Gas Smell in Cabin with Sunroof or Windows Open
Veteran Member
Joined: Aug 2010
Posts: 2,636
Likes: 1,636
From: Southington CT
Look at this TSB (Technical Service Bulletin) on JagRepair (forum member Gus) website:
http://www.jagrepair.com/images/TSB/...pe%20Seals.pdf
Fuel Tank Pipe Seals (Stuffer Pins).
Jim Lombardi
http://www.jagrepair.com/images/TSB/...pe%20Seals.pdf
Fuel Tank Pipe Seals (Stuffer Pins).
Jim Lombardi
Junior Member
Joined: Jul 2014
Posts: 13
Likes: 0
From: Longwood, Florida
RobertJag, you did not post if changing the evap flange component seals fixed your gas problem. Did it work? Were you able to change the quick connect outlet and return hose O-rings from inside the tank? I am having a similar gas vapor smell problem with my 99 XJ8
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Senior Member
Joined: Jan 2013
Posts: 296
Likes: 43
From: Charleston SC
I am sorry for the very tardy follow up on this. I did solve the problem but did it by not cutting corners and doing the job as completely and with new parts as I could.
I ordered a complete new assembly from Barrett. It was shelf worn and rusted. That was OK because I just needed the new gaskets. BTW, the whole unit was a little different than the one that was on mine.
Most of those gaskets are NO LONGER available. I figured if I was going to have the gas tank out I might as well do it correct. Some of the rubber hoses are straight but some have flared ends as one end attaches to a smaller tube than the other. I ordered those rubber tubes from Jag even tho they were expensive.
There is ONLY one way to get the gas tank our properly. You have to use the tool to release the "quick release" tubes that go into the gas tank and you should only use NEW Stuffer Pin attachments with new o rings. My gas tubes under the car were bent because of someone NOT doing it properly before I bought the car. I replaced those. I did not have to remove any under car components to remove and replace the gas lines. I do have a lift which made it easier but I think some really good ramps/stands would be adequate. I do have smaller hands tho and that may have helped.
This is not an easy job but takes patience and some money (we all know that story). If the gas tank level sensing unit looks bad REPLACE IT. Mine had a tiny crimp in the wire that looked close to being exposed. Replaced it.
Get the correct Corbin hose clamps to attach the top hoses to the flange also. Don't use nylon ties and worm clamps will often cut into the rubber tubes.
Once it was all back together it has worked fine and continues to a year later.
Good luck.
I ordered a complete new assembly from Barrett. It was shelf worn and rusted. That was OK because I just needed the new gaskets. BTW, the whole unit was a little different than the one that was on mine.
Most of those gaskets are NO LONGER available. I figured if I was going to have the gas tank out I might as well do it correct. Some of the rubber hoses are straight but some have flared ends as one end attaches to a smaller tube than the other. I ordered those rubber tubes from Jag even tho they were expensive.
There is ONLY one way to get the gas tank our properly. You have to use the tool to release the "quick release" tubes that go into the gas tank and you should only use NEW Stuffer Pin attachments with new o rings. My gas tubes under the car were bent because of someone NOT doing it properly before I bought the car. I replaced those. I did not have to remove any under car components to remove and replace the gas lines. I do have a lift which made it easier but I think some really good ramps/stands would be adequate. I do have smaller hands tho and that may have helped.
This is not an easy job but takes patience and some money (we all know that story). If the gas tank level sensing unit looks bad REPLACE IT. Mine had a tiny crimp in the wire that looked close to being exposed. Replaced it.
Get the correct Corbin hose clamps to attach the top hoses to the flange also. Don't use nylon ties and worm clamps will often cut into the rubber tubes.
Once it was all back together it has worked fine and continues to a year later.
Good luck.
Last edited by robertjag; Jan 31, 2015 at 02:19 PM.
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