Front End Modification
1. Disconnect the vehicle battery.
2. Raise the front of the vehicle and support on stands. Remove the left-hand side front road wheel assembly.
3. Remove the wheel arch liner to gain access to the charcoal canister.
4. Displace the purge hose from the charcoal canister and remove and discard the vapor hose from the charcoal canister to the fuel tank vapor pipe.
5. Remove the nut and bolt from the canister securing clamp, open the clamp and remove the canister.
Fig 1:
6. Refer to Fig. 1 and construct the twin purge valve and pipe assembly in the following manner:
Install clamps CAC 8774 (H,Fig.1) to the purge pipe CBC 8289 (C,Fig.1), fit reducing hoses CAC 7843 (B,Fig.1) to pipe and secure with clamps.
Install clamps CAC 8776 (G,Fig.1) onto hoses, fit purge valves CAC 6874 (A,Fig.1) and secure with clamps.
Install clamps CAC 8776 (F,Fig.1) to straight connecting hoses CAC 5869 (E,Fig.1), install hoses to purge valves and secure with clamps.
Install "Y" connector CBC 8290 (D,Fig.1) to assembly and secure with clamps, note correct orientation.
Fig 2:
7. Install the reducing hose to the charcoal canister stub pipe "P" and secure with clamp CAC 8776 (Fig.2).
8. Slide clamps CAC 8773 (D, Fig.2) onto elbow CAC 4040/2 (B,Fig.2). Install one end to the canister stub pipe marked "T". Reposition clamp to secure.
9. Connect the end of the Rochester valve CBC 7714 (C,Fig.2) marked "CAN" to the elbow, reposition clamp to secure.
10. Install the restrictor CBC 9506 into the large diameter end of vapor hose CAC 1853/7 (F,Fig.2). Note, shoulder end of restrictor to face outwards.
11. Install clamp CAC 8773 onto vapor hose and push restrictor end of hose onto the end of Rochester valve marked "TANK". Reposition clamp to secure.
Note, assembly is shown inverted in Fig. 2 for clarity.
Fig 3:
12. Install the canister assembly to the vehicle, orientate the canister and position the components as detailed in Fig.3, secure using tie wrap AGU 2532.
Fig 4:
13. Slide clamp CAC 8772 onto vapor hose CAC 1853/7 (A,Fig.4) and install hose to the existing vapor pipe. Reposition clamp to secure.
14. Lubricate grommet and push existing purge hose through inner wing into the engine compartment, ensure grommet remains in position.
15. Place new purge hose CAC 5867/37 to front. Measure and cut a 300 mm length from one end of the hose. Place this length aside and retain for use later.
16. Slide clamp CAC 8774 onto long length of purge hose. Connect hose to end of "Y" piece CBC 8290 (C, Fig 4) and position clamp to secure. Route hose as detailed (B, Fig 4), through grommet and into engine compartment.
17. Connect vacuum hoses (D, E & F, Fig 4) and route through lower aperture and into the engine compartment. 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)
Fig 5:
18. Install the wheel arch liner and road wheel and lower the vehicle.
19. Disconnect the air temperature sensor multi-plug from "B" bank air cleaner assembly.
20. Unclip the air cleaner element cover and displace the cover from the element. Remove the element.
21. Disconnect the intake manifold purge pipe vacuum hoses (A,Fig.5) from the throttle housings.
22. Release the retaining clips (B,Fig.5) securing the vacuum purge pipe to Part Load Breather Pipe (PLBP).
23. Remove the bolt (A,Fig.6) securing the purge pipe to "B" bank manifold. Release the retaining clip securing the existing purge hose to the end of the purge pipe. Withdraw the vacuum hose from the thermal vacuum switch situated in "B" bank water rail and remove the purge pipe and hose assembly (C, Fig 6).
24. Remove the vacuum hose from the thermal vacuum switch. Cut and remove ratchet straps, displace and remove from vehicle; purge hose, purge valve, delay valves and vacuum hoses. Remove purge valve and retain for use later. Discard hoses and delay valves.
25. Install the manifold housing front securing bolt (A, Fig 6).
26. Cut and remove the tie wraps securing the coolant/air temperature sensor harness to the PLBP (B, Fig 6).
27. Loosen the clips securing the PLBP hoses to the intake manifold stub pipes (D, Fig 5) and displace hoses from the manifold.
Fig 6:
28. Loosen the clip (D, Fig 6) securing the PLBP hose to the PCV valve, which is situated in the back plate of "B" bank air cleaner box. Remove the pipe and hose assembly; remove and discard the PCV valve hose from the pipe.
29. Remove the lower bolt securing the overrun valve housing to "B" bank manifold. Note, overrun valve may not be fitted to all vehicles.
30. Replace bolt with stub pipe EAC 2899 (N,Fig.7). On vehicles not equipped with an overrun valve, spacer EBC 2439 and washer C30075/2 must be installed in conjunction with stub pipe.
31. Install "T" piece EAC 8839 (L, Fig 7) to vacuum elbow EAC 7965 (M, Fig 7). Install short vacuum hose EAC 8022/26 (K, Fig 7) to tbe central stub of "T" piece. Connect open end of short vacuum hose to one stub of thermal vacuum switch (H, Fig 7) situated in "B" bank water rail.
32. Connect vacuum elbow to previously installed stub pipe in "B" bank manifold (N, Fig 7).
33. Route vacuum hose from Rochester valve (J, Fig 7) and connect to remaining stub of "T" piece.
34. Measure and cut 50 mm from the PCV valve end of the PLBP. Deburr and ensure the pipe is free of dust and debris.
35. Install hoses CAC 5868/37 (P,Fig.7) to each end of "T" piece EBC 4270 (R,Fig.7) and secure with clamps CAC 8774.
36. Install "T" piece assembly to the cut end of the PLBP and secure with clamp.
37. Install and align PLBP assembly to the engine. Connect existing manifold hoses to the intake manifold stub pipes.
38. Connect remaining hose from "T" piece to PCV valve, secure using original clip.
39. Place the previously cut 300 mm length of purge hose to front. Fit small diameter end of the plastic reducer EBC 8837 (F, Fig 7) to hose and secure with clamp CAC 8774.
40. Install stub hose CAC 5869/4 (E, Fig 7) to large diameter end of reducer and secure with clamp CAC 8776.
41. Slide clamp CAC 8776 to remaining end of stub hose. Fit stub hose to 901 stub outlet of previously removed purge valve (D, Fig 7) (Note valve orientation on Fig 7). Reposition clamp to secure.
42. Install remaining stub hose CAC 5869/4 (C, Fig 7) to purge valve stub and secure with clamp CAC 8776.
43. Install second plastic reducer EBC 8837 (B, Fig 7) to stub hose and secure with clamp CAC 8776.
Fig 7:
44. Position assembly to vehicle. Route 300 mm purge hose to "T" piece at PCV valve end of the PLBP (R, Fig 7). Connect hose to "T" piece and secure with clamp CAC 8774.
45. Slide clamp CAC 8774 onto purge hose (A, Fig 7) routed from charcoal canister through inner wing grommet. Connect purge hose to open end of plastic reducer and reposition clamp to secure.
46. Connect vacuum hose EAC 8022/18 (G, Fig 7) between vacuum stub on purge valve and remaining stub on thermal vacuum switch in "B" bank water rail.
47. Install rubber blanking cap C34946 to "A" bank throttle housing stub pipe.
48. Remove the set screws securing the fuel cooler to "B" bank air box and reposition the cooler from air box.
49. Remove the front anchor nut (where fitted) and the air box to throttle housing securing bolts. Displace the air box from the throttle housing and auxiliary air valve hose. Remove and discard gasket.
50. Disconnect the throttle return spring from the throttle housing.
51. Remove the screws securing the throttle housing to the intake manifold and remove throttle housing. Remove and discard the gasket.
52. Using feeler gauge set the throttle butterfly in new throttle housing EBC 8599 to 0.05 mm (.002 inch), refer to operation 19.20.11 in the XJS Service Manual for further details.
53. Position new gasket. Align throttle housing, engage throttle linkage and secure housing with screws.
54. Position new gasket. Reposition auxiliary air hose to air box and secure air box to throttle housing and front anchor (where fitted).
55. Install the return spring to the throttle housing.
56. Connect vacuum hoses as follows:
EAC 8022/38 (T,Fig.7) from rear stub pipe on "B" bank throttle housing to purge valve.
EAC 8022/10 (U,Fig.7) from front stub on "B" bank throttle housing to black face of delay valve EAC 2206.
EAC 8022/19 (S, Fig.7) from white face of delay valve to the second purge valve.
57. Ensure all vacuum hoses from charcoal canister area are routed along the fuel return hose to the fuel cooler and through the fuel cooler mounting brackets to the throttle housing.
58. Install the fuel cooler to the air box and secure with set screws.
59. Install the air cleaner element to the air box. Install and align the air box cover and secure with retaining clips.
60. Reconnect the air temperature sensor multi-plug and secure the harness to the balance pipe with tie wraps.
61. Secure the vacuum hoses as necessary using tie wraps. Ensure all hoses route clear of hot surfaces and moving components. Check for security of fittings and evidence of fouls.