engine JAGUAR X308 1998 2.G Workshop Manual

E
xhaust System - Catalyti
c Converter RH4.0L NA V8 - AJ27/3.2L NA V8 -
AJ26
Re
moval and Installation
Remov

al
1.
O
pen the engine compartment and fit paintwork protection
sheets.
2. Remove the front muffler; refer to Operation 30.10.18 in this
section.

3. CAU
TION: Note the position of the upstream and
downstream (where fitted) o xygen sensor multiplugs for
reassembly.
Disconnect the oxygen sensor multiplugs.
Di
splace the multiplugs from the engine mounting bracket.

D
isconnect the plug(s) from the oxygen sensor(s)

4.
R
emove the four nuts which se
cure the downpipe catalytic
converter to the exhaust manifold.
5. Raise the vehicle on a ramp.

6. R
emove the downpipe catalytic converter.
R

emove the bolts which se
cure the downpipe lower
mounting bracket.
Remove the
downpipe assembly.
7. Remove the oxygen sensor(s).
The downstream sensor i
s fitt
ed only for North American
markets.

6.
Connec
t the oxygen sensor multiplugs.
Con

nect the plug(s) to the respective (previously noted)
sensor(s).
Cor
rectly position the multiplu
gs on the mounting bracket.
7. Raise the ramp.

8. Tigh
ten the mounting brac
ket securing bolts.
9. Fit the front muffler; refer to Operation 30.10.18.
10. Lower the ramp.
11. Remove the paintwork protection sheets and close the engine
cover.

Exha
ust System - Catalytic Conv
erter RH4.0L SC V8 - AJ26
Remo
val and Installation
Remov
a
l
1.
Op
en the engine compartment and fit paintwork protection
sheets.

2. CAUT
ION: Note the position of the upstream and
downstream (where fitted) o xygen sensor multiplugs for
reassembly.
Disconnect the oxygen sensor multiplugs.
Di spl
ace the multiplugs from the engine mounting bracket.

Dis
connect the plug(s) from the oxygen sensor(s).

3.
Re
move the four nuts which se
cure the downpipe catalytic
converter to the exhaust manifold.
4. Raise the vehicle on a ramp.

5. Re
move the bolts which secure
the rear of the front muffler
assembly to the transmission rear mounting.
6. Remove the bolts which secure the front flange of the front
muffler to the downpipe flange.
R e
peat for the flange bolt
s on the opposite side.

9.
Connect
the downpipe catalytic
converter to the front muffler.
1. Position a new gasket to the flange studs at each side.
2. Connect the the front mu ffler assembly to each
downpipe.
3. Fit and tighten the nuts to secure the muffler to the downpipes.

10
.
Fit the front muffler rear mounting.
1. Reposition the front mu ffler and align the rear
mounting.
2. Fit and tighten the bolts; muffler to mounting bracket.
11. Lower the ramp.
12. Remove the paintwork protection sheets and close the engine
cover.

Exha
ust System - Catalyti
c Converter Gasket LH4. 0L NA V8 - AJ27/3.2L
NA V8 - AJ26
Re mo
val and Installation
Remova

l
1.
Op
en the engine compartment and fit paintwork protection
sheets.
2. Remove the front muffler; refer to Operation 30.10.18 in this
section.

3. Re
move the centre trim panel
from the engine compartment.
1. Remove the left hand side enclosure panel.
2. Remove the centre trim panel.

4. Repo
sition the expansion tank from the mounting.
1. Disconnect the coolant level sensor connector.
2. Remove the nuts which secures the tank.

5. CAUT
ION: Note the position of the upstream and
downstream (where fitted) o xygen sensor multiplugs for
reassembly.
Disconnect the oxygen sensor multiplugs.
Re
lease the multiplugs from th
e engine mounting bracket.

Dis
connect the plug(s) from the oxygen sensor(s)
6.
Re
move the four nuts which se
cure the downpipe catalytic
converter to the exhaust manifold.

5. Connec t
the oxygen sensor multiplugs.
Con
n
ect the plug(s) to the respective (previously noted)
sensor(s).
Cor r
ectly position the multiplu
gs on the mounting bracket.

6. Fi
t the coolant header tank.
1. Reposition the tank and fit the securing nuts.
2. Connect the harness connector

7. Re
fit the centre trim panel and th
e left hand enclosure panel to
the engine compartment.
1. Refit the centre trim panel.
2. Refit the left hand enclosure panel.
8. Raise the ramp.
9. Tighten the mounting brac ket securing bolts.

10
.
Fit the front muffler; refer to Operation 30.10.18.
11. Lower the ramp.
12. Remove the paintwork protection sheets and close the engine
cover.

Exha
ust System - Cataly
tic Converter Gasket LH 4.0L SC V8 - AJ26
Remo
val and Installation
Remov
a
l
1.
Op
en the engine compartment and fit paintwork protection
sheets.

2. Re
move the centre trim panel
from the engine compartment.
1. Remove the left hand side enclosure panel.
2. Remove the centre trim panel.

3. Repo
sition the expansion tank from the mounting.
1. Disconnect the coolant level sensor connector.
2. Remove the nuts which secures the tank.

4. CAUT
ION: Note the position of the upstream and
downstream (where fitted) o xygen sensor multiplugs for
reassembly.
Disconnect the oxygen sensor multiplugs.
Di spl
ace the multiplugs from the engine mounting bracket.

Dis
connect the plug(s) from the oxygen sensor(s).

5.
Re
move the four nuts which se
cure the downpipe catalytic
converter to the exhaust manifold.

6. R
aise the vehicle on a ramp.

7. R
emove the bolts which secure
the rear of the front muffler
assembly to the engine rear mounting.

8. R
emove the nuts which secure
the front flanges of the front
muffler to the downpipe flanges.

9. R
emove the gasket from the front
muffler flange at each side.
R
eposition the front silencer rearwards.
R

emove the gasket from each flange.

10
.
Remove the downpipe catalytic converter.
R
emove the bolts which se
cure the downpipe lower
mounting bracket.
Remove the
downpipe assembly.
11. Remove gasket from the manifold flange.
Clean and inspect th
e manifold joint faces.
Clean and inspect th

e threads
on the downpipe studs.

In
stallation
1.
Fit a ne
w gasket to the mani
fold mating flange on the
downpipe.

2. Fit
the downpipe catalytic converter.
1. Fit the downpipe assembly to the manifold.
Fit,
but do not fully tighten, the mounting bracket securing

bolts. (Leave loose until the nu ts securing the downpipe to
the exhaust manifold are fitted.)
3. Lower the ramp.

4. Tigh te
n the nuts securing the downpipe flange to the manifold
flange.

5. Connec t
the oxygen sensor multiplugs.
Con
n
ect the plug(s) to the respective (previously noted)
sensor(s).
Cor r
ectly position the multiplu
gs on the mounting bracket.

6. Fi
t the coolant header tank.
1. Reposition the tank and fit the securing nuts.
2. Connect the harness connector
7. Refit the centre trim panel and th e left hand enclosure panel to
the engine compartment.