Engine Controls - Remove/install/overhaul: Other Jaguar XJS Series 3

Distributor

1. Disconnect ignition coil high tension lead at distributor. Remove distributor cap. Raise front of vehicle and support on jackstands. Rotate crankshaft until No. 1 piston is at TDC of compression stroke. Remove hold-down bolt and distributor.
2. Place Distributor Rotor Setter (JD189) over distributor rotor, ensuring setter is fully seated in the cap locating lug. (Scheme 1) Install distributor. Tighten hold-down bolt. Install distributor cap and high tension (spark plug) leads.

Scheme 1

Crankshaft Position Sensor & Timing Ring

1. Locate crankshaft position sensor on front timing cover. Remove clips securing crankshaft position sensor lead. Disconnect crankshaft position sensor lead. Remove sensor and housing as an assembly. Using an Allen wrench, remove sensor from housing. Remove A/C compressor drive belt. Attach Pulley Lock (18G1437/1) to crankshaft pulley. Rotate engine by hand until pulley lock is against crossmember.
2. Remove crankshaft pulley bolt. Attach Crankshaft Pulley Remover (18G1436) to pulley. Tighten remover center bolt to withdraw pulley. Remove timing ring from crankshaft pulley. To install timing ring and crankshaft position sensor, reverse removal procedure.

Ignition Coil & Amplifier

1. Disconnect negative battery cable. Disconnect high tension lead from coil. Disconnect primary coil wires and condenser. Remove coil clamp bracket screws and ignition coil.
2. Disconnect ignition amplifier. Remove screw and detach ground lead. Remove coil mounting bracket and ignition amplifier. To install amplifier and ignition coil, reverse removal procedure.

FUEL SYSTEM COMPONENTS

Fuel System Pressure Release

On XJS, locate fuel pump relay in right front corner of trunk. Fuse, located near right rear fuse panel, is front relay in a group of 3. On XJ6, remove heated oxygen sensor/fuel pump relay from relay block. On all models, start engine and let idle until it stalls. Turn ignition off. Install heated oxygen sensor/fuel pump relay.

Fuel Pump

1. Remove fuel tank. See «FUEL TANK R & I»(ref-17110-S35547346422000122900000). Disconnect evaporative breather hose. (Scheme 2) Using Lock Ring Wrench (JD174), remove locking ring from evaporative flange.
2. Disconnect fuel pump wiring harness connector. Using Fuel Tank Hose Clip Driver (JD175), disconnect fuel hoses from fuel pump. Remove fuel pump and pump mounting rubber from support bracket.
3. Remove tie wrap from pump mounting rubber. Lift and remove fuel pump by twisting. To install, reverse removal procedure. Ensure pump is fully seated in mounting bracket inside fuel tank.

Scheme 2

Fuel Tank

1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-17110-S25814941372000122900000) . Disconnect battery cables. Remove cover and battery. Using an approved container, drain fuel from fuel tank. Raise and support vehicle.
2. Disconnect fuel lines from fuel tank. Lower vehicle. Remove trunk carpet and trim panels. Remove spare tire mounting bracket. Remove filler housing. Note location of wiring harnesses and connectors for installation reference. Cut and remove straps securing harnesses.
3. Detach clip securing ride level wiring harness to battery tray. Remove battery tray bolts and lay tray on its side to allow fuel tank removal. Disconnect all hoses and wiring harnesses necessary for fuel tank removal. Remove tank. To install, reverse removal procedure.

FUEL PRESSURE REGULATOR

Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE . Disconnect vacuum hose from fuel pressure regulator. Place a shop rag under regulator to trap fuel. Disconnect fuel supply and return hoses. Loosen fuel pressure regulator to fuel rail nut. Remove fuel pressure regulator from mounting bracket. To install, reverse removal procedure.

INERTIA FUEL PUMP SWITCH

Disconnect negative battery cable. Remove driver-side fuse block cover. Disconnect inertia fuel pump switch assembly. Remove inertia fuel pump switch assembly. Place assembly on work bench. Remove inertia switch from bracket. To install, reverse removal procedure.

HEATED OXYGEN SENSOR (HO2S)

1. HO2S is mounted in exhaust pipe, below exhaust header. All oxygen sensors are equipped with permanent pigtail, which must be protected from damage when installing sensor.
2. Ensure sensor is free of contaminants. Sensor may be difficult to remove when engine temperature is less than 120°F (48°C). Always use anti-seize compound on threads before installation. Tighten sensor to 30 ft. lbs. (41 N.m).

IDLE AIR CONTROL VALVE

1. Disconnect negative battery cable. Locate idle air control valve on intake manifold (between injectors). Disconnect idle air control valve. Release air intake elbow hose clip. Disconnect hose from idle air control valve.
2. Remove 4 screws and idle air control valve. Remove and discard idle air control valve gasket. To install, reverse removal procedure. Adjust base idle. See the «ADJUSTMENTS»(ref-17102) article.

MASS AIRFLOW SENSOR

Disconnect negative battery cable. Remove nuts securing air cleaner to inner fender. Release clips securing air cleaner to mass airflow sensor. Release air intake elbow hose clip. Detach ground lead from mass airflow sensor, and disconnect sensor. Remove airflow meter. To install, reverse removal procedure.

THROTTLE POSITION SENSOR

Note. Throttle position sensor must be adjusted and set using Jaguar Diagnostic System (JDS).

1. Disconnect negative battery cable. Release breather and air valve hose clips at intake elbow. Detach hoses from elbow.
2. Release clip at throttle housing and detach elbow hose. Release mass airflow meter elbow hose clip and detach hose. Remove air intake elbow. Disconnect throttle position sensor. Remove screws and throttle position sensor. To install, reverse removal procedure.

Air Injection Pump & Clutch

1. Disconnect negative battery cable. Disconnect air injection pump wiring harness connector. Loosen clips securing air inlet and outlet hoses. Disconnect air inlet and outlet hoses from pump.
2. Loosen link arm adjuster nuts. Loosen, but DO NOT remove, link arm through bolt. Loosen air injection pump pivot bolt. Pivot pump toward engine and remove drive belt.
3. Remove link arm through bolt, and reposition link arm. Remove air injection pump pivot bolt. Remove front spacer, rear cone and air injection pump. Remove nut securing air injection pump pulley.
4. Remove clutch plate and pulley bearing assembly. Remove clutch snap ring and clutch. To install clutch and air injection pump, reverse removal procedure. Ensure clutch mating surface is free of dirt.

Egr Transfer Pipe

1. Disconnect negative battery cable. Loosen transfer pipe union nuts at EGR valve and intake manifold. Raise front of vehicle, and support it using jackstands.
2. Jack up rear of engine to access transfer pipe from below. Disconnect oxygen sensor connector from above. Remove wiring harness/oil dipstick tube bracket bolt. Position bracket and oil dipstick tube "P" clip aside.
3. Disconnect wiring harness from starter solenoid and motor. Disconnect fuel injection wiring harness, and set it aside. Carefully remove EGR transfer pipe. To install, reverse removal procedure.