Engine: Overhaul Jaguar XKR I рестайлинг

Disassembly

Vehicles with supercharger

Scheme 106

Scheme 107

Scheme 108

Scheme 109

Scheme 110

Scheme 111

Scheme 112

Scheme 113

Scheme 114

Scheme 115

Scheme 116

Scheme 117

Scheme 118

Scheme 119

Scheme 120

Scheme 121

Scheme 122

Scheme 123

Scheme 124

Scheme 125

Scheme 126

Scheme 127

Scheme 128

Scheme 129

Scheme 130

Scheme 131

Scheme 132

Scheme 133

Scheme 134

Scheme 135

Scheme 136

Scheme 137

Scheme 138

Scheme 139

Scheme 140

Scheme 141

Scheme 142

Scheme 143

Scheme 144

Scheme 145

Scheme 146

Scheme 147

Scheme 148

Scheme 149

Scheme 150

Scheme 151

Scheme 152

Scheme 153

Scheme 154

Scheme 155

1. Detach the supercharger belt. Use a 1/2 inch square drive bar to rotate the supercharger belt tensioner. Detach the supercharger belt.
2. Remove the supercharger drive belt tensioner. Remove the super charger drive belt.
3. Release the accessory drive belt tension.
4. Detach the accessory drive belt.
5. Remove the drive belt tensioner. Remove the drive belt.
6. Detach the coolant hose.
7. Detach the coolant hose.
8. Detach the coolant hose.
9. Remove the coolant hose.
10. Remove the coolant hose.
11. Remove the left-hand engine mount.
12. Remove the engine mount bracket.
13. Remove the oil level indicator and tube. Remove and discard the O-ring seal.
14. Remove the power steering pump. Remove the securing bolts.
15. Disconnect the electrical connector.
16. Remove the air conditioning (A/C) compressor. Remove the securing bolts.
17. Remove the mount bracket.
18. Detach the wiring harness.
19. Remove the mount bracket.
20. Remove the left-hand exhaust manifold. Remove and discard the gasket.
21. Disconnect the electrical connector.
22. Remove the generator. Remove the retaining bolts.
23. Detach the wiring harness.
24. Remove the mount bracket. Remove the retaining bolts.
25. Remove the right-hand engine mount.
26. Remove the engine mount bracket.
27. Remove the right-hand exhaust manifold. Remove and discard the gasket.
28. Remove the starter motor.
29. Disconnect the crankshaft position sensor electrical connector.
30. Remove the crankshaft position sensor.
31. Detach the wiring harness.
32. Detach the wiring harness.
33. Detach the engine wiring harness.
34. Disconnect the electrical connector.
35. Detach the coolant hose. Reposition the retaining clip.
36. Detach the thermostat housing. Remove the retaining bolts
37. Remove the thermostat housing. Detach the coolant hose.
38. Disconnect the electrical connector.
39. Disconnect the electrical connector.
40. Disconnect the electrical connector.
41. Disconnect the electrical connector.
42. Disconnect the electrical connector.
43. Detach the wiring harness. Remove the retaining bolt.
44. Detach the wiring harness.
45. Detach the breather pipe.
46. Disconnect the breather pipe.
47. Remove the positive crankcase ventilation pipe.
48. Detach the wiring harness.
49. Detach the wiring harness.
50. Remove the ignition coil-on-plug cover.
51. Detach the engine wiring harness.
52. Disconnect the ignition coil-on-plug electrical connectors.
53. Detach the engine wiring harness.
54. Remove the ignition coil-on-plug cover.
55. Disconnect the ignition coil electrical connectors.
56. Detach the engine wiring harness.
57. Detach the engine wiring harness.
58. Remove the engine cover retaining bracket.
59. Detach the engine wiring harness.
60. Disconnect the fuel injector electrical connectors.
61. Disconnect the fuel temperature sensor electrical connector.
62. Disconnect the camshaft position sensor electrical connector.
63. Disconnect the camshaft position sensor electrical connector.
64. Disconnect the fuel temperature sensor electrical connector.
65. Disconnect the throttle motor electrical connector.
66. Disconnect the throttle position (TP) sensor electrical connector.
67. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
68. Disconnect the manifold absolute pressure (MAP) sensor
69. Remove the engine wiring harness.
70. Remove the engine wiring harness.
71. Reposition the retaining clips.
72. Disconnect the coolant hose.
73. Disconnect the coolant hose.
74. Remove the retaining bolt.
75. Remove the retaining bolt.
76. Reposition the retaining clips.
77. Remove the retaining bolts.
78. Remove the throttle body and throttle body elbow assembly. Remove the retaining bolts. Remove and discard the gasket.
79. Remove the intake manifold.
80. Remove the retaining bolt.
81. Remove the retaining bolts.
82. Disconnect the coolant hose. Reposition the retaining clip.
83. Disconnect the vacuum hose.
84. Remove the supercharger. Remove the retaining bolts. Collect the spacer.
85. Remove the retaining bolts.
86. Remove the supercharger outlet pipe to charge air cooler ducts. Remove the retaining bolts.
87. Remove the charge air cooler. Remove the retaining bolts. Remove and discard the gasket.
88. Remove the charge air cooler. Remove the retaining bolts. Remove and discard the gasket.
89. Remove the lower intake manifold. Remove the retaining bolts. Remove and discard the gaskets.
90. Remove the coolant bypass to water pump pipe. Remove the retaining bolts. Remove and discard the O-ring seal.
91. Remove the noise and vibration insulating pad.
92. Remove the knock sensors. Remove the retaining nut.
93. Remove the coolant hose.
94. Detach the coolant hose. Remove the retaining bolts.
95. Remove the engine block insulation grommet.
96. Remove the water pump pulley. Using special tool, retain the water pump pulley.
97. Remove the water pump. Remove and discard the gasket. Remove and discard the O-ring seal.
98. Remove the retaining bolts.
99. Remove the thermostat housing. Remove and discard the O-ring seals.
100. Remove the ignition coil-on-plug
101. Remove the spark plugs.
102. Remove the right-hand camshaft position (CMP) sensor. Remove and discard the O-ring seal.
103. Remove the left-hand camshaft position (CMP) sensor. Remove and discard the O-ring seal.
104. Using special tools, retain the crankshaft pulley. Remove and discard the crankshaft pulley bolt.
105. Remove the special tools.
106. Using special tools, remove the crankshaft pulley. Collect the locking ring. Remove and discard the O-ring seal.
107. Remove the special tools.
108. Remove the crankshaft position (CKP) sensor.
109. Install the special tool 303-645.
110. Remove the right-hand valve cover. Discard the valve cover gaskets.
111. Remove the left-hand valve cover. Discard the valve cover gaskets.
112. Remove the oil pressure sensor.
113. Remove the oil temperature sensor.
114. Remove the engine front cover.
115. Remove the right-hand variable camshaft timing oil control unit housing. Remove and discard the O-ring seals.
116. Remove the left-hand variable camshaft timing oil control unit housing. Remove and discard the O-ring seals.
117. Install the special tool to the left-hand cylinder head.
118. Install the special tool to the Right-hand cylinder head.
119. Remove the primary timing chain tensioner assembly.
120. Remove the primary timing chain tensioner guide.
121. Remove the primary timing chain.
122. Remove the primary timing chain guide.
123. Remove the secondary timing chain tensioner retaining bolts.
124. Remove the camshaft sprockets. Remove the secondary timing chain tensioner and secondary timing chain from the camshaft sprockets.
125. Remove the primary timing chain tensioner assembly.
126. Remove the primary timing chain tensioner guide.
127. Remove the primary timing chain.
128. Remove the crankshaft sprocket.
129. Remove the primary timing chain tensioner guide.
130. Remove the secondary timing chain tensioner retaining bolts.
131. Remove the camshaft sprockets. Remove the secondary timing chain tensioner and secondary timing chain from the camshaft sprockets.
132. Remove the camshaft setting tool.
133. Remove the camshaft setting tool.
134. 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).
135. Remove the right-hand exhaust camshaft.
136. 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).
137. Remove the right-hand intake camshaft.
138. 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).
139. Remove the left-hand exhaust camshaft.
140. 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).
141. Remove the left-hand inlet camshaft.
142. Remove the right-hand cylinder head. Remove the bolts in the indicated sequence. Remove and discard the gasket.
143. Remove the left-hand cylinder head. Remove the bolts in the indicated sequence. Remove and discard the gasket.
144. Remove the crankshaft setting peg 303645 from the crankshaft position sensor location.
145. Remove the drive plate. Remove the drive plate retaining bolts. Remove the drive plate.
146. Remove the lower oil pan. Remove and discard the gasket.
147. Remove the oil strainer. Remove and discard the O-ring seal.
148. Remove the upper oil pan. Remove and discard the gasket.
149. Remove the oil pump. Remove and discard the gasket.
150. Inspect the tops of the cylinder bores. As necessary remove ridge and carbon build up from each cylinder.
151. Remove the piston cooling jets.
152. Remove the connecting rod bolts, the connecting rod caps and the lower connecting rod bearings.
153. Install special tools to the connecting rods.
154. 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.
155. Remove the lower cylinder block. Remove the lower cylinder block retaining bolts in the indicated sequence.
156. Discard the crankshaft rear main oil seal.
157. Remove the crankshaft.
158. Remove the upper crankshaft main bearings. Remove the upper crankshaft thrust washers. Remove the upper crankshaft main bearings.
159. 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 156

Scheme 157

Scheme 158

Scheme 159

Scheme 160

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-311024) .
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 161

Scheme 162

Scheme 163

Scheme 164

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 sealing surfaces.
9. 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.
10. Carefully remove the transit sleeve, leaving the seal in place.
11. Install the special tool to the crankshaft.
12. 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.
13. Using the special tool, install the crankshaft rear seal.
14. Remove the special tool from the crankshaft. Check that the seal is located correctly.
15. Install the 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.
16. Using the special tool compress the rings and install the piston and connecting rod. Lubricate all piston components.
17. Position the connecting rod cap on the appropriate connecting rod. Tighten to 10 Nm Tighten to 30 Nm Tighten to 90°
18. Rotate the crankshaft to check correct operation.
19. Install the piston cooling jets. Tighten to 9 Nm
20. Install the oil pump. Install a new gasket. Tighten to 12 Nm.
21. Install the upper oil pan. Install a new gasket. Tighten to 21 Nm.
22. Install the oil strainer. Install a new O-ring seal. Tighten to 12 Nm.
23. Install the lower oil pan. Install a new gasket. Tighten to 12 Nm.
24. Install the drive plate. Install the drive plate. Install the drive plate retaining bolts. Tighten to 15 Nm. Tighten to 110 Nm.
25. Reposition the crankshaft. Install the crankshaft setting peg 303645 to the crankshaft position sensor location.
26. Install a new left-hand cylinder head gasket. Make sure the cylinder head dowels are correctly located.
27. 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.
28. Install a new right-hand cylinder head gasket. Make sure the cylinder head dowels are correctly located.
29. 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.
30. 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.
31. Install the left-hand inlet camshaft.
32. Install the camshaft bearing cap bolts evenly. Tighten to 10 Nm.
33. 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.
34. Install the left-hand exhaust camshaft.
35. Install the camshaft bearing cap bolts evenly. Tighten to 10 Nm.
36. 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.
37. Install the right-hand inlet camshaft.
38. Install the camshaft bearing cap bolts evenly. Tighten to 10 Nm.
39. 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.
40. Install the right-hand exhaust camshaft.
41. Install the camshaft bearing cap bolts evenly. Tighten to 10 Nm.
42. Install the camshaft setting tool.
43. Install the camshaft setting tool.
44. Using a suitable tool, retain the right-hand timing chain tensioner piston.
45. Install the camshaft sprockets. Install the secondary timing chain tensioner and secondary timing chain to the camshaft sprockets.
46. Install the secondary timing chain tensioner retaining bolts. Tighten to 12 Nm.
47. 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.
48. Install the primary timing chain tensioner guide. Tighten to 12 Nm.
49. Install the crankshaft sprocket.
50. Install the primary timing chain. Install the primary chain over the crankshaft sprocket and the intake sprocket.
51. Install the primary timing chain tensioner guide. Tighten to 12 Nm.
52. Using a suitable tool, hold the left-hand timing chain tensioner ratchet lock mechanism away from the ratchet stem.
53. Slowly compress the left-hand timing chain tensioner.
54. Using a suitable tool, retain the left-hand timing chain tensioner piston.
55. Install the primary timing chain tensioner assembly. Tighten to 12 Nm.
56. Release the tension in the left-hand timing chain tensioner. Remove the retaining tool.
57. 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.
58. Using the special tool apply force to the tool in an anti-clockwise direction. Tighten to 120 Nm.
59. Using a suitable tool, retain the right-hand timing chain tensioner piston.
60. Install the camshaft sprockets. Install the secondary timing chain tensioner and secondary timing chain to the camshaft sprockets.
61. Install the secondary timing chain tensioner retaining bolts. Tighten to 12 Nm.
62. 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.
63. Install the primary timing chain guide. Tighten to 12 Nm.
64. Install the primary timing chain. Install the primary chain over the crankshaft sprocket and the intake sprocket.
65. Install the primary timing chain tensioner guide. Tighten to 12 Nm.
66. Using a suitable tool, hold the right-hand timing chain tensioner ratchet lock mechanism away from the ratchet stem.
67. Slowly compress the right-hand timing chain tensioner.
68. Using a suitable tool, retain the right-hand timing chain tensioner piston.
69. Install the primary timing chain tensioner assembly. Tighten to 12 Nm.
70. Release the tension in the right-hand timing chain tensioner. Remove the retaining tool.
71. 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.
72. Using the special tool apply force to the tool in an anti-clockwise direction. Tighten to 120 Nm.
73. Remove the special tool from the Right-hand cylinder head.
74. Remove the special tool from the left-hand cylinder head.
75. Install the left-hand variable camshaft timing oil control unit housing. Install new O-ring seals. Tighten to 22 Nm.
76. Install the right-hand variable camshaft timing oil control unit housing. Install new O-ring seals. Tighten to 22 Nm.
77. Remove the special tool.
78. Install the crankshaft position sensor.
79. 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.
80. Apply sealant to the eight joints on the engine face. Sealant beads to be 3 mm diameter and 12 mm 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).
81. Install the front cover. Tighten in the sequence shown. Tighten to 13 Nm.
82. Using the special tool, install a new crankshaft front seal.
83. Remove the crankshaft seal protector.
84. Install a new O-ring seal to the crankshaft pulley. Lubricate the new O-ring.
85. Install, but do not tighten, a new crankshaft pulley retaining bolt. Install the crankshaft pulley and locking ring to the crankshaft.
86. Using special tools, retain the crankshaft pulley. Tighten the crankshaft pulley retaining bolt to 375 Nm.
87. Remove the special tools.
88. Carry out a valve clearance check. Refer to «Engine System - General Information»(ref-311024) .
89. Install the left-hand valve cover. Install new valve cover gaskets. Tighten in the sequence shown. Tighten to 10 Nm.
90. Install the right-hand valve cover. Install new valve cover gaskets. Tighten in the sequence shown. Tighten to 10 Nm.
91. Install the spark plugs. Tighten to 27 Nm.
92. Install the thermostat housing. Install new O-ring seals. Tighten to 10 Nm.
93. Remove the retaining bolts.
94. Install the water pump. Install a new O-ring seals and gasket. Tighten to 8 Nm + 90°
95. Install the water pump pulley. Using special tool, retain the water pump pulley. Tighten to 10 Nm + 45°
96. Install the engine block insulation grommet.
97. Install the coolant hose.
98. Attach the coolant hose. Tighten to 18 Nm.
99. Install the knock sensors. Tighten to 20 Nm.
100. Install the noise and vibration insulating pad.
101. Install the coolant bypass to water pump pipe. Install new O-ring seal. Tighten to 9 Nm.
102. Install the lower intake manifold. Install new gaskets. Tighten to 22 Nm.
103. Install the charge air cooler. Install new gaskets. Tighten to 22 Nm.
104. Install the supercharger outlet pipe to charge air cooler ducts. Tighten to 22 Nm.
105. Tighten to 22 Nm.
106. Install the supercharger. Install the spacer. Tighten to 22 Nm.
107. Connect the vacuum hose.
108. Connect the coolant hose. Reposition the retaining clip.
109. Install the retaining bolts. Tighten to 22 Nm.
110. Install the retaining bolts. Tighten to 22 Nm.
111. Install the intake manifold. Tighten to 22 Nm.
112. Install the throttle body and throttle body elbow assembly. Install new gaskets. Tighten to 20 Nm.
113. Install the retaining bolts. Tighten to 20 Nm.
114. Install the retaining bolt. Tighten to 12 Nm.
115. Install the retaining bolt. Tighten to 12 Nm.
116. Connect the coolant hose.
117. Connect the coolant hose.
118. Reposition the retaining clips.
119. Install the engine wiring harness.
120. Install the engine wiring harness.
121. Connect the manifold absolute pressure (MAP) sensor
122. Connect the exhaust gas recirculation (EGR) valve electrical connector.
123. Connect the throttle position (TP) sensor electrical connector.
124. Connect the throttle motor electrical connector.
125. Connect the fuel temperature sensor electrical connector.
126. Connect the camshaft position sensor electrical connector.
127. Connect the fuel injector electrical connectors.
128. Attach the engine wiring harness.
129. Connect the camshaft position sensor electrical connector.
130. Connect the fuel temperature sensor electrical connector.
131. Install the engine cover retaining bracket. Tighten to 6 Nm.
132. Attach the engine wiring harness.
133. Attach the engine wiring harness.
134. Connect the ignition coil electrical connectors.
135. Install the ignition coil-on-plug cover.
136. Attach the engine wiring harness.
137. Connect the ignition coil-on-plug electrical connectors.
138. Attach the engine wiring harness.
139. Remove the ignition coil-on-plug cover.
140. Attach the wiring harness.
141. Attach the wiring harness.
142. Install the positive crankcase ventilation pipe.
143. Connect the breather pipe.
144. Attach the breather pipe.
145. Attach the wiring harness.
146. Attach the wiring harness.
147. Connect the electrical connector.
148. Connect the electrical connector.
149. Connect the electrical connector.
150. Connect the electrical connector.
151. Connect the electrical connector.
152. Install the thermostat housing. Attach the coolant hose. Reposition the retaining clip.
153. Attach the coolant hose. Reposition the retaining clip.
154. Attach the thermostat housing. Tighten to 10 Nm.
155. Connect the electrical connector.
156. Attach the engine wiring harness.
157. Attach the wiring harness.
158. Attach the wiring harness.
159. Install the crankshaft position sensor.
160. Connect the crankshaft position sensor electrical connector.
161. Install the starter motor.
162. Install the right-hand exhaust manifold. Tighten to 25 Nm.
163. Install the engine mount bracket. Tighten to 40 Nm.
164. Install the engine mount. Tighten to 70 Nm.
165. Install the mount bracket. Tighten to 45 Nm.
166. Attach the wiring harness.
167. Install the generator. Tighten the generator upper retaining bolt to 21 Nm. Tighten the generator lower retaining bolt to 40 Nm.
168. Connect the electrical connector.
169. Install the left-hand exhaust manifold. Tighten to 25 Nm.
170. Install the mount bracket. Tighten to 25 Nm.
171. Attach the wiring harness.
172. Install the mount bracket.
173. Install the air conditioning (A/C) compressor. Tighten to 25 Nm.
174. Connect the electrical connector.
175. Install the power steering pump. Tighten to 25 Nm.
176. Install the oil level indicator and tube. Install new O-ring seals.
177. Install the engine mount bracket. Tighten to 40 Nm.
178. Install the engine mount. Tighten to 70 Nm.
179. Install the coolant hose.
180. Install the coolant hose.
181. Attach the coolant hose.
182. Attach the coolant hose.
183. Attach the coolant hose.
184. Install the drive belt. Install the drive belt tensioner.
185. Attach the accessory drive belt.
186. Install the supercharger drive belt tensioner. Install the super charger drive belt.
187. Attach the supercharger belt. Use a 1/2 inch square drive bar to rotate the supercharger belt tensioner. Attach the supercharger belt.

Special Tools Tool Illustration Tool Name Tool Number Engine lifting brackets 303749 Engine lifting brackets 303536

Scheme 165

Scheme 166

1. Apply a thin layer of high-temperature grease to the centering spigot bore on the torque converter.
2. Install the engine using a suitable hydraulic lift.
3. Install two opposing engine to automatic gearbox retaining bolts.
4. Install the retaining bolts. Tighten to 48 Nm.
5. Install the retaining bolts. Tighten to 48 Nm.
6. Lower the engine on to the engine mounts. Remove the automatic gearbox support.
7. Connect the electrical connector.
8. Attach the electrical connector. Tighten the retaining nut.
9. Connect the pipe.
10. Install new air conditioning line O-ring seals. Lubricate the new 0-ring with A/C refrigerant oil.
11. Clean off any oil residue that may contain A/C system fluorescent dye.
12. Remove the front engine lifting bracket.
13. Install the retaining bolt.
14. Remove the rear engine lifting bracket.
15. Connect the electrical connector. Tighten the retaining bolt.
16. Connect the pipe.
17. Connect the coolant hose.
18. Connect the coolant hoses.
19. Connect the fuel line. Refer to «Fuel System - General Information»(ref-311052) .
20. Install new air conditioning line O-ring seals. Lubricate the new O-ring with A/C refrigerant oil.
21. Connect the air conditioning line. Tighten to 12 Nm.
22. Clean off any oil residue that may contain A/C system fluorescent dye.
23. Connect the power steering pump line. Tighten to 25 Nm.
24. Connect the power steering reservoir hose.
25. Raise the vehicle.
26. Install the engine mount retaining bolt. Tighten to 70 Nm.
27. Attach the generator cable. Tighten to 12 Nm.
28. Reposition the generator cable cover.
29. Attach the starter motor cable. Tighten to 10 Nm.
30. Attach the starter motor cable. Tighten to 7 Nm.
31. Reposition the starter motor cable cover.
32. Install the retaining bolts. Install the mount bracket. Tighten to 48 Nm.
33. Install the retaining bolts. Install the mount bracket. Tighten to 48 Nm.
34. Install the retaining bolts. Tighten to 48 Nm.
35. Install the retaining bolts. Tighten to 55 Nm. Rotate the torque converter to gain access to the remaining bolts.
36. Install the rubber access cover.
37. Install the retaining bolt. Attach the transmission fluid cooler tubes to the automatic transmission. Install the retaining plate. Install the retaining bolt. Tighten to 23 Nm.
38. Install the transmission heat shield.
39. Detach the transmission fluid cooler tubes.
40. Install the catalytic converters. Refer to «Exhaust System»(ref-311027) .
41. Install the radiator. Refer to «Engine Cooling»(ref-311046) or «Supercharger Cooling»(ref-311049) .
42. Carry out the A/C system evacuation and charging procedure. Refer to «Climate Control System - General Information»(ref-311053) .
43. Bleed the power steering system. Refer to «Steering System - General Information»(ref-311042) .
44. Carry out a transmission fluid level check. Refer to «TRANSMISSION FLUID LEVEL CHECK - GENERAL PROCEDURES»(ref-311025-S21011166372009032300000) .