Hi all,
New member here so hello to all! Located in NE Ohio.

My son has an '89 Vanden Plas which is his first car that he saved up to buy. He wanted a bit of a project car and oh boy, did he ever get more than he bargained for!

Anyway, I really love these forums because there is so much information and how-to on here.

Current problem:
We recently just changed the fuel pump (outside of tank) and fuel filter. When we reconnected the filter, the backside closest to the pump was no problem. HOWEVER....the engine-side of the filter has a solid metal fuel line with a (I think it's called) banjo bolt on it. This line takes a bit of a right angle u-turn before heading to the front and was severely corroded and rusty. When we re-attached the banjo bolt, we must have cracked open that metal line. Of course, we didn't realize this until starting the car and fuel was spraying out. That was fun. Hey, at least the pump is working!!!

Can anyone help us decipher what that exact fuel line Part Number is and where to possibly order one? Is that one solid piece that goes all the way to the engine bay or is there just a section of it we can replace?

I did search far and wide on these forums for something similar with no luck. Honestly, I tried. If there is a thread that deals with this exact problem/solution, I'm more than happy to check it out.

Also, I have a feeling I'll be asking lots of questions on here over time.

Thanks,
Brian

 

The 90 to 94 cars do not have a Banjo bolt, but they do have flared fittings. On my 94, the outlet side was corroded and I could not get it loose. What I did was to cut the "bad" end of the fuel line off with the filter and used a filter with a hose barb on the outlet side. I then just used a short chunk of high pressure fuel line and hose clamps to make short work of it. Hope you're good otherwise. Post some pics when you get a chance, were all nosy here.

 

Hi Brian,

Welcome to the Jaguar Forums! It's great to have you with us!

The bolt that passes through the banjo fitting should have two copper or aluminum washers, one between the head of the bolt and the banjo fitting, and one between the banjo fitting and the fuel filter. The washers sandwich the banjo fitting. It is a common problem for one or both washers to fall off during disassembly and not be replaced (ideally) or re-used during reassembly. If you forgot to put the washers back in place, you'll have leaks. Also, if you overtightened the bolt you could damage the banjo fitting, bolt, or filter. You'll have to take the bolt out and inspect.

You can look up part numbers and part diagrams at the link below, though many of the parts diagrams for the early XJ40s (1987-1989) are no longer present:

Jaguar Land Rover Classic Parts

Cheers,

Don

 

Ok, so he got the part out and we found a proper diagram. In the diagram, it's #10. In the pic, you can see where the banjo bolt comes out of the filter and it's right around the 90-degree bend where it sprays fuel (in between the red lines). Any suggestions on how to fix this? I'm assuming the line cannot be fixed, no matter how much duct tape I use

So....how does one go about fixing it? Creating a new line? If I cut out the leaky section and replace it with some nickel-copper line, I'm worried about putting a compression fitting on the "good" part of the corroded line as it might just collapse under pressure.

Or...does anyone on the planet have this #10 part available for sale?

 

If you can't find a good used hose from a seller on eBay or a local salvage yard, a shop that makes hydraulic hoses can probably repair or reproduce your hose.

 

Got it sorted. A local shop had the exact right size banjo bolt fitting with a barb (a minor miracle). We just cut the old line's corroded part out by cutting the rubber hose and then put the barb into the hose with a high pressure clamp. Had to slightly re-route the fuel line for it to screw back in but it's working perfect now!

Thanks for everyone's advice!