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 front 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.





6. Refer to Fig. 1 and construct the twin purge valve and pipe assembly as follows:

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. Install 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.





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.





12. Refit the canister assembly to the vehicle, orientate the canister and position the components as detailed in Fig. 3, secure using tie wrap AGU 2532.





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. Slide clamp CAC 8774 onto new purge hose CAC 5867/37 (B, Fig. 4). Connect hose to end of "Y" piece CBC 8290 (C, Fig. 4) and position clamp to secure. Route hose as detailed, through grommet and into engine compartment.

16. 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)

17. Refit the wheel arch liner and road wheel and lower the vehicle.

18. Disconnect the air temperature sensor multi-plug from "B" bank air cleaner assembly.

19. Unclip the air cleaner element cover and displace the cover from the element. Remove the element.





20. Disconnect the intake manifold purge pipe vacuum hoses (A, Fig. 5) from the throttle housings.

21. Release the retaining clips (B, Fig. 5) securing the vacuum purge pipe to Part Load Breather Pipe (PLBP).

22. 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 and remove the purge pipe (C, Fig. 6).

23. Locate the in-line solenoid purge valve (where fitted) situated within the existing purge hose between charcoal canister and engine.

24. Disconnected electrical connections and remove the valve and purge hose from the vehicle and discard.





25. Refit 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.

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. An overrun valve may not be installed on all vehicles.





30. Replace bolt with stub pipe EAC 2899 (E, Fig. 7). On vehicles not equipped with an overrun valve, spacer EBC 2479 and washer C30075/2 must be installed in conjunction with stub pipe.

31. Install connector C33835 (G, Fig. 7) to vacuum elbow EAC 7965 (F, Fig. 7) and install elbow to stub pipe. Route vacuum hose (D, Fig. 7) from Rochester valve and install on to the elbow.

32. Measure and cut 50 mm from the PCV valve end of the PLBP. Deburr and ensure the pipe is free of dust and debris.

33. Install hoses CAC 5868/37 (H, Fig. 7) to each end of "T" piece EEC 4270 (J, Fig. 7) and secure with clamps CAC 8774.

34. Install "T" piece assembly to the cut end of the PLEP and secure with clamp.

35. Install and align PLBP assembly to the engine. Connect existing manifold hoses to the intake manifold stub pipes.

36. Connect remaining hose from "T" piece to PCV valve, secure using original clip.

37. Route new purge hose CAC 5867/37 to "T" piece. Install clamp CAC 8774 to hose and install hose to "T" piece. Reposition clamp to secure.

38. Install rubber blanking cap C34946 to "A" bank throttle housing stub pipe.

39. Remove the set screws securing the fuel cooler to "B" bank air box and reposition the cooler from air box.

40. Remove 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.

41. Disconnect the throttle return spring from the throttle housing.

42. Remove the screws securing the throttle housing to the intake manifold and remove throttle housing. Remove and discard the gasket.

43. 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 XJ-S Service Manual for further details.

44. Position new gasket. Align throttle housing, engage throttle linkage and secure housing with screws.

45. Position new gasket. Reposition auxiliary air hose to air box and secure air box to throttle housing. Install the return spring to the throttle housing.

46. Connect vacuum hoses as follows:

EAC 8022/38 (A, Fig. 7) from rear stub pipe on "B" bank throttle housing to purge valve.

EAC 8022/10 (B, Fig. 7) from front stub on "B" bank throttle housing to black face of delay valve EAC 2206.

EAC 8922/19 (C, Fig. 7) from white face of delay valve to the second purge valve.

47. 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.

48. Install the fuel cooler to the air box and secure with set screws.

49. Install the air cleaner element to the air box. Install and align the air box cover and secure with retaining clips.

50. Connect the air temperature sensor multi-plug and secure the harness to the balance pipe with tie wraps.

51. Secure the vacuum hoses as necessary using tie wraps. Ensure all hose routes clear of hot surfaces and moving components.