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

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Sabina Anthony
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1 Published: 20-Nov-2013 Fuel Charging and Controls - V8 5.0L Petrol - Fuel Rail RH Removal and Installation Special Tool(s) Remover, Fuel Injector Installer, Teflon Seal Re-shape Tool, Teflon Seal Fuel Rail Installation Guide Pins - Threaded Fuel Rail Installation Guide Pins - Unthreaded Removal NOTES: CAUTION: Make sure that tools and equipment are clean, free of foreign material and lubricant. Removal steps in this procedure may contain installation details. Some variation in the illustrations may occur, but the essential information is always correct.

2 1. Refer to: Petrol and Petrol-Ethanol Fuel Systems Health and Safety Precautions ( General Information, Description and Operation). 2. Refer to: Fuel System Pressure Release - V6 3.0L Petrol/V8 5.0L Petrol/V8 S/C 5.0L Petrol ( Fuel System - General Information, General Procedures). 3. Refer to: Battery Disconnect and Connect ( Battery, Mounting and Cables, General Procedures). 4. Refer to: Engine Cover - V8 5.0L Petrol/V8 S/C 5.0L Petrol ( Interior Trim and Ornamentation, Removal and Installation). 5. Refer to: Secondary Bulkhead Panel RH ( Front End Body Panels, Removal and Installation). 6. Refer to: Air Cleaner RH (303-12B Intake Air Distribution and Filtering - V8 5.0L Petrol/V8 S/C 5.0L Petrol, Removal and Installation) CAUTIONS: Be prepared to collect escaping fluids.

Make sure that all openings are sealed. Use new blanking caps. 10. 11.

3 Make sure that all openings are sealed. Use new blanking caps CAUTIONS: Be prepared to collect escaping fluids. Make sure that all openings are sealed. Use new blanking caps. 12. NOTE: LH shown RH similar.

4 13. Refer to: Fuel Injection Component Cleaning (303-04C Fuel Charging and Controls - V8 5.0L Petrol, General Procedures). 14. NOTE: LH shown RH similar CAUTION: Make a note of the fuel injector alignment to the fuel rail prior to removal. NOTE: LH shown RH similar.

Make sure that the special tool is held square to the fuel injector during removal. Make sure that all open ports are covered to prevent any foreign material ingress.

5 17. installed. NOTE: This step is only required if a new fuel rail is Refer to: Fuel Rail Pressure (FRP) Sensor (303-14C Electronic Engine Controls - V8 5.0L Petrol, Removal and Installation). 18. CAUTIONS: Make sure that the special tool is located correctly to the fuel injector prior to removing the fuel injector. Make sure that the special tool is held square to the fuel injector during removal. Make sure that all open ports are covered to prevent any foreign material ingress. Special Tool(s): CAUTIONS: If new fuel injectors are installed, a new injector clamp must be installed. If the fuel injector is being removed without a new component being installed, the fuel injector clamp must remain with the fuel injector it is removed with.

6 20. CAUTIONS: Do not use a knife to remove the Teflon seal as damage could occur to the fuel injector. Do not cut the Teflon seal to deep as damage could occur to the fuel injector. Pinch the Teflon seal to allow the tool to cut the Teflon seal without damaging the fuel injector. 21. CAUTION: Do not use any sharp tools to remove the O-ring seal as damage could occur to the fuel injector. 22. 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. 23. Refer to: Air Deflector ( Front End Body Panels, Removal and Installation). 24. Refer to: Generator - V8 5.0L Petrol (414-02B Generator and Regulator - V8 5.0L Petrol/V8 S/C 5.0L Petrol, Removal and Installation). 25.

7 27. NOTE: Engine shown removed for clarity.

8 CAUTION: Use a wooden block to protect the oil pan when supporting the engine. Using a suitable hydraulic jack, support the engine. 30.

31. 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 vapors are always present and may ignite.

9 31. 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 vapors are always present and may ignite. Failure to follow these instructions may result in personal injury. CAUTIONS: lines. Remove and discard the high-pressure fuel supply Be prepared to collect escaping fluids. Make sure that all openings are sealed. Use new blanking caps. NOTE: Engine shown removed for clarity. Installation 1. CAUTION: Lubricate only the union threads with clean engine oil. NOTES: Engine shown removed for clarity. Install the bolts and unions finger tight before final tightening.

10 Remove and discard the blanking caps. 2. Torque: 48 Nm 3. Remove the special tool.

11 4. Torque: 48 Nm 5. clarity. NOTE: Some components shown removed for Torque: Unions (1) 21 Nm M6 (2) 11 Nm M8 (3) 25 Nm

12 6. Install new O-ring seals. 7. Install new Teflon seals. Special Tool(s):

13 8. Special Tool(s): CAUTION: If the original fuel injector is being installed, the original fuel injector clamp must installed with the fuel injector it was removed with.

10. CAUTION: If a new cylinder head has been installed then the special tool 310-200-02 without the thread must be used to install the fuel rail.

CAUTIONS: Make sure that the area around the open fuel injector ports are clean and free of foreign material and lubricant prior to installing the fuel injector.

NOTE: This step is only required if a new fuel rail is Refer to: Fuel Rail Pressure (FRP) Sensor (303-14C Electronic Engine Controls - V8 5.0L Petrol, Removal and Installation). 13.

14 10. CAUTION: If a new cylinder head has been installed then the special tool without the thread must be used to install the fuel rail. Special Tool(s): , CAUTIONS: Make sure that the area around the open fuel injector ports are clean and free of foreign material and lubricant prior to installing the fuel injector. When Installing the fuel injector(s), make sure that the Teflon seal is clean and free of foreign material and lubricant. 12. installed. NOTE: This step is only required if a new fuel rail is Refer to: Fuel Rail Pressure (FRP) Sensor (303-14C Electronic Engine Controls - V8 5.0L Petrol, Removal and Installation). 13. CAUTIONS: If new fuel injectors are installed, a new injector clamp must be installed Make sure that the fuel injector is aligned and installed into the fuel rail correctly, as noted in the removal step. Tighten the fuel rail retaining bolts a turn at a time until the correct torque is achieved. NOTE: Lubricate the fuel injector O-ring seals with clean engine oil. Torque: 20 Nm 14. NOTE: LH shown RH similar. Special Tool(s): ,

15 15. NOTE: LH shown RH similar. Torque: 20 Nm 16. NOTES: LH shown RH similar. Tighten in the sequence indicated. Torque: Bolt 2 30 Nm Bolt 3 30 Nm Bolt 1 30 Nm Bolt 4 30 Nm 17.

16 18. NOTE: LH shown RH similar. Torque: 7 Nm 19. NOTE: LH shown RH similar. 20. NOTE: Remove and discard the blanking caps. Torque: Unions 21 Nm Nut 6 Nm

Raise and support the vehicle. 22. clarity.

17 21. 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. 22. clarity. NOTE: Some components shown removed for Torque: 21 Nm 23. NOTE: Engine shown removed for clarity. Torque: M10 29 Nm M6 11 Nm

18 25. Torque: 25 Nm

19 26. Refer to: Generator - V8 5.0L Petrol (414-02B Generator and Regulator - V8 5.0L Petrol/V8 S/C 5.0L Petrol, Removal and Installation). 27. Refer to: Air Deflector ( Front End Body Panels, Removal and Installation). 28. Lower the vehicle NOTES: Lubricate the union threads with clean engine oil. Do not tighten at this stage. Remove and discard the blanking caps. 31. Torque: Unions 21 Nm

20 Bolts 8 Nm 32. Torque: 21 Nm

35. 36. Refer to: Air Cleaner RH (303-12B Intake Air Distribution and Filtering - V8 5.0L Petrol/V8 S/C 5.0L Petrol, Removal and Installation). 37.

21 Refer to: Air Cleaner RH (303-12B Intake Air Distribution and Filtering - V8 5.0L Petrol/V8 S/C 5.0L Petrol, Removal and Installation). 37. Refer to: Secondary Bulkhead Panel RH ( Front End Body Panels, Removal and Installation). 38. Refer to: Engine Cover - V8 5.0L Petrol/V8 S/C 5.0L Petrol ( Interior Trim and Ornamentation, Removal and Installation). 39. Refer to: Battery Disconnect and Connect ( Battery, Mounting and Cables, General Procedures). Published: 11-May-2011 Front End Body Panels - Air Deflector Removal and Installation Removal NOTE: Removal steps in this procedure may contain installation details. 1. stands. WARNING: Make sure to support the vehicle with axle Raise and support the vehicle. 2. NOTE: Note the fitted position of the washers.

22 Torque: 7 Nm Installation 1. To install, reverse the removal procedure. Published: 11-May-2011 Electronic Engine Controls - V8 5.0L Petrol - Fuel Rail Pressure (FRP) Sensor Removal and Installation Removal NOTE: Removal steps in this procedure may contain installation details. 1. Refer to: Petrol and Petrol-Ethanol Fuel Systems Health and Safety Precautions ( General Information, Description and Operation). 2. Refer to: Fuel System Pressure Release - V6 3.0L Petrol/V8 5.0L Petrol/V8 S/C 5.0L Petrol ( Fuel System - General Information, General Procedures). 3. Refer to: Battery Disconnect and Connect ( Battery, Mounting and Cables, General Procedures). 4. Refer to: Secondary Bulkhead Panel RH ( Front End Body Panels, Removal and Installation). 5. NOTE: Some variation in the illustrations may occur, but the essential information is always correct.

6. CAUTIONS: Before disconnecting or removing components, ensure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.

Published: 06-Jun-2013 Front End Body Panels - Secondary Bulkhead Panel RH Removal and Installation Removal WARNINGS: To avoid accidental deployment, the restraints control module backup power supply

23 6. CAUTIONS: Before disconnecting or removing components, ensure the area around the joint faces and connections are clean. Plug open connections to prevent contamination. Be prepared to collect escaping fluids. Torque: 32 Nm Installation 1. To install, reverse the removal procedure. Published: 06-Jun-2013 Front End Body Panels - Secondary Bulkhead Panel RH Removal and Installation Removal WARNINGS: To avoid accidental deployment, the restraints control module backup power supply must be depleted. Wait at least one minute after disconnecting the battery ground cable(s) before commencing any repair or adjustment to the supplemental restraint system (SRS), or any component(s) adjacent to the SRS sensors. Failure to follow these instructions may result in personal injury. Always wear safety glasses when working on an air bag equipped vehicle and when handling an air bag module. Failure to follow this instruction may result in personal injury. To minimize the possibility of premature deployment, do not use radio key code savers when working on the supplemental restraint system. Failure to follow this instruction may result in personal injury. To minimize the possibility of injury in the event of premature deployment, always carry a live air bag module with the bag and trim cover pointed away from the body. Failure to follow this instruction may result in personal injury.

To minimize the possibility of premature deployment, live air bag modules must only be placed on work benches which have been ground bonded and with the trim cover facing up.

Failure to follow this instruction may result in personal injury. Painting over the driver air bag module trim cover or instrument panel could lead to deterioration of the trim cover and air bags.

24 To minimize the possibility of premature deployment, live air bag modules must only be placed on work benches which have been ground bonded and with the trim cover facing up. Failure to follow these instructions may result in personal injury. Never probe the electrical connectors of air bag modules or any other supplemental restraint system component. Failure to follow this instruction may result in personal injury. Painting over the driver air bag module trim cover or instrument panel could lead to deterioration of the trim cover and air bags. Do not for any reason attempt to paint discolored or damaged air bag module trim covers or instrument panel. Install a new component. Failure to follow this instruction may result in personal injury. NOTE: Removal steps in this procedure may contain installation details. All vehicles 1. Disconnect the battery ground cable. Refer to: Battery Disconnect and Connect ( Battery, Mounting and Cables, General Procedures). 2. Refer to: Secondary Bulkhead Panel LH ( Front End Body Panels, Removal and Installation). Vehicles with 3.0L diesel engine 3. Vehicles with 5.0L engine 4.

25 5. Torque: 12 Nm All vehicles 6. Torque: 55 Nm 7.

26 Left-hand drive vehicles 8. Torque: 8 Nm 9. Torque: 7 Nm

27 10. Torque: 8 Nm All vehicles 11. Torque: 7 Nm 12.

13. NOTE: Do not disassemble further if the component is removed for access only.

CAUTION: Make sure that the clip is correctly To install, reverse the removal procedure.

28 13. NOTE: Do not disassemble further if the component is removed for access only. Installation 1. located. CAUTION: Make sure that the clip is correctly To install, reverse the removal procedure. Published: 17-Feb-2012 Battery, Mounting and Cables - Battery Disconnect and Connect General Procedures Disconnect 1. 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. 3. Raise and secure the luggage compartment floor covering.

29 4. CAUTION: Take extra care not to damage the wiring harness. 5. Connect 1. Torque: 6 Nm 2. 3.

30 NOTE: Make sure that both the positive and negative battery terminals are correctly located. 4. Lower the luggage compartment floor covering. 5. NOTE: This step is only necessary when installing a new component. Using the Jaguar approved diagnostic equipment, reset the battery monitoring system. 6. Refer to: Door Window Motor Initialization ( Glass, Frames and Mechanisms, General Procedures). 7. Enter the audio unit preset radio frequencies. 8. Reset the clock to the correct time. 9. Start the engine and allow to idle until the engine reaches normal operating temperature. 10. Switch the engine off. Published: 01-Aug-2012 Fuel System - General Information - Fuel System Pressure Release V6 3.0L Petrol/V8 5.0L Petrol/V8 S/C 5.0L Petrol General Procedures Draining 1. 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.

31 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 1. NOTE: 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. Published: 16-Mar-2016 Fuel Charging and Controls - V8 5.0L Petrol - Fuel Injection Component Cleaning General Procedures General Equipment Pneumatic vacuum gun WARNINGS: Cleaning 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: 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.

32 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. 1. 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 Published: 11-May-2011 General Information - Petrol and Petrol-Ethanol Fuel Systems Health and Safety Precautions 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. 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. Published: 14-Jun-2012 Interior Trim and Ornamentation - Engine Cover V8 5.

33 Make sure that the workshop area in which the vehicle is being worked on is as clean and as dust free as possible. Published: 14-Jun-2012 Interior Trim and Ornamentation - Engine Cover V8 5.0L Petrol/V8 S/C 5.0L Petrol Removal and Installation Removal 1. NOTE: Some variation in the illustrations may occur, but the essential information is always correct. Remove the engine cover. Installation 1. To install, reverse the removal procedure. Published: 11-May-2011 Generator and Regulator - V8 5.0L Petrol/V8 S/C 5.0L Petrol - Generator V8 5.0L Petrol Removal and Installation Removal NOTE: Removal steps in this procedure may contain installation details. 1. Refer to: Battery Disconnect and Connect ( Battery, Mounting and Cables, General Procedures). 2. stands. WARNING: Make sure to support the vehicle with axle

34 Raise and support the vehicle. 3. Refer to: Air Deflector ( Front End Body Panels, Removal and Installation) Torque: 25 Nm 6. Torque: 12 Nm 7. NOTE: Tighten the bolts in the indicated sequence. Torque: 48 Nm

0L Petrol - Air Cleaner RH Removal and Installation Removal NOTES: Removal steps in this

35 Installation 1. To install, reverse the removal procedure. Published: 17-Nov-2015 Intake Air Distribution and Filtering - V8 5.0L Petrol/V8 S/C 5.0L Petrol - Air Cleaner RH Removal and Installation Removal NOTES: Removal steps in this procedure may contain installation details. Some variation in the illustrations may occur, but the essential information is always correct

36 3. 4. Torque: 8 Nm 5. Do not disassemble further if the component is removed for access only. 6. NOTE: LH illustration shown, RH is similar.

37 7. NOTE: LH illustration shown, RH is similar. 8. NOTE: LH illustration shown, RH is similar. Installation 1. To install, reverse the removal procedure.

HIGH PRESSURE FUEL PUMP 1

2010 X250, 303-04 FUEL CHARGING AND CONTROLS - V8 5.0L PETROL HIGH PRESSURE FUEL PUMP 1 (G1185928) REMOVAL AND INSTALLATION 19.45.30 HIGH PRESSURE FUEL PUMP FRONT RENEW 5000 CC, AJ V8, NATURALLY ASPIRATED