Reattaching the fuel line was simple. There's some sort of paper/rubber liner underneath the fuel tank which tends to shift while sliding the tank back into place. Other members have experienced the same issue. Since it had shifted I couldn't just slide the fuel line back into the hole in the tank where it snaps in place. I think I used a screwdriver to cut or tear that liner so I could see the hole in the tank. Then I just slid the fuel line up into the hole and it slid right in as if it had been smeared with KY jelly.

I got the safety wire at Harbor Freight Tools. Safety wire is really perfect for that repair because it's strong and it holds a twist. A paper clip would be too stiff. One of those twist-tie things that we used to use to hold trash bags closed might work if you stripped the paper off of it. Those little wire things used to hold Christmas ornaments would work, too, but get the thin, lightweight ones. the heavier ones might be too stiff.

 

Good stuff as usual, Sam. Mine may be just now starting to have this problem develop (3 seconds). Duly noted.

 

Thank you. I bit the bullet and bought a new one. I'm going to put a hose clamp on those tabs that break off that may help them from snapping again.
Haven't made a payment yet and I'm into this thing for a couple grand already. I hope it turns out being dependable after this suspension rebuild and fuel pump. I'm also planning on changing that trans fluid. Is that zf6 dependable? I know the zf5's were not.
Thank you.
Quinn

 

Thanks Sam and Thanks to bzviguy and ccfulton on thread "2003+ Fuel pump tear down and failure analysis".
I had the crank, crank,crank hard starting problem. Putting a pressure gauge on the fuel rail Schrader valve showed the pressure drop to zero after turning the car off. Easily took the fuel pump out tanks to Sam's video. And removed the regulator from the fuel pump and bench tested by applying vacuum to 5/16 port on regulator and found it held vacuum. Check valve look good. But the small o-ring on the regulator port looked swollen so I replaced the O-ring (a dash 109 5/16 x 3/32) . I put the regulator back in the plastic fitting and tested with the new o-ring and it held pressure. Put back everything back together and in now working. Thank for the help.

 

I blame our fuel filter for the valve failure and fuel pump failures on our cars.
Jaguars have no bypass, and most are now clogged in only 2 years,CHANGE IT