I’ve done so much to try to make this work, but I still need help.

so first, I need to get the gas tank out. All that I need to take out left are the fuel lines behind the gas tank. I have no idea how to reach those lines, I’ve looked underneath the car, and I can’t see the lines going into the tank from underneath. Any idea how to get those off?

second, the gas tank is rusted on the inside. Thought I could seal it with a kit online, but most of those are 50/50 with their rating, and don’t want to have to end up re doing the whole thing in a couple months. I wanna find a new gas tank if it’s not too expensive (>$800), but finding one online is impossible. From what I understand, the 95 gas tank is unique, it’s different from any other xjs year, and also, the 12 cylinder and 6 cylinder tanks are different (I have the 4.0l 6 cylinder), and the convertible gas tank if different from the coupe tank (I have the convertible). I dint know if that is 100% true or not, but nonetheless, every picture of the tanks I’ve found are different than the one I have.

if ANYONE has any help for me on EITHER of my questions, on how to get it out or where to find a good tank, I would appreciate the help!!!

 

Hello

Can't help much in the removal of the fuel tank as yours and mine are completely different. But regarding the replacement fuel tank - have you considered getting one fabricated. I looked into that path when I removed my fuel tank - and if it failed the pressure test - I had a fabrication place in town lined up to make a new one out of aluminium, using the old one as a template.

These fuel tanks are getting harder to find - with yours being a very late model - it will even be harder - might have to look/think outside the box.

PS - You wouldn't believe how many baffles are in these tanks

Cheers
Steve.

 

Hi 1995XJSGuy

Help is at hand!

Been there and done that with my 1995 XJS Convertible

Here is my Complete Guide to Removing the Fuel Tank-Cleaning the Fuel Tank-Replacing the In Tank Fuel Pump-Replacing the Fuel Tank

Everything you need to know including loads of Photos

This is a PIA Job if ever there was one

Replacement Tanks are NLA as you have found out but I was lucky and managed to clean my Tank out

The Flow and Return Fuel Pipes are accessed from underneath the Car where you will find the IRS Cage is right in the way!

These Fuel Pipes are pushed into the Tank from underneath the Car where they are sealed against 'O' Rings as they are pushed in (with a Special Tool!) But the Guide also shows you how you can easily make one out of a piece of 1/2 inch Copper Water Pipe

I'm not a big fan of Tank Sealers, so if I were doing this job again I would probably get a Tank Made, which shouldn't be too expensive if you know someone who's hobby is making stuff like that

Apart from that Don't lose the Clips that hold those Fuel Pipes in the Tank when those Fuel Pipes are Pushed in

Repeat: DO NOT LOSE THOSE CLIPS OR IT IS SURE TO END IN TEARS!

How to remove the Fuel Tank and Replace the In-Tank Fuel Pump on a 4.0L XJS Convertible including Refitting the Fuel Tank with lots of Step by Step Photos

 

No help on removal but I just wanted to toss out an alternative to buying a replacement tank.

I've have good luck in sending rusty tanks to the local radiator shop. They soak 'em in their vat of nasty chemicals and they come out clean as a whistle. Sometimes they cut the tank open to zero-in on any especially bad spots

Of course there are limits to how effective this can be if the rust is very severe. But for $75-$150 (typically) it might be worth considering

Cheers
DD

 

Just to second that idea of a radiator shop rebuild. I've had good luck with that in the past with my '56 Cadillac. Just be sure that they do this regularly and are experienced. If they get a blank look on their face or hesitate, look somewhere else.

 

I have a good 1995 convertible tank
500 plus shipping. PM me if interested.

 

1995xjsguy,

Jaguar used the same fuel tank in 4 litre convertibles built from May 1994 through to April 1996.

Also, I'm not sure what are the precise differences but Jaguar show a supersession of numbers for all 4 litre convertible tanks from April 1992 through to April 1996. So the implication is that any 4 litre convertible should fit.

Good luck

Paul

 

Hi Paul (ptjs)

Are any of those available, just in case I might need one myself or are they all NLA

 

Hi OB,

No luck. They've all been superseded to the most recent part number and that's NLA.

Cheers

Paul

 

Hi Paul

Doh!

But Cheers anyway! and thanks for checking that out

Alex

 

my fix for fuel tanks!
20gal. Nascar poly plastic tank(never rust again), all aluminum 1/2" lines , Aero quip fittings, SS pump,and filter!
mounted with straps,blocks at each end , stop movement side to side!
been 26 yrs NO problems! all parts from Summit racing !

 

Thank you 1995XJSGuy! You are confirming a lot of my observations. I plan to print out your guide and continue with this effort this weekend and neutralize the surface rust spots using phosphoric acid. Fortunately the rust is not too bad at this point. If that does not work, I will look into having a new tank fabricated based on the existing tank. Unfortunately, I can't find anyone with 250 miles of Maryland who cleans and repairs fuel tanks for cars anymore.

 

Careful with the acid... Pinholes after the acid 'dug' into the rust spots. Good member here taught me to yes, uses the acid, then have that TINNED at a radiator shop, then to spread over a goooood layer for fast drying JBWeld, the big tubes, and things have been fine ever since....

I like Ron's idea, but wouldn't know where to begin. Looks like a lot, even though when it's done it's done.