Engine (4.2L): Overhaul Jaguar S-type I рестайлинг

Disassembly

Vehicles without supercharger

1. Disconnect the oil cooler hoses.

Vehicles with supercharger

Scheme 323

1. Detach the supercharger belt. Use a 1/2 inch square drive bar to rotate the supercharger belt tensioner. Detach the supercharger belt.

All vehicles

Scheme 324

Scheme 325

Scheme 326

Scheme 327

Scheme 328

1. Release the accessory drive belt tension. Detach the accessory drive belt.
2. Remove the accessory drive belt tensioner. Remove the accessory drive belt.
3. Remove the accessory drive belt idler pulley.
4. Detach the wiring harness.
5. Remove the wiring harness. Remove the retaining nut.
6. Disconnect the generator electrical connector.
7. Remove the generator.
8. Detach the engine wiring harness.
9. Remove the generator mounting bracket.
10. Detach the right hand oxygen sensor retaining bracket.
11. Detach the engine wiring harness.
12. Remove the starter motor.
13. Remove the oil level indicator and tube. Remove and discard the O-ring seal.
14. Remove the heat shield.
15. Remove the heat shield retaining bolt.
16. Remove the left-hand exhaust manifold. Remove and discard the gasket.
17. Remove the left-hand engine mount.
18. Remove the left-hand engine mounting bracket.
19. Disconnect the air conditioning compressor electrical connector.
20. Remove the A/C compressor.
21. Remove the air conditioning compressor mounting bracket.
22. Remove the power steering pump.
23. Remove the power steering pump mounting bracket.
24. Disconnect the crankshaft position sensor electrical connector.
25. Remove the crankshaft position sensor.
26. Detach the engine wiring harness.
27. Detach the engine wiring harness.
28. Detach the engine wiring harness.
29. Detach the engine wiring harness. Disconnect the variable valve timing (VCT) solenoid electrical connector. Detach the engine wiring harness.

Vehicles without supercharger

1. Disconnect the coolant temperature sensor electrical connector.

Vehicles with supercharger

Scheme 329

Scheme 330

Scheme 331

Scheme 332

Scheme 333

Scheme 334

Scheme 335

Scheme 336

Scheme 337

Scheme 338

Scheme 339

Scheme 340

Scheme 341

Scheme 342

Scheme 343

Scheme 344

Scheme 345

Scheme 346

1. Detach the hoses. Reposition the hose retaining clip.
2. Detach the supercharger outlet pipe coolant hose. Cap the coolant ports.
3. Remove the supercharger outlet pipe
4. Remove and discard the supercharger outlet pipe gasket.
5. Remove and discard the supercharger outlet pipe retaining bolt seals.
6. Remove and discard the supercharger outlet pipe to charge air coolers ducts.
7. Disconnect the thermostat housing hoses
8. Disconnect the coolant temperature sensor electrical connector.
9. Reposition the thermostat housing hose retaining clip.
10. Disconnect the hose.
11. Disconnect the hose.
12. Disconnect the hose.
13. Disconnect the hose.
14. Remove the thermostat housing retaining bolts.
15. Remove the thermostat housing. Remove and discard thermostat housing O-ring seals.
16. Disconnect the charge air cooler coolant pipes.
17. Disconnect the intake air temperature (IAT) sensor electrical connector.
18. Disconnect the electrical connectors.
19. Detach the coolant hose from the throttle body.
20. Remove the throttle body. Remove and discard the gasket.
21. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
22. Disconnect the coolant hoses.
23. Remove the EGR valve and the exhaust manifold to EGR valve tube. Remove the retaining bolts. Remove and discard the exhaust manifold to EGR valve tube gasket. Remove and discard the EGR valve to air intake elbow gasket.
24. Disconnect the air intake elbow pipes.
25. Remove the air intake elbow retaining bracket lower retaining bolts.
26. Detach the air intake elbow. Remove and discard the gasket. Remove and discard the retaining bolt seals.
27. Remove the air intake elbow. Disconnect the manifold absolute pressure (MAP) sensor
28. Remove the supercharger.
29. Remove the charge air coolers. Remove and discard the charge air cooler gasket.

All vehicles

1. Disconnect the knock sensor electrical connectors.
2. Remove the ignition coil cover.

Vehicles without supercharger

1. Remove the engine cover retaining bracket.
2. Remove the engine cover retaining bracket.

All vehicles

1. Detach the engine wiring harness.
2. Disconnect the fuel injector electrical connectors.
3. Disconnect the ignition coil electrical connectors.
4. Detach the engine wiring harness.
5. Detach the engine wiring harness.
6. Disconnect the camshaft position sensor electrical connector.
7. Detach the engine wiring harness. Detach the ground cable. Disconnect the variable valve timing (VCT) solenoid electrical connector. Detach the engine wiring harness.

Vehicles without supercharger

1. Disconnect the positive crankcase ventilation pipe.
2. Disconnect the fuel pressure regulator electrical connector.
3. Disconnect the exhaust gas recirculation valve electrical connector.
4. Disconnect the exhaust gas recirculation valve coolant hose.

All vehicles

1. Detach the engine wiring harness.
2. Disconnect the fuel injector electrical connectors.
3. Detach the engine wiring harness.
4. Disconnect the ignition coil electrical connectors.
5. Disconnect the fuel temperature sensor electrical connector.
6. Disconnect the camshaft position sensor electrical connector.
7. Detach the engine wiring harness

Vehicles without supercharger

1. Detach the engine wiring harness.
2. Remove the intake manifold.

All vehicles

1. Remove the oil filter element.

Vehicles without supercharger

Scheme 347

1. Remove the oil cooler.

All vehicles

Scheme 348

Scheme 349

Scheme 350

Scheme 351

Scheme 352

Scheme 353

1. Disconnect the oil pressure switch and oil temperature sensor electrical connectors.
2. Remove the oil filter housing. Remove and discard the O-ring seal.
3. Detach the right-hand oxygen sensor.
4. Detach the engine wiring harness retaining clips.
5. Remove the engine wiring harness
6. Remove the noise and vibration insulating pad.
7. Remove the intake manifold heater coolant hose. Remove the knock sensors. Remove the intake manifold heater coolant hose.
8. Remove the engine block insulation grommet.
9. Remove the water pump pulley. Using special tool, retain the water pump pulley.
10. Remove the water pump. Remove and discard the gasket. Remove and discard the O-ring seal.

Vehicles without supercharger

1. Remove the thermostat housing. Remove and discard the O-ring seals.

All vehicles

Scheme 354

Scheme 355

1. Remove the ignition coils.
2. Remove the spark plugs.
3. Remove the right-hand camshaft position (CMP) sensor. Remove and discard the O-ring seal.
4. Remove the left-hand camshaft position (CMP) sensor. Remove and discard the O-ring seal.
5. Using special tools, retain the crankshaft pulley. Remove and discard the crankshaft pulley bolt.
6. Remove the special tools.
7. Using special tools, remove the crankshaft pulley. Collect the locking ring. Remove and discard the O-ring seal.
8. Remove the crankshaft position (CKP) sensor.
9. Install the special tool 303-645.
10. Remove the right-hand valve cover. Discard the valve cover gaskets.
11. Remove the left-hand valve cover. Discard the valve cover gaskets.
12. Remove the engine front cover.

Vehicles without supercharger

1. Remove the right-hand variable camshaft timing oil control unit housing. Remove and discard the O-ring seals.
2. Remove the left-hand variable camshaft timing oil control unit housing. Remove and discard the O-ring seals.

All vehicles

Scheme 356

Scheme 357

1. Install the special tool to the left-hand cylinder head.
2. Install the special tool to the Right-hand cylinder head.
3. Remove the primary timing chain tensioner assembly.
4. Remove the primary timing chain tensioner guide.
5. Remove the primary timing chain.
6. Remove the primary timing chain guide.
7. Remove the secondary timing chain tensioner retaining bolts.
8. Remove the camshaft sprockets. Remove the secondary timing chain tensioner and secondary timing chain from the camshaft sprockets.
9. Remove the primary timing chain tensioner assembly.
10. Remove the primary timing chain tensioner guide.
11. Remove the primary timing chain.
12. Remove the crankshaft sprocket.
13. Remove the primary timing chain tensioner guide.
14. Remove the secondary timing chain tensioner retaining bolts.
15. Remove the camshaft sprockets. Remove the secondary timing chain tensioner and secondary timing chain from the camshaft sprockets.
16. Remove the camshaft setting tool.
17. Remove the camshaft setting tool.
18. Remove the camshaft bearing caps. Remove the camshaft bearing cap retaining bolts evenly and in stages. Remove the camshaft bearing caps. Note their orientation and markings, each is marked with its position (a number) and orientation (an arrow).
19. Remove the right-hand exhaust camshaft.
20. Remove the camshaft bearing caps. Remove the camshaft bearing cap retaining bolts evenly and in stages. Remove the camshaft bearing caps. Note their orientation and markings, each is marked with its position (a number) and orientation (an arrow).
21. Remove the right-hand intake camshaft.
22. Remove the camshaft bearing caps. Remove the camshaft bearing cap retaining bolts evenly and in stages. Remove the camshaft bearing caps. Note their orientation and markings, each is marked with its position (a number) and orientation (an arrow).
23. Remove the left-hand exhaust camshaft.
24. Remove the camshaft bearing caps. Remove the camshaft bearing cap retaining bolts evenly and in stages. Remove the camshaft bearing caps. Note their orientation and markings, each is marked with its position (a number) and orientation (an arrow).
25. Remove the left-hand inlet camshaft.
26. Remove the right-hand cylinder head. Remove the bolts in the indicated sequence. Remove and discard the gasket.
27. Remove the left-hand cylinder head. Remove the bolts in the indicated sequence. Remove and discard the gasket.
28. Remove the crankshaft setting peg 303645 from the crankshaft position sensor location.
29. Remove the drive plate. Remove the drive plate retaining bolts. Remove the drive plate.
30. Remove the lower oil pan. Remove and discard the gasket.
31. Remove the oil strainer. Remove and discard the O-ring seal.
32. Remove the upper oil pan. Remove and discard the gasket.
33. Remove the oil pump. Remove and discard the gasket.
34. Inspect the tops of the cylinder bores. As necessary remove ridge and carbon build up from each cylinder.

Vehicles with supercharger

1. Remove the piston cooling jets.

All vehicles

Scheme 358

Scheme 359

Scheme 360

Scheme 361

Scheme 362

1. Remove the connecting rod bolts, the connecting rod caps and the lower connecting rod bearings.
2. Install special tools to the connecting rods.
3. Remove the pistons. Rotate the crankshaft to locate pistons at the bottom of travel. Push the piston, connecting rod and upper bearing through the top of the cylinder.
4. Remove the lower cylinder block. Remove the lower cylinder block retaining bolts in the indicated sequence.
5. Discard the crankshaft rear main oil seal.
6. Remove the crankshaft.
7. Remove the upper crankshaft main bearings. Remove the upper crankshaft thrust washers. Remove the upper crankshaft main bearings.
8. Clean the cylinder block with a soap and water solution. Dry the cylinder block completely with compressed air.

Cylinder Head - Assembly and Disassembly

Special Tools Tool Illustration Tool Name Tool Number Valve Spring Compressor 303-252

Scheme 363

Scheme 364

Scheme 365

Scheme 366

Scheme 367

1. Remove the bucket tappet and shim assemblies.
2. Remove the camshaft position (CMP) sensor. Remove and discard the 'O' ring seal.
3. Using the special tool, compress the valve springs. Remove the valve collets.
4. Remove the valve spring retainers and valve springs. Remove the valve spring retainers. Remove the valve springs. Remove the valve stem oil seals.
5. Remove the valves from the cylinder head. Remove the intake valves. Remove the exhaust valves.
6. Inspect the cylinder heads and related components. For additional information, refer to «Engine System - General Information»(ref-311296) .
7. Remove the pipe plugs and alignment dowels as necessary to clean the cylinder heads.

Assembly

1. Clean gasket material, dirt and foreign material from cylinder heads. Wash with a suitable soap and water solution and dry the cylinder head completely using compressed air if pipe plugs have been removed.
2. Install the pipe plugs and alignment dowels to cylinder heads. Apply pipe sealant to plugs prior to installation.
3. Install the valves into the cylinder heads. Install the intake valves. Install the exhaust valves.
4. Install the valve spring retainers and valve springs. Install the valve stem oil seals. Install the valve springs. Install the valve spring retainers.
5. Using the special tool, compress the valve springs. Install the valve collets.
6. Install the camshaft position (CMP) sensor. Install a new 'O' ring seal. Tighten to 7 Nm.
7. Install the bucket tappet and shim assemblies.

Special Tools Tool Illustration Tool Name Tool Number Crankshaft locking, main tool 303-191 Adapter 303-191-02 Crankshaft setting, main tool 303-645 Camshaft setting 303-530 Timing chain tensioning tool 303-532 Cylinder Bore Protectors 303-535 Piston Ring Compressor 303-372 Crankshaft rear oil seal remover/replacer 303-538 Crankshaft front seal installer 303-538

All vehicles

Scheme 368

1. Clean all the mating faces and reusable parts thoroughly and check for damage. If gasket material remains on the cylinder head after cleaning, use a plastic tipped scraper to remove remaining material.
2. Reseal oil passage blanking plugs, as necessary.
3. Install the upper crankshaft main bearings. Install the upper crankshaft thrust washers. Install the upper crankshaft main bearings.
4. Install the crankshaft.
5. Apply a bead of sealant to the cylinder block housing. Use WSS-M4G320-A3-RTV sealant.
6. Install the lower cylinder block to the upper cylinder block. Tighten bolts 21 to 32 to 15 Nm Tighten bolts 33 to 34 to 15 Nm Tighten bolts 1 to 10 to 25 Nm Tighten bolts 11 to 20 to 15 Nm Tighten bolts 1 to 10 to 35 Nm +135° Tighten bolts 11 to 20 to 20 Nm +150° Tighten bolts 21 to 32 to 20 Nm +90° Tighten bolts 33 to 34 to 20 Nm +150°
7. Rotate the crankshaft to check correct operation.
8. Remove excess sealant which may squeeze out at the front cover sealing surfaces.

All vehicles

Scheme 369

1. Make sure the transit sleeve is correctly in place and install the new seal over the crankshaft. Do not use any lubricant on the seal, the transit sleeve or the crankshaft.
2. Carefully remove the transit sleeve, leaving the seal in place.
3. Install the special tool to the crankshaft.
4. Reposition the nuts to hold the special tool against the crankshaft rear seal. Check that the crankshaft rear seal and the special tool are parallel to the rear of the engine.
5. Using the special tool, install the crankshaft rear seal.
6. Remove the special tool from the crankshaft. Check that the seal is located correctly.
7. Install special tools to the connecting rods. Position the crankshaft journal at the bottom of the stroke. Make sure the piston rings are positioned at different positions opposite the thrust side of the piston before installation.
8. Using the special tool compress the rings and install the piston and connecting rod. Lubricate all piston components.
9. Position the connecting rod cap on the appropriate connecting rod. Tighten to 10 Nm Tighten to 30 Nm Tighten to 90°
10. Rotate the crankshaft to check correct operation.

Vehicles with supercharger

1. Install the piston cooling jets. Tighten to 9 Nm

All vehicles

Scheme 370

1. Install the oil pump. Install a new gasket. Tighten to 12 Nm.
2. Install the upper oil pan. Install a new gasket. Tighten to 21 Nm.
3. Install the oil strainer. Install a new O-ring seal. Tighten to 12 Nm.
4. Install the lower oil pan. Install a new gasket.
5. Install the drive plate. Install the drive plate. Install the drive plate retaining bolts. Tighten to 15 Nm. Tighten to 110 Nm.
6. Position the crankshaft. Install the crankshaft setting peg 303645 to the crankshaft position sensor location.
7. Install a new left-hand cylinder head gasket. Make sure the cylinder head dowels are correctly located.
8. Install the left-hand cylinder head. Tighten bolts 1 to 10 to 20 Nm. Tighten bolts 1 to 10 to 35 Nm. Tighten bolts 1 to 10 to 90°. Tighten bolts 1 to 10 to 90°. Tighten bolts 11 to 12 to 25 Nm.
9. Install a new right-hand cylinder head gasket. Make sure the cylinder head dowels are correctly located.
10. Install the right-hand cylinder head. Tighten bolts 1 to 10 to 20 Nm. Tighten bolts 1 to 10 to 35 Nm. Tighten bolts 1 to 10 to 90°. Tighten bolts 1 to 10 to 90°. Tighten bolts 11 to 12 to 25 Nm.
11. Apply oil (EP-90) to the camshaft and bearing surfaces, as follows: To the upper face of each bearing surface in the cylinder head. To the upper face of each bearing surface in each bearing cap. On the cam lobes ONLY, not on the base circle area.
12. Install the left-hand inlet camshaft.
13. Install the camshaft bearing cap bolts evenly. Tighten to 10 Nm.
14. Apply oil (EP-90) to the camshaft and bearing surfaces, as follows: To the upper face of each bearing surface in the cylinder head. To the upper face of each bearing surface in each bearing cap. On the cam lobes ONLY, not on the base circle area.
15. Install the left-hand exhaust camshaft.
16. Install the camshaft bearing cap bolts evenly. Tighten to 10 Nm.
17. Apply oil (EP-90) to the camshaft and bearing surfaces, as follows: To the upper face of each bearing surface in the cylinder head. To the upper face of each bearing surface in each bearing cap. On the cam lobes ONLY, not on the base circle area.
18. Install the right-hand inlet camshaft.
19. Install the camshaft bearing cap bolts evenly. Tighten to 10 Nm.
20. Apply oil (EP-90) to the camshaft and bearing surfaces, as follows: To the upper face of each bearing surface in the cylinder head. To the upper face of each bearing surface in each bearing cap. On the cam lobes ONLY, not on the base circle area.
21. Install the right-hand exhaust camshaft.
22. Install the camshaft bearing cap bolts evenly. Tighten to 10 Nm.
23. Install the camshaft setting tool.
24. Install the camshaft setting tool.

All vehicles

1. Install the camshaft sprockets. Install the secondary timing chain tensioner and secondary timing chain to the camshaft sprockets.
2. Install the secondary timing chain tensioner retaining bolts. Tighten to 12 Nm.
3. Install the timing chain tensioning tool 303-532 to the exhaust camshaft sprocket. Reposition the camshaft sprockets for the most advantageous position for use of the tool.
4. Install the primary timing chain tensioner guide. Tighten to 12 Nm.
5. Install the crankshaft sprocket.
6. Install the primary timing chain. Install the primary chain over the crankshaft sprocket and the intake sprocket.
7. Install the primary timing chain tensioner guide. Tighten to 12 Nm.
8. Secure the left-hand timing chain tensioner in the vice jaws.
9. Using a suitable tool, hold the left-hand timing chain tensioner ratchet lock mechanism away from the ratchet stem.
10. Slowly compress the left-hand timing chain tensioner.
11. Using a suitable tool, retain the left-hand timing chain tensioner piston.
12. Install the primary timing chain tensioner assembly. Tighten to 12 Nm.
13. Release the tension in the left-hand timing chain tensioner. Remove the retaining tool.
14. Using the special tool apply force to the tool in an anti-clockwise direction to tension the primary timing chain on its drive side. Tighten to 120 Nm.
15. Using the special tool apply force to the tool in an anti-clockwise direction. Tighten to 120 Nm.
16. Install the camshaft sprockets. Install the secondary timing chain tensioner and secondary timing chain to the camshaft sprockets.
17. Install the secondary timing chain tensioner retaining bolts. Tighten to 12 Nm.
18. Install the timing chain tensioning tool 303-532 to the exhaust camshaft sprocket. Reposition the camshaft sprockets for the most advantageous position for use of the tool.
19. Install the primary timing chain guide. Tighten to 12 Nm.
20. Install the primary timing chain. Install the primary chain over the crankshaft sprocket and the intake sprocket.
21. Install the primary timing chain tensioner guide. Tighten to 12 Nm.
22. Secure the right-hand timing chain tensioner in the vice jaws.
23. Using a suitable tool, hold the right-hand timing chain tensioner ratchet lock mechanism away from the ratchet stem.
24. Slowly compress the right-hand timing chain tensioner.
25. Using a suitable tool, retain the right-hand timing chain tensioner piston.
26. Install the primary timing chain tensioner assembly. Tighten to 12 Nm.
27. Release the tension in the right-hand timing chain tensioner. Remove the retaining tool.
28. Using the special tool apply force to the tool in an anti-clockwise direction to tension the primary timing chain on its drive side. Tighten to 120 Nm.
29. Using the special tool apply force to the tool in an anti-clockwise direction. Tighten to 120 Nm.
30. Remove the special tool to the Right-hand cylinder head.
31. Remove the special tool to the left-hand cylinder head.

Vehicles without supercharger

1. Install the left-hand variable camshaft timing oil control unit housing. Install new O-ring seals. Tighten to 22 Nm.
2. Install the right-hand variable camshaft timing oil control unit housing. Install new O-ring seals. Tighten to 22 Nm.

All vehicles

1. Remove the special tool.
2. Install the crankshaft position sensor.
3. Install new seals to the timing cover. Install the new seal to the inner groove on the face of the timing cover. Install the new seal to the outer groove on the face of the timing cover.
4. Apply sealant to the eight joints on the engine face. Sealant beads to be 3mm diameter and 12mm long. Cut the nozzle of the sealant tube to produce a 3 mm (0.12 in) bead. (Install and tighten the securing bolts within twenty minutes of sealant application).
5. Install the timing cover. Tighten in the sequence shown.
6. Using the special tool, install a new crankshaft front seal.
7. Remove the crankshaft seal protector.
8. Install a new O-ring seal to the crankshaft pulley. Lubricate the new O-ring.
9. Install, but do not tighten, a new crankshaft pulley retaining bolt. Install the crankshaft pulley and locking ring to the crankshaft.
10. Using special tools, retain the crankshaft pulley. Tighten the crankshaft pulley retaining bolt to 375 Nm.
11. Remove the special tools.
12. Carry out a valve clearance check. «Valve Clearance Check - General Procedures»(ref-311288-S29359674882009032500000) .
13. Install the left-hand valve cover. Install new valve cover gaskets. Tighten in the sequence shown. Tighten to 10 Nm.
14. Install the right-hand valve cover. Install new valve cover gaskets. Tighten in the sequence shown. Tighten to 10 Nm.
15. Install the spark plugs. Tighten to 27 Nm.
16. Install the left-hand camshaft position (CMP) sensor. Install a new O-ring seal.
17. Install the right-hand camshaft position (CMP) sensor. Install a new O-ring seal.
18. Install the ignition coils. Tighten to 5 Nm.

Vehicles without supercharger

1. Install the thermostat housing. Install new O-ring seals. Tighten to 10 Nm.

All vehicles

1. Install the water pump. Install new O-ring seals and gaskets. Tighten to 12 Nm.
2. Install the water pump pulley. Using special tool, retain the water pump pulley. Tighten to 10 Nm + 45°.
3. Install the engine block insulation grommet.
4. Install the intake manifold heater coolant hose. Install the knock sensors. Tighten to 20 Nm. Install the intake manifold heater coolant hose.
5. Install the noise and vibration insulating pad.
6. Install the engine wiring harness
7. Attach the engine wiring harness retaining clips.
8. Attach the right-hand oxygen sensor. Tighten to 10 Nm.
9. Install the oil filter housing. Install a new gasket. Tighten to 21 Nm.
10. Connect the oil pressure switch and oil temperature sensor electrical connectors.

Vehicles without supercharger

1. Install the oil cooler. Install a new O-ring seal. Tighten to 55 Nm.

All vehicles

1. Install a new oil filter. Tighten to 18 Nm.

Vehicles without supercharger

1. Install the intake manifold. Tighten to 22 Nm.
2. Attach the engine wiring harness. Tighten to 10 Nm.

All vehicles

1. Attach the engine wiring harness
2. Connect the camshaft position sensor electrical connector.
3. Connect the fuel temperature sensor electrical connector.
4. Connect the ignition coil electrical connectors.
5. Attach the engine wiring harness.
6. Connect the fuel injector electrical connectors.
7. Attach the engine wiring harness.

Vehicles without supercharger

1. Connect the exhaust gas recirculation valve coolant hose.
2. Connect the exhaust gas recirculation valve electrical connector.
3. Connect the fuel pressure regulator electrical connector.
4. Connect the positive crankcase ventilation pipe.

All vehicles

1. Attach the engine harness. Connect the variable valve timing (VCT) solenoid electrical connector. Attach the engine harness.
2. Connect the camshaft position sensor electrical connector.
3. Attach the engine wiring harness.
4. Attach the engine wiring harness.
5. Connect the ignition coil electrical connectors.
6. Connect the fuel injector electrical connectors.
7. Attach the engine wiring harness.

Vehicles without supercharger

1. Install the engine cover retaining bracket.
2. Install the engine cover retaining bracket.

All vehicles

1. Install the ignition coil cover.
2. Connect the knock sensor electrical connectors.

Vehicles with supercharger

Scheme 371

1. Install the charge air cooler. Install a new charge air cooler gasket. Tighten to 13 Nm.
2. Install the supercharger. Tighten to 24 Nm.
3. Connect the manifold absolute pressure (MAP) sensor.
4. Install the air intake elbow. Install a new gasket. Install new retaining bolt seals. Tighten to 24 Nm.
5. Install the air intake elbow retaining bracket lower retaining bolts. Tighten to 20 Nm.
6. Connect the air intake elbow pipes.
7. Install the throttle body. Install a new throttle body gasket. Tighten to 10 Nm.
8. Attach the coolant hose to the throttle body.
9. Connect the electrical connectors.
10. Install the EGR valve and the exhaust manifold to EGR valve tube. Install a new exhaust manifold to EGR valve tube gasket. Install a new EGR valve to air intake elbow gasket. Tighten to 10 Nm.
11. Tighten to 21 Nm.
12. Connect the coolant hoses.
13. Connect the exhaust gas recirculation (EGR) valve electrical connector.
14. Connect the IAT sensor electrical connector.
15. Connect the charge air cooler coolant pipes.
16. Install new O-ring seals to the thermostat housing.
17. Install thermostat housing.
18. Tighten to 10 Nm.
19. Tighten to 10 Nm.
20. Connect the hose.
21. Connect the hose.
22. Connect the hose.
23. Reposition the thermostat housing hose retaining clip.
24. Connect the coolant temperature sensor electrical connector.
25. Connect the thermostat housing hoses
26. Install new supercharger outlet pipe to charge air coolers ducts. Tighten to 8 Nm.
27. Install a new supercharger outlet pipe gasket.
28. Install new seals to the supercharger outlet pipe retaining bolts
29. Install the supercharger outlet pipe
30. Attach the supercharger outlet pipe coolant hose.
31. Attach the hoses. Reposition the hose retaining clip.

Vehicles without supercharger

1. Disconnect the coolant temperature sensor electrical connector.

All vehicles

1. Attach the engine wiring harness. Connect the variable valve timing (VCT) solenoid electrical connector. Attach the engine wiring harness.
2. Attach the engine wiring harness.
3. Attach the engine wiring harness.
4. Attach the engine wiring harness.
5. Connect the crankshaft position sensor electrical connector.
6. Install the power steering pump mounting bracket. Tighten to 25 Nm.
7. Install the power steering pump. Tighten to 25 Nm.
8. Install the air conditioning compressor mounting bracket. Tighten to 25 Nm.
9. Install the A/C compressor. Tighten to 25 Nm.
10. Connect the air conditioning compressor electrical connector.
11. Install the left-hand engine mounting bracket. Tighten to 25 Nm.
12. Install the left-hand engine mount. Tighten to 43 Nm.
13. Install the left-hand exhaust manifold. Install a new gasket. Tighten to 20 Nm.
14. Remove the heat shield retaining bolt. Tighten to 50 Nm.
15. Install the heat shield. Tighten to 3 Nm.
16. Remove the oil level indicator and tube. Install a new O-ring seal. Tighten to 6 Nm.
17. Install the starter motor. Tighten to 45 Nm.
18. Attach the engine wiring harness.
19. Attach the right hand oxygen sensor retaining bracket.
20. Install the generator mounting bracket. Tighten to 45 Nm.
21. Attach the engine wiring harness.
22. Install the generator. Tighten the generator upper retaining bolt to 21 Nm. Tighten the generator lower retaining bolt to 40 Nm.
23. Connect the generator electrical connector.
24. Install the wiring harness. Tighten to 12 Nm.
25. Attach the wiring harness.
26. Install the accessory drive belt idler pulley. Tighten to 25 Nm.
27. Install the accessory drive belt tensioner. Install the accessory drive belt. Tighten to 45 Nm.
28. Release the accessory drive belt tension. Attach the accessory drive belt.

Vehicles with supercharger

1. Install the supercharger belt. Use a 1/2 inch square drive bar to rotate the supercharger belt tensioner.

Vehicles without supercharger

1. Connect the oil cooler hoses.

Engine - Installation

Special Tools Tool Illustration Tool Name Tool Number Engine lifting brackets 303749 Engine lifting brackets 303536 5 point security torx bit 418-535