I just did this - twice - in the past month on my '93 XJ and now I believe that the fuel
pump mounting arraignment on these cars was designed by a spawn of Satan.
I put in a Bosch pump...then 3 weeks later fuel began seeping out of the fitting where
the wires pass through the mount disk.
The Bosch pump is physically smaller than the Airtex and comes with a spacer sleeve
- but it is the fuel pump/sender hanger that is the source of your problem.
First, the return tube (the one with the rubber cone tip at it's end) has to nestle in
a socket that is tack-welded on the floor inside the tank. This is absolutely essential.
It takes some blind fiddling around (ie: by feel, only) with the pump assembly while
it's being put into the tank to confirm this.
Second, the O-ring has to be positioned perfectly in order for the pump to seat onto
the tank. Apply some grease all around the rim of the tank opening where the O-ring
nestles. This will help hold the O-ring in place while you struggle and curse the pump
assembly in place.
It took me 4-6 attempts each time, and just when I've gone through every curse word
know to me (in 3 languages) - it somehow seats itself correctly in place.
Check to be sure that the O-ring is correctly seated all around before putting on the
locking ring.
