Removal (Supercharged): Removal & Installation Jaguar XKR I

Installation

1. Install a NEW seal to the thermostat. Install the thermostat so that the vent ball valve locates in the recess in the cover. (Scheme 198)
2. Install the thermostat cover and the 3 thermostat cover bolts. Tighten thermostat cover bolts to specification. See «TORQUE SPECIFICATIONS»(ref-160932-S33203884602004030900000).
3. Install the lower radiator hose to the thermostat cover. Reposition hose clamp to secure hose. (Scheme 197)
4. Refill cooling system. See «COOLING SYSTEM»(ref-160932-S05714134782004030900000).
5. Check for leaks and that all coolant hoses are securely connected. Move the engine compartment hood from the service position and connect the gas struts. Remove the body protection covers and close the engine compartment hood.

Scheme 196

Scheme 197

1. Open the engine compartment hood to service position and install body protection covers.
2. Drain the cooling system. See «COOLING SYSTEM»(ref-160932-S05714134782004030900000).
3. If equipped with a supercharger, remove supercharger drive belt by fitting a 1/2 inch square drive ratchet or bar into square opening on front face of tensioner. Rotate tensioner assembly to the right (viewed from front) against spring tension. While holding the tensioner against spring tension, remove supercharger drive belt from tensioner pulley. Release tensioner slowly and remove bar. Disconnect supercharger drive belt from other pulleys and remove it from rear of tensioner. see scheme 94
4. On all models, loosen the 3 bolts which secure the water pump pulley. Using Spanner Wrench (Churchill JD-230 or Snap On XDHM 1415) on the center bolt of the belt tensioner idler pulley, turn the adjuster assembly to the left against spring tension. While holding the tensioner against spring tension, remove the drive belt from the generator pulley. Release the tensioner slowly and remove the spanner wrench. Remove belt from all other pulleys. Remove the 3 screws from the water pump pulley and remove the pulley from the water pump. see scheme 118
5. Remove the 5 water pump bolts and remove water pump from the engine. Remove and discard the water pump gasket and "O" ring. (Scheme 199)
6. Clean any coolant spillage from the engine compartment. Clean all parts and sealing faces.

1. Using a NEW water pump gasket and "O" ring, align and install water pump. Install the 5 water pump bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-160932-S33203884602004030900000). (Scheme 199)
2. Install the following: Water pump pulley and 3 water pump pulley bolts. Tighten bolts after drive belt is installed. Drive belt around all pulleys except the generator. Using Spanner Wrench (Churchill JD-230 or Snap On XDHM 1415) on the center bolt of the belt tensioner idler pulley, turn the adjuster assembly to the left against spring tension. While holding the tensioner against spring tension, install the drive belt around the generator pulley. Release the tensioner slowly and remove the spanner wrench. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-160932-S33203884602004030900000). see scheme 118
3. If equipped with a supercharger, install supercharger drive belt to all pulleys, except tensioner pulley. Using a 1/2 inch square drive ratchet or bar into square opening on front face of tensioner. Rotate tensioner assembly to the right (viewed from front) against spring tension. While holding the tensioner against spring tension, install supercharger drive belt to tensioner pulley. Release tensioner slowly and remove bar. see scheme 94
4. On all models, refill the cooling system. See «COOLING SYSTEM»(ref-160932-S05714134782004030900000).
5. Check for leaks and that all coolant hoses are securely connected. Move the engine compartment hood from the service position and connect the gas struts. Remove the body protection covers and close the engine compartment hood.

Scheme 198

1. Open the engine compartment hood to service position and install body protection covers. Disconnect the battery ground cable and remove the battery cover. Carefully remove the engine covers, taking care not to damage the plastic retainers or the rubber inserts.
2. Remove the 2 bolts which secure the air intake tube to the throttle body. Disconnect the air intake tube from the throttle body. see scheme 13
3. Release the 5 clips which secure the air cleaner cover. see scheme 14 Disconnect the airflow meter connector.
4. 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. see scheme 15 Remove and discard the air intake tube-to-throttle body rubber seal.
5. Cut and remove the strap which secures the vacuum pipe to the intake manifold elbow.
6. Remove the air filter element. Remove the nut which secures the base of the air cleaner assembly to the rubber mountings. Release the assembly from the lower rubber mountings. Release the intake tube from the assembly and move it clear, into the grommet in the inner fender and remove the air cleaner assembly. see scheme 66
7. Remove the electric water pump harness connector from the mounting bracket and disconnect connector. Remove the 2 electric water pump mounting bracket bolts. (Scheme 200)
8. Reposition the electric water pump assembly to access hose clamps. Reposition the hoses clamps and remove the inlet and outlet hoses from the electric water pump (install clamps to the inlet and outlet hoses if cooling system is not being drained for other procedures). (Scheme 201)
9. Remove the nuts which secure the electric water pump clamp to the mounting bracket. Remove the clamp and insulation rubber from the pump. (Scheme 202) Clean the adjacent area of any coolant spillage.

1. Install electric water pump, clamp and rubber insulator to electric water pump mounting bracket. (Scheme 202) Install and tighten electric water pump clamp mounting nuts.
2. Install inlet and outlet hoses and reposition hose clamps to secure hoses to electric water pump (remove the additional clamps on hoses if necessary). (Scheme 201)
3. Connect the electric water pump connector, install connector to mounting bracket and install electric water pump assembly to vehicle. (Scheme 200) Install and tighten mounting bolts.
4. Install the air cleaner assembly into the rubber mountings and install the nut that secures the base of the air cleaner. Install the intake tube into the air cleaner assembly. see scheme 66 Install air filter element.
5. 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. see scheme 15
6. Secure the 5 air cleaner cover clips and connect the airflow meter connector. see scheme 14
7. Connect the air intake tube to the throttle body and install the 2 bolts which secure the air intake tube to the throttle body. see scheme 13
8. Install a NEW strap to secure the vacuum pipe to the intake manifold elbow.
9. Connect battery. See «BATTERY RECONNECT PROCEDURE»(ref-160932-S33171390462004030900000) under MISCELLANEOUS.
10. Carefully install the engine covers, taking care not to damage the plastic retainers or the rubber inserts.
11. Refill the cooling system. See «COOLING SYSTEM»(ref-160932-S05714134782004030900000).
12. Check for leaks and that all coolant hoses are securely connected. Move the engine compartment hood from the service position and connect the gas struts. Remove the body protection covers and close the engine compartment hood.

Scheme 199

Scheme 200

Scheme 201

1. Open engine compartment hood and install body protection covers. Raise and support vehicle. Remove engine oil drain plug and drain the engine oil.
2. Remove the 18 oil pan bolts and remove the oil pan. Remove and discard the oil pan gasket. (Scheme 203)
3. Clean and inspect the sealing faces on the oil pan and mating faces.

1. Install a NEW oil pan gasket to the cylinder block adaptor body by inserting the seal into the locating positions in the groove, working around from a corner. Press in the remainder of the seal, following the same procedure. (Scheme 204)
2. Align and install the oil pan, installing but not tightening all 18 bolts. (Scheme 203)
3. Tighten the oil pan bolts to specification and in the proper sequence. See «TORQUE SPECIFICATIONS»(ref-160932-S33203884602004030900000). see scheme 205
4. Using a NEW sealing washer, install the engine oil drain plug and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-160932-S33203884602004030900000). Install a NEW oil filter.
5. Lower the vehicle. Refill the engine with engine oil of the correct specification. Remove the body protection covers and close the engine compartment hood.

Scheme 202

Scheme 203

Scheme 204