Replacing Fuel Pump In '97 Jag Xk8: Step-By-Step Guide

If you're looking to replace the fuel pump on your 1997 Jaguar XK8, you're in for a challenging task. While it's not impossible to do it yourself, it's recommended to leave this job to professionals due to the risk of fire. The fuel pump is located inside the fuel tank, which needs to be accessed by removing interior panels, the battery, and the tank retaining cover. You'll also need to drain the tank and disconnect the fuel lines, which can be especially tricky.

The average cost for a Jaguar XK8 fuel pump replacement is between $1,697 and $2,146, with labor costs estimated between $322 and $406, and parts priced between $1,375 and $1,740.

If you decide to take on the job yourself, be sure to exercise extreme caution and refer to detailed guides or forums for step-by-step instructions specific to your car model.

Disconnect the battery

Disconnecting the battery is an important first step when replacing the fuel pump in your 1997 Jaguar XK8. Here is a detailed guide on how to do it:

Step 1: Open the Driver's Door

Keep the driver's door open, or both doors if necessary, to allow the side glass to drop. Ensure that the doors remain open until the battery is disconnected. This is an important safety measure.

Step 2: Remove the Luggage Compartment Floor Panel and Battery Cover

If your Jaguar XK8 has a standard-size spare wheel, you will need to remove the luggage compartment floor panel to access the battery. Then, remove the battery cover.

Step 3: Disconnect the Negative Lead

First, reposition the front edge of the side trim to access the ground stud. Then, slacken the clamp of the negative lead at the battery terminal. After that, disconnect the negative lead from the battery terminal. Finally, remove the nut from the ground stud.

Installation

To reconnect the battery, simply follow the above steps in reverse. Remember to reset the clock, reset the window position memory, and perform the Engine Control Module (ECM) adaptation sequence after reconnecting the battery.

Remove the interior panels, then the tank cover

To replace the fuel pump on a 1997 Jaguar XK8, you will first need to remove the interior panels. This will give you access to the fuel tank, which is located in the trunk.

Start by removing the shelf, then the tank cover, and then the two sides. Be careful when removing the panels, as some of the fasteners may snap off. It is recommended to have some replacement fasteners on hand before beginning this process.

Once the panels are removed, you will need to remove the tire and battery. With the tank cover removed, locate and remove the tank retaining cover. There are three bolts on top and two bolts on the bottom. When replacing the cover, it is recommended to put the two bottom bolts in first, followed by the three top bolts.

Now, you can begin to access the fuel tank itself. Remove your gas cap and drain the tank. It is recommended to have less than a quarter of a tank of fuel before beginning this process. Once drained, remove the three screws at the filler and push the rubber back into the trunk.

The next step is to remove the tank filler latch. Hold the latch inside the trunk and turn the nut on the outside a quarter turn, and it will come out. It is a bayonet-type connection. Disconnect the two drain hoses, and you will be ready to move on to removing the fuel tank cover.

The fuel tank cover is a large metal panel held in place with five 10mm bolts—three at the top and two at the bottom. Remove all five bolts to take off the panel. Before doing so, disconnect the electrical sender wires that run through the hole in the middle of the panel.

With the interior panels and the fuel tank cover removed, you will now have access to the fuel pump and can continue with the replacement process.

Drain the tank

To drain the tank of your 1997 Jaguar XK8, you'll first need to remove the gas cap and drain the tank. It is recommended that you do not start this process until you have less than a quarter of a tank of fuel. Once drained, you can then remove the three screws at the filler and push the rubber back into the trunk.

Now, on the inside of your Jaguar, you'll need to remove the tank filler latch. To do this, hold the latch inside the trunk and, on the outside, turn the nut about a quarter turn and it will come out. It is a bayonet-type connection. Once that is removed, disconnect the two drain hoses.

At this point, your tank should be drained and you can move on to removing the tank retaining cover. You will find three bolts on the top and two bolts on the bottom. When putting it back together, it is recommended that you put the two bottom bolts in first, followed by the three on the top.

Disconnect the fuel lines

Disconnecting the fuel lines of your 1997 Jaguar XK8 is a crucial step in replacing the fuel pump. Here is a detailed guide to help you through the process:

Before starting, ensure you have the correct tools for the job. You will need a fuel line disconnect tool, which can be purchased from an auto parts store. This tool will make it easier to remove the fuel lines from the tank. It is also recommended to have a car lift to access the fuel lines more easily, although this is not essential. If you do not have a car lift, you may need to lower the rear subframe to access the fuel lines fully.

Now, locate the fuel lines. They are positioned above the differential at the bottom of the fuel tank. There is an aluminium heat shield above the rear end and the fuel lines go above this. The lines are exposed over the differential, but you may need to use a mirror to get a better view of them.

Once you have located the fuel lines, the next step is to disconnect them. Start by spraying the ports for the lines with a penetrating lubricant, such as PB Blaster or WD40. This will help to prevent rust and make the lines easier to remove. Then, attach the fuel line disconnect tool to the lines. You may need to use a long pry bar to push the tool into the line securely. Once the tool is in place, push the line in and then pull down to disconnect it from the tank. Be careful not to bend the line, as this will make the job more difficult.

Repeat this process for all the fuel lines. There are three lines in total: two on the left and one on the right. Once all the lines are disconnected, you can move on to the next step of removing the fuel pump. Remember to work carefully and take your time, as this is a delicate procedure.

Safety precautions are crucial when working with the fuel system. Always disconnect the battery before beginning work to reduce the risk of fire. Be very cautious not to spill any fuel and ensure the area is well-ventilated.

Remove the old pump and replace with the new one

To remove the old fuel pump and replace it with a new one, you will need to first disconnect the battery to reduce the chance of a fire. Next, you will need to remove the interior panels, starting with the shelf, then the tank cover, and then the two sides. Then, remove the tire and battery.

With the tank cover removed, you will need to remove the tank retaining cover. There are typically three bolts on top and two bolts on the bottom. Once these are removed, you can drain the gas tank and remove the screws at the filler, pushing the rubber back into the trunk.

On the inside, you will need to remove the tank filler latch. Hold the latch inside the trunk and turn the nut on the outside about a quarter turn, and it will come out. Next, disconnect the two drain hoses and the plug for the pump and float.

There will be three lines to remove—two on the left and one on the right. Pull down the roof drain and push in on the canister pipe tabs to lift the hose off. Now, the hard part! Getting the removal tool on the lines can be tricky. You may need to spray the ports for the lines with a lubricant to make this easier.

Once the lines are disconnected, you can remove the locking ring to access the pump. Be careful not to continue hammering on one tab—be sure to use all the tabs. Now, look at the hoses—one side is plastic, and the other is metal. Remove the hoses from the metal lines by applying pressure to push the hose away so as not to put pressure on the plastic pipe.

Now, you can remove the old pump. There is typically only one bolt holding the pump in place, along with a clamp on the hose. Be careful not to pull or tug on the fuel line in the tank.

To install the new pump, simply follow the above steps in reverse. Be sure to install the new pump correctly and tightly, and ensure all wiring is tight and locked into place.

Frequently asked questions