SECTION II - Installation of Recall Kit
WORKSHOP PROCEDURE1. Disconnect the battery.
2. Remove the LHS front road wheel assembly.
3. Remove the wheel arch liner to gain access to the charcoal canister.
4. Disconnect the purge hose from the charcoal canister and the vapor hose from the fuel tank vapor pipe.
5. Remove the nut and bolt from the canister securing clamp, open and remove the canister.
6. Assemble the components as shown in Fig. 3, and fit this sub-assembly to the charcoal canister, ref Fig 4.
7. Fit restrictor CBC 9506 into the larger diameter end of hose CAC 1853/7 (F, Fig. 4).
NOTE:
Shoulder end of restrictor to face outward.
8. Fit clamp CAC 8773, and push larger end of hose onto the end of Rochester valve CBC 7714 (C, Fig. 4), marked 'TANK'. Reposition the clamps to secure.
9. Fit clamps CAC 8773 (D, Fig. 4) to elbow CAC 4040/2 (B, Fig. 4). Fit one end of elbow to Rochester valve marked 'CAN' and the other to the canister stub pipe marked 'T'. Reposition the clamps to secure.
10. Refit charcoal canister assembly to the vehicle, align components, Fig. 5, and secure using tie wrap AGU 2532.
11. Fit clamp CAC 8772 to vapor hose CAC 1853/7 and fit hose to existing vapor pipe. (A, Fig. 6). Reposition clamp to secure.
12. Push existing purge hose through inner fender into the engine compartment, ensure grommet is still in position.
13. Fit clamp CAC 8774 to new purge hose CAC 5867/37. Route hose as shown (B, Fig. 6) and connect to end of 'Y' piece CBC 8290 (C, Fig. 6). Reposition clamp to secure.
14. Connect vacuum hoses (D, E & F, Fig. 6) and route as shown (Fig. 6). Secure together using tie wraps.
NOTE:
D = 1415 mm (55.7 inches) length (EAC 8022/38)
E = 737 mm (29 inches) length (EAC 8022/19)
F = 1240 mm (48.8 inches) length (EAC 8022/39)
15. Route vacuum hoses previously pushed into the engine compartment (D, E & F Fig. 6) along the left side of the engine compartment and allow them to rest on the left fender (until further instruction is given).
16. Refit wheel arch liner and road wheel. Lower the car.
17. Disconnect the air temperature sensor multi-plug.
18. Unclip the air cleaner element cover and displace the cover from the element. Remove the element and the cover.
19. Disconnect the intake manifold purge pipe vacuum hoses (A, Fig. 7) from the throttle housings.
20. Disconnect the retaining clips (B, Fig. 7) securing the vacuum purge pipe to the PCV valve vacuum pipe.
21. Remove the bolt (A, Fig. 8) securing the purge pipe to 'B' bank manifold overrun valve housing. Remove the purge pipe and existing hose assembly (C, Fig. 8).
22. Remove and discard both hoses connected to the purge system thermal vacuum valve.
23. Refit the manifold overrun valve housing securing bolt.
24. Cut and remove the tie wraps securing the coolant/air temperature sensor harness to the Part Load Breather Pipe (PLBP) (B, Fig. 8).
25. Loosen the clamps securing the PLBP hoses to the intake manifold stub pipes (D, Fig. 7). Disconnect the PLBP hoses from the intake manifold stub pipes.
26. Loosen the clamp (D, Fig. 8) securing the PLBP hose to the PCV valve, which is situated in back plate of 'B' bank air cleaner box. Remove the pipe and hose assembly, remove and discard the PCV valve hose from the pipe.
27. Replace the lower bolt securing the overrun valve housing to the 'B' bank manifold housing with stub pipe EAC 2899 (E, Fig. 9) and connect vacuum elbow EAC 7965 (F, Fig. 9). Fit connector C 33835 (G, Fig. 9) to the elbow. Route the vacuum hose CAC 8022/39 (F, Fig. 6 / D, Fig. 9) from the Rochester valve to fit to the connector.
28. Cut 50 mm from the PCV valve end of the PLBP, using a suitable saw. Debur the cut end and ensure that the pipe is free of dust and debris.
29. Fit one of hose CAC 5868/37 (H, Fig. 9) to each end of 'T' piece EBC 4270 (J, Fig. 9) and secure with clamps CAC 8774.
30. Position 'T' piece - ref Fig. 9, and fit clamp CAC 8774 to the end of the hose which aligns with the cut end of the PLBP. Fit hose to pipe and reposition clip to secure.
31. Fit and align PLBP assembly to the engine. Connect existing vacuum hoses to the intake manifold stub pipes.
32. Connect remaining hose CAC 5868/37 to PCV valve. Secure using original clamp.
33. Route new purge hose CAC 5867/37 to 'T' piece. Fit clamp CAC 8774 to hose and fit hose to 'T' piece. Reposition clamp to secure.
34. Fit rubber blanking cap C 34946 to 'A' bank throttle housing stub pipe.
35. Remove the setscrews securing the fuel cooler to 'B' bank air box and reposition the cooler away from the airbox.
36. Remove the air box to throttle housing securing bolts and remove the air box from the throttle housing/auxiliary air valve hose, etc.
37. Remove and discard the gasket.
38. Disconnect the throttle return spring from the throttle housing.
39. Remove the bolts securing the throttle housing to the intake manifold, and remove the throttle housing. Remove and discard the gasket.
40. Using feeler gauges, set the throttle butterfly in the new throttle housing EBC 2799, to 0.05 mm (.002 inch), refer to operation number 19.20.11 in the XJS Service Manual for further details.
41. Fit and align the new gasket to the intake manifold. Fit and align throttle housing. Reconnect hoses to air box and fit and tighten securing bolts.
42. Refit return spring to the throttle housing.
43. Connect vacuum hoses as follows:
CAC 8022/38 1415 mm (55.5 inches) long, from rear stub pipe on 'B' bank throttle housing to purge valve (A, Fig. 9).
CAC 8022/10 635 mm (25 inches) long, from front stub to black face of delay valve (B, Fig. 9).
CAC 8022/19 737 mm (29 inches) long, from white face of delay valve to the other purge valve (C, Fig. 9).
44. Ensure all hoses from the charcoal canister area are routed along the fuel return hose to the fuel cooler and secured to the fuel cooler mounting brackets with tie wraps.
45. Refit the fuel cooler to the air box and secure with the setscrews.
46. Refit the air cleaner element to the air box. Refit and align the air box cover/element assembly and secure with the retaining clips.
47. Reconnect the air temperature sensor multiplug and secure the harness to the balance pipe with tie wraps.
48. If not already done, use two tie wraps to secure the vacuum hoses together.
49. Remove the 2 PSI valve and associated hoses (A, Fig 10) from the vapor separator and charcoal canister pipe (located on the right side of the upper fuel tank).
50. Install hose part number CAC 1853/2 on the charcoal canister pipe (located on the right side of the upper fuel tank) and reuse the old clamp and tighten.
51. Route hose (CAC 1853/2) to the vapor separator upper fitting as shown in (A, fig. 11).
52. Trim the smaller diameter hose end to the proper length, ensuring no kinks or excessive length of hose that can become trapped by the trunk hinge, install the hose and clamp. Tighten the clamp.
CAUTION:
The vapor separator hoses must be carefully routed to avoid contact with the trunk hinge when the trunk is closed. Secure the hoses to the right side fuel tank strap with a tie wrap to ensure proper positioning.
AIR CONDITIONING LINK HARNESS MODIFICATION
NOTE:
Refer to fig. 12 to determine if link harness CBC 6606 has been installed. If the harness has been installed, proceed to step 58. If the link harness has not be installed, continue.
53. Remove the passenger side under dash panel and center console side casing.
54. Remove the screws securing the footwell duct to the air conditioning unit, and remove the duct.
55. Disconnect the harness bulkhead connector from the air conditioning unit mode switch and insert CBC 6606 as follows:
Connect the small male connector of the link harness to the air conditioning unit mode switch (B, Fig. 12). Connect the air conditioning connector to the female connector on the link harness (A, Fig. 12). Connect the remaining multi-plug connector (with two wires), to the air conditioning unit ECU Diagnostic socket (C, Fig. 12).
56. Refit the air conditioning footwell duct to the air conditioning unit, and secure with the screws.
57. Refit the center console side casing and the under dash panel.
58. Reconnect the battery.