Fuel Tank and Lines

Fuel Tank and Lines

Inspection and verification

1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical or electrical damage.

Mechanical Electrical
Fuel line(s) Inertia fuel shutoff (IFS) switch
Push connect fittings Electrical connector(s)
Fuel leak(s) Damaged or corroded wiring harness
Fuel filler cap Fuel pump module
Fuel tank filler pipe Fuel transfer pump
Fuel filter Fuse(s)
Fuel tank
Fuel tank roll-over valve

Mechanical Electrical
Fuel line(s) Inertia fuel shutoff (IFS) switch
Fuel leak(s)
Fuel filler cap
Fuel tank filler pipe
Fuel filter
Fuel tank
Fuel tank roll-over valve

WARNING:
- Vehicles with diesel engine only. Do NOT carry out any work on the fuel system with the engine running. The fuel pressure within the system can be as high as 1600 bar (23,206 lb/ sq in). Failure to follow this instruction may result in personal injury.
- Eye protection must be worn at all times when working on or near any fuel related components. Failure to follow this instruction may result in personal injury.
- Vehicles with diesel engine only. The fuel system remains pressurized after the ignition is switched off. If communications with a suitable tester (able to read fuel rail pressure and temperature) can be established, wait until the tester indicates pressure of less than 20 bar (290 lb/sq in), and temperature of less than 35 degrees C (95 degrees F) before working on the system. If communications with a suitable tester cannot be established, the fuel system must NOT be worked on for a period of fifteen minutes following the ignition being switched off. Failure to follow this instruction may result in personal injury.
- This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow this instruction may result in personal injury.
- Vehicles with diesel engine only. After carrying out repairs, the fuel system must be checked visually for leaks. This should be done after the engine has been run, but with the engine switched OFF. Failure to follow this instruction may result in personal injury.
- If fuel is taken internally, DO NOT induce vomiting. Seek immediate medical attention. Failure to follow this instruction may result in personal injury.
- If fuel contacts the eyes, flush the eyes with cold water or eyewash solution and seek medical attention. Failure to follow this instruction may result in personal injury.
- Wash hands thoroughly after handling, as prolonged contact may cause irritation. Should irritation develop, seek medical attention. Failure to follow this instruction may result in personal injury.

CAUTION:
- Vehicles with diesel engine only. Before disconnecting any part of the system, it is imperative that all dust, dirt and debris is removed from around components to prevent ingress of foreign matter into the fuel system. Failure to follow this instruction may result in damage to the vehicle.
- Vehicles with diesel engine only. The fuel pipes between the injectors and the rail must be discarded after each use, and new pipes installed. Failure to follow this instruction may result in damage to the vehicle.
- Vehicles with diesel engine only. It is essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or lines. Failure to follow this instruction may result in damage to the vehicle.
- Vehicles with diesel engine only. Make sure that the workshop area in which the vehicle is being worked on is as clean and dust-free as possible. Areas in which work on clutches, brakes or where welding or machining are carried out are not suitable in view of the risk of contamination to the fuel system. Failure to follow this instruction may result in damage to the vehicle.
- Vehicles with diesel engine only. Do not interchange fuel injectors. Improper injector installation can cause misfires, poor running and severe engine damage.
- Make sure that any protective clothing worn is clean and made from lint-free non-flocking material. Failure to follow this instruction may result in damage to the vehicle.
- Make sure that any protective gloves worn are new and are of the non-powdered latex type. Failure to follow this instruction may result in damage to the vehicle.
- Vehicles with diesel engine only. Make sure that clean, non-plated tools are used. Clean tools using a new brush that will not lose it's bristles and fresh cleaning fluid prior to starting work on the vehicle. Failure to follow this instruction may result in damage to the vehicle.
- Use a steel-topped work bench and cover it with clean, lint-free, non-flocking material. Failure to follow this instruction may result in damage to the vehicle.
- When probing connectors to take measurements in the course of the pinpoint tests, use the adaptor kit, part number 3548-1358-00. Failure to follow this instruction may result in damage to the vehicle.

NOTE:
- This section contains references to Parameter Identifiers (PIDs). Where the Jaguar approved diagnostic system is not available, a scantool may be used to access these PIDs, all of which give information, and some of which can be used to both read information and to activate components. The format of the information may vary, depending on the tool used.
- Vehicles with diesel engine only. As well as carrying out its normal function the glow plug indicator also acts as an engine check lamp which will flash continuously when a hard diagnostic trouble code (DTC) is detected by the ECM. Soft DTCs are also stored by the ECM but will only be identified if the system is checked for DTCs using the Jaguar approved diagnostic system.
- If a DTC is detected, all DTCs must be cleared after the concern is repaired. Failure to clear all DTCs may cause driveability concerns.
- Vehicles with diesel engine only. If the fuel level in the fuel tank drops below approximately four liters, rough running will occur. This is to signal to the driver that the vehicle requires refuelling in order to prevent the fuel system from running dry.
- When performing voltage or resistance tests, always use a digital multimeter (DMM) accurate to 3 decimal places, and with an up-to-date calibration certificate. When testing resistance, always take the resistance of the DMM leads into account.
- Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.
- If DTCs are recorded and the symptom is not present when performing the pinpoint tests, an intermittent concern may be the cause. Always check for loose connections and corroded terminals.

3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.