Does anyone know about how much fuel line is needed to change out all fuel lines on a 5.3 V12, "87 XJS" I'm planning on buying bulk hose 8mm(5/16") and 10mm(3/8") Gates barricaded EFI line to replace all lines from tank to Injector rail, injectors and return lines. Have not had time to actually start, hoping next week as I have a three day weekend, would like to have everything on hand when I start. I will double the amount as I will be starting on my 83 XJS soon.

Also, one other question, my 83 5.3 does not look like it was modified thru the recall for the fuel injection. It has the round fuel rail, the 87 has the square tube rail. Best as I can tell, the 83's fuel rail uses clamps on the line and push on at the injectors. Is there any issues I need to be aware about this?

Thanks
Johnny

 

I would recommend sticking to the original configuration as far as ferrules and clamps are concerned. Clamps should be the EFI type and great care should be taken when removing old hoses so as not to damage barbs.
I believe the injector hose size on the early cars is not 5/16 but an odd size slightly smaller. They are available from several sources.

 

According to the Jaguar ROM, the injector hoses are 8mm and transfer lines are 10 mm

8mm=0.3149606" 5/16"=7.9375000mm/0.3125000" just slightly smaller than the 8mm
10mm=0.3937000" 3/8"=9.5250000mm/0.3750000" again just slightly smaller than 10mm.

I will be using the smooth EFI clamps on the round rail, the square rail has the push on barbs.

I also will be turning out some new dished washers to the push on hoses to replace the older dished washers.

 

Fuel supply and return lines under the car are steel,supply on the right return o the left. I would keep these as is if they are in good condition.

As far as the flexible hoses (not injector hoses), I would use JIC fittings, make sure the ones you buy are good to use with fuel, especially if your fuel has ethanol in it.

 

Some early HE engines had 7.5mm EFI hose, so you will need to check YOUR car.

The ROM is just that, a guide, not a Bible.

My Red Beast was 7.5mm for the injector short hoses.

The under bonnet are 8mm, mostly. Again, check your car. The supply on the RH side TO the RH FPR on some cars is 10mm then reduces about 6" into the engine bay to 8mm.

The return is a mongrel size. The FPR outlet can be 8 or 10mm, depending on what is fitted, and the spigot at the firewall is 10mm. One of mine had a 8mm FPR on the LH side, NOT original, but Bosch just the same, and 10mm FPR's were NLA at the time, so a hose adaptor was needed, and retained when rehosed.

There are 2 hoses, SHORT, above the rear cradle, one is Hi Pressure, RH side, and the other LO pressure, LH side. Easy to change, NOT. Weepers, hell yes.

The hose into the tank, LH lower corner, is 10mm.

The rest in the boot are 8mm, except the 12.5mm supply from tank to sump tank, and sump tank to pump inlet.

Vent hoses, NO idea in your market. Probably a mix of 6mm and 8mm.

I would get about 3mtrs of 8mm, and 2 mtrs of 10mm EFI hose per car.

The round rail is from the preHE, and is 8mm, with clamps.

 

Thanks Grant, that gives me a idea as to how much to have on hand. I'll probably pick up about 25' of each, and I'll check into the 12.5mm sizes. Unless needed, the steel lines will not be replaced. The round rail on my 83 confused me as it is a HE.

Johnny

 

I would hunt around for a square rail and FPR's.

Those round rails leaked, hence the recall work.

I fitted a square to our PreHE.

When you do the fuel lines in the boot, remove ALL the carpets, and anything else that will contact fuel, as spillage is going to happen. When done, wash the boot out with HOT soapy water. That fuel stink will drive you to drink if it gets on any soft item like carpet etc.

 

The two hoses, supply and return, that go over the top of the cage are quite specialised steel and flexible pieces, and the steel part of them where it is just rearwards of the RHS wheel often rusts and perforates; but not enough to see unless you get close and it looks smokey because of the high pressure and micro droplets. These two hoses are still available, and worth hunting down, which will save a great deal of fettling. This guy in England is brilliantly helpful, and has them:
Jaguar XJS V12 Over axle Fuel Pipes, New, | eBay


Greg

 

Thanks for the tip Greg, I have some time today and was planning on cleaning out the Boot area, carpet, etc.. It's setting on my lift now and I'll raise it and check those lines out. I've looked over most of the steel lines and they look good, no rust. But I will make sure to look over these very closely. When I start removing the flexible hoses, I'm thinking about sealing them off and doing a vacuum test on them, or a pressure test. I had read about replacing the flexible part of those lines doing a double flare on the steel portion and then clamping them back on. We have a local company that makes high pressure lines so if they need replacing, I will take the lines to them with the original fittings so they can duplicate them.

 

Checked all the fuel lines from tank in boot to the motor compartment. Tank fittings and lines in boot, all good, clean, flexible not stiff and connections good. Under the rear of the car, all lines dusty, and dry. Cleaned off and look really good. The two flexible lines over the rear sub frame also were dusty, but clean and dry. Thankfully I have a digital inspection camera or I would not have been able to see these very well. So I will only be replacing the flexible lines under the bonnet. Went ahead and changed the fuel filter while I had the boot cleaned out. Depressurized the fuel lines, and sat a metal bowl under the filter. No spillage. Also first time I had the spare tire out, original Pirelli P5, never looks to have been mounted on car. No dry rot cracks and had plenty of pressure.