Jaguar XJ (X350). Manual — part 703

Installation

WARNING: Wait at least 30 seconds after the engine stops before commencing any repair to

the high-pressure fuel injection system. Failure to follow this instruction may result in personal

injury.

WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working

on or near any fuel related components. Highly flammable mixtures are always present and may

ignite. Failure to follow these instructions may result in personal injury.

WARNING: This procedure involves fuel handling. Be prepared for fuel spillage at all times

and always observe fuel handling precautions. Failure to follow these instructions may result in

personal injury.

WARNING: Do not carry out any repairs to the fuel system with the engine running. The fuel

pressure within the high-pressure fuel system can be as high as 1650 bar. Failure to follow this

instruction may result in personal injury.

CAUTION: Do not disconnect the fuel injector electrical connectors with the engine running.

Failure to follow this instruction may result in serious damage to the vehicle.

CAUTION: Make sure the workshop area in which the vehicle is being worked on is as clean

and as dust free as possible. Foreign matter from work on clutches, brakes or from machining or

welding operations can contaminate the fuel system and may result in later malfunction.

CAUTION: Always carry out the cleaning process before carrying out any repairs to the fuel

injection system components. Failure to follow this instruction may result in foreign matter ingress

to the fuel injection system.

CAUTION: Diesel fuel injection equipment is manufactured to very precise tolerances and

fine clearances. It is therefore essential that absolute cleanliness is observed when working with

these components. Always install blanking plugs to any exposed ports.

CAUTION: Do not disassemble the fuel injectors or clean the nozzles, even with an

ultrasonic cleaner. Always install new fuel injectors when required.

1

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CAUTION: Do not use tools to install the new fuel return line retaining clip. Failure

to follow this instruction may result in damage to the retaining clip.

NOTE:

Install a new fuel return line retaining clip.

NOTE:

Install a new fuel injector sealing washer.

NOTE:

Install a new fuel injector retaining clamp.

Install a new fuel injector retaining clamp.

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2 . NOTE:

Left-hand shown, right-hand similar.

Install the fuel injector.

Tighten to 10 Nm.

3

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CAUTION: Make sure the fuel return line retaining clip is correctly installed to the

fuel injector before installing the fuel return line.

NOTE:

Left-hand shown, right-hand similar.

Connect the fuel return line to the fuel injector.

Visually inspect the fuel return line O-ring for damage.

Apply a light coating of petroleum jelly to the fuel line return line O-ring.

Connect the fuel return line to the fuel injector.

4

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CAUTION: Do not allow the unions to hit the olive ends of the high-pressure fuel

supply line as this may damage the ends of the line and allow foreign matter enter the fuel

injection system.

Position the high-pressure fuel supply line as near to the final installation position as possible

and then remove and discard the blanking plugs from the high-pressure fuel supply line.

5

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CAUTION: Maintain pressure on the high-pressure fuel supply line to keep the olives

in contact with the fuel injectors and the fuel injection supply manifold cones while

installing the unions.

NOTE:

Install the high-pressure fuel supply lines to the fuel rail end first followed by the fuel

injector end.

NOTE:

Left-hand shown, right-hand similar.

Install the new high-pressure fuel supply line.

Tighten the high-pressure fuel supply line in the sequence shown:

Tighten the high-pressure fuel supply line union 1 to fuel injector to 15 Nm.

Tighten the high-pressure fuel supply line union 2 to fuel rail to 15 Nm.

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