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Home >> Jaguar >> 2002 >> XK8 2D Convertible >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine >> In Vehicle Repair >> Intake Manifold >> Installation

Intake Manifold: Installation

  1. Clean all parts and relevant mating faces.
  2. Install eight new seals to the intake manifold ports.
    Fig 1: Installing Seals To Intake Manifold Ports
    G03157088Courtesy of JAGUAR CARS, INC.
  3. Install the intake manifold.
    • Tighten to 21 Nm.
    Fig 2: Installing Intake Manifold
    G03157089Courtesy of JAGUAR CARS, INC.
  4. Connect the engine breather hose to the throttle body elbow.
    • Connect the vacuum hose to the throttle body elbow.
    • Connect the engine breather hose from the throttle body elbow.
    Fig 3: Connecting Engine Breather & Vacuum Hoses
    G03157090Courtesy of JAGUAR CARS, INC.
    5. NOTE: Uncap the fuel line and fuel injection supply manifold.
    NOTE: Remove and dispose of absorbent cloth while complying to local health and safety standards.
    Fig 4: Connecting Fuel Feed Hose
    G03157091Courtesy of JAGUAR CARS, INC.
  5. Connect the fuel feed hose.
    • Connect the fuel feed hose at the Quick Fit connector. Ensure that the hose is fully seated to the feed pipe.
    6. NOTE: Uncap the fuel line and fuel injection supply manifold.
    NOTE: Remove and dispose of absorbent cloth while complying to local health and safety standards.
    Fig 5: Connecting Fuel Return Hose
    G03157092Courtesy of JAGUAR CARS, INC.
  6. Connect the fuel return hose.
    • Connect the fuel return hose at the Quick Fit connector. Ensure that the hose is fully seated to the feed pipe.
    7. NOTE: Left-hand shown, right-hand similar.
    Fig 6: Connecting Fuel Injectors Electrical Connectors
    G03157093Courtesy of JAGUAR CARS, INC.
  7. Connect the fuel injectors electrical connectors.
  8. Connect the KS electrical connectors.
    Fig 7: Connecting KS Electrical Connectors
    G03157094Courtesy of JAGUAR CARS, INC.
  9. Attach the right-hand camshaft sensor wiring harness to the throttle body elbow.
    Fig 8: Attaching Right-Hand Camshaft Sensor Wiring Harness
    G03157095Courtesy of JAGUAR CARS, INC.
  10. Connect the throttle body electrical connectors.
    Fig 9: Connecting Throttle Body Electrical Connectors
    G03157096Courtesy of JAGUAR CARS, INC.
  11. Connect the accelerator inner cable.
    • Reposition the accelerator pulley to the full throttle position. (1)
    • Connect the accelerator inner cable. (2)
    Fig 10: Connecting Accelerator Inner Cable
    G03157097Courtesy of JAGUAR CARS, INC.
    12. NOTE: Uncap the coolant hose.
    Fig 11: Connecting Coolant Hose To Throttle Body
    G03157098Courtesy of JAGUAR CARS, INC.
  12. Connect the coolant hose to the throttle body.
    13. NOTE: Right-hand shown, left-hand similar.
    Fig 12: Installing Intake Elbow Lower Retaining Bolts
    G03157099Courtesy of JAGUAR CARS, INC.
  13. Install the intake elbow lower retaining bolts.
    • Tighten to 18 Nm.
    14. NOTE: Uncap the coolant hose.
    Fig 13: Connecting Coolant Hose To Throttle Body
    G03157100Courtesy of JAGUAR CARS, INC.
  14. Connect the coolant hose to the throttle body
  15. Attach the brake servo vacuum pipe to the throttle body elbow.
    Fig 14: Attaching Brake Servo Vacuum Pipe
    G03157101Courtesy of JAGUAR CARS, INC.
  16. Attach the left-hand CMP sensor wiring harness to the throttle body elbow.
    Fig 15: Attaching Left-Hand CMP Sensor Wiring Harness
    G03157102Courtesy of JAGUAR CARS, INC.
  17. Connect the throttle body electrical connectors.
    Fig 16: Connecting Throttle Body Electrical Connectors
    G03157103Courtesy of JAGUAR CARS, INC.
  18. Install the engine right-hand cover.
    Fig 17: Installing Engine Right-Hand Cover
    G03157104Courtesy of JAGUAR CARS, INC.
  19. Install the engine left-hand cover.
    Fig 18: Installing Engine Left-Hand Cover
    G03157105Courtesy of JAGUAR CARS, INC.
  20. Attach the coolant pipe.
    Fig 19: Attaching Coolant Pipe
    G03157106Courtesy of JAGUAR CARS, INC.
  21. Install the intake tube / air flow meter / air cleaner cover assembly.
    • Install a new rubber seal; air intake tube to throttle body. (1)
    • Install the intake tube / air flow meter / air cleaner cover assembly. (2)
    Fig 20: Installing Intake Tube / Air Flow Meter / Air Cleaner Cover Assembly
    G03157107Courtesy of JAGUAR CARS, INC.
  22. Connect the mass air flow meter electrical connector.
    • Connect the breather pipe from the camshaft cover. (1)
    • Connect the mass air flow meter electrical connector. (2)
    Fig 21: Connecting Mass Air Flow Meter Electrical Connector
    G03157108Courtesy of JAGUAR CARS, INC.
  23. Reconnect the air cleaner cover.
    • Install the five clips which secure the air cleaner cover.
    Fig 22: Installing Air Cleaner Cover
    G03157109Courtesy of JAGUAR CARS, INC.
  24. Connect the intake tube to the throttle body.
    • Install the two bolts which secure the intake tube to the throttle body. (1)
    • Connect the intake tube from the throttle body. (2)
    Fig 23: Connecting Intake Tube To Throttle Body
    G03157110Courtesy of JAGUAR CARS, INC.
  25. Fill the cooling system to the correct level.
  26. Install the coolant expansion tank pressure cap.
  27. Connect the battery and fit the battery cover.
  28. Adjust the accelerator cable. Refer to ACCELERATOR CABLE ADJUSTMENT .
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