After replacing the fuel pump in my 94 convertible Ive had one of the fuel lines under the tank disconnect twice. The D shaped clip is apparently not seating correctly. ANYONe with some experience with this have some advice? I have new clips ordered.

 

The 'C' clips should be on the connector before pushing the fuel lines on.
Is it possible the clips were deformed when removed?
They can be bent if they are not pulled off straight.
I needed to reshape mine the first time I did this job.
Are they rusty? are the couplings cleaned? Did you replace the O-rings with new? Are they seated properly?
I have an extra set of clips if yours are toasted.

 

I did not replace the O-rings. Do you think that's necessary? The largest line is the one coming off. I'll see if I can get the D-clip off and straighten it.

 

By straightening, what you mean is bending.
Usually the D gets stretched out.
The fit should be tight around the fitting and the straight part able to lock it on.
Unless the o rings are modern material like PTFE they need to be replaced.
Especially since the old ones have been disturbed.
The obsessive me wants to make sure all the parts are clean and none of the old rings remain.
I always add a bit of petroleum jelly to them.
That will improve the seal and make it easier to assemble.

 

WHEN i inspected the ends the o-rings looked good. I did apply a thin layers of grease before reinstalling. The design is good, accessibility is bad. (Without a lift)

 

Hi Old Coastie

Sorry to hear your having problems with the Fuel Pipes, all you need do is get yourself the Special Tool they use for doing this Job, which probably costs an eye watering some of money!

Or alternatively you can make one in about 10 minutes from an old piece of 1/2 in Copper Water Pipe, as unless you are a Contortionist with several years of practice under your belt, then after you get the Fuel Pipe entered into the female socket of the Fuel Tank

You then use this Special Tool, to push the fitting into this Socket in order to Compress the 'O' Ring enough to get the Clips on 'if you get my drift'

Here are some Photos of how I did this including everything else about Removing the Fuel Tank and Replacing the Fuel Pump, although it sounds as though you have done that bit already

Anyway this might help others who may be contemplating doing this Job

Loads of Photos included: All about removing the Fuel Tank and Replacing the Fuel Pump on an XJS 4.0L

 

Thanks for the reply. I do like your tool that you invented! Good photos by the way.

 

It's just a better practice to replace all o-rings whenever they are disturbed.
O-rings are cheap and easy to find.
Not doing it could cost a lot of money and could be disastrous.
Installing them then is easier than when they fail.

 

Got it all sorted out. New o-rings and clips along with luring the o-rings and it snapped into place without issues.