(s) and other internal components.
To remove the evaporative fl ange assembly the fuel tank must first be removed.
The evaporative flange variant assemblies are described, together with service information, in Section 303-13.
Fuel R
eturn
Excess fuel
is directed back to
the fuel tank via a return line.
Fuel Pum
p Relay
The
fuel pump relay,
under control of the ECM, switches power to the fuel pump motor.
I
nertia Fuel Shutoff (IFS) Switch
The IF
S switch is located in the right-hand
side footwell behind the footboard carpet . When activated the switch isolates the
ignition system and fuel pump, releases any locked doors and disables unnecessary electrical systems. The system can be
reset by pressing down the flexible cover on the top of the switch.
• NOTE: The doors will not unlock if the IFS switch is tripped when the ignition switch is in position '0'.

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 Li
nes - Fuel Pump
Re
moval and Installation
Remov

al
Installation

1.
WARNING: B
EFORE PROCEEDING, IT IS ESSENTIAL THAT

THE WARNING NOTES GIVEN IN SECTION 100-00 (UNDER THE
HEADING 'SAFETY PRECAUTIONS') ARE READ AND
UNDERSTOOD.
Remove the battery. For additional information, refer to Section
414
-0
1 Battery, Mounting and Cables
.
2.
Drain th
e fuel 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
Fuel System
- General
Information
.
3. R
emove the fuel tank. For addi
tional information, refer to Fuel
Tank
in this section.
4. Remove the fuel tank evaporativ e loss flange sealing ring. For
additional information, refer to Section 303
-13

.
5. R
emove fuel feed hose from tank.
U

sing special tool JD175, slacken fuel feed hose to tank
stub securing clip.
Di
sconnect hose from tank stub.
6. Remove fuel pump assembly.
R
elease bolt securing fuel
pump mounting bracket and
place assembly to front.
Slac
ken securing clip and disc
onnect hose from fuel pump.
R
emove link lead from fuel pump.
Re

move pump.
1. NOTE: Install new sealing ring to evaporative loss flange. For
additional information, refer to Section 303
-13

.
In
stallation is th
e reverse of the removal procedure.

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.