hoses JAGUAR X308 1998 2.G Service Manual

4. Inst
all coolant hoses.

5. R
eposition outer cable
to abutment bracket.
Install but do not tigh
ten adjusting nut.

6. CAUTI
ON: Under no circumst
ances should quadrant be
held clear of throttle stop by cable tension.
• NOTE: Make sure ther e is neither tension nor slack in the cable.
Install throttle cable.
Tigh
ten locknut without altering setting or introducing
twist into the cable outer.
7. Connect conn
ectors and vacuum pipe.

the
intake elbow provide connections for vacuum actuators and are also used to redirect emissions into the engine.
On the right-hand side of the elbow a la rge diameter pipe connects to the brake servo. The smaller pipe provides a vacuum
feed to the fuel rail pressure regulator and throttle cruise control system. On the le ft-hand side of the elbow the front pipe
supplies vacuum control for the evaporative emissions system valves.
Emissions from the engine part load breather (bank 2) and pu rged fuel vapor from the EVAP valve are drawn via a common
T piece into the left-hand side of the intake elbow. Re-cir culated exhaust gas enters the intake elbow via the EGR valve
which is mounted directly on the rear of the elbow : where the EGR system is not used, a blanking plate is fitted.
The fuel system, throttle and emission control system s are described more fully in the relevant sections.
Intake Manifold

Filtered air from the vehicle's intake ducting is metered by th e electronic throttle and distributed to the two cylinder banks
via an integral intake manifold.
The intake manifold is manufactured in plastic with integral plastic fuel rails and metal-thread inserts; the very smooth
internal surfaces give excellent air flow.
Individual ducts lead off a central chamber to the inlet valves of each cylinder.
Silicon-rubber gaskets, loca ted in channels in the intake manifold, seal th e joints between the ducts and the cylinder heads.
Engine Ventilation

The e
ngine is ventilated through two brea
thers; a part-load breather and a full-load breather, one on each camshaft cover.
The outlet hose for the part-load breather is connected between the bank 2 camshaft cover and the intake elbow. The full-
load outlet hose is connected from the bank 1 camshaft cover to the intake duct between the MAF sensor assembly and the
throttle body.
Constructed in plastic, the hoses incorporate O-ring seal s and quick-release connectors; refer to Section 303-01.
I
ntake Air Distribution and Filtering - Supercharged Vehicles
Ai
r is supplied to the supercharger via an
intake cleaner/duct, throttle assembly and intake elbow which are similar to those
used for normally aspirated engines. The su percharger delivers pressurized air to two separate charge air cooler units, each
unit being mounted on the cy linder bank which it supplies. Pr essurized cooled air is fed from the charge air coolers directly
into each inlet port.

is at
tached to the three mounting bosses between the V of the cylinder block
has a fil

led for life inte
rnal lubrication system
is po
sitively aligned with the drive
belt by a doweled mounting bracket
C
harge Air Cooler System
Each cyl
inder bank is fitted with a charge air cooler unit wh
ich supplies pressurized air to the four cylinders via an adaptor
block. The inlet ports to the tw o charge air coolers are connected to the supercharger outlet by an inle t assembly consisting
of rubber ducts and clamp plates . An outlet stub at the rear of each charge air cooler unit provides the connection for the
by-pass valve airflow. The charge air coolers ar e water cooled via a radiator and coolant pump.
Charge Air Cooler Coolant System

Parts List
Each charge air cooler unit is a fin and tube air to liquid heat exchanger. The coolant circuit for the charge air coolers
consists of a pump, ra diator, connecting hoses and a bleed pipe.


It
em
Par
t Number
De
scription
1—Charge air cool

ers

2—Coo
lant hoses
3—Coo

lant pump
4—Radi

ator
5—Ble

ed pipe to main coolant circuit expansion tank
6—Charge air cooler to en

gine
coolant circuit connection
7—Coo
lant top up plug
Supercharger
The supe
rcharger:

Intake Air Distribution and Filtering - Charge Air Cooler LH
Remo
val and Installation
Remov
a
l
Installation
1. Disc onne
ct battery ground cable (IMPORTANT, see SRO
86.15.19 for further information).
2. Drain radiator coolant; refer to 26.10.01.
3. Remove air cleaner cover / intake assembly; refer to 19.10.30.
4. Remove throttle body; refer to 19.70.04.
5. Remove exhaust gas re-circulation valve (EGR) if installed;
refer to 17.45.01.
6. Remove throttle intake elbo w; refer to (SC) 19.70.28.
7. Remove supercharger outlet duct; refer to 18.50.16.
8. Remove coolant outlet pipe; refe r to operation (SC) 26.31.08.
9. Remove supercharger drive belt; refer to 18.50.08.
10. Remove supercharger; refer to operation 18.50.15.
11. Detach engine harness retaining clip from rear of charge air
cooler.

12. Di
sconnect hoses from charge air cooler.
Pla

ce absorbent cloth in appropriate position.
Di
sc
onnect hoses.

13 .
CAUTI
ON: Take care to avoi
d dropping any objects or
foreign matter into engine inle t duct with charge air cooler
removed.
Remove charge air cooler from the engine.
1. Remove eight bolts.
Remove charge air cooler.
2
. Discard gasket.
Cle
a
n all mating faces.
1.
Install ch
arge air
cooler to adaptor.
1. Install new gasket.
2. Install charge air cooler.

2.
Conne
ct hoses to charge air cooler.
Conne

ct hoses.
3. Install supercharger; refer to 18.50.15.
4. Install supercharger driv e belt; refer to 18.50.08.
5. Install engine coolant outlet pipe; refer to 26.31.08.
6. Install supercharger outlet du ct and new gasket; refer to
18.50.16.
7. Install throttle intake elbow; refer to 19.70.28.
8. Install exhaust gas re-circulation valve (EGR) if applicable;
refer to 17.45.01.
9. Install throttle body ; refer to 19.70.04.
10. Install air cleaner cover / intake assembly; re fer to 19.10.30.
11. Refill cooling system; refer to (SC) (26.10.01).
12. Reconnect battery ground cable (IMPORTANT, see SRO
86.15.15 for further information).

Intake Air Distribution and Filtering - Charge Air Cooler RH
Remo
val and Installation
Remov
a
l
Installation
1. Disc onne
ct battery ground cable (IMPORTANT, see SRO
86.15.19 for further information).
2. Drain radiator coolant; refer to 26.10.01.
3. Remove air cleaner cover / intake assembly; refer to 19.10.30.
4. Remove throttle body; refer to 19.70.04.
5. Remove exhaust gas re-circulation valve (EGR) if installed;
refer to 17.45.01.
6. Remove throttle intake elbo w; refer to (SC) 19.70.28.
7. Remove supercharger outlet duct; refer to 18.50.16.
8. Remove coolant outlet pipe; refe r to operation (SC) 26.31.08.
9. Remove supercharger drive belt; refer to 18.50.08.
10. Remove supercharger; refer to operation 18.50.15.
11. Remove intake air temperatur e sensor 2 from charge air
cooler; refer to 18.30.52.
12. Detach engine harness retaining clip from rear of charge air
cooler.

13. Di
sconnect hoses from charge air cooler.
Pla

ce absorbent cloth in appropriate position.
Di
sc
onnect hoses.

14 . CAUTI
ON: Take care to avoi
d dropping any objects or
foreign matter into engine inle t duct with charge air cooler
removed.
Remove charge air cooler from the engine. 1. Remove eight bolts.
Remove charge air cooler.
2
. Discard gasket.
Cle
a
n all mating faces.
1.
Install ch arge air
cooler to adaptor.
1. Install new gasket.
2. Install charge air cooler.

2.
Conne
ct hoses to charge air cooler.
Conne

ct hoses.
3. Install intake air te mperature sensor 2 to charge air cooler;
refer to 18.30.52.
4. Install supercharger; refer to 18.50.15.
5. Install supercharger driv e belt; refer to 18.50.08.
6. Install engine coolant outlet pipe; refer to 26.31.08.
7. Install supercharger outlet du ct and new gasket; refer to
18.50.16.
8. Install throttle intake elbow; refer to 19.70.28.
9. Install exhaust gas re-circulation valve (EGR) if applicable;
refer to 17.45.01.
10. Install throttle body; refer to 19.70.04.
11. Install air cleaner cover / intake assembly; re fer to 19.10.30.
12. Refill cooling system; refer to (SC) (26.10.01).
13. Reconnect battery ground cable (IMPORTANT, see SRO
86.15.15 for further information).

Intake Air Distribution and Filtering - Charge Air Cooler Radiator
Remo
val and Installation
Remov
a
l
1.
Op
en the engine compartment and fit paintwork protection
sheets.
2. Disconnect the battery.
1. Remove the battery cover.
2. Disconnect the battery ground cable.
3. Remove the engine radiator and air conditioning condensor
assembly. Refer to operation 26.40.01.
4. Remove the grill assembly fo r access. Refer to operation
76.55.15.

5. Drain th e charge air cooler radiator.
Reach t
hrough the front bumper
splitter vane to remove
the radiator drain plug.

6. Disc
onnect the radiator
hoses from the radiator.
1. Disconnect the coolant pump to radiator hose.
2. Disconnect the return hose.
3. Disconnect the bleed pipe.

7. Re
move the two radiator fixing bolts.
8. Displace and re-position the am bient air temperature sensor
and bracket.

Intake Air Distribution and Filtering - Supercharger
Remo
val and Installation
Remov
a
l
Installation
1. Disc onne
ct battery ground cable (IMPORTANT, see SRO
86.15.19 for further information).
2. Drain radiator coolant; refer to 26.10.01.
3. Remove air cleaner cover / intake assembly; refer to 19.10.30.
4. Remove throttle body; refer to 19.70.04.
5. Remove exhaust gas re-circulation valve (EGR) if installed;
refer to 17.45.01.
6. Remove throttle intake elbo w; refer to (SC) 19.70.28.
7. Remove supercharger outlet duct; refer to 18.50.16.
8. Remove coolant outlet pipe; refe r to operation (SC) 26.31.08.
9. Remove supercharger drive belt; refer to 18.50.08.
10. Disconnect remaining coolant hoses from charge air coolers.
Position pipes to facilitate removal
of supercharger.
Inst
al
l suitable blanking plugs.

11 .
R
emove supercharger from engine.
1. Remove bolt.
2. Remove bolts .
3. Remove supercharger.

1. Inst al
l supercharger.
2. Connect all hoses to charge air coolers.
3. Install supercharger driv e belt; refer to 18.50.08.
4. Install engine coolant outlet pipe; refer to 26.31.08.
5. Install supercharger outlet du ct and new gasket; refer to
18.50.16.
6. Install throttle intake elbow; refer to 19.70.28.
7. Install exhaust gas re-circulation valve (EGR) if applicable;

Intake Air Distribution and Filtering - Supercharger Outlet Pipe
Remo
val and Installation
Remov
a
l
1.
Re
move air cleaner cover / intake
assembly; refer to 19.10.30.
2. Drain radiator coolant; refer to operation (SC) 26.10.01.

3. Disc
onnect coolant hoses and vacuum pipe from supercharger
outlet duct.
Pl a
ce absorbent rags under
the two coolant hoses which
are connected to the outlet duct.
1. Remove vacuum pipe.
2. Disconnect hoses.
Plu g
hoses and outlet duct stub pipes to prevent spillage.

4. CAUTIO
N: Take care to avoi
d any coolant from dripping
into supercharger.
Remove supercharger outlet duct. 1. Remove three bolts.
2. Remove four bolts.
Di
scard rubber seals from bolts.
3. Remove outlet duct.
Discard ou
tlet duct gasket.
5.
Bla
nk supercharger outlet with
body tape, or similar, to
prevent ingress of foreign matter.

6. Remove charge air c oo
ler inlet assembly.
1. Remove two bolts.
2. Remove two bolts.
3. Remove charge air cooler inlet assembly.
7. Remove ducts from charge air cooler inlet assembly.
1. Remove two clamp plates.
2. Discard two ducts.