[xj] remove and refit fuel level sending unit?

I need to know how to remove the fuel sending unit from my
gas tank before I send it to be rebuilt. Then, how do I put
it back in? Anything special I need to do? What else can
come off of the tank besides the little plastic thing inside
the bottom of the tank and the drain plug? I don’t see this
listed in my s3 service manual (huge green book).
Thanks!
James–
when is my Jag ever working properly?
–Posted using Jag-lovers JagFORUM [forums.jag-lovers.org]–

===================================================
The archives and FAQ will answer many queries on the XJ series…
FAQs: http://www.jag-lovers.org/xjlovers/xjfaq/index.html
Archives: http://www.jag-lovers.org/lists/search.html

To remove yourself from this list, go to http://www.jag-lovers.org/cgi-bin/majordomo.

// please trim quoted text to context only

First, the answer to your rhetorical question, “when is my Jag ever
working properly?” The answer to that question is, “Whenever you’re
driving it with that wondderful smile on your face.”

As to removing the sending units: simply use a set of long nosed needle
nose pliers or something similar to turn the protruding ears
counterclockwise about 20-25 degrees and the sending unit and retaining
ring will fall out. As stated in your big green book, installation is
the reverse of removal.

Earl in Houston===================================================
The archives and FAQ will answer many queries on the XJ series…
FAQs: http://www.jag-lovers.org/xjlovers/xjfaq/index.html
Archives: http://www.jag-lovers.org/lists/search.html

To remove yourself from this list, go to http://www.jag-lovers.org/cgi-bin/majordomo.

// please trim quoted text to context only

James, the fuel senders for both SII & SIII tanks are simply held by a cam
effect by the ears around the unit’s exterior ring/disc. Just get a wooden
dowel and a hammer and whack the sender’s disc counterclockwise to free it and
its gasket from the tank. You can curse the assembly folks who didn’t grease
it! That helps generate more torque. When you reassemble, later, use a
little silicone grease on the gasket and locking ears.–
Alex
79xj6L SII (BRG + wires)
86xj6 SIII (Black)
61 Sprite MkII (Red)
Menlo Park, Calif.

Broken Kitty wrote:

I need to know how to remove the fuel sending unit from my
gas tank before I send it to be rebuilt. Then, how do I put
it back in? Anything special I need to do? What else can
come off of the tank besides the little plastic thing inside
the bottom of the tank and the drain plug? I don’t see this
listed in my s3 service manual (huge green book).
Thanks!
James

===================================================
The archives and FAQ will answer many queries on the XJ series…
FAQs: http://www.jag-lovers.org/xjlovers/xjfaq/index.html
Archives: Jag-lovers Forums - Jag-lovers

To remove yourself from this list, go to Jag-lovers Forums - Jag-lovers.

// please trim quoted text to context only

In reply to a message from Broken Kitty sent Mon 15 Jan 2007:

On an S3, the fuel sender is accessed by removing the rear light.
You get to the sender through the opening left in the bodywork. It
is held in place by a large locking ring that twists open. On ans
S2, the sender is accessed from an opening in the rear of the wheel
arch!

You should get a replacement rubber seal before refitting the
sender.

Are you removing the tank for rebuilding or just the sender.
Taking the tank out is trickier. There are three pipes to
disconnet - fuel feed to pumps, fuel return line and vapour
recovery line. You need to remove rear silencer/muffler and heat
shield to get at some of the bolts holding tank in place.

There’s nothing else–
The original message included these comments:

I need to know how to remove the fuel sending unit from my
gas tank before I send it to be rebuilt. Then, how do I put
it back in? Anything special I need to do? What else can


David Womby 76 XJ12C&78 XJ6L 5speed - in storage
Temporarily : Auckland, New Zealand
–Posted using Jag-lovers JagFORUM [forums.jag-lovers.org]–
–Support Jag-lovers - Donate at http://www.jag-lovers.org/donate04.php

===================================================
The archives and FAQ will answer many queries on the XJ series…
FAQs: http://www.jag-lovers.org/xjlovers/xjfaq/index.html
Archives: Jag-lovers Forums - Jag-lovers

To remove yourself from this list, go to Jag-lovers Forums - Jag-lovers.

// please trim quoted text to context only

Cannara wrote:

James, the fuel senders for both SII & SIII tanks are simply held by a
cam effect by the ears around the unit’s exterior ring/disc. Just get
a wooden dowel and a hammer and whack the sender’s disc
counterclockwise to free it and its gasket from the tank.

I’ve had the senders in and out of both my SIIIs over the past month or
so. I’ve never been able to generate enough torque straight from the
back with needle nose pliers or any other tool. Jag refers to a special
tool for this, but real men would never invest in anything so
specialized. Anyway, Alex, you forgot to mention that you come from the
side, through the side lamp hole, with the whacking dowel. It’s really
quite simple. Also, I don’t remember anyone mentioning driving the tank
down to almost empty before proceeding and, at that, I always hedged the
bet by parking the car facing down my slightly sloped driveway.

Oh, and BTW, while it is commonly believed that the floats are not
available separately, I found them under XJS listings on Ebay. I got
four of them, and he said he had more. Here’s his address (he’s in NJ
somewhere): Jaguar1355@aol.com NAY.

BT===================================================
The archives and FAQ will answer many queries on the XJ series…
FAQs: http://www.jag-lovers.org/xjlovers/xjfaq/index.html
Archives: Jag-lovers Forums - Jag-lovers

To remove yourself from this list, go to Jag-lovers Forums - Jag-lovers.

// please trim quoted text to context only

Bill,

Appears I’m gonna have to send you some vitamins! The needle-nose
plier technique is all I’ve ever used for this job! Tell you what,
I’ll send you some vitamins and you send me some common sense! I’d
never thought of the dowel through the side tactic. It does sound a
bit easier!

Earl in Houston===================================================
The archives and FAQ will answer many queries on the XJ series…
FAQs: http://www.jag-lovers.org/xjlovers/xjfaq/index.html
Archives: http://www.jag-lovers.org/lists/search.html

To remove yourself from this list, go to http://www.jag-lovers.org/cgi-bin/majordomo.

// please trim quoted text to context only

In reply to a message from Earl Kiker sent Tue 16 Jan 2007:

yeah, the tank is being sent in for a rebuild. One at a
time. Things are slow with work and I’m getting hardly any
hours since they hired a new guy. But the tank place doesn’t
want me to send in any spare parts, just the tank. No
bobbers, filters (which I assume is what the plastic part is
in the bottom of the tank?) or sending unit.
James–
when is my Jag ever working properly?
–Posted using Jag-lovers JagFORUM [forums.jag-lovers.org]–
–Support Jag-lovers - Donate at http://www.jag-lovers.org/donate04.php

===================================================
The archives and FAQ will answer many queries on the XJ series…
FAQs: http://www.jag-lovers.org/xjlovers/xjfaq/index.html
Archives: http://www.jag-lovers.org/lists/search.html

To remove yourself from this list, go to http://www.jag-lovers.org/cgi-bin/majordomo.

// please trim quoted text to context only

Bill, yes for the SIII, coming through the lamp hole is easier, but I have a
manly screwdriver (plus hammer) which works quite nicely at the angles allowed
by the taillight hole alone. The SII units are in the rear wheel wells, so
better access. I only suggested the dowel to cover my innate brutishness.
:]
And, I’d definitely pick up a couple of spare floats, noting the SII and SIII
ones are different, and all will become rarer and rarer!

Also, whenever a sender is out, pop the little square cover off the wiper and
resistor to see how the wear pattern is on the resistor’s wires. If it’s
significant, you can bend the wiper a little to make it wipe a larger arc,
thus prolonging the unit’s life. You can even reduce the wiper’s pressure
this way, to the same end.–
Alex
79xj6L SII (BRG + wires)
86xj6 SIII (Black)
61 Sprite MkII (Red)
Menlo Park, Calif.

Bill Thom wrote:

Cannara wrote:

James, the fuel senders for both SII & SIII tanks are simply held by a
cam effect by the ears around the unit’s exterior ring/disc. Just get
a wooden dowel and a hammer and whack the sender’s disc
counterclockwise to free it and its gasket from the tank.

I’ve had the senders in and out of both my SIIIs over the past month or
so. I’ve never been able to generate enough torque straight from the
back with needle nose pliers or any other tool. Jag refers to a special
tool for this, but real men would never invest in anything so
specialized. Anyway, Alex, you forgot to mention that you come from the
side, through the side lamp hole, with the whacking dowel. It’s really
quite simple. Also, I don’t remember anyone mentioning driving the tank
down to almost empty before proceeding and, at that, I always hedged the
bet by parking the car facing down my slightly sloped driveway.

Oh, and BTW, while it is commonly believed that the floats are not
available separately, I found them under XJS listings on Ebay. I got
four of them, and he said he had more. Here’s his address (he’s in NJ
somewhere): Jaguar1355@aol.com NAY.

===================================================
The archives and FAQ will answer many queries on the XJ series…
FAQs: http://www.jag-lovers.org/xjlovers/xjfaq/index.html
Archives: Jag-lovers Forums - Jag-lovers

To remove yourself from this list, go to Jag-lovers Forums - Jag-lovers.

// please trim quoted text to context only

In reply to a message from Broken Kitty sent Mon 15 Jan 2007:

Hi James

It must be fuel tank month - I’ve just done mine, and so has
Stephen of Pittsburg PA.

As your tank is coming out, the best way is to remove the
sender unit after the tank is out of the car. I found it
easy to tap off the lock ring with a large screwdriver and
hammer. Unless it’s rusted in, it will turn well before you
shear the little ears. If it has rusted in, chances are the
tank is scrap anyway.

You can also remove the drain bung and the inlet strainer,
this should pull off the pipe with fingers or pliers, but
take care as they are not cheap to replace. The 3 pipe
unions can be screwed off, in fact I think the top one has
to come out to get the tank out of the car anyway. Lastly,
remove the sender unit wiring. Your tank is now ready to go
away.

Good luck!–
The original message included these comments:

I need to know how to remove the fuel sending unit from my
gas tank before I send it to be rebuilt. Then, how do I put
it back in? Anything special I need to do? What else can
come off of the tank besides the little plastic thing inside
the bottom of the tank and the drain plug? I don’t see this


Bill '80 XJ Ser III 4.2
Brisbane/Qld, Australia
–Posted using Jag-lovers JagFORUM [forums.jag-lovers.org]–
–Support Jag-lovers - Donate at http://www.jag-lovers.org/donate04.php

===================================================
The archives and FAQ will answer many queries on the XJ series…
FAQs: http://www.jag-lovers.org/xjlovers/xjfaq/index.html
Archives: Jag-lovers Forums - Jag-lovers

To remove yourself from this list, go to Jag-lovers Forums - Jag-lovers.

// please trim quoted text to context only

In reply to a message from Hooksie sent Tue 16 Jan 2007:

I pretty much cut the bastard tank out with the sawzall from
my parts car because every fitting, bolt, screw, inlet, pipe
etc was seized on beyond a graceful removal. So I too got
MANLY! GRRRRRRRRRRRRRRR! POWER TOOOLS! AGH AGH AGH!

james–
when is my Jag ever working properly?
–Posted using Jag-lovers JagFORUM [forums.jag-lovers.org]–
–Support Jag-lovers - Donate at http://www.jag-lovers.org/donate04.php

===================================================
The archives and FAQ will answer many queries on the XJ series…
FAQs: http://www.jag-lovers.org/xjlovers/xjfaq/index.html
Archives: http://www.jag-lovers.org/lists/search.html

To remove yourself from this list, go to http://www.jag-lovers.org/cgi-bin/majordomo.

// please trim quoted text to context only

Gonna try out for American Power-Tool Idol?! You sound better in print than
most of tonight’s contestants.
:]–
Alex
79xj6L SII (BRG + wires)
86xj6 SIII (Black)
61 Sprite MkII (Red)
Menlo Park, Calif.

Broken Kitty wrote:

In reply to a message from Hooksie sent Tue 16 Jan 2007:

I pretty much cut the bastard tank out with the sawzall from
my parts car because every fitting, bolt, screw, inlet, pipe
etc was seized on beyond a graceful removal. So I too got
MANLY! GRRRRRRRRRRRRRRR! POWER TOOOLS! AGH AGH AGH!

james

===================================================
The archives and FAQ will answer many queries on the XJ series…
FAQs: http://www.jag-lovers.org/xjlovers/xjfaq/index.html
Archives: Jag-lovers Forums - Jag-lovers

To remove yourself from this list, go to Jag-lovers Forums - Jag-lovers.

// please trim quoted text to context only