JAGUAR X308 1998 2.G Workshop Manual

Engine - Engine
Installation
Installation
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. Position the engine into the engine compartment.
Traverse the engine / transmission assembly to the
vehicle and lower the assembly into the engine
compartment and onto front mounting locations.
2. Align the engine front mountings.

Align th
e engine front mountings and fit the securing nuts.
Tighte

n to the stated torque value.
3. Operate the crane controls and the ramp simultaneously (with
assistance) to raise the vehicle to a convenient working height.

4. Po
sition the transmission jack and raise it to take the weight of
the transmission. Fit and adjust the chains to secure the
transmission to the jack.

5. Fit th
e engine rear mounting bracket.
Fi

t the four bolts which secu
re the crossmember to the
body.
Fi t t
he bolt which secures the
engine rear mounting rubber
to the transmission.

6. Tigh ten th
e rear mounting bolts
to the stated torque figure.
7. Release and remove the transmission jack.
8. Operate the crane controls and the ramp simultaneously (with
assistance) to lower the vehicle to a convenient working height.

9. Lower th e cran
e and remove th
e chain assembly and lifting
eyes.

R
emove the engine re
ar lifting eyes.
10. Move the crane away from the vehicle.
11. Raise the vehicle on the ramp.

12
.
Connect the transmission selector cable.
1. Fit the selector lever to the cross shaft.
2. Fit the nut which secures the selector lever to the transmission cross shaft.
3. Reposition the selector cable abutment bracket to the transmission and fit the securing bolts.

13
.
Connect the transmission harness connector.
1. Connect the transmission harness connector.
2. Secure the leve r lock mechanism.

14
.
Reposition the ground lead to the transmission casing and fit
the securing bolt.
15. Fit the brackets which suppo rt the downpipe catalytic
converters to the bell housing.
Po
sition the mounting bracket and fit the two bolts which
secure it to the bell housing.

Repeat
the above procedure for the other side.

16 . Connect
the driveshaft (propshaft
) flange to the transmission
output flange.
F i
t the three bolts which secure the flange.

17 . F
it the downpipe catalytic converters.
1. Fit a new gasket to the downpipe flange and fit the
downpipe assembly. to the manifold.
F i
t the bolts which secure
the downpipe to the lower
mounting bracket.
Repeat the above operation
s
for the other downpipe
catalytic converter.

18 . F
rom above the vehicle, tighte
n the manifold flange nuts, A-
Bank and B-Bank flanges, to the correct torque.
19. Fit the front muffler assembly.
Locate the front muf fler into the
downpipe catalytic
converters.
20. Move the front muffler forwar d to allow the intermediate
mufflers to be connected.

Connect
the front muffler to
the intermediate muffler,
noting the alignment of the indicator rings.
W
ith the front muffler positioned correctly, tighten the
clamps (left-hand and right-hand sides) to the catalytic
converter.

21
.
Tighten the clamps (left-hand and right-hand sides),
intermediate mufflers to front muffler.

22
.
Tighten the downpipe bracket se curing bolts to the correct
torque

23
.
Connect the oil cooler pipes (w here fitted) to the engine.
1. Remove the blanking plugs from the pipes and from the mating unions on the engine.
2. Fit new O-ring seals to the pipes and lubricate with new engine oil.
3. Connect the pipes to the engine and fit the clamping
plate and bolt.
24. Lower the vehicle on the ramp.
25. Connect the heater and brake servo hoses.
1. Connect the heat er return hose.
2. Connect the heater feed hose and secure the locking
lever.

3. Conne
ct the brake servo hose.

26. Conne
ct the P.I. harness to the engine management
harness.
1. Reposition the engi ne management harness
connector to the bracket.
2. Fit the nut which secures the engine management harness connector to the mounting bracket.
3. Connect the connectors.
4. Fit the bolt which secures the P.I. harness connector to the engine management harness.

27 . Conne
ct the transmission rotary
switch harness connector.
Re
position and connect the harness.

28 . Con
nect the throttle cable.
1. Fit the bolts which secure the abutment bracket to the throttle body. Tighten to 4-6 Nm.
2. Rotate the butterfly actuator cam and connect the cable. Reposition the cable into the cam.
Re
move any tape or plastic
strap which was fitted when
disconnecting the cable abutment.
29. Connect the pipes to the purge valve.
1. Connect the part load breather hose.
2. Fit the clip which secures the part load breather hose
to the purge valve.

WARNING: B
EFORE PROCEEDING, IT IS ESSENTIAL THAT
THE WARNING NOTES GIVEN IN SECTION 100-00 (UNDER
THE HEADING 'SAFETY PRECAUTION S') ARE READ AND UNDERSTOOD.
3.
Connect the vacuum hose to the purge valve.

30

.
Connect the fuel feed and return hoses.
R
emove the blanking plugs
from the mating pipes.
1. Connect the hoses at the Quick Fit connectors.
F
it the return hose into the feed hose clip.

31
.
Connect the starter motor power cable.
1. Reposition and connect the power cable to the power stud. Fit the securing nut to the stud.
2. Reposition the protective boot over the starter motor power stud.
3. Connect the harness connector, engine management harness to starter motor. Fit the connector to the
mounting bracket.
R
enew the tie strap which secures the power cable to the
right hand enclosure.

32
.
Connect the generator suppressi on module (where fitted)
harness.
Re
position the harn
ess under the suppression module and
connect the harness connector.
33. Connect the hoses to the power steering pump.

1.
Remove the blanking plugs from the pipes and
unions. Fit a new sealing washer to the high pressure
hose joint.
2. Connect the high pressure hose union.
3. Connect the feed hose to the pump.

34 . Conne
ct the engine oil
pressure transmitter.

35 .
Fit the radiator and
condense
r assembly. Check that the
lower mounting rubbers are located correctly.

36 . Fit the radiator top
retaining panel.
1. Fit the panel.
2. Check that the radiator top mounting bushes are
located correctly.
37. Fit the radiator top retaining panel.
Fit
the ten bolts which secure the panel.

38
.
Connect the radiator top hose.
1. Connect the hose to the radiator.
2. Reposition and secure the hose retaining clip.

39
.
Connect the radiator bottom hose.
1. Connect the hose to the radiator.
2. Reposition and secure the hose retaining clip.

40
.
Connect the discharge hose to the condenser.
1. Remove the blanking plugs from the hose and condenser.
2. Fit and fully seat a new O-ring seal to the hose.
Lubricate the seal with clean compressor oil
3. Fit the hose to the condenser and tighten the securing bolt.
41. Connect the jump hose to the receiver/drier.
1. Remove the blanking plugs from the hose and receiver/drier.
2. Fit and fully seat a new O-ring seal to the hose.
Lubricate the seal with clean compressor oil

3.
Fit the hose and tighten the securing bolt.

42 . Conne
ct the transmission
oil cooler upper pipe.
1. Remove the blanking plugs from the pipe and the radiator.
Fit and
fully seat a new O-ring
seal to the pipe. Lubricate
the seal with clean transmission oil
2. Reposition and connect the union nut, upper cooler pipe to radiator.

43 . Conne
ct the transmission oil cooler lower pipe.
1. Remove the blanking plugs from the pipe and the radiator.
Fit and
fully seat a new O-ring
seal to the pipe. Lubricate
the seal with clean transmission oil
2. Reposition and connect the union nut, lower cooler
pipe to radiator.
44. Fit the twin fan and motor assembly. Refer to Operation
26.25.12.

45 . Connect
the radiator breather hose.
Re
po
sition the Quick-Fit hose (radiator to expansion tank)
and connect the hose to the radiator.
46. Fit the expansion tank to the vehicle.
1. Remove the pipe clamp if still in place and connect
the hose to the expansion tank.