After an inspiring post from Don B about the fuel sending unit being a relatively straightforward job on these XJ40s, I figured I'd take a stab at it.

Sourcing the part itself proved to be a bit tricky. None of the local chain auto parts stores had one listed, nor did RockAuto. A bit of "creative googling" lead me to the following part on : the "Eurospare DBC012042" (Mods: if the amazon link is frowned upon here, please remove it.)

For $67, I took a chance and went with it. Although Don commented that below 1/4 tank of fuel was the sweet spot for replacing this thing without making a mess, the actual fuel level was a bit difficult to determine. I filled up, drove a couple hundred miles, and hoped for the best.

Here's the part:



Removing the spare tire and associated tools from the trunk, the carpeted panel was a snap to remove, and the lockring for the sending unit was readily accessible. Not having a brass punch handy, I used a wooden block and a hammer to tap the ring (slowly!) counter-clockwise to the release position. After just a couple of taps, I started seeping gas. I guess 200 miles was not enough! Quickly tapping the ring back into position (with the wooden block, to avoid sparks in my now fuel-rich environment) I siphoned out another 7.5 gallons of fuel. Another experimental release of the lock ring made it clear that this was /just/ enough, and the fuel level was exactly at the base of the opening.

Here we are, with the original sending unit still in place.




Installing the new sending unit was trivial, of course, so I buttoned everything up and tested it out. Turning the key to "run," I was met with the following:


So.. Success! Mostly? It is definitely reading "a level" now, but I have concerns that there may be a calibration error, as it's reading higher than the ~1/4 tank that the actual fuel level implies. I haven't yet filled it up and run it through a cycle, so I don't yet know if this is normal, or if perhaps I don't have the right sending unit after all. Time (and/or input from the rest of you) will tell.

For anyone interested on a "postmortem" on the original sending unit, here's what the contacts looked like after (potentially) 24 years of use. I wish I'd taken a similar photo of the new unit, but needless to say, this one is pretty badly "burned up."

 

Just throwing this out there- did you compare the units side by side for bends or lack of, in the rod? If not, maybe you can do a study and make an "adjustment" after you decide where the float should be registering. I know..."Its not MY fuel tank, no more work for me to say that!" But I got my "fill" when my tank collapsed.

 

Mike,

Great job, and thank you for taking the time to take photos and to post them here! They'll be helpful to many other members for years to come.

Your indicated level may be accurate - the tank never fills up completely, otherwise raw fuel could make its way into the charcoal canister and foul it. It is possible to snag the sender float rod on the wiring harness for the fuel pump or its plastic canister, but if the level indicated by your gauge declines as you drive the next few days, it's probably fine.

Cheers,

Don

 

Thanks Jerry, Don,

I definitely considered the idea of "adjusting" the rod on the new sending unit if required. At a glance, they both looked similar, although in hindsight I don't think I did a direct "side by side" on them. My muscle memory is telling me I did pretty much the same contortions to get the old one out, as it took to install the new one.

I'll run it through a tank or two and see where we end up.

It's funny.. I told myself I'd drive it in the winter, as it's a very nice car, but not a "perfect" car.. Yet, with it all polished up and sitting in the garage, I haven't had the heart to expose it to the snow yet, and have been driving the pickup instead.. She sure is pretty..

 

Jags will definitely do that to you. They seem to invite an emotional connection that is unique in my experience.

 

Mike: Nice work recording your efforts as Don said for future "Mike's" of the world. You are now immortal, well digitally speaking

 

Well, I know how valuable the "writeups" can be, and I have yet to establish quite how much history exists within these pages.

Hopefully I haven't duplicated anyone else's efforts, but I'm happy to be contributing useful content to this forum. I'm kind of under the assumption that I will be dealing with all of the typical "new to me XJ40" issues.

 

FWIW . I wish I had a garage for mine, but it is what it is and I don't. I also don't live on a paved road but on a dirt road in the mountains. Last Winter I had 4 directional snow tires on mine and that thing was just amazing in the snow. With the limited slip and the good tires I a passed more cars without issue. So if you do and it has good tires you'll be amazed on how well it does.

 

Thanks, Jeh. I can appreciate your gravel road in the mountains. It sounds like a peaceful existence. I was fortunate to find a house with a 3 car garage, but I'm in the suburbs. It's definitely a compromise.

I'm pleased to hear these things perform well in the snow. The tires that came on mine have plenty of tread, but they're old, and clearly of the (non-performance) road going variety. I'm pleased to hear this thing may have a limited slip rear in it. Was that standard? The vast majority of my winter driving experience is in big, rear-drive Town Cars, from what I'm hearing, the XJ40 may well be superior to those.

I've got a road trip to Fargo (yup.. that Fargo) this weekend. About 300 miles each way.. I'm really itching to take the Jag. Last time, we took this trip in the girlfriend's Versa. It's reliable, gets good mileage, and is equipped with excellent snow tires, but it's noisy, and only comfortable for about 2-3 hours. (it also has surprisingly sub-par defrost capability..) I'm thinking it's time to switch things up..

 

Limited slip is not standard on these. Neither of mine have. It would be nice though.

 

I don't have it on my VDP either

Larry

 

Neither our '89 Sovereign nor our '93 VDP came with an LSD. To my recollection, I haven't actually worked on any XJ40 that came with one.

 

I took my 92 to a Professional import guy for what I hoped would be a rebuild. He had the car over 6 weeks ( which was fine because I timed it for off season) and kept me posted as he decided against unit after unit. I think he had at least 4. One was a limited slip which I really hoped for but he decided it was in need of work too. I am not sure they are all that common given their apparent "weakness."