Engine: Removal & Installation Jaguar XKR I

Removal

1. Park the vehicle on a 4 post ramp and set the gear selector to "N" position. Do not apply the hand brake. Using tire wedges, block one wheel to prevent movement of the vehicle.
2. Open the engine compartment hood to service position and install body protection covers. Disconnect the battery ground cable and remove the battery cover.
3. Apply masking tape to the front edge of the engine compartment hood to protect the hood during removal and storage. With assistance, support the hood and release the hood struts. (Scheme 10)
4. Disconnect the ground lead from the left hood hinge. With assistance, remove the 6 bolts which retain the hood and remove the hood. (Scheme 11)
5. Carefully remove the engine covers, taking care not to damage the plastic retainers or the rubber inserts. (Scheme 12)
6. Drain the cooling system. See «COOLING SYSTEM»(ref-160932-S05714134782004030900000).
7. Recover/recycle the air conditioning system refrigerant. For 1999 models, see «REFRIGERANT RECOVERY/RECYCLING»(ref-1761-S28353700642000031400000) in A/C SYSTEM GENERAL SERVICING PROCEDURES article in HVAC. For 2000-2001 models, see «REFRIGERANT RECOVERY/RECYCLING»(ref-98975-S05260558422001060700000) in A/C SYSTEM GENERAL SERVICING article in HVAC. For 2002-2003 models, see REFRIGERANT RECOVERY/RECYCLING in appropriate A/C SYSTEM GENERAL SERVICING article in HVAC.
8. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-160932-S14367905272004030900000).
9. Remove the 2 bolts which secure the air intake tube to the throttle body. Disconnect the air intake tube from the throttle body. (Scheme 13)
10. Release the 5 clips which secure the air cleaner cover. (Scheme 14) Disconnect the airflow meter connector.
11. Disconnect the breather pipe from the "A" bank valve cover. Remove and discard the "O" ring from the breather pipe. Remove the air intake tube/airflow meter/air cleaner cover assembly. (Scheme 15) Remove and discard the air intake tube-to-throttle body rubber seal.
12. Cut and remove the strap which secures the vacuum pipe to the intake manifold elbow.
13. Place a absorbent cloth under the expansion tank to absorb any spillage caused by removing coolant hoses. Loosen the hose clamps for the expansion tank-to-thermostat housing hose and the radiator air bleed hose. Remove both hoses from the expansion tank and remove clamps from hoses. (Scheme 16)
14. Remove the expansion tank bolt and remove expansion tank from the rear mounting grommets. Disconnect the coolant level sensor connector. (Scheme 17)
15. Lifting the expansion tank for access, loosen the lower expansion tank hose clamp and remove the lower hose from the expansion tank. Remove the expansion tank from the vehicle. (Scheme 18) Empty any surplus coolant from the expansion tank and remove the absorbent cloth.
16. Remove the radiator assembly. See «RADIATOR»(ref-160932-S08894469872004030900000).
17. Disconnect the engine oil pressure sensor. (Scheme 19)
18. Remove the power steering reservoir cap and the engine oil dipstick.
19. Place a drain pan under the power steering pump and remove the high pressure hose. Allow the fluid to drain into the drain pan. Discard the "O" ring from the high pressure hose and install a cap on the line and a plug in the fitting on the pump. Remove the power steering pump supply hose. Install plugs to the pump fitting and supply line. (Scheme 20) Discard the fluid.
20. Noting position, remove the oxygen sensor from the mounting bracket and disconnect oxygen sensor connectors. (Scheme 21)
21. Remove the downpipe catalytic converter nut from both exhaust manifolds. (Scheme 22)
22. Raise and support vehicle and drain the engine oil.
23. Loosen front and intermediate muffler clamps (both left and right sides) to allow front muffler to slide forward and disconnect from the intermediate muffler. Slide front muffler down to disconnect from down pipe catalytic converters. (Scheme 23)
24. Remove catalytic converter mounting bracket bolts and remove catalytic converter. (Scheme 24) Remove the 2 bolts from the catalytic converter mounting bracket and remove the bracket. Repeat for the other catalytic converter.
25. Remove the parking brake relay lever mounting bracket. (Scheme 25)
26. Mark the transmission flange and coupling assembly. Remove the 3 coupling assembly bolts and remove the drive shaft from the transmission flange. (Scheme 26)
27. Move the drive shaft sliding joint into the minimum length position. (Scheme 27)
28. Mark the final drive flange and coupling assembly. Remove the 4 coupling assembly bolts and remove drive shaft from vehicle. (Scheme 28)
29. Remove the ground cable bolt and ground cable at the transmission housing. (Scheme 29)
30. If equipped, remove the oil cooler lines clamping plate and bolt from the engine. Place a drain pan beneath the oil cooler lines and remove the lines from the engine. Allow the oil to drain into the pan. Remove and discard the "O" rings and install plugs to the lines and the fittings on the engine. (Scheme 30) Lower the vehicle.
31. If equipped, disconnect the generator suppression module harness connector and reposition the harness from under the generator suppression module. (Scheme 31)
32. Disconnect the engine management harness-to-starter motor connector. Reposition the protective boot from the starter motor positive cable stud. Remove the positive cable nut and disconnect the positive cable from the stater. (Scheme 32) Cut the tie strap which secures the positive cable to the enclosure and route the cable through the heatshield into the engine area.
33. Loosen the engine management harness connector bolt and disconnect connector. Remove the engine management harness connector and reposition connector from the mounting bracket. (Scheme 33)
34. Disconnect the transmission rotary switch harness connector and reposition the harness connector. (Scheme 21)
35. Using the Quick Fit Connector Release Tool (310-044), disconnect the fuel feed hose. (Scheme 34)
36. Using the Quick Fit Connector Release Tool (310-054), disconnect the fuel return hose. (Scheme 35)
37. Remove the partial load breather hose clamp and remove the partial load breather hose from the purge valve. Disconnect the purge valve vacuum hose from the purge hose and reposition the hose. (Scheme 36)
38. Secure the throttle cable to the throttle cable bracket with tape or a tie strap. Remove the 2 throttle cable bracket screws which secure the throttle cable bracket to the throttle body. Rotate the throttle actuator cam and disconnect the throttle cable. Reposition the cable. (Scheme 37)
39. Release the heater supply and return hose clamps and remove hoses. Remove the brake servo hose. (Scheme 38)
40. Install the rear Engine Lifting Brackets (303-536). (Scheme 39)
41. Position the engine hoist to the engine compartment and lower it to working height.
42. Install the lifting chains to the engine hoist and connect to the engine lifting brackets. Use longer chains to the rear lifting brackets to allow the engine to tilt rearwards when removing from the vehicle.
43. Remove the engine front mounting nuts. (Scheme 40) Raise and support the vehicle.
44. Release the transmission harness connector lock lever and disconnect the transmission harness connector. (Scheme 41)
45. Remove the transmission cross shaft nut and remove the selector lever from the cross shaft. Remove the 2 selector cable bracket bolts and remove selector cable from the transmission. (Scheme 42)
46. Remove the bolt which secures the transmission mount. (Scheme 43)
47. Position a transmission jack and raise the support bed of the jack to take the weight of the transmission. Install and adjust the chains to secure the transmission to the jack. (Scheme 44)
48. Remove the 4 crossmember mounting assembly bolts and remove the crossmember mounting assembly. (Scheme 45)
49. Take the weight of the engine/transmission with the engine hoist and move it towards the front of the vehicle. Lower the transmission jack slightly to release the securing chains. Remove the transmission jack from below the vehicle. Remove the engine/transmission assembly, upwards and forwards, from the vehicle. (Scheme 46)

Installation

1. Position the engine/transmission into the engine compartment and lower the assembly into position. (Scheme 46)
2. Align the engine mount brackets to the front engine mounts and install the engine mount nuts. (Scheme 40) Tighten the engine mount nuts to specification. See «TORQUE SPECIFICATIONS»(ref-160932-S33203884602004030900000).
3. Operate the engine hoist and the vehicle lift simultaneously to raise the vehicle to a convenient working height.
4. Position a transmission jack and raise the support bed of the jack to take the weight of the transmission. Install and adjust the chains to secure the transmission to the jack. (Scheme 44)
5. Install the crossmember mounting assembly. Install, but do not tighten the 4 crossmember mounting assembly bolts. (Scheme 45) Install the transmission mount nut. (Scheme 43) Tighten the transmission mount nut and the crossmember bolts to specification. See «TORQUE SPECIFICATIONS»(ref-160932-S33203884602004030900000).
6. Release transmission jack chains and remove the transmission jack.
7. Operate the engine hoist and the vehicle lift simultaneously to lower the vehicle to a convenient working height.
8. Lower the engine hoist and remove the chain assembly and engine lifting brackets. (Scheme 39) Move the engine hoist away from the vehicle.
9. Raise and support the vehicle. Install the selector lever of the transmission selector cable to the transmission cross shaft. Install the transmission cross shaft nut. Install the selector cable bracket to the transmission and install the selector cable bracket bolts. (Scheme 42) Tighten cross shaft nut and selector cable bracket bolts to specification. See «TORQUE SPECIFICATIONS»(ref-160932-S33203884602004030900000).
10. Connect the transmission harness connector and secure the connector lock lever. (Scheme 41)
11. Install and tighten the ground cable to the transmission housing. (Scheme 29)
12. Install the downpipe catalytic converter bracket to the bell housing. (Scheme 24) Install the 2 mounting bracket bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-160932-S33203884602004030900000). Repeat for the other catalytic converter.
13. Noting the position marked during removal and using NEW bolts, install the drive shaft to the final drive flange. Tighten the 4 coupling assembly bolts to specification. See «TORQUE SPECIFICATIONS»(ref-160932-S33203884602004030900000). (Scheme 47)
14. Noting the position marked during removal and using NEW bolts, move the drive shaft sliding joint from the minimum length position and install the drive shaft to the transmission flange. Tighten the 3 coupling assembly bolts to specification. See «TORQUE SPECIFICATIONS»(ref-160932-S33203884602004030900000). (Scheme 26)
15. Install a NEW gasket to the downpipe catalytic converter flange and install the downpipe catalytic converter to the exhaust manifold. Install the downpipe catalytic converter-to-lower mounting bracket bolts but do not tighten. Repeat for the other downpipe catalytic converter. Lower vehicle.
16. Install and tighten the downpipe catalytic converter-to-exhaust manifold flange nuts (both "A" bank and "B" banks). See «TORQUE SPECIFICATIONS»(ref-160932-S33203884602004030900000). (Scheme 22)
17. Raise and support the vehicle. Slide front muffler up and connect to the downpipe catalytic converters. Slide muffler back and connect to the intermediate muffler. Align as necessary, reposition all muffler clamps and tighten clamps to specification. Tighten the downpipe catalytic converter-to-lower mounting bracket bolts to specification. See «TORQUE SPECIFICATIONS»(ref-160932-S33203884602004030900000).
18. If equipped, connect the oil cooler lines to the engine. Remove the plugs from the oil cooler lines and fittings on the engine. Install NEW "O" rings on the oil cooler lines and lubricate with clean engine oil. Install the oil cooler lines to the engine. Install the clamping plate with bolt and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-160932-S33203884602004030900000). (Scheme 30)
19. Install the parking brake relay lever mounting bracket. (Scheme 25) Lower the vehicle.
20. Install the heater return and supply hoses. Tighten heater hose clamps. Install the brake servo hose. (Scheme 38)
21. Install the engine management harness connector to the mounting bracket. Connect the engine management harness connectors and tighten the bolt. (Scheme 33)
22. Noting position marked during removal, connect the transmission rotary switch harness connector and oxygen sensor connectors. Install connector to mounting bracket. (Scheme 21)
23. Install the throttle cable bracket and throttle cable bracket screws. Rotate the throttle actuator cam and connect the throttle cable and position the cable into the cam. Remove any tape or plastic tie strap. Tighten throttle cable bracket screws to specification. See «TORQUE SPECIFICATIONS»(ref-160932-S33203884602004030900000). (Scheme 37)
24. Connect the partial load breather hose and tighten the clamp securing the part load breather hose to the purge valve. Connect the vacuum hose to the purge valve. (Scheme 36)
25. Connect the fuel feed hose to the fuel feed pipe. (Scheme 34) Ensure that quick fit connector is fully seated to the fuel feed pipe.
26. Connect the fuel return hose to the fuel return pipe. (Scheme 35) Ensure that the quick fit connector is fully seated to the fuel return pipe.
27. Route the positive cable through the heatshield and install the cable to the starter motor positive cable stud. Install and tighten the nut to the stud. Reposition the protective boot over the starter cable power stud. Connect the engine management harness-to-starter motor connector. Install the connector to the mounting bracket and secure the cable with a NEW tie strap. (Scheme 32)
28. If equipped, connect the generator suppression module harness connector and reposition the harness under the suppression module. (Scheme 31)
29. Remove the plugs and cap from the power steering lines and fittings. Install a NEW sealing washer to the high pressure hose, install and tighten the high pressure line. Install the supply hose to the pump and position the hose clamp to secure the hose. (Scheme 20)
30. Connect the engine oil pressure sensor connector. (Scheme 19)
31. Install the radiator. See «RADIATOR»(ref-160932-S08894469872004030900000).
32. Connect the lower expansion tank hose to the expansion tank and install and position the hose clamp to secure the hose. Install the expansion tank to the left side enclosure panel. (Scheme 18)
33. Connect the coolant level sensor connector. Install the tank to the rear mounting grommets and install expansion tank bolt. (Scheme 17)
34. Install the expansion tank-to-thermostat housing hose and the radiator air bleed hose to the expansion tank. Position the hose clamps to secure the hoses. (Scheme 16)
35. Install a NEW air intake tube-to-throttle body seal. Install a NEW "O" ring to the "A" bank breather pipe and install the air intake tube/airflow meter/air cleaner cover assembly. (Scheme 15)
36. Secure the 5 air cleaner cover clips and connect the airflow meter connector. (Scheme 14)
37. Connect the air intake tube to the throttle body and install the 2 bolts which secure the air intake tube to the throttle body. (Scheme 13)
38. Install a NEW strap to secure the vacuum pipe to the intake manifold elbow.
39. Connect battery. See «BATTERY RECONNECT PROCEDURE»(ref-160932-S33171390462004030900000) under MISCELLANEOUS.
40. Refill the cooling system. See «COOLING SYSTEM»(ref-160932-S05714134782004030900000).
41. Refill the engine with engine oil of the correct specification.
42. Refill the automatic transmission.
43. Refill and bleed the power steering system.
44. Using approved A/C equipment, evacuate and recharge A/C system.
45. Check for leaks and that all lines and hoses are securely connected. Carefully install the engine covers, taking care not to damage the plastic retainers or the rubber inserts.
46. With assistance, install the engine compartment hood and install the 6 bolts. Install the ground lead to the original location on the left hand hinge. (Scheme 11)
47. Move the engine compartment hood from the service position and connect the gas struts. (Scheme 10) Remove the body protection covers and close the engine compartment hood.

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