Engine: Removal & Installation Jaguar XKR I рестайлинг

Removal

All vehicles

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1. Remove the timing cover. Refer to «Engine Front Cover - In-Vehicle Procedures»(ref-311051-S02372063922009032300000) .
2. Remove the spark plugs.
3. Disconnect the crankshaft position sensor electrical connector.
4. Remove the crankshaft position sensor.
5. Install the special tool 303-645.
6. Remove the right-hand variable camshaft timing oil control unit housing. Remove and discard the O-ring seals.
7. Remove the left-hand variable camshaft timing oil control unit housing. Remove and discard the O-ring seals.
8. Install the special tool to the left-hand cylinder head.
9. Install the special tool to the Right-hand cylinder head.
10. Loosen the camshaft sprockets.
11. Remove the primary timing chain tensioner assembly.
12. Remove the primary timing chain tensioner blade.
13. Remove the primary timing chain.
14. Remove the primary timing chain tensioner guide.
15. Remove the camshaft sprockets.
16. Remove the special tool from the left-hand cylinder head.
17. 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).
18. Remove the left-hand exhaust camshaft.
19. 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).
20. Remove the left-hand inlet camshaft.

Installation

All vehicles

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1. 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.
2. Install the left-hand inlet camshaft.
3. Install the camshaft bearing cap bolts evenly. Tighten to 10 Nm.
4. Install the left-hand exhaust camshaft.
5. Install the camshaft bearing cap bolts evenly. Tighten to 10 Nm.
6. Install the camshaft setting tool.
7. Using a suitable tool, retain the right-hand timing chain tensioner piston.
8. Install the camshaft sprockets. Install the secondary timing chain tensioner and secondary timing chain to the camshaft sprockets.
9. Install the secondary timing chain tensioner retaining bolts. Tighten to 12 Nm.
10. 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.
11. Install the primary timing chain tensioner guide. Tighten to 12 Nm.
12. Install the primary timing chain. Install the primary chain over the rear crankshaft sprocket and the intake sprocket.
13. Install the primary timing chain tensioner blade. Tighten to 12 Nm.
14. Using a suitable tool, hold the left-hand timing chain tensioner ratchet lock mechanism away from the ratchet stem.
15. Install the primary timing chain tensioner assembly. Tighten to 12 Nm.
16. 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 70 Nm + 90°.
17. Using the special tool apply force to the tool in an anti-clockwise direction. Tighten to 70 Nm + 90°.
18. Release the tension in the left-hand primary timing chain tensioner. Remove the retaining tool.
19. Remove the special tool from the right-hand cylinder head.
20. Remove the special tool from the left-hand cylinder head.
21. Install the left-hand variable camshaft timing oil control unit housing. Install new O-ring seals. Tighten to 22 Nm.
22. Tighten to 12 Nm.
23. Install the right-hand variable camshaft timing oil control unit housing. Install new O-ring seals. Tighten to 22 Nm.
24. Remove the special tool.
25. Install the crankshaft position sensor.
26. Connect the crankshaft position sensor electrical connector.
27. Install the spark plugs.
28. Install the timing cover. Refer to «Engine Front Cover - In-Vehicle Procedures»(ref-311051-S02372063922009032300000) .

1. Remove the crankshaft pulley. Refer to «Crankshaft Pulley - In-Vehicle Procedures»(ref-311051-S25832805312009032300000) .
2. Using the special tool, remove the crankshaft front seal.

1. Using the special tool, install the crankshaft front seal.
2. Remove the crankshaft seal protector.
3. Install the crankshaft pulley. Refer to «Crankshaft Pulley - In-Vehicle Procedures»(ref-311051-S25832805312009032300000) .

1. Install a new crankshaft front seal. Refer to «Crankshaft Front Seal»(ref-311051-S04178196572009032300000) .
2. Install a new O-ring seal to the crankshaft pulley. Lubricate the new O-ring.
3. Install, but do not tighten, a new crankshaft pulley retaining bolt. Install the crankshaft pulley and locking ring to the crankshaft.
4. Using special tools, retain the crankshaft pulley. Tighten the crankshaft pulley retaining bolt to 375 Nm.
5. Remove the special tools.
6. Install the accessory drive belt . Refer to «Accessory Drive Belt»(ref-311044-S41080257832009032300000) .
7. Install the cooling fan motor and shroud. Refer to «Cooling Fan Motor and Shroud»(ref-311046-S28772974112009032300000) .

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 the flexplate. Refer to «Flexplate - In-Vehicle Procedures»(ref-311051-S00607721332009032300000) .

Scheme 40

1. Remove the left-hand camshafts. Refer to «Camshafts LH»(ref-311051-S33594011022009032300000) .
2. Remove the left-hand cylinder head. Remove the bolts in the indicated sequence. Remove and discard the gasket.
3. Remove the cylinder head gasket. Clean the gasket mating faces. Clean the cylinder head locating dowels.

1. Vehicles fitted with VCT: Remove the blind rivet from the VCT oil gallery. NOTE: The center bore of the blind rivet is 6 mm (0.24 inch) diameter. Identify the VCT oil supply gallery and the 8 mm (0.31 inch) blind rivet. Using a suitable 3 mm (0.12 inch) punch release the center of the blind rivet until it is released from the outer part of the blind rivet. Using a suitable extraction tool, remove the remaining part of the blind rivet.
2. Clean the component mating faces.
3. Check cylinder head face for distortion, across the center and from corner to corner.
4. For cylinder head face distortion data, refer to «Specifications»(ref-311024-S03103894482009032300000) .
5. Measure the cylinder head material. Check measurement from the center of the exhaust dowel to the cylinder head face as shown. If the measurement is less than 51.88 mm the cylinder head requires replacement.
6. 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.
7. Install the left-hand camshafts. Refer to «Camshafts LH»(ref-311051-S33594011022009032300000) .

All vehicles

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1. Remove the cooling fan motor and shroud. Refer to «Engine Cooling»(ref-311046) .
2. Remove the left-hand valve cover. Refer to «Valve Cover LH»(ref-311051-S06304565052009032300000) .
3. Remove the right-hand valve cover. Refer to «Valve Cover RH»(ref-311051-S23621229922009032300000) .
4. Remove the crankshaft front seal. Refer to «Crankshaft Front Seal»(ref-311051-S04178196572009032300000) .
5. Remove supercharger drive belt tensioner. Refer to «Accessory Drive»(ref-311044) .
6. Disconnect the electrical connector.
7. Detach the coolant hose. Reposition the retaining clip.
8. Detach the thermostat housing. Remove the retaining bolts
9. Remove the thermostat housing. Detach the coolant hose.
10. Remove the supercharger idler pulley and mount. Remove the retaining bolts. NOTE: The retaining bolt will remain captive. Remove the supercharger idler pulley and mount.
11. Remove the water pump pulley.
12. Remove the accessory drive belt idler pulley.
13. Remove the drive belt tensioner.
14. Remove the power steering pump upper securing bolts.
15. Raise the vehicle.
16. Remove the power steering pump rear lower securing bolt.
17. Lower the vehicle.
18. Detach the power steering pump. Remove the power steering pump front lower securing bolt.
19. Detach the wiring harness.
20. Remove the power steering pump mount bracket. Remove the retaining bolts.
21. Remove the engine front cover. Remove and discard the seals.

All vehicles

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Scheme 49

1. 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.
2. 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).
3. Install the timing cover. Tighten in the sequence shown. Tighten to 13 Nm.
4. Install the power steering pump mounting bracket. Tighten to 25 Nm.
5. Attach the wiring harness.
6. Attach the power steering pump. Tighten to 25 Nm.
7. Raise the vehicle.
8. Install the power steering pump rear lower securing bolt. Tighten to 25 Nm.
9. Lower the vehicle.
10. Install the power steering pump upper securing bolts. Tighten to 25 Nm.
11. Install the drive belt tensioner. Tighten to 42 Nm.
12. Install the accessory drive belt idler pulley. Tighten to 25 Nm.
13. Install the water pump pulley. Tighten to 10 Nm + 45°.
14. Install the supercharger idler pulley and mount. Tighten the retaining bolt. Tighten the retaining bolts.
15. Attach the coolant hose. Reposition the retaining clip.
16. Attach the thermostat housing. Tighten to 10 Nm.
17. Attach the coolant hose. Reposition the retaining clip.
18. Connect the electrical connector.
19. Install the supercharger drive belt. Refer to «Accessory Drive»(ref-311044) .
20. Install the crankshaft front seal. Refer to «Crankshaft Front Seal - In-Vehicle Procedures»(ref-311051-S04178196572009032300000) .
21. Install the left-hand valve cover. Refer to «Valve Cover LH - In-Vehicle Procedures»(ref-311051-S06304565052009032300000) .
22. Install the right-hand valve cover. Refer to «Valve Cover RH - In-Vehicle Procedures»(ref-311051-S23621229922009032300000) .
23. Install the cooling fan motor and shroud. Refer to «Engine Cooling»(ref-311046) .

Special Tools Tool Illustration Tool Name Tool Number Engine support beam 303-021 Engine lifting brackets 303-749

All vehicles

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1. Raise and support the vehicle. Refer to «Identification Codes»(ref-311010) .
2. Remove both engine mount lower retaining bolts.
3. Remove the radiator splash shield. Refer to «Front End Body Panels»(ref-311035) .
4. Remove the underbody front cross brace.
5. Remove the steering column lower shaft pinch bolt.
6. Detach the steering column lower shaft.
7. Detach the steering gear. Using suitable tie straps support the steering gear.
8. Lower the vehicle.
9. Install the front engine lifting bracket.
10. Install the front engine lifting bracket.
11. Using the special tool support the weight of the engine. Position the special tool to the fender channels and tighten beam fixings. Attach the hooks to the engine front lifting brackets. Tighten the hook adjustment nuts until the weight of the engine is supported.
12. Raise the vehicle.
13. Remove the engine mount.

All vehicles

Scheme 57

1. Install the engine mount. Tighten to 40 (+/- 15%) Nm.
2. Lower the vehicle.
3. Remove the special tool. Loosen the hook adjustment nuts. Detach the hooks from the engine front lifting brackets. Remove the special tool.
4. Remove the front engine lifting brackets.
5. Remove the front engine lifting brackets.
6. Raise the vehicle.
7. Attach the steering gear. Remove the suitable tie straps supporting the steering gear. Tighten to 45 Nm.
8. Attach the steering column shaft.
9. Install the steering column shaft retaining bolt. Tighten to 25 Nm.
10. Install the radiator splash shield. Refer to «Front End Body Panels»(ref-311035) .
11. Install the underbody front cross brace.
12. Install the engine mount retaining bolt. Tighten to 30 (+/- 15%) Nm.
13. Lower the vehicle.

Special Tools Tool Illustration Tool Name Tool Number Engine support beam. 303021 Engine lifting brackets 303749

All vehicles

1. Remove the air cleaner. Refer to «Intake Air Distribution and Filtering»(ref-311036) .
2. Install the front engine lifting brackets.
3. Support weight of engine. Position special tool in RH and LH fender channels and tighten beam fixings. Engage hooks into the engine front lifting eyes. Tighten hook adjustment nuts until weight of engine is supported.
4. Remove the steering gear. Refer to «Power Steering»(ref-311030) .
5. Remove the engine mount retaining bolt.
6. Remove the engine mount retaining nut.
7. Lower the vehicle.
8. Remove the engine mount.

All vehicles

1. Install the engine mount. Tighten to 40 (+/- 15%) Nm.
2. Raise the vehicle.
3. Install the engine mount retaining bolt. Tighten to 30 (+/- 15%) Nm.
4. Install the steering gear. Refer to «Power Steering»(ref-311030) .
5. Remove the special. Release hook adjustment nuts. Release hooks from brackets. Remove special tool.
6. Remove the front engine lifting brackets.
7. Install the air cleaner. Refer to «Intake Air Distribution and Filtering»(ref-311036) .

All vehicles

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1. Remove the right-hand catalytic converter. Refer to «Exhaust System»(ref-311027) .
2. Remove the steering gear. Refer to «Power Steering»(ref-311030) .
3. Remove and discard the retaining nuts.
4. Lower the vehicle.
5. Remove the air cleaner. Refer to «Intake Air Distribution and Filtering»(ref-311036) .
6. Remove the exhaust manifold to EGR valve tube retaining nuts. Remove and discard the retaining nuts and gasket.
7. Remove the exhaust manifold. Remove and discard the retaining nuts and heat shield/gasket.

All vehicles

1. Install the exhaust manifold. Install new retaining nuts and a new heat shield/gasket. Tighten to 25 Nm.
2. Attach the exhaust manifold to EGR valve tube retaining nuts. Install new retaining nuts and a new gasket. Tighten to 22 Nm.
3. Install the air cleaner. Refer to «Intake Air Distribution and Filtering»(ref-311036) .
4. Raise the vehicle.
5. Tighten to 25 Nm. Install new retaining nuts.
6. Install the steering gear. Refer to «Power Steering»(ref-311030) .
7. Install the right-hand catalytic converter. Refer to «Exhaust System»(ref-311027) .

1. Remove the automatic transmission. For additional information, Refer to «Transmission - 4.2L»(ref-311025) .
2. Remove the flexplate. Remove the 8 bolts.

1. Install the flexplate. Prevent the flexplate from rotating.
2. Tighten to 15 Nm.
3. Tighten to 110 Nm.
4. Install the automatic transmission. For additional information, Refer to «Transmission - 4.2L»(ref-311025) .

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1. Release the fuel system pressure. Refer to «Fuel System - General Information»(ref-311052) .
2. Remove the air cleaner outlet pipe. Refer to «Intake Air Distribution and Filtering»(ref-311036) .
3. Remove the engine cover retaining brackets. Detach the knock sensor (KS) electrical connectors.
4. Detach the engine wiring harness.
5. Disconnect the hose.
6. Disconnect the pipe.
7. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
8. Disconnect the fuel temperature sensor electrical connector.
9. Disconnect the right-hand camshaft position (CMP) sensor.
10. Detach the wiring harness. Disconnect the electrical connectors. Detach the wiring harness.
11. Disconnect the fuel pressure regulator electrical connector.
12. Release the cooling system pressure.
13. Disconnect the coolant hose from the expansion tank.
14. Detach the wiring harness. Disconnect the electrical connectors. Detach the wiring harness.
15. Disconnect the electrical connector.
16. Disconnect the throttle body electrical connectors.
17. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
18. Disconnect the coolant hose.
19. Disconnect the coolant hose.
20. Disconnect the hose.
21. Remove the exhaust manifold to exhaust gas recirculation (EGR) valve tube heat shield retaining nut.
22. Remove the exhaust manifold to EGR valve tube heat shield.
23. Remove the exhaust manifold to EGR valve tube retaining bolts. Remove and discard the gasket.
24. Remove the intake manifold. Remove and discard the gaskets.

1. Install the intake manifold. Install new gaskets. Tighten to 22 Nm.
2. Install the exhaust manifold to EGR valve tube retaining bolts. Install a new gasket. Tighten to 21 Nm.
3. Install the exhaust manifold to EGR valve tube heat shield. Tighten to 9 Nm.
4. Install the exhaust manifold to EGR valve tube heat shield retaining nut. Tighten to 60 Nm.
5. Connect the hose.
6. Connect the coolant hose.
7. Connect the coolant hose.
8. Connect the electrical connector.
9. Connect the manifold absolute pressure (MAP) sensor electrical connector.
10. Connect the throttle body electrical connectors.
11. Connect the CMP electrical connector.
12. Attach the wiring harness. Connect the electrical connectors. Attach the wiring harness.
13. Connect the hose to the expansion tank.
14. Connect the fuel pressure regulator electrical connector.
15. Attach the wiring harness. Connect the electrical connectors. Attach the wiring harness.
16. Connect the right-hand CMP sensor.
17. Disconnect the fuel temperature sensor electrical connector.
18. Connect the EGR valve electrical connector.
19. Connect the pipe.
20. Connect the hose.
21. Attach the engine wiring harness.
22. Install the engine cover retaining brackets. Detach the knock sensor (KS) electrical connectors. Tighten to 6 Nm.
23. Install the air cleaner outlet pipe. Refer to «Intake Air Distribution and Filtering»(ref-311036) .
24. Check and top up the cooling system.

Vehicles built up to 05/2004

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1. Raise and support the vehicle. Refer to «Using the Workshop Jack»(ref-311011) .
2. Remove the radiator splash shield. Refer to «Radiator Splash Shield»(ref-311035-S26129426482009032300000) .
3. Detach the power steering oil cooler
4. Detach the oil cooler lines. Remove and discard the oil cooler O ring seals.
5. Remove the oil cooler.

All vehicles

1. Install the oil cooler. Tighten to 7 Nm.
2. Attach the oil cooler lines. Install new oil cooler pipe O ring seals. Tighten to 20 Nm.
3. Attach the power steering oil cooler
4. Install the radiator splash shield. Refer to «Radiator Splash Shield»(ref-311035-S26129426482009032300000) .
5. Lower the vehicle.
6. Check and top up the engine oil level.

Vehicles without convertible top

1. Raise and support the vehicle. Refer to «Jacking and Lifting»(ref-311011) .
2. Remove the radiator splash shield. Refer to «Front End Body Panels»(ref-311035) .
3. Remove the underbody front cross brace.
4. Drain the engine oil.
5. Remove the oil pan. Remove the oil pan retaining bolts. Remove the oil pan from the oil pan body. Remove the gasket from the oil pan body assembly.

All vehicles

1. Install the oil pan gasket to the oil pan body assembly.
2. Install the oil pan. Install the oil pan. Install, but do not fully tighten the retaining bolts.
3. Tighten to 12 Nm, in the sequence indicated.
4. A new oil pan is supplied with the drain plug installed. Check that the drain plug is tightened to 25 Nm.
5. Remove the underbody front cross brace.
6. Install the radiator splash shield. Refer to «Front End Body Panels»(ref-311035) .
7. Lower the vehicle.
8. Fill the engine with engine oil to the correct level.

Scheme 76

1. Raise and support the vehicle. Refer to «Jacking and Lifting»(ref-311011) .
2. Remove the generator lower cooling duct.
3. Disconnect the oil pressure switch electrical connector.
4. Remove the oil pressure switch.

1. Install the oil pressure switch. Tighten to 15 Nm.
2. Connect the oil pressure switch electrical connector.
3. Install the generator lower cooling duct. Tighten to 2 Nm.
4. Lower the vehicle.
5. Check and, if necessary, top up the engine oil.

All vehicles

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Scheme 78

1. Remove the engine front cover. Refer to «Engine Front Cover - In-Vehicle Procedures»(ref-311051-S02372063922009032300000) .
2. Remove the spark plugs.
3. Remove the oil pan. Refer to «Oil Pan - In-Vehicle Procedures»(ref-311051-S31111717652009032300000) .
4. Remove the oil strainer. Remove and discard the O-ring seal.
5. Disconnect the crankshaft position sensor electrical connector.
6. Remove the crankshaft position sensor.
7. Install the special tool 303-645.
8. Remove the right-hand variable camshaft timing oil control unit housing. Remove and discard the O-ring seals.
9. Remove the left-hand variable camshaft timing oil control unit housing. Remove and discard the O-ring seals.
10. Install the special tool to the left-hand cylinder head.
11. Install the special tool to the Right-hand cylinder head.
12. Loosen the camshaft sprockets.
13. Remove the primary timing chain tensioner assembly.
14. Remove the primary timing chain tensioner guide.
15. Remove the primary timing chain.
16. Remove the primary timing chain guide.
17. Loosen the camshaft sprockets.
18. Remove the primary timing chain tensioner assembly.
19. Remove the primary timing chain tensioner guide.
20. Remove the primary timing chain.
21. Remove the primary timing chain tensioner guide.
22. Remove the crankshaft sprocket.
23. Remove the oil pump. Remove and discard the gasket.

All vehicles

Scheme 79

1. Install the oil pump. Install a new gasket. Tighten to 12 Nm.
2. Install the crankshaft sprocket.
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 primary timing chain. Install the primary chain over the crankshaft sprocket and the intake sprocket.
6. Install the primary timing chain tensioner guide. Tighten to 12 Nm.
7. Using a suitable tool, hold the left-hand timing chain tensioner ratchet lock mechanism away from the ratchet stem.
8. Install the primary timing chain tensioner assembly. Tighten to 12 Nm.
9. 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.
10. Using the special tool apply force to the tool in an anti-clockwise direction. Tighten to 120 Nm.
11. Install the primary timing chain guide. Tighten to 12 Nm.
12. Install the primary timing chain. Install the primary chain over the crankshaft sprocket and the intake sprocket.
13. Install the primary timing chain tensioner guide. Tighten to 12 Nm.
14. Using a suitable tool, hold the right-hand timing chain tensioner ratchet lock mechanism away from the ratchet stem.
15. Install the primary timing chain tensioner assembly. Tighten to 12 Nm.
16. 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.
17. Using the special tool apply force to the tool in an anti-clockwise direction. Tighten to 120 Nm.
18. Release the tension in the left-hand timing chain tensioner. Remove the retaining tool.
19. Release the tension in the right-hand timing chain tensioner. Remove the retaining tool.
20. Remove the special tool from the right-hand cylinder head.
21. Remove the special tool from the left-hand cylinder head.
22. Install the left-hand variable camshaft timing oil control unit housing. Install new O-ring seals. Tighten to 22 Nm.
23. Install the right-hand variable camshaft timing oil control unit housing. Install new O-ring seals. Tighten to 22 Nm.
24. Remove the special tool.
25. Install the crankshaft position sensor.
26. Connect the crankshaft position sensor electrical connector.
27. Install the oil strainer. Install new O-ring seals. Tighten to 12 Nm.
28. Install the oil pan. Refer to «Oil Pan - In-Vehicle Procedures»(ref-311051-S31111717652009032300000) .
29. Install the spark plugs.
30. Install the engine front cover. Refer to «Engine Front Cover - In-Vehicle Procedures»(ref-311051-S02372063922009032300000) .

1. Disconnect the crankshaft position (CKP) sensor electrical connector.
2. Remove the CKP sensor.
3. Install the special tool.
4. Remove the valve cover. Refer to «Valve Cover LH»(ref-311051-S06304565052009032300000) and «Valve Cover RH»(ref-311051-S23621229922009032300000) .
5. Install the special tool to the left-hand cylinder head.
6. Using the special tool, remove the exhaust camshaft sprocket retaining bolt.
7. Remove the secondary timing chain tensioner retaining bolts.
8. Remove the secondary timing chain tensioner. Reposition the exhaust camshaft sprocket and secondary timing chain. Remove the secondary timing chain tensioner.

1. Install the secondary timing chain tensioner. Install the secondary timing chain tensioner. Reposition the exhaust camshaft sprocket and secondary timing chain.
2. Install the secondary timing chain tensioner retaining bolts. Tighten to 12 Nm.
3. Release the tension in the secondary timing chain tensioner. Remove the retaining tool.
4. Using the special tools, install the exhaust camshaft sprocket retaining bolt. Tighten to 120 Nm.
5. Remove the special tool.
6. Install the valve cover. Refer to «Valve Cover LH»(ref-311051-S06304565052009032300000) and «Valve Cover RH»(ref-311051-S23621229922009032300000) .
7. Remove the special tool.
8. Install the CKP sensor.
9. Connect the crankshaft position (CKP) sensor electrical connector.

All vehicles

1. Remove the engine front cover. Refer to «Engine Front Cover - In-Vehicle Procedures»(ref-311051-S02372063922009032300000) .
2. Remove the spark plugs.
3. Disconnect the crankshaft position sensor electrical connector.
4. Remove the crankshaft position sensor.
5. Install the special tool 303-645.
6. Remove the right-hand variable camshaft timing oil control unit housing. Remove and discard the O-ring seals.
7. Remove the left-hand variable camshaft timing oil control unit housing. Remove and discard the O-ring seals.
8. Install the special tool to the left-hand cylinder head.
9. Install the special tool to the Right-hand cylinder head.
10. Loosen the camshaft sprockets.
11. Remove the primary timing chain tensioner assembly.
12. Remove the primary timing chain tensioner blade.
13. Remove the primary timing chain.
14. Remove the primary timing chain guide.
15. Remove the secondary timing chain tensioner retaining bolts.
16. Remove the camshaft sprockets. Remove the secondary timing chain tensioner and secondary timing chain from the camshaft sprockets.
17. Remove the left hand primary timing chain tensioner assembly.
18. Remove the left hand primary timing chain tensioner guide.
19. Remove the primary timing chain.
20. Remove the primary timing chain tensioner guide.
21. Remove the secondary timing chain tensioner retaining bolts.
22. Remove the camshaft sprockets. Remove the secondary timing chain tensioner and secondary timing chain from the camshaft sprockets.
23. Remove the crankshaft sprocket.

All vehicles

Scheme 80

1. Install the crankshaft sprocket.
2. Install the camshaft sprockets. Install the secondary timing chain tensioner and secondary timing chain to the camshaft sprockets.
3. Install the secondary timing chain tensioner retaining bolts. Tighten to 12 Nm.
4. 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.
5. Install the primary timing chain tensioner guide. Tighten to 12 Nm.
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. Using a suitable tool, hold the left-hand timing chain tensioner ratchet lock mechanism away from the ratchet stem.
9. Install the primary timing chain tensioner assembly. Tighten to 12 Nm.
10. 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 70 Nm +90°.
11. Using the special tool apply force to the tool in an anti-clockwise direction. Tighten to 70 Nm +90°.
12. Install the camshaft sprockets. Install the secondary timing chain tensioner and secondary timing chain to the camshaft sprockets.
13. Install the secondary timing chain tensioner retaining bolts. Tighten to 12 Nm.
14. 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.
15. Install the primary timing chain guide. Tighten to 12 Nm.
16. Install the primary timing chain. Install the primary chain over the crankshaft sprocket and the intake sprocket.
17. Install the primary timing chain tensioner guide. Tighten to 12 Nm.
18. Using a suitable tool, hold the right-hand timing chain tensioner ratchet lock mechanism away from the ratchet stem.
19. Install the primary timing chain tensioner assembly. Tighten to 12 Nm.
20. 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 70 Nm +90°.
21. Using the special tool apply force to the tool in an anti-clockwise direction. Tighten to 70 Nm +90°.
22. Release the tension in the left-hand timing chain tensioner. Remove the retaining tool.
23. Release the tension in the right-hand timing chain tensioner. Remove the retaining tool.
24. Remove the special tool to the Right-hand cylinder head.
25. Remove the special tool to the left-hand cylinder head.
26. Install the left-hand variable camshaft timing oil control unit housing. Install new O-ring seals. Tighten to 22 Nm.
27. Tighten to 12 Nm.
28. Remove the special tool.
29. Install the crankshaft position sensor.
30. Connect the crankshaft position sensor electrical connector.
31. Install the spark plugs.
32. Install the engine front cover. Refer to «Engine Front Cover - In-Vehicle Procedures»(ref-311051-S02372063922009032300000) .

Vehicles without supercharger

Scheme 81

Scheme 82

Scheme 83

Scheme 84

Scheme 85

1. Remove the oil filler cap.
2. Remove the engine cover.
3. Disconnect the hose.
4. Remove the retaining bolt.
5. Disconnect the hose.
6. Remove the retaining bolt.
7. Remove the ignition coil-on-plug cover.
8. Detach the wiring harness.
9. Disconnect the ignition coil-on-plug electrical connectors.
10. Remove the ignition coil on-plugs.
11. Remove the oil level indicator and tube. Remove and discard the O-ring seal.
12. Detach the fuel line. Refer to «Fuel System - General Information»(ref-311052) .
13. Remove the left-hand engine cover bracket.
14. Detach the engine wiring harness. Disconnect the variable camshaft timing oil control solenoid electrical connector. Detach the engine wiring harness.
15. Detach the engine wiring harness.
16. Detach the engine wiring harness.
17. Remove the valve cover assembly. Remove and discard valve cover gaskets.
18. Remove the valve cover retaining bolts. Remove and discard the valve cover retaining bolt O-ring seals.
19. Remove the seals from the valve cover. Remove and discard the outer seal. Remove and discard the two seals from around the spark plug apertures. Remove the seal for the variable camshaft timing oil control solenoid.

All vehicles

Scheme 86

1. Install the new main seals to the valve cover. Install the new outer seal. Install the two new spark plug aperture seals. Install the seal to the variable camshaft timing oil control solenoid.
2. Install the valve cover retaining bolts. Install new valve cover retaining bolt O-ring seals.
3. Apply bead of silicone gasket sealant or equivalent meeting Jaguar specification on the two places where the cylinder head and front cover join. The application of sealant must be 3mm diameter by 12mm long. Install the valve cover immediately after applying the sealant. The cover should be fitted directly to the head without smearing the sealant or the seals.
4. Install the valve cover. Install new valve cover gaskets. Complete the tightening sequence. Tighten to 12 Nm.
5. Detach the engine wiring harness.
6. Detach the engine wiring harness.
7. Attach the engine wiring harness. Connect the variable camshaft timing oil control solenoid electrical connector. Attach the engine wiring harness.
8. Install the left-hand engine cover bracket. Tighten to 6 Nm.
9. Install the oil level indicator and tube. Install a new O-ring seal. Tighten to 6 Nm.
10. Install the ignition coil on-plugs. Tighten to 5 Nm.
11. Disconnect the ignition coil-on-plug electrical connectors.
12. Detach the wiring harness.
13. Install the ignition coil-on-plug cover.
14. Connect the hose.
15. Install the retaining bolt.
16. Connect the hose.
17. Install the retaining bolt.
18. Install the engine cover.
19. Install the oil filler cap.

Vehicles without supercharger

Scheme 87

Scheme 88

Scheme 89

Scheme 90

Scheme 91

1. Remove the oil filler cap.
2. Remove the engine cover.
3. Remove the air cleaner. Refer to «Intake Air Distribution and Filtering»(ref-311036) .
4. Remove the ignition coil-on-plug cover.
5. Detach the wiring harness.
6. Disconnect the electrical connectors.
7. Remove the ignition coil-on-plugs. Remove the retaining bolts.
8. Disconnect the hose.
9. Remove the right-hand engine cover bracket. Detach the knock sensor (KS) wiring harness.
10. Detach the engine wiring harness. Detach the ground harness Disconnect the variable camshaft timing (VCT) oil control solenoid electrical connector. Detach the engine wiring harness.
11. Remove the retaining bolt.
12. Detach the engine wiring harness.
13. Detach the hose.
14. Detach the engine wiring harness.
15. Detach the engine wiring harness.
16. Detach the engine wiring harness.
17. Remove the valve cover assembly.
18. Remove the valve cover retaining bolts. Remove and discard the valve cover retaining bolt O-ring seals.
19. Remove the seals from the valve cover. Remove and discard the outer seal. Remove and discard the two seals from around the spark plug apertures. Remove the seal for the variable camshaft timing oil control solenoid.

All vehicles

Scheme 92

Scheme 93

1. Install the new main seals to the valve cover. Install the new outer seal. Install the two new spark plug aperture seals. Install the seal to the variable camshaft timing oil control solenoid.
2. Install the valve cover retaining bolts. Install new valve cover retaining bolt O-ring seals.
3. Apply bead of silicone gasket sealant or equivalent meeting Jaguar specification on the two places where the cylinder head and front cover join. The application of sealant must be 3mm diameter by 12mm long. Install the valve cover immediately after applying the sealant. The cover should be fitted directly to the head without smearing the sealant or the seals.
4. Install the valve cover. Tighten to 12 Nm.
5. Attach the engine wiring harness.
6. Attach the engine wiring harness.
7. Attach the engine wiring harness.
8. Attach the hose.
9. Attach the engine wiring harness.
10. Install the retaining bolt.
11. Attach the engine wiring harness. Attach the ground harness Connect the variable camshaft timing oil control solenoid electrical connector. Attach the engine wiring harness.
12. Install the right-hand engine cover bracket. Detach the knock sensor (KS) wiring harness. Tighten to 6 Nm.
13. Connect the hose.
14. Install the ignition coil-on-plugs. Tighten to 5 Nm.
15. Connect the electrical connectors.
16. Attach the wiring harness.
17. Install the ignition coil-on-plug cover.
18. Install the air cleaner. Refer to «Intake Air Distribution and Filtering»(ref-311036) .
19. Install the engine cover.
20. Install the oil filler cap.

Special Tools Tool Illustration Tool Name Tool Number Engine lifting brackets 303-536 Engine lifting brackets 303-749

Scheme 94

Scheme 95

Scheme 96

Scheme 97

Scheme 98

Scheme 99

Scheme 100

Scheme 101

Scheme 102

Scheme 103

Scheme 104

1. Reclaim the air conditioning refrigerant. Refer to «Climate Control System - General Information»(ref-311053) .
2. Remove the radiator. Refer to «Engine Cooling»(ref-311046) or «Supercharger Cooling»(ref-311049) .
3. Remove the catalytic converters. Refer to «Exhaust System»(ref-311027) .
4. Detach the transmission fluid cooler tubes.
5. Remove the transmission heat shield.
6. Detach the transmission fluid cooler tubes from the automatic transmission. Remove the retaining bolt. Remove the retaining plate. CAUTION: Make sure the transmission fluid cooler tubes are not removed from the automatic transmission by using a pry bar. Failure to follow this instruction may result in damage to the vehicle. Detach the transmission fluid cooler tubes from the automatic transmission. Allow the transmission fluid to drain into a suitable container.
7. Remove the rubber access cover.
8. Remove the retaining bolts. Rotate the torque converter to gain access to the remaining bolts.
9. Remove the retaining bolts.
10. Remove the retaining bolts. Collect the mount bracket.
11. Remove the retaining bolts. Collect the mount bracket.
12. Reposition the starter motor cable cover.
13. Detach the starter motor cables.
14. Reposition the generator cable cover.
15. Detach the generator cable.
16. Remove the engine mount retaining bolt.
17. Lower the vehicle.
18. Disconnect the power steering reservoir hose.
19. Disconnect the power steering pump line. Remove and discard the O-ring seal.
20. Disconnect the air conditioning line. Remove the retaining nut. Remove and discard the O-ring seal.
21. Release the fuel system pressure. Refer to «Fuel System - General Information»(ref-311052) .
22. Disconnect the fuel line. Refer to «Fuel System - General Information»(ref-311052) .
23. Disconnect the coolant hoses.
24. Disconnect the coolant hose.
25. Disconnect the pipe.
26. Disconnect the electrical connector.
27. Install the rear engine lifting bracket.
28. Remove the retaining bolt.
29. Install the front engine lifting bracket.
30. Disconnect the air conditioning line. Remove the retaining nut. Remove and discard the O-ring seal.
31. Disconnect the pipe.
32. Detach the electrical connector. Remove the retaining nut.
33. Disconnect the electrical connector.
34. Using suitable hydraulic lift raise the engine. Support the automatic gearbox.
35. Remove the retaining bolts.
36. Remove the retaining bolts.
37. Remove the engine using a suitable hydraulic lift.

Special Tools Tool Illustration Tool Name Tool Number Crankshaft locking, main tool 303-191 Adapter 303-191-02 Crankshaft pulley/damper remover 303-588 Crankshaft setting, main tool 303-645 Camshaft setting 303-530 Cylinder Bore Protectors 303-535

Scheme 105