manifold JAGUAR X308 1998 2.G Repair Manual

Pa
rts List
The pressure regulator is a diap hragm-operated valve that regula tes fuel-rail pressure at 3,0 bar above the intake manifold
pressure. A pipe connects the throttle induction elbow to the pressure regulator to provide the vacuum control signal. On
supercharged engines, the pressure regulator vacuum feed is taken from the top of the supercharger outlet duct.
The regulator is fitted between the rear end of the right-hand fuel rail (bank 1) and the fuel return line to the tank.
Circuit Diagram, Fuel Injection Syst em - Normally Aspirated Vehicles

Ite
m
Par
t
Number
De
scr
iption
1—F
u
el Return
2—F
u
el Pressure Regulator
3—Inta
k
e Manifold Pressure

Fuel Char
ging and Controls - Fu
el Injection Supply Manifold LH
Remo
val and Installation
Remov
a
l
Installation
1. Re
move fuel injectors; refer to (SC) 18.10.01.

2. Disc
onnect fuel feed
pipe from fuel rail.
1. Remove two bolts.
2. Reposition fuel feed pipe.
3. Discard O-ring.

3. Re
move fuel rail from charge air cooler adaptor.
1. Remove three bolts.
2. Reposition fuel rail and remove cross-over pipe securing bolt.
Di
scard O-ring from fuel cross-over pipe.
R
e
move fuel rail.

4. Re
move seals between fuel rail
and charge air cooler adaptor.
1. Discard seals.
2. Clean and inspect mating faces.
1. Install new seals between fuel rail and charge air cooler
adapter ensuring that they are fully seated.
2. Install fuel rail to fuel cross-over pipe.
Inst al
l new O-ring and lubricate with petroleum jelly.
1. Install bolt.

Fuel Char
ging and Controls - Fu
el Injection Supply Manifold RH
Remo
val and Installation
Remov
a
l
1.
Re
move fuel injectors; refer to (SC) 18.10.01.

2. Disc
onnect fuel pressure regulator.
1. Remove bolts.
2. Reposition pres sure regulator.
Disc
ard O-ring.

3. Re
move fuel rail from charge air cooler adaptor.
1. Remove three bolts.
2. Remove fuel rail; still co nnected to fuel crossover pipe
and fuel return pipe.

4. Re
move fuel rail from fuel cross-over pipe.
1. Remove bolt.
2. Discard O-ring.

5. Re
move fuel rail to charge air cooler adaptor seals.
1. Discard seals.
2. Clean and inspect mating faces.

Fuel Char
ging and Controls - Fuel
Injection Supply Manifold Pipe
Remo
val and Installation
Remov
a
l
WARNING: B
E
FORE PROCEEDING, IT IS ESSENTIAL THAT
THE WARNING NOTES GIVEN IN SECTION 100-00 (UNDER
THE HEADING 'SAFETY PRECAUTION S') ARE READ AND UNDERSTOOD.
In
stallation


1.
De
pressurize fuel syst
em; refer to 19.50.02.
2. Disconnect battery ground cable (IMPORTANT, see SRO
86.15.19 for further information).

3. Re
move inlet manifold
fuel cross-over pipe.
Plac
e cloth under pipe elbows
to collect any spillage.
Remove e
lbow securing screws.
Di
sc
onnect first elbow.
Disc

onnect remaining elbow and remove assembly.
Discard O
-
ring seals
from pipe elbows.
Clean relevant parts and mating faces.

1. NOTE : Install
and lubricate new O-ring seals.
Installation is th e reverse of the removal procedure.

Fuel Ch
arging and Controls
- Fuel Injector4.0L NA V8 - AJ27/3.2L NA V8 -
AJ26
Re
moval and Installation
Remov

al
S
pecial Tool(s)

R

emover - Fuel Injector
303-539 (JD 231)
1. Disconnect battery ground cable (IMPORTANT, see SRO
86.15.19 for further information).
2. WARNING: BEFORE PROCEEDING, IT IS ESSENTIAL THAT
THE WARNING NOTES GIVEN IN SECTION 100-00 (UNDER THE
HEADING 'SAFETY PRECAUTIONS') ARE READ AND
UNDERSTOOD.
Depressurize the fuel sy stem; refer to 19.50.02.

3. R
emove engine covers.

4. Di
sconnect bank 1 or 2 inject
or connectors and reposition
harness to allow access to injectors.
5. Remove bolts which secure fuel injector clamp plate to inlet
manifold.

En
gine Emission Control -
Torque Specific
ations


De

scription
Nmlb
-ft
lb
-in
EGR valve tube to EGR valv

e retaining bolts
2115-
Exhaus

t manifold to EGR valve tube retaining bolts
2115-
Exhaus

t manifold to EGR valve tube retaining nuts
2115-
Evaporati

ve emission canister purge valve retaining bolts
6-53
EGR valve to th

rottle body elbow retaining bolts
129-

Diagnostic Trouble Code (D
TC) Index
Pinpoint Tests
Fue
l lines
Harness damage


Throttl

e sensors
Throttl

e motor
Spark plugs

fouled
Ignition coil

failure(s)
HT sho

rt to ground (tracking) check
rubber boots for cracks/damage
Exhaus
t gas recirculation (EGR)
F
or air intake syst
em information,
REFER to Section 303
-12
Intake Air

Distribu
tion and Filtering
.
F
or fuel pressure
regulator tests,
REF
ER to Section 303
-04
Fuel
Charging and Con

trols
.
F
or fuel line information,
REFER to Section 310
-01
Fuel Tank

and Lines.
F
or throttle sensor
circuit tests,
REFER to Section 303
-14
Electronic
Engine

Controls
.
Fo
r throttle motor
circuit tests,
REFER to Section 303
-04
Fuel
Charging and Con

trols
.
For ign
ition system tests,
REFER to Section 303
-07
Engine
Ignition.
Inspe
ct EGR components, for circuit
tests, GO to Pinpoint Test A.
.
DT
C
De
scription
Possib
le Source
Acti
on
P0400Exhaus

t gas
recirculation (EGR) flow malfunction
EGR
valve connector pins high
resistance
EGR pipe/exhaust manifold leak EGR pipe block
ed
EGR val

ve stuck open/closed,
blocked
EGR
valve failure
Check the EGR pi
pe, valve and manifold for
leaks/blockages. Check the EGR valve function.
For EGR valve circuit tests,GO to Pinpoint Test A.
.
P0405Exhaus
t gas
recirculation (EGR) drive
circuits open circuit
EGR valve power supply circuit o
pen circuit
EGR valve t

o ECM drive circuit
pair - EGR pins 1/3, 4/6 open circuit, high resistance
EGR val
ve failure (stepper motor
open circuit)
F
or EGR valve circuit tests,GO to Pinpoint Test
A.
.
P0406Exhaus
t gas
recirculation (EGR) drive
circuits short circuit
EGR valve t
o ECM drive circuit
pair - EGR pins 1/3, 4/6 short
circuit to ground or high voltage
EGR val
ve failure (stepper motor
short circuit)
F
or EGR valve circuit tests,GO to Pinpoint Test
A.
.
P
INPOINT TEST A : DTC P0400, P0405; EGR VALV
E FLOW MALFUNCTION/DRIVE CIRCUITS OPEN
CIRCUIT
TE
ST
CONDITIONS
D
ETAILS/RESULTS/ACTIONS
A1: CHECK

THE EMS POWER SU
PPLIES TO THE EGR VALVE
D
isconnect the EGR valve electrical connector, PI34.
1
Turn the ignition swi

tch to the ON
position.
2
Make sure the EMS re lay i
s energized.
Vehicles with AJ26 engine:
Me
asure the voltage between PI34, pins 02 and 05 (WP) and GROUND
Vehicles with AJ27 engine:
Me
asure the voltage between PI34, pins 02 and 05 (WU) and GROUND
3
Is th

e voltage at either pin less than 10 volts?
Yes

6. R
emove the EGR valve to throttle
body elbow retaining bolts.
Remove an
d discard the EGR valve to throttle body elbow
gasket.

7. R
emove the exhaust manifold to EGR valve tube retaining
bolts.
Remove an
d discard the exhaust manifold to EGR valve
tube gasket.

8. N
OTE: Note the orientation of the coolant hose to EGR valve
before removal.
Remove the coolant hose.
9. NOTE: Note the orientation of the coolant hose to EGR valve
before removal.
• NOTE: Cap the coolant hose to minimize coolant loss.
Remove the EGR valve.

In
stallation


1.
NO TE
: Make sure the EGR valve to the coolant hose is installed
to the orientation noted during removal.
• NOTE: Un-cap the coolant hose.
Install the EGR valve.

2. NO TE
: Make sure the EGR valve to the coolant hose is installed
to the orientation noted during removal.
Install the coolant hose.

3. NOTE:
Install a new exhaust manifold to EGR valve tube
gasket.
• NOTE: Install a new EGR valve to throttle body elbow gasket.
Loosely install the exhaust manifold to EGR valve tube and the
EGR valve to throttle body elbow.
4. Tighten the exhaust manifold to EGR valve tube retaining
bolts.
Tigh te
n to 21 Nm.

E
ngine Emission Control - Exhaust Ma
nifold to Exhaust Gas Recirculation
(EGR) Valve Tube
Re
moval and Installation
Remov

al
1.
R
emove the engine cover.
For additional informat ion, refer to Section 501
-0
5 Interior
Trim and Ornamen

tation
.

2. Di
sconnect the evaporative emission canister purge valve
electrical connector.

3. De
tach and reposition the evaporative emission canister purge
valve.

4. Di
sconnect the exhaust gas recirc
ulation (EGR) valve electrical
connector.
5. Remove the exhaust manifold to EGR valve tube retaining
bolts.
Remove an
d discard the exhaust manifold to EGR valve
tube gasket.