I have faced new issues trying to rescue Rose. The new injectors have been fitted and engine now starts fine. However, the fuel pipes under the fuel tank are causing problems. I already sourced a new fuel feed pipe (the high pressure one) a while ago, but the other one, the return fuel pipe was found to be broken at the tip knot, so fuel was leaking from the tank. Thought that there would be many used parts lying around but the common feedback is these pipes are usually badly rusted and are therefore normally trashed after breaking the car. The use one (see picture) I got from eBay was a rare find, but it was no good because the male connector part of the pipe (called the quick-fit design) is tilted and the lower part of the pipe was bent at various curves. Obviously it was brutally removed from the fuel tank by force rather than following Jaguar's advice of using special release tool made by Huron.

The two quick-fit female connectors on the fuel tank bottom; one for the feed line, the other return line:


The broken male connector


A used male connector - unfortunately no good as it has a tilted tip


The trouble is that although new part (NNA6102AG) is available overseas (the local dealer and parts suppliers do not keep them in stock) it is not only expensive (around GBP150), but it is also a one long piece running from boot bottom to the front engine. Shipping alone is more than 5 times the cost of the part. Why Jaguar wanted to make the return pipe such a long piece is difficult to understand. I believe that if I can find a fuel hose connector of the right size and design, I can use rubber fuel hose to connect to the rest of the pipe that runs to the car front. The return fuel pipe is 9.5mm in diameter. I found some universal fuel hose connectors on the web, and wonder if folks have any experience tackling the same issues and what would be the best way to go.

 

When I rebuilt my car some years ago the fuel pipes were very rusty. I had similar issues with new parts. They were very expensive and were on back order with no expected availability date.

I decided to make my own. I was not able to find the correct quick fit ends as a separate part and as the ends on the old pipes were not in a terminal state I cut them off reused them.

I made all of the new pipework from Kunifer tube. I used the old pipes as a pattern and using a cheap mini pipe bender managed to make something pretty close to the original shape. All joints, including attaching the old fittings, were made by brazing a straight copper connector - same as used for plumbing.

Copper may not be the best choice (galvanic corrosion?) but was all I could find at the time. The car has been back on the road since 2012 so pipes are holding up OK.

For the flexi parts I used standard rubber fuel hose. I put a slight flare on the end on the Kunifer pipe where it was being inserted in to the rubber hose and used standard fuel hose clips doubled up. Again no issues since 2012.

Hope this gives you some ideas. I've attached a few pics to help also.

 

Could you thread the outlet and install a suitable 90 degree elbow?

Or a 90 degree bulkhead fitting?

 

b1mcp, very ingenious DIY solutions! I can certainly try this route if I can't find any good used ones. There are also some off-the-shelf fuel hose connectors on the web. I found a couple of examples:




However, I don't have the skills and tools to make the pipe myself, and since this is fuel-related installation, I will have to find a local machine shop for help.

 

Have you tried SNG? When my pipe rusted out a couple of years ago, in a thread somewhere, I got the pipe from them and they deal with the shipping. It looks like it is $206. I will tell you it took them a few weeks to get it, so you should clarify that with them, but they generally have parts here or in there UK facilities. Unfortunately for us because of the short model run some parts are hard to get. I also toyed with having one made, but this was easier.



PIPE-FUEL RE
MORE PRODUCT INFO
PRODUCT CODE: NXF6102AB
QUANTITY OF FIT: 1

 

I have found a new fuel pipe from David Manners and too have seen the part available in a few UK websites. However, I am giving up because of shipping due to the unusually long fuel pipe running from back to the front of the car. I too believe SNG would have the fuel pipe as well, but I can never be able beat the hurdle posed by international shipping. Am looking at some used pipes, failing which the last resort would be to fabricate one by a machine shop.

 

Found a used fuel pipe from a forum member in NZ; only the head section by about two feet is needed, which helped with packing and shipping. The pipe fitted perfectly well to the fuel tank and there is no more leak. With the tank thoroughly cleaned, new fuel pumps, new + used fuel pipes and fuel rails cleaned and cleared of rust, Rose starts on first crank! I would say the wisdom gained from all no-start threads in this forum has finally paid off. It was a great relief and joy to me and my mechanic to witness Rose's recovery from the dead. We have added some lubricant oil to the fuel to help Rose's deal with any rust that might have built up inside the engine chamber.

The next phase is engine refinement: replacing the valve cover gasket and the badly eroded valve cover, spark plug well rings, the leaking exhaust manifolds (I have a stainless steel set custom-made by an exhaust specialist workshop in the UK), as well as tackling the rattling noise during cold start by replacing the timing chain tensioner.

 

Could any of you tell me what size male quick disconnect adapters I will need to track down to fit the female fittings on the bottom of the tank? I have the same issue as Qvhk in that the fuel pipe for the return has broken right at the fitting and I am also attempting to make something custom so that I can avoid purchasing the oem style return line that is so long and difficult to install. Any suggestions on fittings are much appreciated, thanks!

 

The diameter of the fuel pipe is 8mm, and the male connector is built into the pipe. Ideally, find a used Jaguar of similar model (X300/308) that still has the fuel pipes intact, and ask the breaker to remove them *carefully* for you. Mind you, many breakers simply discard the pipes as they are mostly badly rusted, and hence they just pull and sway by force hence distorting or breaking the quick connectors. If they have fuel line pliers the fuel pipes will come out nice and easy. Good luck!

 

Hi Oscuridad,

In the U.S. the closest size fuel line quick connect tool is 3/8 inch, and the best tip I know of is to give yourself extra leverage by making a supplemental tool from a piece of PVC pipe as devised by aholbro1. See his posts #1 and #10 in his thread at this link:

https://www.jaguarforums.com/forum/x...quired-163902/

By the way, you've posted in a thread related to the X300, but fortunately the fuel pipes are the same size and part number on your X308.

Cheers,

Don