HIGH PRESSURE FUEL PUMP 1

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1 2010 X250, FUEL CHARGING AND CONTROLS - V8 5.0L PETROL HIGH PRESSURE FUEL PUMP 1 (G ) REMOVAL AND INSTALLATION HIGH PRESSURE FUEL PUMP FRONT RENEW 5000 CC, AJ V8, NATURALLY ASPIRATED HIGH PRESSURE FUEL PUMP FRONT RENEW 5000 CC, AJ V8, SUPERCHARGED HIGH PRESSURE FUEL PUMP REAR RENEW 5000 CC, AJ V8, NATURALLY ASPIRATED HIGH PRESSURE FUEL PUMP REAR RENEW 5000 CC, AJ V8, SUPERCHARGED REMOVAL USED WITHINS USED WITHINS USED WITHINS USED WITHINS

2 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. CAUTION: Make sure that tools and equipment are clean, free of foreign material and lubricant. Some variation in the illustrations may occur, but the essential information is always correct. Refer to: Petrol and Petrol-Ethanol Fuel Systems Health and Safety Precautions ( General Information, Description and Operation). 2. Refer to: Fuel System Pressure Release - V8 5.0L Petrol/V8 S /C 5.0L Petrol ( Fuel System - General Information, General Procedures). 3. Refer to: Secondary Bulkhead Panel LH - TDV6 3.0L Diesel /V8 5.0L Petrol/V8 S/C 5.0L Petrol ( Front End Body Panels, Removal and Installation). 4. Refer to: Secondary Bulkhead Panel RH - TDV6 3.0L Diesel /V8 5.0L Petrol/V8 S/C 5.0L Petrol ( Front End Body Panels, Removal and Installation). 5.

3 Refer to: Engine Cover - V8 5.0L Petrol/V8 S/C 5.0L Petrol ( Interior Trim and Ornamentation, Removal and Installation). 6. Refer to: Fuel Injection Component Cleaning (303-04A Fuel Charging and Controls - V8 5.0L Petrol, General Procedures) Refer to: Air Cleaner Outlet Pipe RH (303-12A Intake Air Distribution and Filtering - V8 5.0L Petrol, Removal and Installation). 10. CAUTIONS:

4 Be prepared to collect escaping fluids. Make sure that all openings are sealed. Use new blanking caps CAUTIONS: Be prepared to collect escaping fuel. Make sure that all openings are sealed. Use new blanking caps.

5 13. WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands. Raise and support the vehicle. 14. Refer to: Engine Mount RH (303-01A Engine - V8 5.0L Petrol, Removal and Installation). 15. Refer to: Generator - V8 5.0L Petrol ( Generator and Regulator - V8 5.0L Petrol/V8 S/C 5.0L Petrol, Removal and Installation). 16. Engine shown removed for clarity.

6 17. Engine shown removed for clarity. 18.

7 Engine shown removed for clarity. 19. CAUTION: Make sure that all openings are sealed. Use new blanking caps.

8 20. CAUTIONS: Remove and discard the high-pressure fuel supply lines. Be prepared to collect escaping fluids. Make sure that all openings are sealed. Use new blanking caps. Engine shown removed for clarity. 2

9 22. CAUTION: Be prepared to collect escaping fluids. Loosen the Torx screws a turn each at a time.

10 23. CAUTION: Be prepared to collect escaping fluids. INSTALLATION Lubricate the fuel rail high-pressure fuel pump bucket with clean engine oil.

11 2. CAUTION: Tighten the Torx screws a turn at a time until the correct torque is achieved. Lubricate the fuel rail high-pressure fuel pump O-ring seal with clean engine oil.

12 Install the high-pressure fuel pump. Torque: 12 Nm 3. Loosen the Torx screws half a turn each. 4.

13 5. CAUTIONS: Install new high-pressure fuel supply lines. Lubricate the high-pressure fuel supply line unions with clean engine oil. NOTES: Engine shown removed for clarity. Remove and discard the blanking caps.

14 Install the high-pressure fuel supply lines, tighten the bolts and unions finger tight at stage. 6. CAUTION: Care must be taken when positioning the fuel rail highpressure fuel pump cover to one side.

15 Tighten the Torx screws. Torque: 12 Nm Lower the vehicle. Engine shown removed for clarity.

16 Torque: Unions (1) 21 Nm M6 (2) 11 Nm M8 (3) 25 Nm M5 nut (4) 6 Nm 9. Remove and discard the blanking caps.

17 Torque: Unions 21 Nm Bolt 12 Nm 10. Install the bolt and unions finger tight before final tightening.

18 Torque: Unions 21 Nm M6 11 Nm 1 Engine shown removed for clarity. Torque: M10 29 Nm M6 11 Nm

19 12. Torque: 25 Nm 13. Refer to: Generator - V8 5.0L Petrol ( Generator and Regulator - V8 5.0L Petrol/V8 S/C 5.0L Petrol, Removal and Installation). 14. Refer to: Engine Mount RH (303-01A Engine - V8 5.0L Petrol, Removal and Installation) NOTES:

20 Do not tighten at this stage. Lubricate the union threads with clean engine oil. Remove and discard the blanking caps. 17. Torque: Unions 21 Nm Bolts 8 Nm 18.

21 Refer to: Air Cleaner Outlet Pipe RH (303-12A Intake Air Distribution and Filtering - V8 5.0L Petrol, Removal and Installation). 2 Refer to: Engine Cover - V8 5.0L Petrol/V8 S/C 5.0L Petrol ( Interior Trim and Ornamentation, Removal and Installation).

22 22. Refer to: Secondary Bulkhead Panel RH - TDV6 3.0L Diesel /V8 5.0L Petrol/V8 S/C 5.0L Petrol ( Front End Body Panels, Removal and Installation). 23. Refer to: Secondary Bulkhead Panel LH - TDV6 3.0L Diesel /V8 5.0L Petrol/V8 S/C 5.0L Petrol ( Front End Body Panels, Removal and Installation). 24. Refer to: Battery Disconnect and Connect ( Battery, Mounting and Cables, General Procedures) X250, BATTERY, MOUNTING AND CABLES BATTERY DISCONNECT AND CONNECT (G ) GENERAL PROCEDURES DISCONNECT If a new battery is installed, the battery monitoring system (BMS) must be reset using Jaguar approved diagnostic equipment.

23 Refer to: Battery and Battery Charging Health and Safety Precautions ( General Information, Description and Operation). 2. Obtain and record the audio unit preset radio frequencies Where fitted. 5. CAUTION: Take extra care not to damage the wiring harness.

24 6. 7. CAUTION: Make sure that the battery negative cable does not move when detaching the negative terminal from the battery.

25 CONNECT CAUTION: Make sure that the battery negative cable to the body retaining bolt is not loose and fully tightened.

26 Torque: 13 Nm 2. Torque: 6 Nm 3.

27 4. Make sure that both the positive and negative battery terminals are correctly located.

28 5. Where fitted. 6. This step is only necessary when installing a new battery. Using Jaguar approved diagnostic equipment, reset the battery monitoring system (BMS). 7. Refer to: Door Window Motor Initialization ( Glass, Frames and Mechanisms, General Procedures). 8. Enter the audio unit preset radio frequencies. 9. Reset the clock to the correct time. 10. Start the engine and allow to idle until the engine reaches normal operating temperature. 1 Switch the engine off.

29 2010 X250, INTERIOR TRIM AND ORNAMENTATION ENGINE COVER - V8 5.0L PETROL/V8 S/C 5.0 L PETROL (G ) REMOVAL AND INSTALLATION ENGINE COVER RENEW 3000 CC, TDV6 0.1 USED WITHINS ENGINE COVER RENEW 5000 CC, AJ V8 0.1 USED WITHINS REMOVAL Removal steps in this procedure may contain installation details. Some variation in the illustrations may occur, but the essential information is always correct.

30 INSTALLATION To install, reverse the removal procedure X250, GENERAL INFORMATION

31 DESCRIPTION AND OPERATION WARNINGS: Fuel may not give adequate warning before toxic or harmful effects arise. Exposure to fuel can be harmful and can cause severe health damage or death. Extreme care must be exercised when handling hot fluids. Always wash off spilled fluids from affected areas of skin immediately. Highly flammable mixtures are always present and may ignite when working on fuel systems. Do not allow naked flames, sparks or lighted substances to come near fuel related components. Fuel must not be used as a cleaning agent. Keep fuel containers tightly closed, out of direct sunlight and in a cool area. Keep away from heat sources, ignition sources and oxidizing agents. SKIN CONTACT: Excessive or prolonged skin contact with diesel fuel may cause serious skin disorders including skin cancer. SKIN CONTACT: Fuel is mildly irritating to the skin and may cause dermatitis due to defatting effect. Remove contaminated clothing. Wash affected areas of skin with soap and water. Seek medical attention for any persistent skin irritation or abnormality. Wash contaminated clothing before reuse. EYE CONTACT: Fuel is mildly irritating to the eyes. Flush with plenty of running water, blinking as often as possible. Do not force the eyelid open. Seek medical attention for any persistent eye irritation or abnormality.

32 SWALLOWED: Fuel is moderately toxic and tends to foam on vomiting. If drawn into the lungs, inflammation may develop. Do not induce vomiting. If spontaneous vomiting occurs place the victim in a forward position to reduce the risk of fuel being drawn into the lungs. Give nothing by mouth. If breathing but unconscious, place in the recovery position. If breathing has stopped, apply artificial respiration. Seek immediate medical attention. INHALED: Fuel is toxic to the respiratory and other body systems. Exposure may result in various symptoms including drowsiness, unconsciousness or severe health damage. Move a victim to fresh air. Keep a victim warm and at rest. If unconscious, place in the recovery position. If not breathing, apply artificial respiration. Give cardiac massage if necessary. Seek immediate medical attention. CAUTIONS: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is essential that absolute cleanliness is observed when working with these components. Make sure that the workshop area in which the vehicle is being worked on is as clean and as dust free as possible X250, GENERATOR AND REGULATOR - V8 5.0L PETROL/V8 S/C 5.0L PETROL GENERATOR - V8 5.0L PETROL (G )

33 GENERATOR - V8 5.0L PETROL (G ) REMOVAL AND INSTALLATION GENERATOR - RENEW 3000 CC, AJ-V6 0.6 USED WITHINS GENERATOR - RENEW 3000 CC, TDV6 1 USED WITHINS GENERATOR - RENEW 5000 CC, AJ V8, NATURALLY ASPIRATED GENERATOR - RENEW 5000 CC, AJ V8, SUPERCHARGED USED WITHINS USED WITHINS REMOVAL Removal steps in this procedure may contain installation details. Refer to: Battery Disconnect and Connect ( Battery, Mounting and Cables, General Procedures). 2. WARNING: Make sure to support the vehicle with axle stands. Raise and support the vehicle. 3. Refer to: Air Deflector ( Front End Body Panels, Removal and Installation).

34 4. 5. Torque: 25 Nm 6. Torque: 12 Nm 7. Tighten the bolts in the indicated sequence.

35 Torque: 48 Nm INSTALLATION To install, reverse the removal procedure X250, FUEL CHARGING AND CONTROLS - V8 5.0L PETROL FUEL INJECTION COMPONENT CLEANING GENERAL PROCEDURES FUEL INJECTION COMPONENT CLEANING USING A VACUUM GUN ***DO NOT ISSUE*** GENERAL EQUIPMENT 5000 CC, AJ V8 0 USED WITHINS (G )

36 GENERAL EQUIPMENT EQUIPMENT NAME Pneumatic vacuum gun CLEANING WARNINGS: Do not carry out any repairs to the fuel system with the engine running. Failure to follow this instruction may result in personal injury. Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury. If fuel contacts the eyes, flush the eyes with cold water or eyewash solution and seek immediate medical attention. Place the vehicle in a well ventilated, quarantined area and arrange ' No Smoking/Petrol Fumes' signs about the vehicle. Wash hands thoroughly after fuel handling, as prolonged contact may cause irritation. Should irritation develop, seek medical attention. Do not carry or operate cellular phones when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury. CAUTIONS:

37 Before using the cleaning fluid, protect all electrical components and connectors with lint-free non-flocking material. Make sure that all parts removed from the vehicle are placed on the lint-free non-flocking material. Make sure that any protective clothing worn is clean and made from lint-free non-flocking material. Make sure that clean non-plated tools are used. Clean tools using a new brush that will not lose its bristles, prior to starting work on the vehicle. Use a steel topped workbench and cover it with clean, lint-free non-flocking material. 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. Using a new brush that will not lose its bristles, brush the components being removed and the surrounding area. 2. Using a pneumatic vacuum gun, remove all traces of foreign material. General Equipment: Pneumatic vacuum gun 2010 X250, ENGINE - V8 5.0L PETROL ENGINE MOUNT RH (G )

38 ENGINE MOUNT RH (G ) REMOVAL AND INSTALLATION ENGINE MOUNTING - RIGHT HAND RENEW 3000 CC, AJ-V6 0.7 USED WITHINS ENGINE MOUNTING - RIGHT HAND RENEW 3000 CC, TDV6 5.1 USED WITHINS ENGINE MOUNTING - RIGHT HAND RENEW 5000 CC, AJ V8 0.8 USED WITHINS REMOVAL Removal steps in this procedure may contain installation details. All vehicles Refer to: Battery Disconnect and Connect ( Battery, Mounting and Cables, General Procedures). 2. WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.

39 Raise and support the vehicle. 3. Refer to: Air Deflector ( Front End Body Panels, Removal and Installation). All vehicles CAUTION: Support the engine on a jack. The angle may need to be adjusted during this procedure. Support the engine with the lifting equipment. Right-hand drive vehicles 2. Note the fitted position.

40 Torque: 35 Nm 3. Torque: 100 Nm All vehicles

41 Torque: 63 Nm 2. Torque: 48 Nm 3. Do not disassemble further if the component is removed for access only.

42 Torque: 48 Nm INSTALLATION To install, reverse the removal procedure X250, INTAKE AIR DISTRIBUTION AND FILTERING - V8 5.0L PETROL AIR CLEANER OUTLET PIPE RH (G ) REMOVAL AND INSTALLATION AIR CLEANER OUTLET PIPE RIGHT HAND RENEW 5000 CC, AJ V8 0.1 USED WITHINS

43 REMOVAL Removal steps in this procedure may contain installation details. INSTALLATION To install, reverse the removal procedure X250, FRONT END BODY PANELS SECONDARY BULKHEAD PANEL LH - TDV6 3.0 L DIESEL /V8 5.0L PETROL/V8 S/C 5.0L PETROL (G )

44 REMOVAL AND INSTALLATION ENGINE COMPARTMENT LEFT HAND COVER RENEW 3000 CC, TDV6 0.7 USED WITHINS ENGINE COMPARTMENT LEFT HAND COVER RENEW 5000 CC, AJ V8 0.7 USED WITHINS REMOVAL Removal steps in this procedure may contain installation details. All vehicles Refer to: Secondary Bulkhead Center Panel ( Front End Body Panels, Removal and Installation). 2.

45 Torque: 25 Nm Right-hand drive vehicles Left-hand drive vehicles Vehicles with 5.0L

46 Torque: 7 Nm All vehicles Torque: 5 Nm 2.

47 Do not disassemble further if the component is removed for access only. INSTALLATION To install, reverse the removal procedure X250, FRONT END BODY PANELS SECONDARY BULKHEAD PANEL RH - TDV6 3.0 L DIESEL /V8 5.0L PETROL/V8 S/C 5.0L PETROL (G )

48 REMOVAL AND INSTALLATION ENGINE COMPARTMENT RIGHT HAND COVER RENEW 3000 CC, AJ-V6 0.9 USED WITHINS ENGINE COMPARTMENT RIGHT HAND COVER RENEW 3000 CC, TDV6 0.9 USED WITHINS ENGINE COMPARTMENT RIGHT HAND COVER RENEW 5000 CC, AJ V8 0.9 USED WITHINS REMOVAL Removal steps in this procedure may contain installation details. All vehicles Refer to: Secondary Bulkhead Center Panel ( Front End Body Panels, Removal and Installation). 2.

49 Torque: 25 Nm Right-hand drive vehicles Some variation in the illustrations may occur, but the essential information is always correct. Left-hand drive vehicles

50 2. Some variation in the illustrations may occur, but the essential information is always correct. Vehicles with 5.0L Refer to: Air Cleaner RH (303-12A Intake Air Distribution and Filtering - V8 5.0L Petrol, Removal and Installation).

51 Vehicles with diesel engine All vehicles 2.

52 INSTALLATION To install, reverse the removal procedure X250, FUEL SYSTEM - GENERAL INFORMATION

53 FUEL SYSTEM PRESSURE RELEASE - V8 5.0L PETROL/V8 S/C 5.0L PETROL (G ) GENERAL PROCEDURES FUEL SYSTEM 3000 CC, AJ-V6 DEPRESSURISE 0.1 USED WITHINS FUEL SYSTEM 5000 CC, AJ V8 DEPRESSURISE 0.1 USED WITHINS DRAINING Remove the fuel pump fuse. 2. Remove the fuel filler cap. 3. CAUTION: When depressurising the fuel system, make sure that there is no throttle input. Failure to follow this instruction may cause damage to the vehicle. Start the engine and allow it to idle until the engine stalls. 4. Crank the engine for approximately five seconds to make sure that the fuel rail pressure is released. FILLING

54 Make sure all repairs have been carried out before proceeding to the following steps. Install the fuel pump fuse. 2. Install the fuel filler cap. 3. Read and clear stored DTC fault codes.

CAUTION: Make sure that tools and equipment are clean, free of foreign material and lubricant.

CAUTION: Make sure that tools and equipment are clean, free of foreign material and lubricant. Published: 20-Nov-2013 Fuel Charging and Controls - V8 5.0L Petrol - Fuel Rail RH Removal and Installation Special Tool(s) 310-197 Remover, Fuel Injector 310-198 Installer, Teflon Seal 310-199 Re-shape