1996 XJ Sport, 356,000 miles
What are your takes on fuel tanks? Looks like Rock Auto beats Amazon on everything suspected of being decent quality:
https://www.rockauto.com/en/catalog/...fuel+tank,6268
From what they list, Spectra and Dorman might be candidates for me. Just don't know if either has problems.

Also, they seem to be better on fuel pumps from a casual look between Rock Auto and Amazon,, especially Delphi, Bosch, and Denzo:
https://www.rockauto.com/en/catalog/...fuel+pump,6256

I thought there was some issue with the new pumps not fitting right without some hack into 1996 and older XJ's? Maybe misremembering.
Is any one of them significantly better than the other?

 

Been quite a while since I've read a discussion about fuel pumps for our '96s. Seems the only solution was a complete unit like Crown offers due to our pressure regulator being part of that unit so it's in the tank instead of on the fuel rail. I will say the price has come down a lot.
https://www.quadratec.com/products/51306_0147.htm

 

Just be aware the '96 has a unique fuel pump assembly, in that the regulator, fuel pump, and fuel level circuitry is all together in a cradle, within the tank, and although hard to get, can be purchased a s a complete assembly, maybe as a "Carter"..its expensive

If you are just talking about the fuel pump itself, for a '96, the pump body & filter sock is the same as a "95, as is the regulator (runs with no vacuum going to it on a '96)
I installed a '95 pump and sock in a failed '96 assembly, and that got the vehicle going

I have a failed fuel level circuit on one of my '96ers, and I havent had the time or inclination to fault-find it yet..I dont think any discrete replacement is available ?

Not sure , but you should check the 94-96 Parts Manual, available free online, to make sure the '96 fuel tank is not unique as well..I have a sneaking suspicion it may be

 

None listed by Rock Auto for 1996 XJ have a regulator on the unit? And from looking at it, this might not be the correct pressure regulator for 1996:
https://www.rockauto.com/en/moreinfo...0314&jsn=10412

They do list a Spectra "All in One Kit"
https://www.rockauto.com/en/moreinfo...0406&jsn=10406
But that one doesn't look like it has what the Crown unit has either.

 

My thought was, when I replace this fuel line and IF the fuel is muddy coming out of it, I might replace the tank and all that is inside it. The pump was replaced (prematurely, real problem was fuel pump relay) in 2001ish. I was there when it was replaced, but I don't remember if he replaced all the guts in the tank or just the pump and sock.

 

The fuel gauge and all has always worked fine, so if I go for a new tank I could do fine with pulling the old pump and sock off and putting a new one on. IF that is a possibility with this setup.

 

Don't know if can be done like that or not. As far as I know the only option is a unit like Crown offers. Price use to be in the $260 range.
We are lucky in that the pump unit can be removed without dropping the tank unless it needs to be dropped maybe like yours. 1995 lists the same tank part number as ours. 1997 and up the tank changed configuration with the opening being on top instead in the front like ours.

 

Not sure how to remove mine without dropping the tank. The fuel line attaches to a fitting on the front face, near the top, of the fuel tank.

Is that configuration removable without dropping the tank?

However, if I suspect my tank is trashed it will get dropped to replace it anyway.

 

I've been saving this link just in case I need it. It doesn't mention nor have I read from those here who've done it of having to drop or even lower the tank. Mine had the unit replaced by the original owner a couple years after she bought it. Luckily the warranty covered it.

https://itstillruns.com/replace-cher...p-7201395.html

 

So one of my '96 I got real cheap, as the fuel pump was failed, and the tank described as "full of black stuff"

I had it towed home, and ordered just the fuel pump body and sock (not knowing any better at that time)...I removed the tank by taking down the front J-bolts and straps (use penetrant)..remove the tank,
and just cleaned it out..it was ok. Placed the new fuel pump and sock in the assembly, ad it all worked

To the very best of my knowledge, the regulator can be replaced exactly the same way, just order a '95 regulator, and fit within '96 assembly

There is a very comprehensive "96 fuel pump" thread on NAXJA..Google or search it out

 

Nice article. When I get up under there tomorrow to do the first round of PB Blaster therapy to that fuel line clamp and a few other pieces, will try to remember to get some pictures and see of there is actually enough clearance to do what they describe.

 

Did it have any fasteners or tricky clips and watnot in there?

 

This was the thread I found, but since I haven't been in the pump assembly yet I don't know how useful it is.
https://www.naxja.org/forum/showthread.php?t=88346

 

Just my 2 cents..... If you're going through all that trouble to drop and replace the tank... why put a 20+ year old pump assembly back into it? Unless the price was obscenely expensive then I'd say do you really want to go through the process again when that byzantine aged one decides to go ***** up?...

 

If you are a '96 owner, its one of those parts that its handy to have as a spare, be it a new Crown assembly, a used unit, or a '95 pump and regulator.

In my case I have a used unit, working ones in my (not) daily driver, and a new pump that I have acquired with the many other spares I have

I will probably get a spare regulator from Rock Auto next time I place an order.

A new Crown would have to be air freighted from USA, and take a few days minimum, maybe 1 month, so you wouldnt want to get stuck in that situation

from memory pretty sure you dont need to drop the tank to replace the pump..except if you have to clean it out..which is what I did..I stress to double check the tank part number is compatible

My old Jags have dual fuel tanks and pumps, a tremendously reassuring situation in a 50 or 70 year old vehicle.

For a true off-road vehicle, a supplementary tank, dual pump setup would be beneficial, probably doable on an XJ ?