Home ReviewsRefund Car not listed?
Home/Jaguar/XKR/Jaguar XKR II (2006-2008)/Repair manual/Mechanical/Engine (With Supercharger): Removal & Installation
Contents Wiring diagrams Section: Mechanical All sections

Engine (With Supercharger): Removal & Installation Jaguar XKR II

Mechanical 80 illustrations ~6146 words

Installation

  1. Install the camshafts. Clean the component mating faces. Replace the valve shims, with the smallest shim available. Lubricate the journals and camshaft lobes.
  2. Install the camshaft bearing caps. Clean the component mating faces. Evenly and progressively tighten the bolts in the sequence shown to 10 Nm (7 lb.ft).
  3. Install the special tool to the LH cylinder head. Install the 3 bolts.
  4. Install the timing drive components. See «Timing Drive Components»(ref-312582-S17330064762009041400000) .
  5. For cylinder head data, refer to «Specifications»(ref-312582-S35712731582009041400000) .
  6. Rotate the engine clockwise to position the camshaft lobe away from the valve tappet.
  7. Using the feeler gauge set, measure the clearance between the camshaft and the valve shim.
  8. Repeat the above procedure for the remaining 15 shims.
  9. Install the special tool 303-540, to the cylinder head. Tighten the 2 bolts to 10 Nm (7 lb.ft).
  10. Attach the special tool 303-540/02 to 303-540. Secure with the 2 wing nuts.
  11. Position the special tool to the tappet as shown.
  12. Using the special tool, compress the valve spring.
  13. Remove, clean and measure the shim. Surround the immediate working area with a cloth, to retain any loose shims displaced by the compressed air. Use the special tool 303-590, aimed at the edge of the shim, to lift it from the tappet. Note the position of each one.
  14. Install the new shim. Clean the components. Lubricate the shim with clean engine oil. Release and remove the special tools as required.
  15. Using the feeler gauge set, measure the clearance between the camshaft and the valve shim.
  16. Repeat the above procedure for the remaining valves.
  17. Connect the battery ground cable and install the cover. Refer to «Specifications»(ref-312564-S31890761012009041400000) article.

Removal

  1. Remove the crankshaft pulley. See «Crankshaft Pulley»(ref-312582-S23070497382009041400000) .
  1. Install the crankshaft pulley. See «Crankshaft Pulley»(ref-312582-S23070497382009041400000) .
  1. Using the special tool, install the crankshaft front seal. Clean the component mating faces.
  2. Remove the seal protector.
  3. Install the crankshaft pulley. Lubricate the seal with clean engine oil. Install the locking ring.
  4. Install, but do not tighten, the new crankshaft pulley bolt.
  5. Using the special tools, retain the crankshaft pulley. Tighten the crankshaft pulley bolt to 380 Nm (280 lb.ft). Remove the special tools.
  6. Attach the accessory drive belt.
  7. Install the oil filter housing. See «Oil Filter Housing»(ref-312582-S03278937262009041400000) .
  8. Install the cooling fan motor and shroud. Refer to «Cooling Fan Motor and Shroud - Vehicles With: Supercharger»(ref-312545-S11247936492009041400000) article.
  9. Connect the battery ground cable and install the cover. Refer to «Specifications»(ref-312564-S31890761012009041400000) article.
  1. Partially install the crankshaft rear oil seal. Make sure the components are clean and dry. Carefully remove the transit sleeve, leaving the seal on the crankshaft.
  2. Using the special tool, install the crankshaft rear oil seal. Tighten the special tool nuts evenly and progressively to fully install the seal.
  3. Install the torque converter flexplate. See «Flexplate»(ref-312582-S09814843192009041400000) .
  4. Check and top-up the engine oil.
  5. Connect the battery ground cable. Refer to «Specifications»(ref-312564-S31890761012009041400000) article.

Scheme 312

Scheme 312: Removal
Scheme 312: Removal

Scheme 313

Scheme 313
Scheme 313

Scheme 314

Scheme 314
Scheme 314

Scheme 315

Scheme 315
Scheme 315

Scheme 316

Scheme 316
Scheme 316

Scheme 317

Scheme 317
Scheme 317

Scheme 318

Scheme 318
Scheme 318
  1. Remove the cover and disconnect the battery ground cable. Refer to «Specifications»(ref-312564-S31890761012009041400000) article.
  2. Raise and support the vehicle.
  3. Remove the fuel injection supply manifold. Refer to «Fuel Injection Supply Manifold»(ref-312585-S26557405782009041400000) article.
  4. Remove the LH charge air cooler adaptor assembly. Remove the 5 bolts. Discard the gasket.
  5. Remove the timing drive components. See «Timing Drive Components»(ref-312582-S17330064762009041400000) .
  6. Remove the special tool from the LH cylinder head.
  7. Remove the camshaft bearing caps. Remove the 20 bolts.
  8. Remove the camshafts.
  9. Remove the 16 tappets.
  10. Remove the CMP sensor. Remove the Torx bolt. Remove and discard the O-ring seal.
  11. Release the LH catalytic converter. Remove and discard the 2 nuts.
  12. Remove the 12 cylinder head bolts.
  13. With assistance remove the cylinder head.
  14. Remove and discard the cylinder head gasket. Clean the cylinder head locating dowels. Clean and inspect the cylinder head and cylinder block.
  15. Remove the LH heat shield. Remove the 4 screws.
  16. Remove the exhaust manifold. Remove and discard the 8 bolts. Remove the 8 spacers.
  17. Remove and discard the exhaust manifold gasket. Remove the bolt.

Scheme 319

Scheme 319: Installation
Scheme 319: Installation
  1. Clean the component mating faces.
  2. Check cylinder head face for distortion, across the center and from corner to corner.
  3. For cylinder head face distortion data, refer to «Specifications»(ref-312582-S35712731582009041400000) .
  4. 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.
  5. Install the exhaust manifold gasket. Clean the component mating faces. Tighten the bolt to 50 Nm (37 lb.ft).
  6. Install the exhaust manifold. Clean the component mating faces. Install the spacers. Evenly and progressively, tighten the new bolts in the sequence shown, to 24 Nm (18 lb.ft).
  7. Install the heat shield. Tighten the screws.
  8. Install a new cylinder head gasket.
  9. With assistance install the cylinder head.
  10. Install the cylinder head bolts. Lubricate the new cylinder head bolt threads with clean engine oil. Tighten the bolts 1 to 10 to 20 Nm (15 lb.ft). Tighten the bolts 1 to 10 to 35 Nm (26 lb.ft). Tighten the bolts 1 to 10, a further 90 degrees. Tighten the bolts 1 to 10, a further 90 degrees. Tighten the M8 bolts 11 and 12, to 25 Nm (18 lb.ft).
  11. Attach the catalytic converter. Tighten the nuts to 40Nm (30 lb.ft).
  12. Install the CMP sensor. Clean the components. Install a new O-ring seal. Tighten the Torx bolt to 7 Nm (5 lb.ft).
  13. Install the tappets. Clean the components. Lubricate the components with clean engine oil.
  14. Install the camshafts. Clean the component mating faces. Lubricate the journals and camshaft lobes with clean engine oil.
  15. Install the camshaft bearing caps. Clean the component mating faces. Evenly and progressively tighten the bolts in the sequence shown to 10 Nm (7 lb.ft).
  16. Install the special tool to the LH cylinder head. Install the 3 bolts.
  17. Install the timing drive components. See «Timing Drive Components»(ref-312582-S17330064762009041400000) .
  18. Install the charge air cooler adaptor assembly. Clean the component mating faces. Install a new gasket. Tighten the bolts to 25 Nm (18 lb.ft).
  19. Install the fuel injection supply manifold. Refer to «Fuel Injection Supply Manifold»(ref-312585-S26557405782009041400000) article.
  20. Rotate the engine clockwise to position the camshaft lobe away from the valve tappet.
  21. Using the feeler gauge set, measure the clearance between the camshaft and the valve shim.
  22. Repeat the above procedure for the remaining 15 shims.
  23. Install the special tool 303-540, to the cylinder head. Tighten the 2 bolts to 10 Nm (7 lb.ft).
  24. Attach the special tool 303-540/02 to 303-540. Secure with the 2 wing nuts.
  25. Position the special tool to the tappet as shown.
  26. Using the special tool, compress the valve spring.
  27. Remove, clean and measure the shim. Surround the immediate working area with a cloth, to retain any loose shims displaced by the compressed air. Use the special tool 303-590, aimed at the edge of the shim, to lift it from the tappet. Note the position of each one.
  28. Install the new shim. Clean the components. Lubricate the shim with clean engine oil. Release and remove the special tools as required.
  29. Using the feeler gauge set, measure the clearance between the camshaft and the valve shim.
  30. Repeat the above procedure for the remaining valves.
  31. Connect the battery ground cable and install the cover. Refer to «Specifications»(ref-312564-S31890761012009041400000) article.

Scheme 320

Scheme 320: Removal
Scheme 320: Removal

Scheme 321

Scheme 321
Scheme 321

Scheme 322

Scheme 322
Scheme 322

Scheme 323

Scheme 323
Scheme 323

Scheme 324

Scheme 324
Scheme 324

Scheme 325

Scheme 325
Scheme 325

Scheme 326

Scheme 326
Scheme 326

Scheme 327

Scheme 327
Scheme 327

Scheme 328

Scheme 328
Scheme 328

Scheme 329

Scheme 329
Scheme 329
  1. Remove the cover and disconnect the battery ground cable. Refer to «Specifications»(ref-312564-S31890761012009041400000) article.
  2. Recover the A/C refrigerant.
  3. Raise and support the vehicle.
  4. Remove the hood. Refer to «Hood»(ref-312586-S13177222332009041400000) article.
  5. Vehicles with secondary air injection: Remove the air control valve to exhaust manifold tube. Refer to «Secondary Air Injection (AIR) Control Valve to Exhaust Manifold Tube»(ref-312587-S23276289932009041400000) article.
  6. Remove the coolant manifold. Refer to «Coolant Manifold - Vehicles With: Supercharger»(ref-312545-S29792368762009041400000) article.
  7. Remove the LH valve cover. See «Valve Cover LH»(ref-312582-S17997148672009041400000) .
  8. Remove the RH valve cover. See «Valve Cover RH»(ref-312582-S14300286472009041400000) .
  9. Remove the crankshaft pulley. See «Crankshaft Pulley»(ref-312582-S23070497382009041400000) .
  10. Remove the radiator bottom hose. Release the clip.
  11. Remove the power steering pump. Refer to «Power Steering Pump - Vehicles With: Supercharger»(ref-312571-S40167833902009041400000) article.
  12. Remove the coolant pump pulley. Remove the 3 bolts.
  13. Remove the accessory drive belt idler pulley. Remove the bolt.
  14. Remove the accessory drive belt tensioner. Remove the bolt.
  15. Disconnect the refrigerant lines from the A/C compressor. Remove the 2 bolts. Remove and discard the 2 O-ring seals.
  16. Position the A/C compressor aside to access the A/C compressor mounting bracket.
  17. Remove the A/C compressor mounting bracket. Remove the 4 bolts.
  18. Remove the power steering pump mounting bracket. Remove the 4 bolts.
  19. LH side: Release the wiring harness. Release the 2 clips.
  20. RH side: Release the wiring harness. Remove the bolt. Release the clip.
  21. Remove the engine front cover. Remove the 24 bolts. Remove and discard the 2 gaskets. Remove and discard the 3 O-ring seals.

Scheme 330

Scheme 330: Installation
Scheme 330: Installation
  1. Install the engine front cover. Clean the component mating faces. Install the gaskets. Install the O-ring seals. Apply a bead of sealant 3 mm diameter, by 12 mm long, to the 8 places indicated.
  2. Install the engine front cover bolts. Evenly and progressively tighten the bolts in the sequence shown to 12 Nm (9 lb.ft).
  3. RH side: Attach the wiring harness. Secure the clip. Tighten the bolt to 10 Nm (7 lb.ft).
  4. LH side: Attach the wiring harness. Secure the clips.
  5. Install the power steering pump mounting bracket. Tighten the bolts to 25 Nm (18 lb.ft).
  6. Install the A/C compressor mounting bracket. Tighten the bolts to 25 Nm (18 lb.ft).
  7. Connect the refrigerant lines. Clean the component mating faces. Install the new O-ring seals. Tighten the bolts to 9 Nm (7 lb.ft).
  8. Install the accessory drive belt tensioner. Tighten the bolt to 45 Nm (33 lb.ft).
  9. Install the accessory drive belt idler pulley. Tighten the bolt to 45 Nm (33 lb.ft).
  10. Install the coolant pump pulley. Tighten the bolts to 10 Nm (7 lb.ft).
  11. Install the power steering pump. Refer to «Power Steering Pump - Vehicles With: Supercharger»(ref-312571-S40167833902009041400000) article.
  12. Install the radiator bottom hose. Secure the clip.
  13. Install the crankshaft pulley. See «Crankshaft Pulley»(ref-312582-S23070497382009041400000) .
  14. Install the RH valve cover. See «Valve Cover RH»(ref-312582-S14300286472009041400000) .
  15. Install the LH valve cover. See «Valve Cover LH»(ref-312582-S17997148672009041400000) .
  16. Install the coolant manifold. Refer to «Coolant Manifold - Vehicles With: Supercharger»(ref-312545-S29792368762009041400000) article.
  17. Vehicles with secondary air injection: Install the air control valve to exhaust manifold tube. Refer to «Secondary Air Injection (AIR) Control Valve to Exhaust Manifold Tube»(ref-312587-S23276289932009041400000) article.
  18. Install the hood. Refer to «Hood»(ref-312586-S13177222332009041400000) article.
  19. Recharge the A/C system.
  20. Connect the battery ground cable and install the cover. Refer to «Specifications»(ref-312564-S31890761012009041400000) article.
  1. Install the exhaust manifold gasket. Clean the component mating faces. Tighten the bolt to 50 Nm (37 lb.ft).
  2. Install the exhaust manifold. Clean the component mating faces. Install the spacers. Evenly and progressively, tighten the new bolts in the sequence shown, to 24 Nm (18 lb.ft).
  3. Install the heat shield. Tighten the screws.
  4. Install the LH engine mount. See «Engine Mount LH»(ref-312582-S00763963022009041400000) .
  5. Install the exhaust system. Refer to «Exhaust System»(ref-312563-S34918148862009041400000) article.
  6. Install the oil level indicator and tube. See «Oil Level Indicator and Tube»(ref-312582-S03081737932009041400000) .
  7. Connect the battery ground cable and install the cover. Refer to «Specifications»(ref-312564-S31890761012009041400000) article.

Scheme 331

Scheme 331: Removal
Scheme 331: Removal
  1. Remove the cover and disconnect the battery ground cable. Refer to «Specifications»(ref-312564-S31890761012009041400000) article.
  2. Raise and support the vehicle.
  3. Remove the oil level indicator and tube. See «Oil Level Indicator and Tube»(ref-312582-S03081737932009041400000) .
  4. Remove the exhaust system. Refer to «Exhaust System»(ref-312563-S34918148862009041400000) article.
  5. Remove the LH engine mount. See «Engine Mount LH»(ref-312582-S00763963022009041400000) .
  6. Release the LH exhaust manifold heat shield. Remove the 4 screws.
  7. Release the AIR tube from the LH exhaust manifold.
  8. Remove the LH exhaust manifold heat shield.
  9. Remove the exhaust manifold. Remove and discard the 8 bolts. Remove the 8 spacers.
  10. Remove and discard the exhaust manifold gasket. Remove the bolt.
  1. Install the exhaust manifold gasket. Clean the component mating faces. Tighten the bolt to 50 Nm (37 lb.ft).
  2. Install the exhaust manifold. Clean the component mating faces. Install the spacers. Evenly and progressively, tighten the new bolts in the sequence shown, to 24 Nm (18 lb.ft).
  3. Install the exhaust manifold heat shield.
  4. Attach the air tube. Tighten the union to 35 Nm (26 lb.ft).
  5. Secure the exhaust manifold heat shield. Tighten the screws.
  6. Install the LH engine mount. See «Engine Mount LH»(ref-312582-S00763963022009041400000) .
  7. Install the exhaust system. Refer to «Exhaust System»(ref-312563-S34918148862009041400000) article.
  8. Install the oil level indicator and tube. See «Oil Level Indicator and Tube»(ref-312582-S03081737932009041400000) .
  9. Connect the battery ground cable and install the cover. Refer to «Specifications»(ref-312564-S31890761012009041400000) article.

Scheme 332

Scheme 332: Removal
Scheme 332: Removal

Scheme 333

Scheme 333
Scheme 333

Scheme 334

Scheme 334
Scheme 334
  1. Remove the cover and disconnect the battery ground cable. Refer to «Specifications»(ref-312564-S31890761012009041400000) article.
  2. Raise and support the vehicle.
  3. Remove the intake air resonator. Refer to «Intake Air Resonator»(ref-312577-S29213660842009041400000) article.
  4. Release the EGR valve to exhaust manifold pipe. Remove the 2 nuts. Remove and discard the gasket.
  5. Remove the exhaust system. Refer to «Exhaust System»(ref-312563-S34918148862009041400000) article.
  6. Remove the RH engine mount. See «Engine Mount RH»(ref-312582-S07660712202009041400000) .
  7. Remove the RH heat shield. Remove the 4 screws.
  8. Remove the exhaust manifold. Remove and discard the 8 bolts. Remove the 8 spacers.
  9. Remove and discard the exhaust manifold gasket. Remove the bolt.
  1. Install the exhaust manifold gasket. Clean the component mating faces. Tighten the bolt to 50 Nm (37 lb.ft).
  2. Install the exhaust manifold. Clean the component mating faces. Install the spacers. Evenly and progressively, tighten the new bolts in the sequence shown, to 24 Nm (18 lb.ft).
  3. Install the heat shield. Tighten the screws.
  4. Install the RH engine mount. See «Engine Mount RH»(ref-312582-S07660712202009041400000) .
  5. Install the exhaust system. Refer to «Exhaust System»(ref-312563-S34918148862009041400000) article.
  6. Attach the EGR valve to exhaust manifold pipe. Clean the component mating faces. Install a new gasket. Tighten the nuts to 25 Nm (18 lb.ft).
  7. Install the intake air resonator. Refer to «Intake Air Resonator»(ref-312577-S29213660842009041400000) article.
  8. Connect the battery ground cable and install the cover. Refer to «Specifications»(ref-312564-S31890761012009041400000) article.
  1. Remove the cover and disconnect the battery ground cable. Refer to «Specifications»(ref-312564-S31890761012009041400000) article.
  2. Raise and support the vehicle.
  3. Remove the intake air resonator. Refer to «Intake Air Resonator»(ref-312577-S29213660842009041400000) article.
  4. Release the EGR valve to exhaust manifold pipe. Remove the 2 nuts. Remove and discard the gasket.
  5. Remove the exhaust system. Refer to «Exhaust System»(ref-312563-S34918148862009041400000) article.
  6. Remove the RH engine mount. See «Engine Mount RH»(ref-312582-S07660712202009041400000) .
  7. Release the RH exhaust manifold heat shield. Remove the 4 screws.
  8. Release the AIR tube from the RH exhaust manifold.
  9. Remove the RH exhaust manifold heat shield.
  10. Remove the exhaust manifold. Remove and discard the 8 bolts. Remove the 8 spacers.
  11. Remove and discard the exhaust manifold gasket. Remove the bolt.
  1. Install the exhaust manifold gasket. Clean the component mating faces. Tighten the bolt to 50 Nm (37 lb.ft).
  2. Install the exhaust manifold. Clean the component mating faces. Install the spacers. Evenly and progressively, tighten the new bolts in the sequence shown, to 24 Nm (18 lb.ft).
  3. Install the exhaust manifold heat shield.
  4. Attach the air tube. Tighten the union to 35 Nm (26 lb.ft).
  5. Secure the exhaust manifold heat shield. Tighten the screws.
  6. Install the RH engine mount. See «Engine Mount RH»(ref-312582-S07660712202009041400000) .
  7. Install the exhaust system. Refer to «Exhaust System»(ref-312563-S34918148862009041400000) article.
  8. Attach the EGR valve to exhaust manifold pipe. Clean the component mating faces. Install a new gasket. Tighten the nuts to 25 Nm (18 lb.ft).
  9. Install the intake air resonator. Refer to «Intake Air Resonator»(ref-312577-S29213660842009041400000) article.
  10. Connect the battery ground cable and install the cover. Refer to «Specifications»(ref-312564-S31890761012009041400000) article.
  1. Remove the cover and disconnect the battery ground cable.
  2. Raise and support the vehicle.
  3. Remove the transmission. Refer to «Transmission»(ref-312552-S28492934492009041400000) article.
  4. Remove the torque converter flexplate. Remove the 8 bolts.

Scheme 335

Scheme 335: Installation
Scheme 335: Installation
  1. Install the torque converter flexplate. Clean the component mating faces. Tighten the bolts evenly in 2 stages to the sequence shown. Tighten the bolts to 15 Nm (11 lb ft). Tighten the bolts to 110 Nm (81 lb.ft).
  2. Install the transmission. Refer to «Transmission»(ref-312552-S28492934492009041400000) article.
  3. Connect the battery ground cable and install the cover.

Scheme 336

Scheme 336: Removal
Scheme 336: Removal

Scheme 337

Scheme 337
Scheme 337
  1. Raise and support the vehicle.
  2. Remove the engine under shield. Refer to «Air Deflector»(ref-312542-S37767534682009041400000) article.
  3. Remove the oil pan drain plug. Position a container to collect the fluid. Discard the oil pan drain plug seal.
  4. Remove the oil pan. Position a container to collect the oil spillage. Remove the 17 bolts. Remove and discard the gasket.
  1. Install the oil pan. Clean the components. Install the new gasket. Install the bolts, but do not tighten fully at this stage.
  2. Evenly and progressively tighten the bolts in the sequence shown to 12 Nm (9 lb.ft).
  3. Tighten the drain plug to 25 Nm (18 lb.ft). Install a new seal.
  4. Install the engine under shield. Refer to «Air Deflector»(ref-312542-S37767534682009041400000) article.
  5. Fill the engine with the recommended oil to the correct level.
  1. Remove the cover and disconnect the battery ground cable. Refer to «Specifications»(ref-312564-S31890761012009041400000) article.
  2. Raise and support the vehicle.
  3. Remove the timing drive components. See «Timing Drive Components»(ref-312582-S17330064762009041400000) .
  4. Remove the oil pan. See «Oil Pan»(ref-312582-S06727425242009041400000) .
  5. Remove the oil strainer pick-up assembly. Remove the 2 bolts. Remove and discard the O-ring seal.
  6. Remove the oil pump assembly. Remove the 4 bolts. Remove and discard the O-ring seal.
  1. Install the oil pump assembly. Clean the components mating faces. Install a new O-ring seal. Tighten the bolts to 12 Nm (9 lb.ft).
  2. Install the oil strainer pick-up assembly. Install a new O-ring seal. Tighten the bolts to 12 Nm (9 lb.ft).
  3. Install the oil pan. See «Oil Pan»(ref-312582-S06727425242009041400000) .
  4. Install the timing drive components. See «Timing Drive Components»(ref-312582-S17330064762009041400000) .
  5. Connect the battery ground cable and install the cover. Refer to «Specifications»(ref-312564-S31890761012009041400000) article.

Note. This procedure covers the removal and installation of the following components: timing chains, chain guides, tensioners and sprockets.

Scheme 338

Scheme 338
Scheme 338

Scheme 339

Scheme 339
Scheme 339

Scheme 340

Scheme 340
Scheme 340
  1. Remove the cover and disconnect the battery ground cable. Refer to «Specifications»(ref-312564-S31890761012009041400000) article.
  2. Raise and support the vehicle.
  3. Remove the engine front cover. See «Engine Front Cover»(ref-312582-S33079532482009041400000) .
  4. Remove the crankshaft position (CKP) sensor. Refer to «Crankshaft Position (CKP) Sensor»(ref-312544-S34852218182009041400000) article.
  5. Lock the crankshaft. Install the special tool. Install the screw.
  6. Remove the RH variable camshaft timing (VCT) control solenoid housing. Remove the 3 bolts. Remove and discard the O-ring seals.
  7. Install the special tool to the RH cylinder head. Rotate the crankshaft until the flats on the camshafts are parallel with the cylinder head joint faces. Install the 3 bolts.
  8. Remove the RH primary timing chain tensioner. Remove the 2 bolts.
  9. Remove the RH upper and lower primary timing chain tensioner guides. Remove the 2 bolts.
  10. Remove the RH primary timing chain.
  11. Remove the LH variable camshaft timing (VCT) control solenoid housing. Remove the 2 bolts. Remove the nut. Remove and discard the O-ring seals.
  12. Install the special tool to the LH cylinder head. Install the 3 bolts.
  13. Remove the LH primary timing chain tensioner. Remove the 2 bolts.
  14. Remove the LH upper and lower primary timing chain tensioner guides. Remove the 2 bolts.
  15. Remove the LH primary timing chain.
  16. Release the LH camshaft sprocket assembly. Remove the 2 Torx bolts.
  17. Remove the LH secondary timing chain, tensioner and sprocket assembly. Remove the 2 bolts.
  18. Release the RH camshaft sprocket assembly. Remove the 2 Torx bolts.
  19. Remove the RH secondary timing chain, tensioner and sprocket assembly. Remove the 2 retaining bolts.
  20. Remove the crankshaft sprocket. Remove the crankshaft sprocket key.

Scheme 341

Scheme 341: Installation
Scheme 341: Installation

Scheme 342

Scheme 342
Scheme 342
  1. Install the crankshaft sprocket. Clean the components. Install the crankshaft sprocket key.
  2. Install the LH secondary timing chain, tensioner and sprocket assembly. Clean the components. Install the Torx bolts, but do not tighten fully at this stage.
  3. Install the special tool to the exhaust camshaft sprocket. Reposition the camshaft sprockets for the most advantageous position for use of the special tool.
  4. Install the LH secondary timing chain tensioner retaining bolts. Tighten the bolts to 12 Nm (9 lb.ft).
  5. Install the LH primary timing chain. Clean the components. Make sure the timing chain slack is on the tensioner side of the timing chain.
  6. Install the LH primary timing chain tensioner guides. Clean the components. Tighten the bolts to 12 Nm (9 lb.ft).
  7. Install the LH primary timing chain tensioner. Clean the components. Using 3 mm diameter metal rod, retain the chain tensioner piston. Tighten the bolts to 12 Nm (9 lb.ft). Remove the retaining rod.
  8. Install the special tool to the LH exhaust camshaft sprocket. Tighten the intake camshaft sprocket retaining bolt to 120 Nm (88 lb.ft). Tighten the exhaust camshaft retaining bolt to 120 Nm (88 lb.ft).
  9. Install the LH VCT control solenoid housing. Clean the components. Install the new O-ring seals. Tighten the new bolts to 22 Nm (16 lb.ft). Tighten the nut to 10 Nm (7 lb.ft).
  10. Install the RH secondary timing chain, tensioner and sprocket assembly. Clean the components. Install the Torx bolts, but do not tighten fully at this stage.
  11. Install the RH secondary timing chain tensioner retaining bolts. Tighten the bolts to 12 Nm (9 lb.ft).
  12. Install the RH primary timing chain. Clean the components. Make sure the timing chain slack is on the tensioner side of the timing chain.
  13. Install the RH primary timing chain tensioner guides. Tighten the bolts to 12 Nm (9 lb.ft).
  14. Install the RH primary timing chain tensioner. Clean the components. Using 3 mm diameter metal rod, retain the chain tensioner piston. Tighten the bolts to 12 Nm (9 lb.ft). Remove the retaining rod.
  15. Install the special tool to the RH exhaust camshaft sprocket. Tighten the intake camshaft sprocket retaining bolt to 120 Nm (88 lb.ft). Tighten the exhaust camshaft retaining bolt to 120 Nm (88 lb.ft).
  16. Install the RH VCT control solenoid housing. Clean the components. Install the new O-ring seals. Tighten the new bolts to 22 Nm (16 lb.ft).
  17. Remove the special tool from the RH cylinder head. Remove the 3 bolts.
  18. Remove the special tool from the LH cylinder head. Remove the 3 bolts.
  19. Install the engine front cover. See «Engine Front Cover»(ref-312582-S33079532482009041400000) .
  20. Remove the crankshaft locking tool. Remove the screw.
  21. Install the CKP sensor. Refer to «Crankshaft Position (CKP) Sensor»(ref-312544-S34852218182009041400000) article.
  22. Connect the battery ground cable and install the cover. Refer to «Specifications»(ref-312564-S31890761012009041400000) article.

Scheme 343

Scheme 343: Removal
Scheme 343: Removal

Scheme 344

Scheme 344
Scheme 344

Scheme 345

Scheme 345
Scheme 345

Scheme 346

Scheme 346
Scheme 346

Scheme 347

Scheme 347
Scheme 347

Scheme 348

Scheme 348
Scheme 348

Scheme 349

Scheme 349
Scheme 349

Scheme 350

Scheme 350
Scheme 350
  1. Remove the cover and disconnect the battery ground cable. Refer to «Specifications»(ref-312564-S31890761012009041400000) article.
  2. Remove the purge valve. Refer to «Evaporative Emission Canister Purge Valve - Vehicles With: Supercharger»(ref-312588-S00631791002009041400000) article.
  3. Remove the ignition coil-on-plug. Refer to «Ignition Coil-On-Plug - Vehicles With: Supercharger»(ref-312589-S14866751932009041400000) article.
  4. Remove the remaining ignition coil-on-plugs.
  5. Remove the oil level indicator and tube. Remove the nut. Remove and discard the O-ring seal.
  6. Remove the engine breather line.
  7. Disconnect the variable camshaft timing (VCT) oil control solenoid electrical connector.
  8. Remove the engine cover bracket. Remove the 3 nuts. Release the wiring harness.
  9. Disconnect fuel line from the fuel rail. Refer to «Spring Lock Couplings»(ref-312590-S15048345952009041400000) article.
  10. Release the engine wiring harness. Release the 3 clips.
  11. Release the coil-on-plug wiring harness. Release the 3 clips.
  12. Remove the valve cover. Remove the 14 valve cover retaining bolts.
  13. Remove and discard the valve cover retaining bolt O-ring seals.
  14. Remove and discard the valve cover gasket. Carefully remove the sealant.
  15. Remove and discard the valve cover plug aperture seals.
  16. Remove and discard the VCT oil control solenoid seal.
  17. Remove the oil filler pipe. Remove and discard the O-ring seal.

Scheme 351

Scheme 351: Installation
Scheme 351: Installation
  1. Install the oil filler pipe. Install a new O-ring seal.
  2. Install the new VCT oil control solenoid seal.
  3. Install the new valve cover plug aperture seals.
  4. Install a new valve cover gasket. Clean the components.
  5. Install the valve cover. Clean the component mating faces.
  6. Install valve cover retaining bolts to their position previously noted. Install new valve cover bolt O-ring seals. Tighten the bolts to 12 Nm (9 lb.ft). Complete the tightening sequence as illustrated.
  7. Attach the coil-on-plug wiring harness. Secure with the clips.
  8. Attach the engine wiring harness. Secure with the clips.
  9. Install the engine cover bracket. Tighten the nuts to 6 Nm (4 lb.ft). Attach the wiring harness.
  10. Connect the VCT oil control solenoid electrical connector.
  11. Install the engine breather line.
  12. Install the oil level indicator and tube. Install a new O-ring seal. Tighten the nut to 6 Nm (4 lb.ft).
  13. Connect the fuel line. Refer to «Spring Lock Couplings»(ref-312590-S15048345952009041400000) article.
  14. Install the ignition coil-on-plug. Refer to «Ignition Coil-On-Plug - Vehicles With: Supercharger»(ref-312589-S14866751932009041400000) article.
  15. Install the remaining ignition coil-on-plugs.
  16. Install the purge valve. Refer to «Evaporative Emission Canister Purge Valve - Vehicles With: Supercharger»(ref-312588-S00631791002009041400000) article.
  17. Connect the battery ground cable and install the cover. Refer to «Specifications»(ref-312564-S31890761012009041400000) article.

Scheme 352

Scheme 352: Removal
Scheme 352: Removal

Scheme 353

Scheme 353
Scheme 353

Scheme 354

Scheme 354
Scheme 354

Scheme 355

Scheme 355
Scheme 355

Scheme 356

Scheme 356
Scheme 356

Scheme 357

Scheme 357
Scheme 357
  1. Remove the cover and disconnect the battery ground cable. Refer to «Specifications»(ref-312564-S31890761012009041400000) article.
  2. Remove the ignition coil-on-plug. Refer to «Ignition Coil-On-Plug - Vehicles With: Supercharger»(ref-312589-S14866751932009041400000) article.
  3. Remove the remaining ignition coil-on-plugs.
  4. Disconnect the positive crankcase ventilation (PCV) line.
  5. Remove the engine cover bracket. Remove the 3 nuts. Release the 2 wiring harness clips. Release the hose.
  6. Release the engine wiring harness. Release the 4 clips.
  7. Release the coil-on-plug wiring harness. Release the 2 clips.
  8. Disconnect the variable camshaft timing (VCT) oil control solenoid electrical connector.
  9. Remove the valve cover. Remove the 14 valve cover retaining bolts.
  10. Remove and discard the valve cover retaining bolt O-ring seals.
  11. Remove and discard the valve cover gasket. Carefully remove the sealant.
  12. Remove and discard the valve cover plug aperture seals.
  13. Remove and discard the VCT oil control solenoid seal.
  14. Remove the PCV valve. Remove the 2 Torx screws. Remove and discard the O-ring seal.
  1. Install the PCV valve. Clean the component mating faces. Install a new O-ring seal. Tighten the Torx screws.
  2. Install the new VCT oil control solenoid seal.
  3. Install new valve cover plug aperture gaskets.
  4. Install a new valve cover gasket.
  5. Install the valve cover. Clean the component mating faces.
  6. Install valve cover retaining bolts to their position previously noted. Install new valve cover bolt O-ring seals. Tighten the bolts to 12 Nm (9 lb.ft). Complete the tightening sequence as illustrated.
  7. Connect the VCT oil control solenoid electrical connector.
  8. Attach the coil-on-plug wiring harness. Secure with the clips.
  9. Attach the engine wiring harness. Secure with the clips.
  10. Install the engine cover bracket. Tighten the nuts to 6 Nm (4 lb.ft). Secure the wiring harness. Secure the hose.
  11. Connect the PCV line.
  12. Install the ignition coil-on-plug. Refer to «Ignition Coil-On-Plug - Vehicles With: Supercharger»(ref-312589-S14866751932009041400000) article.
  13. Install the remaining ignition coil-on-plugs.
  14. Connect the battery ground cable and install the cover. Refer to «Specifications»(ref-312564-S31890761012009041400000) article.
  1. Install the EOP sensor. Clean the components. Apply sealant of the correct specification to the sensor thread. Tighten the sensor to 15 Nm (11 lb.ft).
  2. Install the engine oil temperature sensor. Clean the components. Apply sealant of the correct specification to the sensor thread. Tighten the sensor to 15 Nm (11 lb.ft).
  3. Install the oil filter housing. Clean the component mating faces. Install a new O-ring seal. Tighten the bolts to 20 Nm (15 lb.ft).
  4. Connect the engine oil cooler lines. Clean the component mating faces. Install new O-ring seals. Tighten the bolts to 7 Nm (5 lb.ft).
  5. Using the special tool, install the oil filter. Lubricate the oil filter seal with clean engine oil and tighten to 18 Nm (13 lb.ft).
  6. Connect the EOP sensor electrical connector.
  7. Connect the engine oil temperature sensor electrical connector.
  8. Install the engine under shield. Refer to «Air Deflector»(ref-312542-S37767534682009041400000) article.
  9. Connect the battery ground cable and install the cover. Refer to «Specifications»(ref-312564-S31890761012009041400000) article.
  10. Check and top-up the engine oil.

Scheme 358

Scheme 358: Removal
Scheme 358: Removal

Scheme 359

Scheme 359
Scheme 359
  1. Remove the cover and disconnect the battery ground cable.
  2. Remove the engine cover. Refer to «Engine Cover»(ref-312547-S27687687872009041400000) article.
  3. Remove the LH intake air resonator. Remove the bolt. Release the 2 clips. Disconnect the engine breather line.
  4. Remove the LH ignition coil-on-plug cover. Release the 2 clips.
  5. Raise and support the vehicle.
  6. Turn the steering on to full lock for access.
  7. Remove the oil level indicator and tube. Remove the nut. Discard the O-ring seal.
  1. With assistance, install the oil level indicator and tube. Clean the components. Install a new O-ring seal. Lubricate the O-ring seal with clean engine oil. Tighten the nut to 6 Nm (4 lb.ft).
  2. Install the LH ignition coil-on-plug cover.
  3. Install the intake air resonator. Secure with the clips. Tighten the bolt to 10 Nm (7 lb.ft). Connect the engine breather line.
  4. Install the engine cover. Refer to «Engine Cover»(ref-312547-S27687687872009041400000) article.
  5. Connect the battery ground cable and install the cover.

Scheme 360

Scheme 360: Removal
Scheme 360: Removal

Scheme 361

Scheme 361
Scheme 361

Scheme 362

Scheme 362
Scheme 362
  1. Raise and support the vehicle.
  2. Remove the radiator splash shield. Refer to «Radiator Splash Shield»(ref-312542-S16146995052009041400000) article.
  3. Remove the front bumper air ducting. Remove the 7 clips. Release the 4 clips.
  4. Remove the air deflector. Remove the 4 retainers.
  5. Disconnect the 2 oil cooler lines. Position a container to collect the engine oil. Remove the 2 nuts. Remove and discard the 2 O-ring seals.
  6. Remove the oil cooler. Remove the 2 bolts. Remove the retainer. Remove the 2 support brackets.
  1. Install the oil cooler. Install the support brackets. Tighten the bolts to 5 Nm (4 lb.ft). Install the retainer.
  2. Connect the oil cooler lines. Clean the components. Install new O-ring seals. Tighten the nuts to 7 Nm (5 lb.ft).
  3. Install the air deflector. Install the retainers.
  4. Install the front bumper air ducting. Secure with the clips.
  5. Install the radiator splash shield. Refer to «Radiator Splash Shield»(ref-312542-S16146995052009041400000) article.
  6. Check and top-up the engine oil.

Scheme 363

Scheme 363: Removal
Scheme 363: Removal
  1. Raise and support the vehicle.
  2. Remove the radiator splash shield. Refer to «Radiator Splash Shield»(ref-312542) article.
  3. Disconnect the 2 oil cooler lines. Position a container to collect the engine oil. Remove the 2 nuts. Remove and discard the 2 O-ring seals. Remove the 2 brackets.
  4. Remove the oil cooler. Remove the 4 securing nuts.
  1. Install the oil cooler. Install the support brackets. Install the retainer. Tighten to 5 Nm.
  2. Connect the oil cooler lines. Clean the components. Install new O-ring seals. Tighten to 7 Nm.
  3. Install the radiator splash shield. Refer to «Radiator Splash Shield»(ref-312542) article.
  4. Check and top-up the engine oil.

Engine - Removal

Special Tools Tool Illustration Tool Name Tool Number Engine lifting brackets 303-536 Engine lifting brackets 303-749 Engine lifting bracket 303-1297 Fuel spring lock decoupling tool 310-D005

Scheme 364

Scheme 364: Engine - Removal
Scheme 364: Engine - Removal

Scheme 365

Scheme 365: Removal
Scheme 365: Removal

Scheme 366

Scheme 366
Scheme 366

Scheme 367

Scheme 367
Scheme 367

Scheme 368

Scheme 368
Scheme 368

Scheme 369

Scheme 369
Scheme 369

Scheme 370

Scheme 370
Scheme 370

Scheme 371

Scheme 371
Scheme 371

Scheme 372

Scheme 372
Scheme 372

Scheme 373

Scheme 373
Scheme 373

Scheme 374

Scheme 374
Scheme 374

Scheme 375

Scheme 375
Scheme 375

Scheme 376

Scheme 376
Scheme 376

Scheme 377

Scheme 377
Scheme 377

Scheme 378

Scheme 378
Scheme 378

Scheme 379

Scheme 379
Scheme 379

Scheme 380

Scheme 380
Scheme 380

Scheme 381

Scheme 381
Scheme 381

Scheme 382

Scheme 382
Scheme 382

Scheme 383

Scheme 383
Scheme 383

Scheme 384

Scheme 384
Scheme 384

Scheme 385

Scheme 385
Scheme 385

Scheme 386

Scheme 386
Scheme 386

Scheme 387

Scheme 387
Scheme 387

Scheme 388

Scheme 388
Scheme 388

Scheme 389

Scheme 389
Scheme 389
  1. Remove the cover and disconnect the battery ground cable. Refer to «Specifications»(ref-312564-S31890761012009041400000) article.
  2. Evacuate the A/C system. Refer to «Air Conditioning (A/C) System Recovery, Evacuation and Charging»(ref-312533-S11090926322009041400000) article.
  3. Remove the hood. Refer to «Hood»(ref-312586-S13177222332009041400000) article.
  4. Remove the cowl vent screen. Refer to «Cowl Vent Screen»(ref-312542-S31370477722009041400000) article.
  5. Remove the engine compartment braces. Release the grommet. Remove the 4 Torx bolts. Repeat the above procedure for the other side.
  6. Remove the intake air resonator. Refer to «Intake Air Resonator»(ref-312577-S29213660842009041400000) article.
  7. Disconnect the brake booster vacuum hose quick release connector.
  8. Release and disconnect the engine wiring harness electrical connector. Fully loosen the bolt.
  9. Release the ground cable from the power distribution box bracket. Remove the nut.
  10. Release the engine wiring harness from the engine compartment side wall. Release the grommet.
  11. Disconnect the fuel line.
  12. Release the clip and disconnect the purge inlet line.
  13. Raise and support the vehicle.
  14. Remove the air deflector. Refer to «Air Deflector»(ref-312542-S37767534682009041400000) article.
  15. Drain the cooling system. Refer to «Cooling System Draining, Filling and Bleeding - Vehicles With: Supercharger»(ref-312545-S38638734802009041400000) article.
  16. Disconnect the LH catalytic converter from the exhaust manifold. Remove and discard the 2 nuts.
  17. Disconnect the RH catalytic converter from the exhaust manifold. Remove and discard the 2 nuts.
  18. Disconnect the 2 engine oil cooler lines. Remove the 2 bolts. Remove and discard the 2 O-ring seals. Position hoses in front of the anti roll bar.
  19. Disconnect the high pressure line from the power steering gear. Remove and discard the Torx bolt. Remove and discard the O-ring seal. Release from the clip.
  20. Disconnect the A/C high-pressure line from the intermediate joint. Remove the nut. Discard the O-ring seal.
  21. Disconnect the refrigerant lines from the A/C compressor. Remove the 2 bolts. Remove and discard the 2 O-ring seals. Remove the lower A/C pipe. Disconnect and tie aside the upper A/C pipe.
  22. Disconnect the transmission ground cable. Remove the bolt.
  23. Release the transmission fluid lines from the engine. Remove the nut. Release the clip.
  24. Release the wiring harness from the RH side of the transmission. Disconnect the 2 electrical connectors. Carefully release the 2 clips.
  25. Disconnect the battery positive and generator cables. Release the cover. Remove the nut.
  26. With assistance, remove the A-frame. Remove the 6 bolts.
  27. Release the flexplate. Remove the access plugs. Rotate the crankshaft to access the retaining bolts. Remove and discard the 3 bolts.
  28. Release the engine mounts. Remove and discard the 2 nuts.
  29. Lower the vehicle.
  30. Disconnect the charge air cooler coolant hoses. Position an absorbent cloth to collect fluid spillage. Release the 2 clips. Tie aside. Repeat the above procedure on the opposite side.
  31. Disconnect the radiator upper hose. Release the hose clip.
  32. Remove the radiator top hose. Release the clips. Disconnect the quick release connector. Tie the hose assembly aside for access.
  33. Disconnect the radiator lower hose. Release the hose clip.
  34. Remove the radiator lower hose. Release the clip.
  35. Disconnect the secondary air injection (AIR) control valve supply hose.
  36. Disconnect the secondary air injection (AIR) reservoir vacuum line. Release the clip.
  37. Release the power steering fluid reservoir. Remove the 2 bolts.
  38. Disconnect the power steering supply hose. Position a container to collect the fluid spillage. Release the hose clip.
  39. Release the transmission from the engine. Remove the 15 bolts. Support the transmission.
  40. Install the special tools to the engine. Support the engine.
  41. With assistance, carefully remove the engine.
  42. Install the torque converter retainer.

Engine - Disassembly

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 Crankshaft damper holding tool 303-D055 Cylinder Bore Protectors 303-535

Scheme 390

Scheme 390: Engine - Disassembly
Scheme 390: Engine - Disassembly

Scheme 391

Scheme 391
Scheme 391
  1. Remove the torque converter retainer.
  2. With assistance, carefully install the engine. Clean the component mating faces. Tighten the bolts to 45 Nm (33 lb.ft).
  3. Carefully lower the engine onto the engine mounts. Clean the components. Tighten the new nuts to 63 Nm (46 lb.ft).
  4. Remove the special tools.
  5. Raise and support the vehicle.
  6. Attach the flexplate to the torque converter. Rotate the crankshaft to access the retaining bolts. Tighten the bolts to 45 Nm (33 lb.ft). Install the access plugs.
  7. With assistance, install the A-frame. Tighten the bolts to 55 Nm (40 lb.ft).
  8. Connect the battery positive and generator cables. Tighten the nut to 10 Nm (7 lb.ft). Secure the cover.
  9. Attach the wiring harness. Connect the electrical connectors. Secure the clips.
  10. Attach the transmission fluid lines to the engine. Secure with the clip. Tighten the nut to 6 Nm (4 lb.ft).
  11. Connect the transmission ground cable. Tighten the bolt to 45 Nm (33 lb.ft).
  12. Connect the A/C high-pressure line intermediate joint. Clean the component mating faces. Install the new O-ring seals. Tighten the nut to 10 Nm (7 lb.ft).
  13. Attach the power steering gear high-pressure line. Clean the components. Install a new O-ring seal. Tighten the Torx bolt to 25 Nm (18 lb.ft). Secure in the clip.
  14. Connect the low pressure line to the power steering pump. Secure with the clip.
  15. Connect the engine oil cooler lines. Clean the component mating faces. Install new O-ring seals. Tighten the bolts to 7 Nm (5 lb.ft).
  16. Secure the LH catalytic converter to the exhaust manifold. Tighten the nuts to 40 Nm (29.5 lb.ft).
  17. Secure the RH catalytic converter to the exhaust manifold. Tighten the nuts to 40 Nm (29.5 lb.ft).
  18. Install the air deflector. Refer to «Air Deflector»(ref-312542-S37767534682009041400000) article.
  19. Secure the power steering fluid reservoir. Tighten the bolts to 6 Nm (4 lb.ft).
  20. Connect the AIR reservoir vacuum line.
  21. Install the radiator bottom hose. Install the hoses and secure with the clips. Connect the hoses and secure with the clips.
  22. Install the radiator top hose. Connect the quick release connector. Connect the hoses and secure with the clips.
  23. Attach the engine wiring harness to the engine compartment side wall. Position and secure the grommet.
  24. Attach the ground cable to the power distribution box bracket. Tighten the nuts to 25 Nm (18 lb.ft).
  25. Connect the engine wiring harness electrical connector and secure with the captive bolt.
  26. Connect the fuel line. Refer to «Spring Lock Couplings»(ref-312590-S15048345952009041400000) article.
  27. Connect the brake booster vacuum hose quick release connector.
  28. Install the engine compartment braces. Tighten the 4 Torx bolts to 25 Nm (18 lb.ft). Install the grommet. Repeat the above procedure for the other side.
  29. Install the cowl vent screen. Refer to «Cowl Vent Screen»(ref-312542-S31370477722009041400000) article.
  30. Install the hood. Refer to «Hood»(ref-312586-S13177222332009041400000) article.
  31. Recharge the A/C system.
  32. Connect the battery ground cable and install the cover.
  33. Refill and bleed the power steering. Refer to «Power Steering System Bleeding»(ref-312538-S03829372012009041400000) article.

More articles — Engine (With Supercharger)