Jaguar XK8 Fuel Pump Replacement (and Fuel Tank Removal)

This video shows (more or less) how to replace the fuel pump on a Jaguar XK8. My car is a 2003, which has a slightly different fuel system than the 2002 and earlier cars. Starting in 2003 the cars utilized a "returnless" fuel system, which means that there is no return fuel line from the engine. Prior to 2003 there was a regulator up in the engine bay, and that regulator controlled the fuel pressure by directing excess fuel back to the tank in a return fuel line. The procedure for a pre-2003 car is essentially the same, the only difference being that there would be TWO of the incredibly difficult fuel lines to disconnect.

[@JohnDoe-ev9kt]

I worked for Hein-Werner, and also imported tools for any years, and I would get the call from the dead guy's wife or lawyer after the jack blew a seal and the car fell on him and killed him. Remember, that jack is only supported by a 10¢ O-ring. That one jack stand used above would not have helped much if the jack failed - the car comes down at free fall speed. Always assume the jack will fail and use jack stands accordingly. Glad you made it.

[@sam1174]

Good tip, John. Thanks.

[@rkm35758]

Excellent instructions!!! Having convinced myself that the check valve on the fuel pump in my '03 XK8 was leaking, I decided to follow your video directions. Sure enough, the check valve "ears" were damaged and it was halfway out. The two most difficult steps were getting the fuel line to release from the tank (made a tool similar to yours), and plugging the fuel line back into the tank - it's hard to get leverage in such a tight spot. You saved me a bundle of cash! Thanks again!

[@uhhhhbr549]

Your my hero Sam! I too had to make a few tools. I found that if you leave more plastic to go around the 10mm line more (like 3/4 of the way around) it worked like a charm. You have to snap it over the line with a bit of force. You saved me atleast $1600 on my 2004 XKR, I had a similiar problem where a plastic piece on top of the fuel pump had come apart due to a broken clip. Wired it up like you did and Walla! Thank you Sam and God Bless!

[@ScenEverywhere]

I liked your vid. First rule of Jag repair... NOTHING IS SIMPLE!!! I have experience going back into the early 90's with a friend's Jag. I swore then I would never own one and you certainly underscored that sentiment. Last week I bought an 05 XJ8L at a Copart auction to flip but the car has sat for several months and the E-gas has broken down. Hoping to "SIMPLY" drain the tank and put in new fuel led me to your video and it was most helpful in many ways. The car delivery guy wanted to buy the Jag for 5K... I bought it for 3K and as soon as the title clears I hope to be a very short term Jag owner on my way to the next flip. Thanks again for a great vid and I wish you all the best... ST

[@younglee6281]

Great video. It is very helpful. Thanks

[@JagXK8SpitfireMK3]

Great Job! Have not had to do this yet, and hope I don't. But good to know this is here.

[@LuckTR]

Must've been the camera man @ 4:32 hahah. Thanks for the effort and solid instruction, Sam!

[@tony9069]

YOU ARE THE MAN I HAVE THE CAR N JACK AND STILL CAN'T MOVE BOTTOM FUEL LINE

[@sam1174]

It is probably the fuel pressure sensor. The ECU regulates the fuel pressure by pulsing the fuel pump on and off. Normal fuel pressure is about 55 PSI. If the fuel pressure sensor is constantly telling the ECU that the pressure is too high, then the ECU will never tell the pump to turn on and you'll have no fuel pressure.

[@bertglorney847]

Great help thanks.

[@pamelabrown7469]

Gary Page, that's the way I do it too. the rear speaker is right over the top of the tank opening.

[@garypage7530]

I just removed the speaker above the fuel tank and replaced it through there. Easy job.

[@fredgiligan4346]

Ima try that

[@danquartarone3458]

@@fredgiligan4346 Did you try it? And how did it work?

[@ronpinto9588]

Thinking out of the box... or out of the trunk. Thank you, I was already thinking that I should bring it to my mechanic.

[@ronpinto9588]

I should ask: Is your XK 8 a 2001 model?

[@vicago1148]

I used the plastic harbor freight fuel line disconnect tool (smallest one in the pack) and used a long flathead to push it up there. Took about 45min to get both off and it was my first time doing it. Its not as hard a task as some people make it out to be. Also my XK8 assembly didnt look anything like this.

[@MadelynUY]

My fuel pump went out on a 03 XKR. Would it be the dance steps? I have about 5psi at the fuel rail, thanks

[@vqlive]

thanks

[@dfcvda]

WOW saved me from buying a jag with this problem

[@MKMK-sn4dw]

Hi Sam. Its excellent job you did there. How you drained the fuel from the tank before this procedure?

[@ameanton3260]

Hi there sam, i still have the same issue after getting fuel pump replaced: suspension fault. I have the cat sys 2001 xkr, do you think is some sort of wiring issue?

[@haywoodublowme8850]

well? did it start??? I hope you changed the fuel filter in the tank while you had it apart

[@simonlucas3835]

hey where can I find those clips holding the fuel lines under the tank ? I broke them when I disconnected the tank and tried to straight them up but they broke. A new fuel hose costs about 100 £ piece

[@ZR1Pete1]

Hi Sam I have a friends 2003 XK8 the issue is it cranks but will not start i have fuel (pump 1 year old)& spark. I do have code PO193 Pressure Sensor Voltage Hi. On the scaner the ragulator is stuck at 70PSI no matter if i'm cranking or not. I will order a new sensor today,let me know if you think of anything other then the pressure sensor. Very nice video. Thanks Pete

[@nexusofice9135]

Am I seeing this right? Is the fuel tank behind the rear passenger seats above the spare tire space?

[@robertpower6521]

It is a 99 XK8. I hadn't started it for several months. I also have a problem with it going into Limp Home Mode ocassionally. The readout says it is a coil. #3B I think. Do you know which bank ia A and which cylinder is #1 (front/rear)? Thanks for the info! Regards Bob

[@elsifu85]

The pipe thing is cool but.. Hopefully ill patent my idea of the tool... I just use the white little fuel disconnect tool and push it in with the 3/8 extension that is long enough...

[@arbonnev]

2001 XKR, I had a guy replace my fuel pumps (2) last week. When I went ot pick up the car now I have a suspension fault. I never had suspension fault until pumps were replaced. the 2001 has the CAT system. have you ever heard of this situation? I read another guy on internet with same car had same scenario. But never posted fix?

[@lisabeach6865]

does anybody out there know what size fuel line I need for a jaguar xj8 2001

[@robertpower6521]

How do you tell if the problem is the pressure sensor or the pump?

[@ocwolfy]

Hey do you know where the fuel sender unit is placed on this? I've seen other people have a straightforward design where the sender unit is right there on the front of the tank where you can easily access it but on mind it's just a blank hole like yours

[@sam1174]

It's inside the tank. It's integrated with the fuel pump, You have to remove the tank to get to it.

[@1995RangeRover]

Wow what a pain this job was...

[@sam1174]

You can unplug the connector which powers the pump and apply 12 volts from the battery straight to the pins in the connector. If you hear the pump running then you can assume the problem isn't the pump. What year is your car? The design of the fuel system changed in 2003. If you'll tell me what year it is I'll look up the connector and pin numbers. for the 2003+ cars the connector is in the trunk on the front wall of the trunk towards the bottom right.

[@jessenhartman]

Any info on a 2004 XK8 would be awesome! My girlfriend has one and she is barely getting by with priming the pump by cycling the pump 3 time with the ignition switch. It finally gets enough fuel to start then runs fine.

[@shendereh3910]

hi sam,I have a 03 xk8 it cranks but won't start.don't have owner's or shop manual.paid alldata 30 bucks,all I got was bunch of worthless drawings! can't locate fuel pump relay or fuse.

[@sam1174]

Go to jaguarforums.com. There are lots of good people there who can help you out. Look for the XK8 subforum. Here's a link, but I'm not sure if KZbin will actually show the link: www.jaguarforums.com/forum/xk8-xkr-17/

[@shendereh3910]

thank you very much.

[@Fangioparis]

Maybe I’m a Phili#tine but: cut a hole in the rear deck and remove it from the top. If you’re a purist, put in a hinge. You can also do this by loosening the tank, lines and filler and tilting the tank back. Be careful the fuel return lines are not disturbed inside the tank or the pump will run forever and burn out again.

[@calebadam1676]

If you lower the differential down slightly (which is easy to do) you can get up to the lines much easier with out having to play with a pcv pipe, just a standard disconnect tool. AS for moving the tank out from it spot all you have to do is use pry bars underneath the tank to get it to move. The job was easy, I don't know why you freaked out.

[@bigmacdaddy1234]

Um no. If you have to move the differential down that right there makes the job NOT easy.

[@elsifu85]

1:18 you did alot of unnecessary steps... With the fuel bowl and actuator...

[@DaytonCarCare]

Screw all of that. Get a German car easy access remove a panel and bam there it is. ;)

[@Anthony-qj7qe]

Omg no wonder why these cars are so cheap!