Thanks this post was awesome and exactly what I was hoping for. The factory tank lasted from '95 till now - by the time the replacement rusts out too, it'll be 2035 and the rest of the XJ will be 40 years old or rusted away to nothing! Sorry to poop on your idea, but having done it I'd rather save you the headache than say nothing.
say battery is 12v but at pump its 8v, and ground is good then pump is drawing excessive current. I did it on my 96 XJ because I had no idea what I was doing at the time and figured a 97 tank would fit a 96 (it's only one year off, right?! ) and didn't want it rusting out either. best tests is cranking, also the voltage is key here, some pumps run and pull 3 times normal current (we use an ammeter too, test 4, sure) and will cause voltages to drop at the pump. Further, the 97-01 sender uses a $65 combination check valve, pressure regulator, and filter mounted on top of the sender that requires dropping the tank to get access to it, and it's known for failing and causing hard starts.īasically the plastic tank is great for not rusting but that's all it has going for it. So your fuel gauge will basically never work again. The problem is, none of the resistance curves on the gauge senders are the same. The reason you will need to swap the fuel rail is that the 95 down XJ uses a vacuum FPR on the rail and supply/return lines, while the 96 up XJ uses a returnless system. fill and vent tubes (the rubber ones) to the fill neck
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