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Some hose assemblies in the fuel system have clampless barbs to connect metal tubing to hose, similar to those fittings
on the rail described above. However, these may have a deep cup covering the end of the hose instead of the dished
washer used on the injector hoses; this deep cup looks like a crimp collar except that it isn’t crimped. The deep cup can
make it a bit more difficult to get the old hose off, since getting the razor knife on the hose will be all but impossible
and getting a soldering iron tip in there will be no picnic either. To make life easier the next time you replace hoses,
you might want to order some of the dished washers used on the injectors, EAC7876, and reassemble the fuel lines with
these instead of the cups. That will also make disassembly easier this time, since you can just cut the cups off to get
them out of your way.
If you get those cups off intact and intend to reuse them, note that when putting the new hose on you may have trouble
telling if it’s on all the way. So, prior to assembly, slip the cup onto the end of the hose and mark on the hose so you’ll
know when it is fully inserted into the cup. This is especially important with a really thick-walled hose like the
Weatherhead cloth-surfaced stuff described above because it fits so tightly in the cup that it makes it very difficult to get
on the barb.
The author’s solution here worked well. I used a hacksaw to cut these deep cups circumferentially, separating each one
into a sleeve and a shallow cup -- obviously being careful not to saw all the way through the hose and damage the barb
underneath. I was then able to simply slide the sleeve up the hose out of the way and slice the hose away using the
same method as with the hoses on the rail with the dished washers. When reassembling with new hose, I reinstalled the
shallow cup (cleaned up a little) and discarded the sleeve. The finished assembly looks good, arguably better than the
dished washers at the rail.
Fuel Tank and Filler
FUEL FILLER CONFIGURATION: In the 70’s, the fuel filler pipe on the XJ-S had a flange on it and was rigidly
mounted behind the filler door with three screws. This author’s ’83, however, has no flange; all it has is a small tang
that engages a small bracket to prevent the filler pipe from rotating as the cap is tightened. The same three screws are
used instead to fasten a metal collar that holds a rubber boot around the filler pipe. Hence the filler pipe is mounted
flexibly; it can move around a bit since it is held in place only by the boot, an O-ring seal at the tank, the hose clamped
onto its outside, and of course that little tang that prevents it from rotating.
With either design filler, the clamp on the hose connection to the tank is accessible from within the trunk by removing
some carpet. Then you can pull the filler out through the filler door after removing three screws.
On the later design, the filler itself inserts into the opening in the tank with a really fat O-ring for a seal, and then the
entire assembly is enclosed in a short section of 2” hose. If the fat O-ring works, the 2” hose only serves to hold the
assembly together, not to contain fuel or odors. This assembly might have been designed this way because Jaguar
couldn’t find a 2” hose that would positively prevent fuel odors. Remember, the fuel-filler-to-tank connection in most
other cars is underneath the car, not inside the trunk -- perhaps for good reason. If you have odors, you might consider
pulling this assembly apart and replacing that O-ring, which is part number C46157.
FUEL FILLER CAP: ...is discussed on page 259 under the vapor recovery system.
FUEL FILLER DRAIN: Derek Hibbs says: “The answer for my fuel smell was simple: the fuel cap overflow pipe
was disconnected and any spillage during refueling was draining directly into the boot/trunk instead of onto the ground.
Reconnected the overflow pipe and no smells (I also take more care when refueling).”