[xj40] 1994 XJ6 fuel tank connectors


(Brazierje) #1

I’m attempting to remove my fuel tank to replace the fuel pump
pump on my '94 XJ6.

Has anyone come up with an easier way to remove the two con
connectors on the bottom of the fuel tank?

Thanks gents.
Eric–
Merlin 1994 XJ6
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(Brazierje) #2

In reply to a message from Brazierje sent Mon 4 Jan 2016:

I have power at the relay, verified that the replay was
good and applied power directly to the pump so I am certain
that the pump is bad.–
The original message included these comments:

I’m attempting to remove my fuel tank to replace the fuel pump
pump on my '94 XJ6.


Merlin 1994 XJ6
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(Jaguarpete) #3

In reply to a message from Brazierje sent Mon 4 Jan 2016:

You don’t have to remove the two clips on the fuel line
connections, just rotate them in their grooves 90 degrees and
the lines will pull out. The clips will turn easier in one
direction than the other, but either direction will work.
It’s also easier to get to them if you reach in on the right
side of the drive shaft.–
The original message included these comments:

Has anyone come up with an easier way to remove the two con
connectors on the bottom of the fuel tank?


Pete Peterson 70E(193K) XJ40s(88-270K,89-97K, 94-122K)
Severna Park, Maryland, United States
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(Bryan N) #4

In reply to a message from Brazierje sent Mon 4 Jan 2016:

Eric,

Do you mean the feed and return fuel lines on the bottom of
the tank?

If so they are only accessible from under the car with a
long flexible forearm and a pair of long nose pliers to grip
the spring wire clips and turn them through 90� before
pulling on the fuel lines to wrench them off the spigots. DO
NOT ATTEMPT TO REMOVE THE SPRING WIRE CLIPS - only rotate
them through 90� and leave them on the lines.–
The original message included these comments:

I’m attempting to remove my fuel tank to replace the fuel pump
pump on my '94 XJ6.
Has anyone come up with an easier way to remove the two con
connectors on the bottom of the fuel tank?


Bryan N, now Jag-less, but fun while it lasted.
Cambridgeshire, United Kingdom
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(Bryan N) #5

In reply to a message from Brazierje sent Mon 4 Jan 2016:

Eric,

Another possibility is that the wiring inside the
evaporative loss flange from its external connector (which
is where I assume you applied 12 volts) to the wires which
run down to the fuel pump module is corroded/burnt and when
you apply power directly to the pump once removed from the
tank, the pump will run OK.

Problem is of course that you cannot prove that without
first removing the pump.–
The original message included these comments:

I have power at the relay, verified that the replay was
good and applied power directly to the pump so I am certain
that the pump is bad.


Bryan N, now Jag-less, but fun while it lasted.
Cambridgeshire, United Kingdom
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( Larry ) #6

In reply to a message from Brazierje sent Mon 4 Jan 2016:

Hi - I just replaced the fuel pump on my 94 this past
September, releasing and resetting those clips is not too
bad a job if you can get hold of some REALLY long needle
nose pliers.

I used a pair about 14’’ long - I found a good trick to
‘‘lock’’ them on to the clips, once you have the jaws on the
clip, keep squeezing then take a rubber band and band the
handles together, effectively locking the jaws on the clip.

As there isn’t much room to maneuver under there, you can
let go of the pliers (which will be hanging from the clip
) get into a better position and rotate the clip easily.
Remove the rubber band and the pliers will open, releasing
itself ready to grab the other clip.

This works well for both removal and reassembly.

If the connector fittings are a bit sticky in the tank,
they’ll rotate ok but might not want to pull out right away.
The lines are a bit awkward to get hold of ‘‘up there’’ but
you can make the removal a bit easier by looping a length of
wire over the line fitting and giving it a good tug from
‘‘down below’’.

If you’ve done a reasonable drain on the tank, very little
if any gas will spill when you remove the lines.

The lines are different sizes too, so you can’t mix them up.

Good luck and remember, no matter what the brand of pump,
all of them are Walbros, reboxed. My Airtex from amazon was
the cheapest I could find but had Walbro impressed on it too

  • so don’t waste money buying a Bosch or other fancy brand,
    they will all be Walbros in fancy boxes!!

cheers

Larry–
Larry '94 VDP VIN 701729
Victoria BC, Canada
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(Win) #7

In reply to a message from Brazierje sent Mon 4 Jan 2016:

Getting to the fuel lines at the bottom of the tank is tough
but not impossible.

As others have noted, the clip only needs to be turned 90�
to free the hose and then the hose will pop out with a tug
or two.

On reassembly, reorient the clips on the stubs before
positioning the tank back into place. The flat of each clip
fits across the slot in the stub.

Once the tank is back in place, the two hoses simply pop
back into place and the clips lock them in.

I always found it easiest to lay under the car with the diff
just above my chest, can reach up with arms on each side of
the drive shaft to get to the hoses. Can’t see a thing that
way but once your hands are in there, you can’s see anything
anyway!

I will say the later X300 is worst, use those collar
disconnects to free the hoses from the stubs – much less
fun than the simple turn of each clip.–
02 VDP – Driveway’s got too many SAABs in it!
Tampa Fl, United States
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(Brazierje) #8

In reply to a message from Brazierje sent Mon 4 Jan 2016:

Mission completed. Merlin rides again.

Pump change out when fairly smooth thanks to you guys.

Appreciate the help.–
The original message included these comments:

I’m attempting to remove my fuel tank to replace the fuel pump
pump on my '94 XJ6.


Merlin 1994 XJ6
–Posted using Jag-lovers JagFORUM [forums.jag-lovers.org]–
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#9

[quote=“Win, post:7, topic:287534”]
I always found it easiest to lay under the car with the diff
just above my chest, can reach up with arms on each side of
the drive shaft to get to the hoses.
[/quote]Thank you! I don’t think I would have figured out access without your description.

[quote=“abercanadian, post:6, topic:287534”]
releasing and resetting those clips is not too
bad a job if you can get hold of some REALLY long needle
nose pliers.
[/quote]LoL how do you even get long pliers in there?

Here’s me tackling the job. Skip to 1:30 for the tank shenanigans…


( Larry ) #10

here you go, long like this!

,long-needlenose1

fun vid tho, thanks!


(Joseph) #11

Luckily my forearm is this skinny and long so it was no problem for me reaching there. Phew!