Anyone replacing the fuel pump on their xj8 for the first time needs to know this important step that seems to be left out of every post and instruction manual. Maybe some see it as common sense, but it didn't occur to me that when you install a new fuel pump, the crossover tubes that connect to the balancing pump on the other side of the tank do not just slide across the bottom of the tank to the other side when you install it. Arrrgh, what is an otherwise 1-2 hour job turned into an 8 hour job because this key step seems to be left out of every procedure and post I could find, including the Jag service Guide.

When you remove the balancing pump from the left side of the car, disconnect the two tubes and tie some bailing wire to the tubes, THEN remove the fuel pump on the right side, dragging the fuel tubes and wire across the tank hump. Now tie yor new pump tubes to the bailing wire and pull it across the tank from the left side while installing it. You'll get the idea when you reach this point in the install.

If, like me, you're reading this trying to figure out how to get those tubes accross because you didn't do this step, I found after many hours trying it shove things accross the tank that wouldn't go over the hump, only one thing worked. Cut off the small tube from the old pump at the base and cut off the fitting at the other end, but leave about a 45 degree turn in the knurled part. You'll be able to fish this accross tank fromm one end to the other while "cheating" towards the front side of the tank. Then follow the procedure above.

Hope I can save somebody some time with this tip, not sure why it isn't mentioned anywhere that I can find.

 

Hi Dudeman44,

Thanks for sharing this helpful tip. Just for clarity, on what model year car did you perform this procedure, and at what mileage?

Thanks!

Don

 

Sorry, I should have mentioned this is on a 2004 XJ8. I have about 90,000 miles on it and the engine shut off in the highway with the dreaded 1338 error code meaning failed fuel pump. The error code was right on the money. Towed home, replaced pump and gaskets, all is well again.

 

This is useful information since a failed fuel pump is a PTIA, you have to be

towed home and you end up staring into a foot of petrol when you replace

the pump.

This might be a case of preventative replacement a la batteries although

I have not seen many reports of failed pumps on this forum.