Turns out, my 1996 XJS with the 4.0 AJ16 engine has the metal evaporative loss flange for a 6.0 engine, or an early XK8. (NNA5954AA, not NNA5955AA)

I'm pretty sure the tank might be from a 6.0v as well, as I don't have the pipes needed to make the right (plastic) flange work, so I'm not sure I can find the right flange and install that. I only have one 1/4" pipe to tie into. Everything else is plumbed with hard pipe.

Here's my problem. The metal flange has a 3/8" plastic valve that ties into a 1/4" metal pipe. I am going to have problems finding that kind of hose, since it's only 1-1/2" long.

I'm going to try a 5/16" Gates Barricade hose and maybe I'll get lucky enough to get a tight enough fit on both ends. I don't think the 3/8" hose is doing a good enough job? I've also ordered a new fuel sealing ring gasket for this metal part. The plastic flange that was supposed to be on the car shows the sealing ring as NLA.

 

There is a dual branded black plastic valve (?) on this part. It is both Ford and Stant apparently. It is part #F6DC9B593AA in case anyone ever needs this info. It doesn't appear to be available separately as that part number only pulls up this part for those who don't know Jaguar's flange assembly part number, NNA5954aa, or ab.

 

Vee
I know nothing about the piece in question (let alone the way the facelifts connect their fuel pipes) and thus cannot offer any definite suggestion. But what i have done in the past on such problems (with ordinary clip-tightened hose joins) is to wind PTFE tape round the smaller fitting in order to make the hose a tight fit on the fitting before the clip goes on.

 

Thank you Greg, that is valuable information. I appreciate your help.

 

Well, I went back in there today. I replaced the evaporative flange with one I bought used on eBay.

I also replaced the evap gasket with one that I cut out myself from a piece of Viton. It seemed slightly thicker.

If the fuel smell comes back, then I'm afraid I'll have to deal with the tank itself, which I am not looking forward to.

 

Ive owned several XJS’ and they all smell like fuel. My most recent car has had the fuel pump replaced twice and it has always vented into the cabin while its parked, but never while being driven. I honestly dont know how to fix the issue, but Ive actually had women pull their panties down when the smell of leather, vinyl, oil and gas stimulates something. Now just to be clear. The car attracts more men than women. But when women are around they always talk about the glorious smell of sex and and motorcycle grit. It’s the gasoline

 

Steady on Brewtech I cannot take this sort of stuff at my age! Now, of course, expect a thread about "How to get a fuel smell into the cabin"!

 

Have you looked at the charcoal canister? Is the valve shut closed? You could simply disconnect the end at the front of the car and see if the smell goes away, if it does remove and clean the valve or replace it with a new GM version.

 

Well….I replaced the evap assembly at the top of the tank, with all new Gates Barricade hoses.. and I disconnected the Hose from the tank to the Rochester valve… and then filled up the tank.

The smell is back.

So the tank has got to be fixed or replaced. What is the best solution? This will be a summer project for me. This car is my daily driver, so I can’t pull the tank and then send it away for cleaning/repair. I’ll have to have the replacement solution on hand.

What would you do if you were me?

 

Repair or Replace the tank. Only thing for it.

 

Vee,

You're probably aware of the infamous XJS rivet underneath that has pinholed so many tanks. I don't know if it was still there on late facelift models? I guess I should find out in case mine gets damaged one day.

Perhaps that's the cause of the trouble? In which case, you might want to grind off the rivet whilst the tank is out.

Good luck

Paul

 

Have you tried using a gas sniffer to try and pinpoint the source? I bought a used TIF 8800 off ebay for maybe $80 when I had an XJS. After some practice you get pretty good at figuring out what may be a small part of the problem (like lingering smell in carpet or insulation) and what sends the sniffer off the charts, such as a particular connection or area of the tank. It may not eliminate the need to pull the tank but it could give a better idea of what is the biggest contributing factor.

 

Thanks. I did get a sniffer. You’re right, it does take some practice, but I think I know what to do with it. Problem is that I need to remove that damn steel plate in the back to access the tank.

I feel like the sniffer sniffed a lot behind the tank, at the center, which is why I suspected that the evap flange was leaking.

I also get pings at the gasket for the tank level sender and the elbow that connects to the filler. Everything has been replaced. Nothing is wet, or stained. I guess I could stiff a bunch of paper towels around suspect areas to see if I get any evidence of a leak.

The smell is worst with a full tank, but the time I’m down to a quarter tank; I feel the stink is gone. After replacing the evap flange, the car sat for several weeks. No smell! I drove the car, and no smell! I refilled the tank; and the smell came back. (I did disconnect the hose to the Rochester valve first)

Lastly, I believe the rivet is not found on the facelift tanks.

 

If the smell is not there with a 1/4 full tank, then that seems to eliminate a tank bottom leak. I reckon though, then unless you pull the tank and go though everything, you are unlikely to pinpoint the source.

 

Hmm, given the symptoms and everything you’ve tried, it sounds like pulling the tank is inevitable. Frustrating. I think you’re right that the facelift models don’t have the offending rivet under the tank.

 

I've been driving the car in the cold weather and it seems that the smell is stronger in the cabin than in the trunk....or maybe it vents easier out of the trunk.

The hose to the charcoal canister is still disconnected. Is there anyway that the fuel smell could get to the cabin through any other means than the tank in the trunk? I keep the AC/Heat on recirculation all the time...but.....????

By the way....is there any harm in driving without the canister connected? The car doesn't seem to notice.