Jaguar XJ (X350). Service manual — part 1121

Fuel Tank and Lines - 2.7L V6 - TdV6

Principles of Operation

The fuel tank shares many features of the petrol variant, being of the same shape to facilitate the

driveshaft, using a fuel pump module in the right hand side and a fuel transfer pump in the left hand

side to transfer fuel across the tank. The 2.7L diesel also uses a critical fuel level switch which

activates an anti air suction strategy, preventing air from entering the system during a low fuel level

condition by preventing the pump from running.

For additional information,

Fuel Tank and Lines - VIN Range: G45704->G99999

Overview

There are changes to the engine management system (EMS) for 2006 my, the most obvious of which

will be the change to 7-digit diagnostic trouble codes (DTCs) from the familiar 5-digit.

Refer to the DTC index in this section for guidance on how to use these codes with the Jaguar

approved diagnostic system or a scan tool.

Inspection and Verification

WARNING: Do NOT carry out any work on the fuel system with the engine running. The fuel

pressure within the system can be as high as 1600 bar (23,206 lb/in²). Failure to follow this

instruction may result in personal injury.

WARNING: Eye protection must be worn at all times when working on or near any fuel

related components. Failure to follow this instruction may result in personal injury.

WARNING: This procedure involves fuel handling. Be prepared for fuel spillage at all times

and always observe fuel handling precautions. Failure to follow this instruction may result in

personal injury.

WARNING: After carrying out repairs, the fuel system must be checked visually for leaks.

This should be done after the engine has been run, but with the engine switched OFF. Failure to

follow this instruction may result in personal injury.

WARNING: If taken internally, DO NOT induce vomiting. Seek immediate medical attention.

Failure to follow this instruction may result in personal injury.

WARNING: If fuel contacts the eyes, flush the eyes with cold water or eyewash solution and

seek medical attention. Failure to follow this instruction may result in personal injury.

WARNING: Wash hands thoroughly after handling, as prolonged contact may cause

irritation. Should irritation develop, seek medical attention. Failure to follow this instruction may

result in personal injury.

CAUTION: Before disconnecting any part of the system, it is imperative that all dust, dirt

and debris is removed from around components to prevent ingress of foreign matter into the fuel

system. Failure to follow this instruction may result in damage to the vehicle.

CAUTION: The fuel pipes between the injectors and the rail must be discarded after each

use, and new pipes installed. Failure to follow this instruction may result in damage to the vehicle.

CAUTION: It is essential that absolute cleanliness is observed when working with these

components. Always install blanking plugs to any open orifices or lines. Failure to follow this

instruction may result in damage to the vehicle.

CAUTION: Make sure that the workshop area in which the vehicle is being worked on is as

clean and dust-free as possible. Areas in which work on clutches, brakes or where welding or

machining are carried out are not suitable in view of the risk of contamination to the fuel system.

Failure to follow this instruction may result in damage to the vehicle.

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CAUTION: Make sure that any protective clothing worn is clean and made from lint-free

non-flocking material. Failure to follow this instruction may result in damage to the vehicle.

CAUTION: Make sure that any protective gloves worn are new and are of the non-powdered

latex type. Failure to follow this instruction may result in damage to the vehicle.

CAUTION: Make sure that clean, non-plated tools are used. Clean tools using a new brush

that will not lose it's bristles and fresh cleaning fluid prior to starting work on the vehicle. Failure

to follow this instruction may result in damage to the vehicle.

CAUTION: Use a steel-topped work bench and cover it with clean, lint-free, non-flocking

material. Failure to follow this instruction may result in damage to the vehicle.

NOTE:

This section contains references to Parameter Identifiers (PIDs). Where the Jaguar approved

diagnostic system is not available, a scantool may be used to access these PIDs, all of which give

information, and some of which can be used to both read information and to activate

components. The format of the information may vary, depending on the tool used.

1 . Verify the customer concern.

2 . Visually inspect for obvious signs of mechanical or electrical damage.

Mechanical

Electrical

Fuel level

Contaminated fuel

Fuel supply line(s)

Fuel return line(s)

Battery charge and condition

Fuse(s)

Inertia fuel shutoff (IFS) switch

Fuel pump module relay

High-pressure fuel supply line(s)

Fuel tank filler pipe

Fuel leak(s)

Fuel tank

Fuel filler cap

Fuel filter

Push connect fittings

Fuel rail

Fuel injection pump

Exhaust gas recirculation (EGR) system

Fuel pump module

Electrical connector(s)

Damaged or corroded wiring harness

Fuel volume control valve (FVCV)

Fuel pressure control valve (FPCV)

Rear electronic module (REM)

Engine control module (ECM)

3 . If an obvious cause for an observed or reported concern is found, correct the cause (if possible)

before proceeding to the next step.

4 . If the cause is not visually evident use the Jaguar approved diagnostic system or a scan tool to

retrieve the fault codes before proceeding to the DTC index, or the symptom chart if no DTCs are set.

The fuel system interacts with a number of modules, therefore a complete vehicle DTC read will

be necessary.

Symptom Chart

Symptom

Possible source

Action

Engine cranks, but

does not start

Inertia fuel shutoff (IFS) switch

Low/contaminated fuel

Anti air suction initiated

Fuel pump module fault

Low pressure fuel system fault

Blocked fuel filter

Fuel volume control valve

Check that the inertia switch has not

tripped. Check the fuel level/condition,

Fuel Charging and Controls If there is

sufficient fuel check the critical fuel level

switch, GO to Pinpoint Test G552807p2.

Check Check the fuel pump module

operation, GO to Pinpoint Test G552807p8.

Check the low pressure fuel system for

leaks/damage, GO to Pinpoint Test

G552807p9.

Check the fuel filter, check the FVCV and

FPCV,

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