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.
3. Remove the wheel arch liner to gain access to the charcoal canister.
4. Displace the purge hose from the charcoal canister and remove the vapor hose with the 2 psi valve, if fitted, from the charcoal canister and fuel tank vapor pipe.
5. Remove the nut and bolt from the canister securing clamp, open the clamp and remove the canister.
Fig 2:
6. Refer to Fig 2 and construct the twin purge valve and pipe assembly in the following manner:
Install clamps CAC 8774 (H, Fig 2) to the purge pipe CBC 8289 (C, Fig 2), install reducing hoses CAC 7843 (B, Fig 2) to pipe and secure with clamps.
Install clamps CAC 8776 (G, Fig 2) onto hoses, install purge valves CAC 6874 (A, Fig 2) and secure with clamps.
Install clamps CAC 8776 (F, Fig 2) to straight connecting hoses CAC 5869/4 (E, Fig 2), install hoses to purge valves and secure with clamps.
Install "Y" connector CBC 8290 (D, Fig 2) to assembly and secure with clamps, note correct orientation.
Fig 3:
7. Install the reducing hose to the charcoal canister stub pipe "P" and secure with clamp CAC 8776 (Fig 3).
8. Slide clamps CAC 8773 (D, Fig 3) onto elbow CAC 4040/2 (B, Fig 3). 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 3) 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 3). 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 3 for clarity.
Fig 3:
Fig 4:
12. Install the canister assembly to the vehicle, orientate the canister and position the components as detailed in Fig 4, secure using tie wrap AGU 2532 (J, Fig 3).
Fig 5:
13. Slide clamp CAC 8772 onto vapor hose CAC 1853/7 (A, Fig 5) 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 5) and position clamp to secure. Route hose as detailed (B, Fig 5), through grommet and into engine compartment.
17. Connect vacuum hoses (D, E & F, Fig 5) 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 6:
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 6) from the throttle housings.
Fig 7:
22. Disconnect vacuum signal hose (A, Fig 7) from manifold purge pipe vacuum, hose and remove hose, delay valve (B, Fig 7), vacuum reservoir (C, Fig 3) and elbow from purge control valve (D, Fig 7). Discard assembly.
23. Release the retaining clips (B, Fig 6) securing the vacuum urge pipe to Part Load Breather Pipe (PLBP).
Fig 8:
24. Remove the bolt (A, Fig 8) securing the purge pipe to "B" bank manifold. Release the clip securing the existing purge hose to the end of the purge pipe and remove and discard the purge assembly.
25. Remove the purge hose complete with purge control valve (E, Fig 7). Release and withdraw the purge valve from the connecting hoses and retain the valve for use later.
26. Install the manifold housing front securing bolt (A, Fig 8).
Cut and remove the tie wraps securing the coolant/air temperature sensor harness to the PLBP (B, Fig 8).
Fig 6:
28. Loosen the clips securing the PLBP hoses to the intake manifold stub pipes (D, Fig 6) and displace hoses from the manifold.
29. Loosen the clip (D, Fig 8) 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.
30. Remove the lower bolt securing the overrun valve housing to "E" bank manifold.
31. Replace bolt with stub pipe EAC 2899 (N, Fig 9). On vehicles not equipped with an overrun valve, space EBC 2479 and washer C30075/2 must be installed in conjunction with stub pipe.
32. Install "T" piece EAC 8839 (L, Fig 9) to vacuum elbow EAC 3965 (M, Fig 9).
33. Connect vacuum, elbow to previously installed stub pipe in "B" bank manifold (N, Fig 9).
34. Route vacuum hose from Rochester valve (J, Fig 9) and connect to opposite end of "T" piece.
35. Measure and cut 50 mm from the PCV valve end of the PLBP. Deburr and ensure the pipe valve is free of dust and debris.
36. Install hoses CAC 5868/37 (P, Fig 9) to each end of "T" piece EEC 4270 (R, Fig 9) and secure with clamps CAC 8734.
37. Install "T" piece assembly to the modified end of the PLBP and secure with clamp.
38. Install align PLBP assembly to the engine. Connect existing manifold hoses to the intake manifold stub pipes.
39. Connect remaining hose from "T" piece to PCV valve, secure, using original clip.
40. Place the previously cut 300 mm length of purge hose to front. Install small diameter end of the plastic reducer EBC 8833 (F, Fig 9) to hose and secure with clamp CAC 8774.
41. Install stub hose CAC 5869/4 (E, Fig 9) to large diameter end of reducer and secure with clamp CAC 8776.
42. Slide clamp CAC 8776 to remaining end of stub hose. Install stub hose to 90~ stub outlet of previously removed purge valve (D, Fig 9) (Note valve orientation on Fig 9), reposition clamp to secure.
43. Install remaining stub hose CAC 5869/4 (C, Fig 9) to purge valve stub and secure with clamp CAC 8336.
44. Install second plastic reducer EBC 8837 (B, Fig 9) to stub hose and secure with clamp CAC 8776.
Fig 9:
45. Position assembly to vehicle. Route 300 mm purge hose to "T" piece at PCV valve end of the PLBP (R, Fig 9). Connect hose to piece and secure with clamp CAC 8774.
46. Slide clamp CAC 8774 onto purge hose (A, Fig 9) routed from charcoal canister through inner wing grommet. Connect purge hose to open end of plastic reducer and reposition clamp to secure.
47. The following operation must only be performed on a cold or cool engine: Carefully remove the pressure cap from the remote header tank to release any cooling system residual pressure. Replace cap tightly.
48. Locate the coolant temperature transmitter situated in "A" bank water rail. Disconnect transmitter harness connector.
49. Placing suitable rag around the transmitter, undo and remove the transmitter from the water rail.
50. Remove and disgard copper washer and clean sealing faces of water rail and transmitter.
51. Install copper washer C 2296/20 to the transmitter (D, Fig 10), apply Hylomar to the threads and install transmitter to the top of adapter EBC 9091 (A, Fig 10), tighten to secure.
52. Install copper washer C 2296/20 to base of adapter, apply Hylomar to the threads and screw adapter into water rail, tighten through transmitter. Torque to 8 - 10 ft.lbs. (11-14 N-m)
53. Install copper washer C 2296/1 and apply Hylomar to the threads of the thermal vacuum valve EAC 2360 (B, Fig 10).
Fig 10:
54. Install the valve to the most accessible and forward facing hole in the adapter, tighten to secure.
55. Install copper washer C 2296/1 to blanking plug EAC 5063 (C, Fig 10), apply Hylomar to the threads and install plug to the remaining hole in adapter, tighten to secure.
56. Reconnect coolant transmitter connector.
57. Connect vacuum hose EAC 8022/34 to one stub outlet of thermal vacuum valve (H, Fig 9).
58. Connect vacuum hose EAC 8022/45 to second stub outlet of thermal vacuum valve.
Fig 11:
59. Route both vacuum hoses across the top of the engine, passing over the cam covers and compressor unit to the left-hand sides as detailed in Fig 11. Ensure hoses are clear of moving components, hot surfaces and cannot be caught or trapped.
60. Connect shorter vacuum hose EAC 8022/45 (K, Fig 9) to the central stub of "T" piece EBC 8839 (L, Fig 9) installed at "B" bank manifold.
61. Connect second vacuum hose EAC 8022/34 (G, Fig 9) to vacuum stub of purge control valve (D, Fig 9).
62. Secure the vacuum hoses routed across the engine at four appropriate positions using tie wraps C 44468.
63. Install rubber blanking cap C34946 to "A" bank throttle housing stub pipe.
64. Remove the set screws securing the fuel cooler to "B" bank air box and reposition the cooler from air box.
65. Remove the air box to throttle housing securing bolts. Displace the air box from the throttle housing, PCV valve and auxiliary air valve hose. Remove and discard gasket.
66. Disconnect the throttle return spring from the throttle housing.
61. Remove the screws securing the throttle housing to the intake manifold and throttle housing. Remove and discard the gasket.
68. 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.
69. Position new gasket. Align throttle housing, engage throttle linkage and secure housing with screws.
70. Position new gasket. Reposition auxiliary air hose to air. box and secure air box to throttle housing.
71. Install the return spring to the throttle housing.
72. Connect vacuum hoses roated from beneath the wheel arch as follows:
EAC 8022/38 (T, Fig 9) from rear stub pipe on "B" bank throttle housing to purge valve.
EAC 8022/10 (U, Fig 9) from front stub on "B" bank throttle housing to black face of delay valve EAC 2206.
EAC 8022/19 (S, Fig 9) from white face of delay valve to the second purge valve.
73. 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.
74. Install the fuel cooler to the air box and secure with set screws.
75. Install the air cleaner element to the air box. Install and align the air box cover and secure with retaining clips.
76. Reconnect the air temperature sensor multi-plug and secure the harness to the balance pipe with tie wraps.
77. 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.