XJ XJ8 / XJR ( X308 ) 1997 - 2003

Fuel pump through parcel tray

Old Mar 30, 2025 | 08:04 PM
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From: Indiana
Default Fuel pump through parcel tray

Hey all. I did the fuel pump through the package tray, and thought I'd try to contribute. Thank you all for helping me in my previous post.

Unhook the negative battery cable and drain the tank. I couldn't get my tube past where the fill neck hit the tank, so I drained it once I got the top off the tank.


Remove the kick panels, seat bottom & seat back. Seat back will go up & forward. You can leave it there & sit on it while you work, or completely remove the seat belts and remove it. I did the former. Then remove the package tray cover. There's not a great way to do it. I lifted lightly in the middle and shimmied each side out.

The method for the hole was a 9 inch Amazon hole saw and a cordless Milwaukee right angle drill.

If you wish to center it the best you can, you'll put the guide bit on the bottom edge of the center car seat anchor bracket. I suggest you come through the trunk and put something over the top of the fuel tank & vapor assembly. I think your best bet would be a flexible cutting board.

There are 3 tubes going in to the top of the tank. The 2 smaller are easy to remove, and easy to replace should you have to cut them off. The larger tube is different sizes on each side. That tube is harder to replace, so try to save it. I had to buy a short piece in the smaller size and stretch it over the larger size. It wasn't easy.

Once you get in there by removing the friction ring (hammer and a really long flat screwdriver), remove the 2 electrical plugs on top and 1 underneath. Don't drop the underside plug if you can help it.

I would leave the fuel level level sensor in there, but if it comes out, just be careful with it. It's plastic, and if you drop it, it will almost certainly break.

The pump has 1 machine screw and a tab at the bottom that pushes into a slot. Easy to come out. That's how it's held in. There are 2 worm clamps for the fuel hose from the pump out of the tank. I suggest you use a small socket for these, not a screwdriver. Then it's out!

Depending on your new pump, you may have all the rubber bits you need, or you may have to reuse the vibration dampners from the old pump. I had a bunch of new pieces with the pump, but none fit. I reused and it went fine. Be sure to get a new pre filter, the old one is most certainly trash. Also, a new piece of fuel line from the the pump out.

Now work backwards to reinstall. Stop before you cover it back up with upholstery.

A tip from me is to hook the vapor cap electrical back up in the trunk. Then hook up your old pump and turn the key to on, not start. Or jump the relay socket. Do the same on the new one afterwards. Hopefully the old one is inoperable and the new one is running.

Once reassembled, make sure the battery is hooked back up with a small amount of fuel in the tank. Key on, key off x3 while the pump runs for a few seconds. Give her a start.

These are the 2 drawbacks, in my opinion. 1. You'll lose the center car seat anchor. 2. You will lose the leverage of approaching the tank however you'd like. You will be at the mercy of the position of the tank in the car.

Thanks for reading. I have attached a picture of the hole and the boys buttoning it back up.






 
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