Fitting Instructions
PURGE MODIFICATION KIT - PART NO. JLM 832MODEL APPLICATION XJ-S V12
Parts in Kit JML 832
Procedure
Connect the center harness terminals to the two relays in accordance with the information shown.
Remove starter relay cover at rear of engine bay to expose feedback inhibit relay A Fig. 1.
Displace white cable from feedback inhibit relay connector block (terminal 86) using a small screwdriver.
Route the green/black and two white cables of the new harness rearwards through the brace bar support bracket to the feedback inhibit relay following the main harness.
Fit white cable with bare Lucar Connector into terminal 86 of the feedback inhibit relay connector block and replace relay. Connect displaced white cable to insulated white of new harness. Connect green/black piggy back connector to the green/black joint adjacent to the starter relay, Fig. 1, and replace relay cover. (Ensure piggy back connector is well insulated).
Position relay mounting bracket on the R.H. inner fender panel to approximate dimensions shown in Fig. 2 and mark hole positions. Dimensions "A" and "B" are measured from the rear face of the headlamp housing. Dimensions "C" and "D" are measured from the top lip of the inner fender. Drill 1/8" holes. Attach relays to bracket as shown in Fig. 2 and fix bracket to inner fender panel using self tapping screws, also securing the harness ground eyelet to the relay bracket.
Route green/brown cable of new harness along the front water rail, under the air conditioning compressor and connect to green/brown cable joint at L.H. side of compressor, see Fig. 3. Secure to water rail using suitable ratchet straps ensuring adequate clearance with drive belt. (Ensure piggy back connector is well insulated).
Disconnect and remove electrical purge valve and short hose to inlet pipe. Remove and discard purge valve harness from water rail, disconnecting bullet connectors from R.H. side of engine. Restrap air conditioning harness to water rail.
Strap harness as necessary using suitable ratchet straps and tape to joints to ensure good insulation.
Remove L.H. air cleaner cover and element.
Break pink/white cable to supplementary air valve at joint behind air cleaner. Connect supplementary air valve lead to yellow/black of new harness pink/white of existing harness to pink/white of the new harness.
Cut and retain 13.5" from purge hose to charcoal canister. From parts supplied and referring to Fig. 4, fit reducers A to short hoses and connect to vacuum purge control valve E. Connect to inlet pipe as shown in Fig. 4. Secure to inlet pipe with previously displaced hose clip.
From vacuum hose supplied cut 4" and 17" lengths. Referring to Fig. 4, fit elbow C and reservoir D to the purge valve E. Connect short length of hose between reservoir D and the red side of the delay valve F. Connect long hose between delay valve and T piece. Secure hoses as necessary.
Fix vacuum routing label over existing label.
Remove and discard fuel rail temperature switch. Connect yellow/pink wires together. Remove vacuum hose from outlet fuel pressure regulator to inlet manifold and discard, retaining the elbow and connector. Fit Thermal vacuum valve to fuel rail and cut 2-15" lengths of vacuum hose. Connect vacuum hoses as shown in Fig. 5. Resecure all harnesses and hoses.
To check supplementary air valve operation remove the supplementary air valve from the R.H. air cleaner backplate and start the engine. Wait for 1 minute. Switch on the air conditioning and set to 65°. The supplementary air valve should not operate as the A/C clutch cycles. Apply brakes firmly and select drive. The supplementary air valve should now operate when the A/C clutch cycles. Switch off A/C and check that the valve ceases to operate.
Repair Times Information