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FUEL SYSTEM
The D-Jetronic XJ-S fuel system involves a fuel tank with a drain that feeds a small surge tank. A screened pickup in
the surge tank leads to a soft-mounted fuel pump just below and to the right of the spare tire. The line leads to a fuel
filter and then to two separate fuel rails on the engine, one for the left bank and one for the right. A pressure regulator
on each rail directs excess flow through a fuel cooler and then back to the tank.
The Digital P uses a similar system except that the two separate fuel rails were replaced with a single rail. There are
still two pressure regulators, but in this case one is a supply regulator and one is a return regulator. Supposedly the
return regulator, the one on the LF corner of the engine, is the only one that actually does anything. While the D-
Jetronic regulators held rail pressure constant, the Digital P regulators vary rail pressure with intake manifold vacuum
and therefore have vacuum lines connected to them.
The earliest saloons are fitted with carburetors, which use much lower fuel pressure than EFI. The EFI saloons have
fuel systems resembling those in the XJ-S. The most notable difference in the saloon fuel system, though, is that the
Jaguar saloons have two fuel tanks and a switchover system so the driver can choose which tank to use.
In 1992 the XJ-S fuel system changed markedly. The external fuel pump was replaced with a submersible pump inside
the tank. The fuel rails were redesigned to connect to the injectors with O-rings instead of short hoses. The worthless
supply regulator was omitted.
Fuel Fires
Besides the usual general concerns about fuel fires -- fuel lines left in place too long until they rot, etc. -- there are also a
couple of specific worries:
EARLY D-JECTRONIC FUEL RAIL: The early Digital P XJ-S’s (early 80’s) had a problem with engine fires. There
was a recall to address the problem in which the fuel rail on the engine was replaced; the newer design is indicated by
rectangular tubing, while the pre-recall rail was made of round tubing. All Digital P XJ-S’s were subject to this recall,
but indications are the recall was not as conscientiously applied outside the US. Unfortunately, word is that the recall is
“closed” and dealers will no longer perform it. If you have a Digital P with round tubing in the fuel rail, you probably
should consult your favorite junkyard and collect all the parts that look different and perform the recall yourself. Note
that the D Jetronic still uses fuel rails with round tubing.
Leaking fuel in an engine compartment is remarkably difficult to ignite. Usually there have been obvious odors and
visible leakage for some time. Please do not ignore fuel odors; the XJ-S shouldn’t have any.
MARELLI IGNITION WIRES: The later XJ-S with Marelli ignition also has a reputation for engine fires. Peyton Gill
reports on “an XJ-S that had a little pyrotechnics under bonnet. I asked the guy about it and he said that the fire was put
out within 30 sec (owner had a fire extinguisher) and the estimate to repair was $2000.00. There was not that much
damage. The cause of the fire was the ignition coil wire was about 1/4 inch from one of the fuel injection lines
(between rail and injector). The ignition wire had been arcing to the line and eventually worked its way through. I
guess the physical damage and ozone created by the arc eventually broke down the line.”
Julian Mullaney adds, “There was a recall for cracked injector hoses and injector bodies. Ozone from the distributor
leads causes the perished plastic. The recall replaces the lead with a shorter one, and replaces the injector. They looked
up my car (vin no.) in their database and the fix had already been done a long time ago, however the problem persisted.