[xj40] Fuel filler latch box replacement

I only paid �750 in 2008 for my XJ40 3.2 ('93 model) and still got
a very reliable, usable car. But there were still a few little
jobs to attend to. Only one outstanding now is to permanently cure
a water leak into the boot which I traced to the rubber diaphragm
around the fuel filler cap/pipe. Silicone sealant worked as a
temporary repair. But I then managed to track down a brand-
new ‘‘fuel filler latch box’’ complete assembly. The car was in for
another job anyway and I so asked my local garage to fit this. But
the fitter, whom I know well and trust, had a good long look at the
box’s installation and was pretty sure that the tank would either
have to come out completely or at least be released from its
mountings to be moved in order for the fuel tank filler pipe to
clear the latch box’s frame. Has anyone done this job and does the
car’s fuel tank have to be moved/removed to get the new latch box
in?
Also, looking at our forum’s ‘‘XJ40 E-book’’ item 6.16 - ‘‘Fuel Filler
Door Release’’, it definitely looks as if the latch box comes out
pretty easily i.e without disturbing the tank. But before I book
the car into the garage again, hope you don’t mind if a get
a ‘‘second opinion’’.
Many thanks as always.
Clive
Liverpool
UK–
Clive Liverpool UK '93 XJ40 3.2 RHD
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In reply to a message from Mad Moggie sent Fri 13 May 2011:

I’ve replaced that rubber gaiter on a couple XJ40’s and I’ve
got to admit, I’m unsure the latch box can be removed
without disturbing the tank. I’ve read it can be and I’m
not bad with puzzles, but that one defeats me.

Having said that, you can unbolt the box from the car and
(gasp! OH NO!) flex the filler neck rearwards and down
enough to remove the box. Sort of scary stuff, but it works.

Once replaced, a similar amount of force will re-position
the filler neck and you can reattach the box. Don’t forget
the gasket between the box and car body!

An alternative is to simply replace the gaiter with the box
in place. Getting to the rearmost 3 or so of the 8 screws
is really a challenge. Getting the new gaiter on followed
with it’s retaining collar and the screws is an even greater
challenge, but it is possible.–
The original message included these comments:

Also, looking at our forum’s ‘‘XJ40 E-book’’ item 6.16 - ‘‘Fuel Filler
Door Release’’, it definitely looks as if the latch box comes out
pretty easily i.e without disturbing the tank. But before I book
the car into the garage again, hope you don’t mind if a get
a ‘‘second opinion’’.


91 XJ6, 97 Sov – Driveway needs another!
Tampa Fl, United States
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In reply to a message from Mad Moggie sent Fri 13 May 2011:

Clive

Yes this can be replaced without moving the tank - its a bit of a
job and needs some nuts done by feel as they are not able to be
seen when doing teh job (ones that are right up in there in front
of the filler pipe !)

Latch itself is quite easy to remove - again some is by ‘feel’

Have to obviously disconnect and loosen all teh pipes and clipsthe
rubber diapragm itself has enough ‘give’ in it to be able to
unhitch the plastic filler fitting from the top of the filler pipe
to the tank

If I recall it took me most of the day to remove and replace with
new but thats probably because I had never done it before and
was ‘feeling’ my way
The parts diagram was extremely useful when I did this as it shows
quite clearly what seperates from what

Obviously if the tank is moved/displaced then it woudl probably be
a little easier howver I felt that the additional work involved
with that was not worth it

Nigel–
1987 XJ40 3.6 Auto Sov SAJJHALH3AA512874
Singapore, Singapore
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In reply to a message from Mad Moggie sent Fri 13 May 2011:

Well you are all right in that to remove the latch box on cars
after 89 you remove the tank early cars have a removable filler
neck later weld on see parts manual for calrifcation.
In order to change the rubber gasket on post 89 cars you have to
remove the 6-8 small screws that hold the rubber gasket in place
from inside the car, then remove the gaiter spring from around the
filler neck(outside of car) then remove gaiter, to refit new item
use silcone greese on the lip to latch box area slip the gasket
over the filler neck then engage lip into latch box, front the
outside of the car ensure that the gasket sits into the recess
correctly by running your finger round the joint fit spring gaiter
then refit screws to hold retainer in position, this is the only
way it can be done without removing tank, I have done at leats 3
cars this way.
Just to add further confusion there are 2 part numbers for the
gasket CBC9792 and BEC7532 the first is to suit early cars but is
said to be a replacement for BEC7532, not so the fit is perfect for
early cars but you have to streach it over the neck for later cars
(welded on filler neck)thus you will strain the rubber gasket to
get it to fit, contact me off line as I may be able to help.
I also contacted JDHT to advise that the parts are different and
when this part was listed as new parts it states early models.–
The original message included these comments:

Also, looking at our forum’s ‘‘XJ40 E-book’’ item 6.16 - ‘‘Fuel Filler
Door Release’’, it definitely looks as if the latch box comes out
pretty easily i.e without disturbing the tank. But before I book
the car into the garage again, hope you don’t mind if a get
a ‘‘second opinion’’.


Mick Gannon Daimler 4.0 1991 XJ40, D Six 1996 X300 England
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In reply to a message from Mad Moggie sent Fri 13 May 2011:

Many thanks in indeed to you all. And Mick’s answer makes it clear
that I need to track down the later type BEC 7532 gaiter. I was
lucky that the garage did not attempt to fit the latch box with the
CAC 9792 item which would not have fitted properly over the later
metal pipe. Once more, my thanks to all on this great forum for
comimg up with the answer.
All the best,
Clive.–
Clive Liverpool UK '93 XJ40 3.2 RHD
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I made this part again BEC7532 / CAC9792.
You can order it here http://www.keepyourjagontheroad.com/