1998 JAGUAR X308 manifold

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.

In
stallation


6.
Re
move the exhaust manifold to EGR valve tube.
Remove and discard the ex

haust manifold to EGR valve
tube gasket.

1. NOTE:
Install a new exhaust manifold to EGR valve tube
gasket.
Loosely install the exhaust manifold to EGR valve tube.

2. NOTE:
Install a new exhaust manifold to EGR valve tube
gasket.
Install the exhaust manifold to EGR valve tube retaining bolts.
Tigh te
n to 21 Nm.
3. Tighten the exhaust manifold to EGR valve tube retaining bolts.
Tighte
n to 21 Nm.

Intake Air Distribution and Filtering -
Torque Specificat
ions


Comp

onent
Nm
Thr
o
ttle intake elbow to intake manifold
18
-
24
Thro
tt
le body to throttle intake elbow
18
-
24
Left-hand support
bracket to
th
rottle intake elbow
16
-
20
Right-hand support
bracket to
throttle intake elbow
16
-
20
B
l
anking plate to throttle intake elbow
18
-
24
Inta
k
e manifold to engine
20
-
22
Supe
rcharger
drive belt idler pulley bolt
34
-
46
Supercharger
drive belt te
nsioner to alternator mounting bracket bolt
39
-
51
Supercharger
to eng
ine bolts
18
-
24
Charge air cooler in
let assembly to charge ai
r cooler bolts
18
-
24
Supercharger
outlet duct to supercharger bolts9-1
1
Charge air cooler in
let assembly to superchar
ger ou
tlet duct bolts
18-
24
Charge air cool
er to charge
air cooler adaptor
11
-
13
B
y
-pass valve to throttle intake elbow
8-
1
2