Supercharger: Removal & Installation Jaguar XKR I

Removal

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. Drain the cooling system. See «COOLING SYSTEM»(ref-160932-S05714134782004030900000).
3. 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
4. Release the 5 clips which secure the air cleaner cover. see scheme 14 Disconnect the airflow meter connector.
5. 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.
6. Cut and remove the strap which secures the vacuum pipe to the intake manifold elbow.
7. Disconnect the throttle body and Camshaft Position (CMP) sensor connectors from the right side of the throttle body. see scheme 49
8. Disconnect the coolant hose from the throttle body. see scheme 51 Cap coolant hoses to minimize coolant loss.
9. Remove the lower throttle body support bolts from the throttle body. see scheme 52
10. Turn the throttle pulley to the fully open position and disconnect the throttle cable from the pulley. see scheme 53
11. Remove and discard the throttle cable retaining strap and remove the accelerator cable from the bracket. see scheme 54
12. Disconnect the throttle body and CMP sensor connectors from the left side of the throttle body. see scheme 49
13. Disconnect the throttle body electrical connector. (Scheme 76)
14. Disconnect the air assist control valve hose. (Scheme 77)
15. Remove the 4 throttle body bolts and remove the throttle body from the intake manifold elbow and discard the throttle body gasket. (Scheme 78)
16. Remove the catalytic converter heat shield upper retaining bolts. Detach the catalytic converter heat shield. (Scheme 79)
17. Remove the exhaust manifold-to-Exhaust Gas Recirculation (EGR) valve tube heat shield. (Scheme 80)
18. Remove EGR valve connector. (Scheme 81)
19. Remove the EGR coolant hose from the throttle body. (Scheme 82)
20. Remove EGR transfer pipe and EGR valve bolts. (Scheme 83) Remove EGR valve.
21. On the right side of the intake manifold elbow, remove the vacuum line and upper bolt from the intake manifold elbow support bracket. (Scheme 84)
22. On the left side of the intake manifold elbow, remove the vacuum and engine breather line. Remove the upper bolt from the intake manifold elbow support bracket. Loosen, but do not remove, the 2 lower bolts at the intake manifold elbow support bracket. (Scheme 85)
23. Reposition the supercharger by-pass hose clamps at the charge air coolers. Remove the 4 bolts securing the intake manifold elbow and remove the intake manifold elbow assembly. Remove and discard gasket. (Scheme 86)
24. Place absorbent rags under the 2 coolant hoses which are connected to the outlet duct. Remove vacuum line, disconnect and plug the coolant hoses and outlet duct stub pipes to prevent spillage. (Scheme 87)
25. Taking care to avoid any debris or coolant from entering into supercharger, remove the 3 bolts that secure the supercharger outlet duct to the charge air cooler inlet assembly and the 4 bolts that secure the supercharger outlet duct to the supercharger. (Scheme 88) Remove outlet duct and discard the rubber bolt seals and the outlet duct gasket. Blank off the supercharger outlet with body tape, or equivalent, to prevent contamination.
26. Remove the 4 bolts from the charge air cooler inlet assembly and remove charge air cooler inlet assembly from charge air coolers. (Scheme 89)
27. Remove the ducts from charge air cooler inlet assembly by removing the 2 clamp plates. (Scheme 90) Discard the 2 ducts.
28. Remove the following from the coolant outlet pipe: Upper radiator hose clamp and hose. Breather hose quick fit connector. Temperature sensor connector. Loosen and reposition the by-pass hose clamp at the coolant outlet pipe. (Scheme 91)
29. Reposition the lower radiator hose clamp and remove from thermostat housing. (Scheme 92)
30. Remove the 4 coolant outlet pipe bolts and remove coolant outlet pipe from the by-pass hose and cylinder heads. (Scheme 93) Reposition the heater hose clamp and remove the heater hose from the coolant outlet pipe.
31. 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. (Scheme 94)
32. Remove the bolts securing the supercharger and remove the supercharger from the engine. (Scheme 95)
33. Clean all parts and sealing surfaces.

Installation

1. Install supercharger and any charge air cooler hoses that have been disconnected. (Scheme 95) Tighten supercharger bolts to specification. See «TORQUE SPECIFICATIONS»(ref-160932-S33203884602004030900000).
2. Install supercharger drive belt to all pulleys except the 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. (Scheme 94)
3. Install NEW sealing rings to the coolant outlet pipe grooves. Install the outlet pipe to the by-pass hose and to the cylinder heads. (Scheme 93) Install the 4 coolant outlet pipe bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-160932-S33203884602004030900000). Install the heater hose to the coolant outlet pipe and reposition the heater hose and by-pass hose clamps to secure the hoses.
4. Install the lower radiator hose to the thermostat housing and reposition clamp to secure the lower radiator hose. (Scheme 92)
5. Install or connect the following to the coolant outlet pipe: Upper radiator hose and hose clamp. Breather hose quick fit connector. Temperature sensor connector. (Scheme 91)
6. Install NEW ducts and assemble charge air cooler inlet assembly. (Scheme 90)
7. Install the charge air cooler inlet assembly to charge air coolers. (Scheme 89) Install charge air cooler inlet assembly bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-160932-S33203884602004030900000).
8. Remove blanking tape from outlet port of supercharger. Clean supercharger outlet mating face and install a NEW gasket. Install supercharger outlet duct. Install NEW rubber seals on the 4 supercharge outlet duct bolts and install. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-160932-S33203884602004030900000). (Scheme 88)
9. Install the charge air cooler inlet assembly to supercharger outlet duct. Install and tighten the charge air cooler inlet assembly bolts to specification. See «TORQUE SPECIFICATIONS»(ref-160932-S33203884602004030900000).
10. Install coolant hoses and vacuum line to supercharger outlet duct. (Scheme 87)
11. Install 2 bolts through the intake manifold elbow to install and position a NEW intake manifold elbow gasket. Install intake manifold elbow into position with by-pass hoses located on the charge air cooler stub pipes. Install and tighten the 4 intake manifold elbow bolts to specification. See «TORQUE SPECIFICATIONS»(ref-160932-S33203884602004030900000). (Scheme 86) Install the by-pass hose clamps to secure the by-pass hoses.
12. On the left side of the intake manifold elbow, install the upper bolt to the intake manifold elbow support bracket. Connect the vacuum and the engine breather lines. (Scheme 85)
13. On the right side of the intake manifold elbow, install the upper bolt to the intake manifold elbow support bracket and tighten the intake manifold elbow support bracket bolts (both left and right sides) to specification. See «TORQUE SPECIFICATIONS»(ref-160932-S33203884602004030900000). Connect the vacuum line to the intake manifold elbow. (Scheme 84)
14. Using NEW EGR valve gaskets, install the EGR valve and transfer pipe into position. (Scheme 83) Install EGR valve and transfer pipe bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-160932-S33203884602004030900000).
15. Connect the EGR coolant hose to the throttle body. (Scheme 82)
16. Connect EGR valve connector. (Scheme 81)
17. Install the exhaust manifold-to-EGR valve tube heat shield. (Scheme 80) Install retaining bolt and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-160932-S33203884602004030900000).
18. Attach the catalytic converter heat shield and install the catalytic converter heat shield upper retaining bolts. (Scheme 79) Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-160932-S33203884602004030900000).
19. Using a NEW throttle body gasket, install the throttle body to the intake manifold elbow. (Scheme 78) Install the 4 throttle body bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-160932-S33203884602004030900000).
20. Connect the air assist control valve hose. (Scheme 77)
21. Connect the throttle body and CMP sensor connectors to the left side of the throttle body. see scheme 49
22. Position the throttle pulley to the full throttle position and connect the throttle cable. see scheme 54 Secure throttle cable to bracket.
23. Remove the plugs from the throttle body hoses and connect hoses to the positions noted during removal. Reposition hose clamps to secure throttle body hoses in position. see scheme 51
24. Install the lower throttle body support bolts to the throttle body. see scheme 52
25. Connect the throttle body and CMP sensor connectors to the right side of the throttle body. see scheme 49
26. Install the coolant line. see scheme 48
27. 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
28. Secure the 5 air cleaner cover clips and connect the airflow meter connector. see scheme 14
29. 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
30. Install a NEW strap to secure the vacuum pipe to the intake manifold elbow.
31. Connect battery. See «BATTERY RECONNECT PROCEDURE»(ref-160932-S33171390462004030900000) under MISCELLANEOUS.
32. Carefully install the engine covers, taking care not to damage the plastic retainers or the rubber inserts.
33. Refill cooling system. See «COOLING SYSTEM»(ref-160932-S05714134782004030900000).
34. 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 76

Scheme 77

Scheme 78

Scheme 79

Scheme 80

Scheme 81

Scheme 82

Scheme 83

Scheme 84

Scheme 85

Scheme 86

Scheme 87

Scheme 88

Scheme 89

Scheme 90

Scheme 91

Scheme 92

Scheme 93

Scheme 94

Scheme 95

Scheme 96