Hello everyone !

I have a 1994 XJS convertible 6cyl 4l. It is leaking Gas from the filler cap to the gas tank.

I need help locating what part to order, based on the attached pictures.
I did order the rubber gasket part number HHC3105AA, but it looks like something is rotten, and something is rusted in the picture


I am in a time crunch, and I am not in the same place as the car, so I will need to order the parts and have them delivered to the US by the 20th of July.



It is leaking gas from the chrome filler cap (with integrated lock) to the gas tank.


Please, any help will be greatly appreciated !

 

On that diagram, if HHC3105AA is Part Number 11 then that is not the Part that Stops it leaking between the Fuel Filler and the Tank

There are 2 Parts that Stop it leaking between the Fuel Filler and the Tank and neither one of those 2 Parts appear to be Shown on that Schematic diagram

I will see if I can get you a Photo of those 2 Parts you need, even though they may be no longer available

 

thank you so much, that will be grately apreciated !

I did not order part 11, I ordered this part "BBC3693" replaced by part no HHC3105AA - it's a rubber gasket with 3 holes, that I have no idea what does. I was told over the phone to order

 

I did find this website if we can determine what it is that I need to order

https://www.jagbits.com/category/XJS_FuelDeliv_2.html#/filter:model_year_2:XJS$252F1994

My vin number is SAJNX2746RC190390

 

That rubber Gasket only seals the filler Cap to the Bodywork (under wing/fender in the boot/trunk to prevent rain getting into the Boot/Trunk)

If its only a few Bucks, then you may as well order it anyway

 

Ok here we go, this is what you need although you may have to get 'Creative'!

First take a very close look at these 3 pics of the Filler Cap, especially Pics 2 and 3

Where if you look very closely you will see a very big 'O' Ring round the neck of the Filler Cap Stem about half way down, this is the first line of defense against Fuel coming out of the neck of the Fuel Tank

You should be able to get one like it 'Aftermarket' from anywhere that sells 'O' Rings (make sure that its Fuel Proof)





That Rubber Gasket 'Thingy' in your Pic will go on here



Can you see that 'O' Ring around the Stem of the Filler Cap?

Now off to try and get you the Next Pic of the other Part that you will need

 

Unfortunately couldn't get to the Part in order to take the Pic but basically its a big piece of hose that goes over the Stem of the Fuel Filler and then over the neck of the Fuel Tank Inlet to join the two pieces together

Only its not quite that simple as that piece of hose that joins the Fuel Tank to the Filler Cap is Shaped and I spend all of 2 days trying to get the thing off

After which I cut it through with a bread knife 'Big Mistake' as so far I have been unable to find a replacement, although I believe that they are still available

So I will probably end up having to make one, to go on the XJS I'm fixing now

 

I do beleive This is what I will need, but I will also need more parts... :-/

This is obviously where the problem lies... I'm just trying to find out how much work and what parts to get hold of

 

O.B. ! Dude, thank you so much, great pics and a bit more understanding.

My issue now is that I am in Norway, and my XJS is in the USA. I will only travel to the car's location for 2-3 days during the summer, so: I will h ve to order all the parts I need and have them there and ready so I can bang it out in a couple days

do you think I can order this

and then make the rest on site ??

 

OK here's the problem part ( I think ) ...

Which I believe to be this part of the cylinder
But my part is not identical to the schematic picture, as the return nipple on mine is out from the center and not the top, or am I completely off ... ?

And then, I guess "the filler neck" goes over it ...

 

Yup! That's the very thing you are going to need!

And should be a nice easy to fit (if you give it a smear of Copper Grease, where it goes over the Inlet of the Fuel Tank

(Put it on the Neck of the Fuel Tank First and then Secure it with a Jubilee Clip (Tight but not Stupid Tight as Grant would say)

Then Put another Jubilee Clip on the other end (From inside the Boot/Trunk)

After which you can then slide the Neck of the Filler Cap (With its Big 'O' Ring on) through the Wing/Fender from outside the Boot/Trunk and then into the Collar, where you have already Clamped it to the Neck of the Filler of the Fuel Tank

Then Clamp it up and that's it!

Apart from fitting the Breather Tubes etc

But before you do any of that, do a Check for any other parts you may have missing, using that Schematic Diagram

After which you should be good to go!

 

OK, a little update people: And I do have a couple of questions;



This is a RUSTY part that needs replacement, but I can NOT find a schematic or a part number


This part is now loose, but I can NOT remove it The filler cap is unscrewed from the top, but when it is Pulled upwards, there is still something stuck inside, NOT allowing us to remove the chrome filler mechanism. Does someone know how to get it up and out?


Out from the RUSTY part (that I still can't find pictures or part number of) there is a exit nipple for the return hose here. I'm assuming this part is of Steel, as it is completely rusted out. Does anyone know what this part is, of what is looks like ??


I know I will need part 19-20-21-22. BUT; The top of the rubber FUEL FILLER NECK GAITER (part 21) goes into the "missing part, before it goes into the chrome filler mechanism.

 

Hi it's almost impossible to see what you mean from those Photos, except to say it looks as though the neck of the Filler Cap Tube has been jammed in at an angle, which means that you can't move it up or down

Sorry I can't be more helpful but those Photos are much too dark to see what has gone wrong

 

Yes, they are dark. It is at an angle because we are trying to show what part is rusty, and to where it is attached. the gas filler cap is loose, unscrewed from the top, but something is suck inside so we can't pull it out

I'm basically a bit lost now until I actually get to the car