303 JAGUAR X308 1998 2.G Workshop Manual

Installation
20. Clean and inspect all relevant components.

1. Push the tensioner piston (secon dary chain) into the body to
provide clearance for fitting.
1. Insert a thin rigid wire th rough the hole in the end of
the tensioner piston to displace the ball from the non-
return valve seat.
2. With the wire in position, press the piston fully into the tensioner body.
Remove the wire.

2. Fit the VVT unit to the engine.
Assemble the VVT unit, the exhaust camshaft sprocket
and the secondary chain, in pr eparation for fitting to the
engine.
1. Fit the above assembly to the camshafts with the chain correctly positioned over the tensioner; VVT
unit to the inlet and the sprocket to the exhaust.
2. Fit, but do not tighten, each bolt which secures the VVT unit and the exhaust sprocket to the camshafts.
Allow the VVT unit sufficien t space to fit the primary
chain, in a la ter operation.

3. Fit the chain tensioning tool 303 - 532 to the exhaust camshaft
sprocket.
Reposition the sprocket (and the VVT unit) for the most
advantageous position for use of the tool.
Remove the tool.

4. Refit the primary timing chain.
1. Lift the primary chain an d position it over the VVT
unit sprocket (the VVT unit mu st be pulled forward to
clear the cylinder head casting). There must be no
slack on the drive side of the primary chain and the
VVT unit must not be rotated on the camshaft.
2. Slide the VVT unit fully on to the camshaft.
5. Fit the primary chain tensioner blade.
1. Position the tensioner blade to the cylinder block.

2. Fit the retaining / pivot bolt and tighten it to 12-16 Nm.

6. Refit the primary chain tensione r assembly. Refer to Operation
12.65.55 in this Section.
Use a wedge 303 - 533 (or two if required) between the
primary chain tensioner and te nsioner blade, to take up
the slack in the chain.

7. Tighten the exhaust camshaft sprocket securing bolt.
1. Fit the chain tensioner tool 303 - 532 to the sprocket holes.
Apply force to the tool in an anti-clockwise direction to
tension the chain on its drive side.
2. Whilst applying the opposing force to the sprocket and chain, tighten the sprock et securing bolt to 115 -
125 Nm.

8. Tighten the VVT unit securing bolt.
1. Whilst still applying the opposing force to the
sprocket and chain (using 303 - 532), check that the
wedges are still in place, tighten the VVT unit
securing bolt to 115 - 125 Nm.
Remove the chain tensioning tool and the wedge(s).
9. Remove the camshaft locking tool 303 - 530 .
10. Raise the vehicle on the ramp.
11. Remove the crankshaft setting tool 303 - 531.
12. Refit the crankshaft position sensor.
1. Fit the sensor to the fl ywheel housing and fit the
securing bolt. Tighten to 8-12 Nm.

Engine - Variable Camshaft Timing Oil Control Unit RH
In-vehicle Repair
Removal
Special Tool(s)

Camshaft setting
303-530

Timing chain tensioning
303-532

Wedges, primary chain
303-533

Crankshaft setting
303-531
1. Open the engine compartment and fit paintwork protection
sheets.
2. Set the engine compartment cover to the service access
position.

3. Disconnect the batt ery ground cable.
Remove the battery cover.
4. Remove the Timing Co ver. Refer to Operation 12.65.01 in this
Section.
5. Remove the Variable Valve Ti ming Bush Carrier Assembly.
Refer to Operation 12.65.51 in this Section
6. Raise the vehicle on a ramp.
7. Remove the crankshaft position sensor.

1. Remove the bolt which secures the crankshaft position sensor to the flywheel housing.
Remove the sensor and allow it to hang free under the
engine.
2. Remove the access grommet (for torque converter bolts) from the housing.
8. Fit the damper securing bolt (old one) to the crankshaft, hand-
tight only.

9. Rotate the crankshaft until the triangular arrow indent on
the drive plate is visible thro ugh the access hole; confirm
that the timing flat on ea ch camshaft is uppermost.

10. Fit the crankshaft setting peg 303 - 531 to the crankshaft
position sensor location.
1. Fit the crankshaft setting peg 303 - 531.
Position the crankshaft so that the setting peg engages
fully into the timing slot.
2. Fit and tighten the bolt to secure the setting peg.
11. Remove the damper securing bolt from the crankshaft.
12. Lower the vehicle on the ramp.

13. Fit the camshaft locking tool 303 - 530 to the A-Bank
camshafts, aligning the shafts slightly as necessary.
14. Remove the primary chain tens ioner. Refer to operation
12.65.54, in this Section

3. Fit the chain tensioning tool 303 - 532 to the exhaust camshaft
sprocket.
Reposition the sprocket (and the VVT unit) for the most
advantageous position for use of the tool.
Remove the tool.

4. Refit the primary timing chain.
1. Fit the primary chain to position over the crankshaft sprocket and the VVT unit sprocket. There must be no
slack on the drive side of the primary chain.
2. The VVT unit must not be rotated on the camshaft

5. Fit the primary chain tensioner blade.
1. Position the tensioner blade to the cylinder block.
2. Fit the retaining / pivot bolt and tighten it to 12-16 Nm.
6. Refit the primary chain tensione r assembly. Refer to Operation
12.65.54 in this Section.
Use a wedge 303 - 533 (or two if required) between the
primary chain tensioner and te nsioner blade, to take up
the slack in the chain.

7. Tighten the exhaust camshaft sprocket securing bolt.
1. Fit the chain tensioner tool 303 - 532 to the sprocket holes.
Apply force to the tool in an anti-clockwise direction to
tension the chain on its drive side.
2. Whilst applying the opposing force to the sprocket and chain, tighten the sprock et securing bolt to 115 -
125 Nm.

8. Tighten the VVT unit securing bolt.
1. Whilst still applying the opposing force to the
sprocket and chain (using 303 - 532), check that the
wedges are still in place, tighten the VVT unit
securing bolt to 115 - 125 Nm.
Remove the chain tensioning tool and the wedge(s).
9. Remove the camshaft locking tool 303 - 530.
10. Raise the vehicle on the ramp.
11. Remove the crankshaft setting tool 303 - 531.

12. Refit the crankshaft position sensor.
1. Fit the sensor to the fl ywheel housing and fit the
securing bolt. Tighten to 8-12 Nm.
2. Refit the access grommet to the housing.
13. Lower the ramp.
14. Refit the A-Bank VVT Bush Carrier Assembly. Refer to
operation 12.65.51 in this Section.
15. Refit the Timing Cover. Refer to Operation 12.65.01 in this
Section.

Engine - Engine
Removal
Removal
Special Tool(s)

Engine Lifting Brackets
303-536

Quick Fit Connector Release Tool
310-044

Quick Fit Connector Release Tool
310-054

Quick Fit Connector Release Tool
303-623

Fuel Injection Pressure Test Equipment
310-058
1. Park the vehicle on a four post ramp, over which, an overhead
lifting crane is available, and set the gear selector to 'N'.
The crane should be rated at a minimum of 500 kg Safe
Working Load and have suffici ent fore and aft movement
to traverse the engine assemb ly clear of the vehicle.
Do not apply the handbrake, but use wedges to chock one
wheel to prevent movement of the vehicle.
2. Open the engine compartment and fit paintwork protection
sheets.
3. Disconnect the batt ery ground cable.
Remove the battery cover.

16. Disconnect the air cleaner cover.
Remove the five clips which se cure the air cleaner cover.

17. Remove the intake tube / air flow meter / air cleaner cover
assembly.
1. Remove the intake tube / air flow meter / air cleaner
cover assembly.
2. Remove and discard the ru bber seal; air intake tube
to throttle body.

18. Remove the centre trim panel from the engine compartment.
1. Remove the left hand side enclosure panel.
2. Remove the centre trim panel.
19. Release the hoses (Quick Fit connections) from the expansion
tank, using 303 - 623.
1. Release the hose, expansion tank to thermostat housing (coolant outlet pipe on supercharged
engines).

2. Release the hose, expansion tank to recovery tank.
3. Release the hose, expansion tank to radiator.
20. Fit blanking plugs to the pipes and the tank.

21. Remove the expansion tank from the mounting.
1. Disconnect the coolant level sensor connector.
2. Remove the nuts which secure the tank.

22. Remove the expansion tank from the vehicle.
1. It may be necessary to us e a pipe clamp to clamp the
bottom hose branch.
2. Release the pipe clip an d move it along the pipe.
3. Disconnect the tank from the bottom hose and remove it from the vehicle.
23. Empty any remaining coolant from the expansion tank into a
drain tray.
24. Remove the cloth from the engine and clean any spillage from
the engine bay.

25. Disconnect the radiator breather hose.
Release the Quick-Fit hose (radiator to expansion tank)
using 303 - 623, and disconnect the hose from the
radiator.
26. Remove the twin fan and motor assembly. Refer to Operation
26.25.12.

3. Disconnect the brake servo hose.

60. Fit engine rear lifting eyes (303 - 536).
61. Traverse the hoist to the engine compartment and lower it to
working height.
62. Fit lifting chains to the hoist and connect to each engine
lifting eye. Use longer chains to the rear lifting eyes to allow
the engine to tilt rearwards wh en removing from the vehicle.

63. Remove the engine front mounting nuts.
64. Raise the ramp.

65. Disconnect the transmission connector.
1. Release the lever lock on the transmission harness
multi-plug.
2. Disconnect the connector.
66. Disconnect the transmission selector cable.