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Engine - Disassembly: Disassembly

Vehicles with supercharger 

  1. Detach the supercharger belt.
    • Use a 1/2 inch square drive bar to rotate the supercharger belt tensioner.
    • Detach the supercharger belt.
      GJ0000606Courtesy of JAGUAR CARS, INC.
  2. Remove the supercharger drive belt tensioner.
    • Remove the super charger drive belt.
      GJ0000609Courtesy of JAGUAR CARS, INC.

    3. All vehicles 

  3. Release the accessory drive belt tension.
    GJ0002046Courtesy of JAGUAR CARS, INC.
  4. Detach the accessory drive belt.
    GJ0002047Courtesy of JAGUAR CARS, INC.
  5. Remove the drive belt tensioner.
    • Remove the drive belt.
      GJ0002048Courtesy of JAGUAR CARS, INC.

    6. Vehicles with supercharger 

  6. Detach the coolant hose.
    GJ0002049Courtesy of JAGUAR CARS, INC.
  7. Detach the coolant hose.
    GJ0002050Courtesy of JAGUAR CARS, INC.
  8. Detach the coolant hose.
    GJ0002051Courtesy of JAGUAR CARS, INC.
  9. Remove the coolant hose.
    GJ0002052Courtesy of JAGUAR CARS, INC.
  10. Remove the coolant hose.
    GJ0002053Courtesy of JAGUAR CARS, INC.

    11. All vehicles 

  11. Remove the left-hand engine mount.
    GJ0002054Courtesy of JAGUAR CARS, INC.
  12. Remove the engine mount bracket.
    GJ0002055Courtesy of JAGUAR CARS, INC.
  13. Remove the oil level indicator and tube.
    • Remove and discard the O-ring seal.
      GJ0002056Courtesy of JAGUAR CARS, INC.
  14. Remove the power steering pump.
    • Remove the securing bolts.
      GJ0002057Courtesy of JAGUAR CARS, INC.
  15. Disconnect the electrical connector.
    GJ0002058Courtesy of JAGUAR CARS, INC.
  16. Remove the air conditioning (A/C) compressor.
    • Remove the securing bolts.
      GJ0002059Courtesy of JAGUAR CARS, INC.
  17. Remove the mount bracket.
    GJ0002060Courtesy of JAGUAR CARS, INC.
  18. Detach the wiring harness.
    GJ0002061Courtesy of JAGUAR CARS, INC.
  19. Remove the mount bracket.
    GJ0002062Courtesy of JAGUAR CARS, INC.
  20. Remove the left-hand exhaust manifold.
    • Remove and discard the gasket.
      GJ0002063Courtesy of JAGUAR CARS, INC.
  21. Disconnect the electrical connector.
    GJ0002064Courtesy of JAGUAR CARS, INC.
  22. Remove the generator.
    • Remove the retaining bolts.
      GJ0002065Courtesy of JAGUAR CARS, INC.
  23. Detach the wiring harness.
    GJ0002066Courtesy of JAGUAR CARS, INC.
  24. Remove the mount bracket.
    • Remove the retaining bolts.
      GJ0002067Courtesy of JAGUAR CARS, INC.
  25. Remove the right-hand engine mount.
    GJ0002068Courtesy of JAGUAR CARS, INC.
  26. Remove the engine mount bracket.
    GJ0002055Courtesy of JAGUAR CARS, INC.
  27. Remove the right-hand exhaust manifold.
    • Remove and discard the gasket.
      GJ0002069Courtesy of JAGUAR CARS, INC.
  28. Remove the starter motor.
    GJ0002070Courtesy of JAGUAR CARS, INC.
  29. Disconnect the crankshaft position sensor electrical connector.
    GJ0002071Courtesy of JAGUAR CARS, INC.
  30. Remove the crankshaft position sensor.
    GJ0002072Courtesy of JAGUAR CARS, INC.
  31. Detach the wiring harness.
    GJ0002073Courtesy of JAGUAR CARS, INC.
  32. Detach the wiring harness.
    GJ0002074Courtesy of JAGUAR CARS, INC.

    33. Vehicles with supercharger 

  33. Detach the engine wiring harness.
    GJ0002075Courtesy of JAGUAR CARS, INC.
  34. Disconnect the electrical connector.
    GJ0002076Courtesy of JAGUAR CARS, INC.
  35. Detach the coolant hose.
    • Reposition the retaining clip.
      GJ0002077Courtesy of JAGUAR CARS, INC.
  36. Detach the thermostat housing.
    • Remove the retaining bolts
      GJ0002078Courtesy of JAGUAR CARS, INC.
  37. Remove the thermostat housing.
    • Detach the coolant hose.
      GJ0002079Courtesy of JAGUAR CARS, INC.
  38. Disconnect the electrical connector.
    GJ0002080Courtesy of JAGUAR CARS, INC.
  39. Disconnect the electrical connector.
    GJ0002081Courtesy of JAGUAR CARS, INC.
  40. Disconnect the electrical connector.
    GJ0002082Courtesy of JAGUAR CARS, INC.
  41. Disconnect the electrical connector.
    GJ0002083Courtesy of JAGUAR CARS, INC.
  42. Disconnect the electrical connector.
    GJ0002084Courtesy of JAGUAR CARS, INC.
  43. Detach the wiring harness.
    • Remove the retaining bolt.
      GJ0002085Courtesy of JAGUAR CARS, INC.
  44. Detach the wiring harness.
    GJ0002086Courtesy of JAGUAR CARS, INC.
  45. Detach the breather pipe.
    GJ0002087Courtesy of JAGUAR CARS, INC.
  46. Disconnect the breather pipe.
    GJ0002088Courtesy of JAGUAR CARS, INC.

    47. All vehicles 

  47. Remove the positive crankcase ventilation pipe.
    GJ0002089Courtesy of JAGUAR CARS, INC.

    48. Vehicles with supercharger 

  48. Detach the wiring harness.
    GJ0002090Courtesy of JAGUAR CARS, INC.
  49. Detach the wiring harness.
    GJ0002091Courtesy of JAGUAR CARS, INC.

    50. All vehicles 

  50. Remove the ignition coil-on-plug cover.
    GJ0002092Courtesy of JAGUAR CARS, INC.
  51. Detach the engine wiring harness.
    GJ0002093Courtesy of JAGUAR CARS, INC.
  52. Disconnect the ignition coil-on-plug electrical connectors.
    GJ0002094Courtesy of JAGUAR CARS, INC.
    53. NOTE: Right hand shown, left hand similar.
  53. Detach the engine wiring harness.
    GJ0002095Courtesy of JAGUAR CARS, INC.
  54. Remove the ignition coil-on-plug cover.
    GJ0002096Courtesy of JAGUAR CARS, INC.
  55. Disconnect the ignition coil electrical connectors.
    GJ0002097Courtesy of JAGUAR CARS, INC.
  56. Detach the engine wiring harness.
    GJ0002098Courtesy of JAGUAR CARS, INC.
  57. Detach the engine wiring harness.
    GJ0002095Courtesy of JAGUAR CARS, INC.

    58. Vehicles without supercharger 

    NOTE: Left hand shown, right hand similar.
  58. Remove the engine cover retaining bracket.
    GJ0002099Courtesy of JAGUAR CARS, INC.
    59. NOTE: Left hand shown, right hand similar.
  59. Detach the engine wiring harness.
    GJ0002100Courtesy of JAGUAR CARS, INC.
    60. NOTE: Left hand shown, right hand similar.
  60. Disconnect the fuel injector electrical connectors.
    GJ0002101Courtesy of JAGUAR CARS, INC.
  61. Disconnect the fuel temperature sensor electrical connector.
    GJ0002102Courtesy of JAGUAR CARS, INC.
    62. NOTE: Right hand shown, left hand similar.
  62. Disconnect the camshaft position sensor electrical connector.
    GJ0002103Courtesy of JAGUAR CARS, INC.

    63. Vehicles with supercharger 

    NOTE: Right hand shown, left hand similar.
  63. Disconnect the camshaft position sensor electrical connector.
    GJ0002104Courtesy of JAGUAR CARS, INC.
  64. Disconnect the fuel temperature sensor electrical connector.
    GJ0002105Courtesy of JAGUAR CARS, INC.

    65. All vehicles 

  65. Disconnect the throttle motor electrical connector.
    GJ0002106Courtesy of JAGUAR CARS, INC.
  66. Disconnect the throttle position (TP) sensor electrical connector.
    GJ0002107Courtesy of JAGUAR CARS, INC.
  67. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
    GJ0002108Courtesy of JAGUAR CARS, INC.
  68. Disconnect the manifold absolute pressure (MAP) sensor
    GJ0002109Courtesy of JAGUAR CARS, INC.

    69. Vehicles without supercharger 

  69. Remove the engine wiring harness.
    GJ0002110Courtesy of JAGUAR CARS, INC.

    70. Vehicles with supercharger 

  70. Remove the engine wiring harness.
    GJ0002111Courtesy of JAGUAR CARS, INC.
  71. Reposition the retaining clips.
    GJ0002112Courtesy of JAGUAR CARS, INC.

    72. All vehicles 

  72. Disconnect the coolant hose.
    GJ0002113Courtesy of JAGUAR CARS, INC.
  73. Disconnect the coolant hose.
    GJ0002114Courtesy of JAGUAR CARS, INC.

    74. Vehicles with supercharger 

  74. Remove the retaining bolt.
    GJ0002115Courtesy of JAGUAR CARS, INC.
  75. Remove the retaining bolt.
    GJ0002116Courtesy of JAGUAR CARS, INC.
  76. Reposition the retaining clips.
    GJ0002112Courtesy of JAGUAR CARS, INC.
  77. Remove the retaining bolts.
    GJ0002117Courtesy of JAGUAR CARS, INC.
  78. Remove the throttle body and throttle body elbow assembly.
    • Remove the retaining bolts.
    • Remove and discard the gasket.
      GJ0002118Courtesy of JAGUAR CARS, INC.

    79. Vehicles without supercharger 

  79. Remove the intake manifold.
    GJ0002119Courtesy of JAGUAR CARS, INC.

    80. Vehicles with supercharger 

  80. Remove the retaining bolt.
    GJ0002120Courtesy of JAGUAR CARS, INC.
  81. Remove the retaining bolts.
    GJ0002121Courtesy of JAGUAR CARS, INC.
  82. Disconnect the coolant hose.
    • Reposition the retaining clip.
      GJ0002122Courtesy of JAGUAR CARS, INC.
  83. Disconnect the vacuum hose.
    GJ0002123Courtesy of JAGUAR CARS, INC.
  84. Remove the supercharger.
    • Remove the retaining bolts.
    • Collect the spacer.
      GJ0002124Courtesy of JAGUAR CARS, INC.
  85. Remove the retaining bolts.
    GJ0002125Courtesy of JAGUAR CARS, INC.
  86. Remove the supercharger outlet pipe to charge air cooler ducts.
    • Remove the retaining bolts.
      GJ0002126Courtesy of JAGUAR CARS, INC.
  87. Remove the charge air cooler.
    • Remove the retaining bolts.
    • Remove and discard the gasket.
      GJ0002127Courtesy of JAGUAR CARS, INC.
  88. Remove the charge air cooler.
    • Remove the retaining bolts.
    • Remove and discard the gasket.
      GJ0002128Courtesy of JAGUAR CARS, INC.
  89. Remove the lower intake manifold.
    • Remove the retaining bolts.
    • Remove and discard the gaskets.
      GJ0002129Courtesy of JAGUAR CARS, INC.
  90. Remove the coolant bypass to water pump pipe.
    • Remove the retaining bolts.
    • Remove and discard the O-ring seal.
      GJ0002130Courtesy of JAGUAR CARS, INC.

    91. All vehicles 

  91. Remove the noise and vibration insulating pad.
    GJ0002131Courtesy of JAGUAR CARS, INC.
    92. NOTE: Left hand shown, right hand similar.
  92. Remove the knock sensors.
    • Remove the retaining nut.
      GJ0002132Courtesy of JAGUAR CARS, INC.
  93. Remove the coolant hose.
    GJ0002133Courtesy of JAGUAR CARS, INC.
  94. Detach the coolant hose.
    • Remove the retaining bolts.
      GJ0002134Courtesy of JAGUAR CARS, INC.
  95. Remove the engine block insulation grommet.
    GJ0002135Courtesy of JAGUAR CARS, INC.
  96. Remove the water pump pulley.
    • Using special tool, retain the water pump pulley.
      GJ0002136Courtesy of JAGUAR CARS, INC.
  97. Remove the water pump.
    • Remove and discard the gasket.
    • Remove and discard the O-ring seal.
      GJ0002137Courtesy of JAGUAR CARS, INC.

    98. Vehicles without supercharger 

  98. Remove the retaining bolts.
    GJ0002138Courtesy of JAGUAR CARS, INC.
  99. Remove the thermostat housing.
    • Remove and discard the O-ring seals.
      GJ0002139Courtesy of JAGUAR CARS, INC.

    100. All vehicles 

    NOTE: Left hand shown, right hand similar.
  100. Remove the ignition coil-on-plug
    GJ0002140Courtesy of JAGUAR CARS, INC.
  101. Remove the spark plugs.
  102. Remove the right-hand camshaft position (CMP) sensor.
    • Remove and discard the O-ring seal.
      GJ0002141Courtesy of JAGUAR CARS, INC.
  103. Remove the left-hand camshaft position (CMP) sensor.
    • Remove and discard the O-ring seal.
      GJ0002142Courtesy of JAGUAR CARS, INC.
    104. CAUTION: Under no circumstances should the crankshaft setting peg 303645 be used in the following operations to lock the crankshaft.
    NOTE: The crankshaft retaining bolt will be very tight.
  104. Using special tools, retain the crankshaft pulley.
    • Remove and discard the crankshaft pulley bolt.
      GJ0002143Courtesy of JAGUAR CARS, INC.
  105. Remove the special tools.
    106. NOTE: The crankshaft pulley will be very tight.
  106. Using special tools, remove the crankshaft pulley.
    • Collect the locking ring.
    • Remove and discard the O-ring seal.
      GJ0002144Courtesy of JAGUAR CARS, INC.
  107. Remove the special tools.
  108. Remove the crankshaft position (CKP) sensor.
    GJ0002072Courtesy of JAGUAR CARS, INC.
    109. CAUTION: Make sure the spark plugs are removed to enable the engine to rotate freely.
    CAUTION: Do not rotate the crankshaft counterclockwise. The timing chains may bind causing engine damage.
    CAUTION: Rotate the crankshaft clockwise to position the engine to top dead center (TDC) No. 1 cylinder
  109. Install the special tool 303-645.
    GJ0002145Courtesy of JAGUAR CARS, INC.
  110. Remove the right-hand valve cover.
    • Discard the valve cover gaskets.
      GJ0002146Courtesy of JAGUAR CARS, INC.
  111. Remove the left-hand valve cover.
    • Discard the valve cover gaskets.
      GJ0002147Courtesy of JAGUAR CARS, INC.
  112. Remove the oil pressure sensor.
    GJ0002148Courtesy of JAGUAR CARS, INC.
  113. Remove the oil temperature sensor.
    GJ0002149Courtesy of JAGUAR CARS, INC.
  114. Remove the engine front cover.
    GJ0002150Courtesy of JAGUAR CARS, INC.

    115. Vehicles without supercharger 

  115. Remove the right-hand variable camshaft timing oil control unit housing.
    • Remove and discard the O-ring seals.
      GJ0002151Courtesy of JAGUAR CARS, INC.
  116. Remove the left-hand variable camshaft timing oil control unit housing.
    • Remove and discard the O-ring seals.
      GJ0002152Courtesy of JAGUAR CARS, INC.

    117. All vehicles 

  117. Install the special tool to the left-hand cylinder head.
    GJ0002153Courtesy of JAGUAR CARS, INC.
  118. Install the special tool to the Right-hand cylinder head.
    GJ0002154Courtesy of JAGUAR CARS, INC.
  119. Remove the primary timing chain tensioner assembly.
    GJ0002155Courtesy of JAGUAR CARS, INC.
  120. Remove the primary timing chain tensioner guide.
    GJ0002156Courtesy of JAGUAR CARS, INC.
  121. Remove the primary timing chain.
    GJ0002157Courtesy of JAGUAR CARS, INC.
  122. Remove the primary timing chain guide.
    GJ0002158Courtesy of JAGUAR CARS, INC.
  123. Remove the secondary timing chain tensioner retaining bolts.
    GJ0002159Courtesy of JAGUAR CARS, INC.
  124. Remove the camshaft sprockets.
    • Remove the secondary timing chain tensioner and secondary timing chain from the camshaft sprockets.
      GJ0002160Courtesy of JAGUAR CARS, INC.
  125. Remove the primary timing chain tensioner assembly.
    GJ0002161Courtesy of JAGUAR CARS, INC.
  126. Remove the primary timing chain tensioner guide.
    GJ0002162Courtesy of JAGUAR CARS, INC.
  127. Remove the primary timing chain.
    GJ0002163Courtesy of JAGUAR CARS, INC.
  128. Remove the crankshaft sprocket.
    GJ0002164Courtesy of JAGUAR CARS, INC.
  129. Remove the primary timing chain tensioner guide.
    GJ0002165Courtesy of JAGUAR CARS, INC.
  130. Remove the secondary timing chain tensioner retaining bolts.
    GJ0002166Courtesy of JAGUAR CARS, INC.
  131. Remove the camshaft sprockets.
    • Remove the secondary timing chain tensioner and secondary timing chain from the camshaft sprockets.
      GJ0002167Courtesy of JAGUAR CARS, INC.
  132. Remove the camshaft setting tool.
    GJ0002168Courtesy of JAGUAR CARS, INC.
  133. Remove the camshaft setting tool.
    GJ0002169Courtesy of JAGUAR CARS, INC.
  134. Remove the camshaft bearing caps.
    • Remove the camshaft bearing cap retaining bolts evenly and in stages.
    • Remove the camshaft bearing caps. Note their orientation and markings, each is marked with its position (a number) and orientation (an arrow).
      GJ0002170Courtesy of JAGUAR CARS, INC.
  135. Remove the right-hand exhaust camshaft.
    GJ0002171Courtesy of JAGUAR CARS, INC.
  136. Remove the camshaft bearing caps.
    • Remove the camshaft bearing cap retaining bolts evenly and in stages.
    • Remove the camshaft bearing caps. Note their orientation and markings, each is marked with its position (a number) and orientation (an arrow).
      GJ0002172Courtesy of JAGUAR CARS, INC.
  137. Remove the right-hand intake camshaft.
    GJ0002173Courtesy of JAGUAR CARS, INC.
  138. Remove the camshaft bearing caps.
    • Remove the camshaft bearing cap retaining bolts evenly and in stages.
    • Remove the camshaft bearing caps. Note their orientation and markings, each is marked with its position (a number) and orientation (an arrow).
      GJ0002174Courtesy of JAGUAR CARS, INC.
  139. Remove the left-hand exhaust camshaft.
    GJ0002175Courtesy of JAGUAR CARS, INC.
  140. Remove the camshaft bearing caps.
    • Remove the camshaft bearing cap retaining bolts evenly and in stages.
    • Remove the camshaft bearing caps. Note their orientation and markings, each is marked with its position (a number) and orientation (an arrow).
      GJ0002176Courtesy of JAGUAR CARS, INC.
  141. Remove the left-hand inlet camshaft.
    GJ0002177Courtesy of JAGUAR CARS, INC.
  142. Remove the right-hand cylinder head.
    • Remove the bolts in the indicated sequence.
    • Remove and discard the gasket.
      GJ0002178Courtesy of JAGUAR CARS, INC.
  143. Remove the left-hand cylinder head.
    • Remove the bolts in the indicated sequence.
    • Remove and discard the gasket.
      GJ0002179Courtesy of JAGUAR CARS, INC.
  144. Remove the crankshaft setting peg 303645 from the crankshaft position sensor location.
    GJ0002145Courtesy of JAGUAR CARS, INC.
  145. Remove the drive plate.
    1. Remove the drive plate retaining bolts.
    2. Remove the drive plate.
      GJ0002180Courtesy of JAGUAR CARS, INC.
  146. Remove the lower oil pan.
    • Remove and discard the gasket.
      GJ0002181Courtesy of JAGUAR CARS, INC.
  147. Remove the oil strainer.
    • Remove and discard the O-ring seal.
      GJ0002182Courtesy of JAGUAR CARS, INC.
  148. Remove the upper oil pan.
    • Remove and discard the gasket.
      GJ0002183Courtesy of JAGUAR CARS, INC.
  149. Remove the oil pump.
    • Remove and discard the gasket.
      GJ0002184Courtesy of JAGUAR CARS, INC.
  150. Inspect the tops of the cylinder bores. As necessary remove ridge and carbon build up from each cylinder.

    151. Vehicles with supercharger 

  151. Remove the piston cooling jets.

    152. All vehicles 

    CAUTION: Pistons, connecting rods and connecting rod bearings should be numbered to make sure they are reassembled in the same position.
    NOTE: Mark the position of the connecting rod caps to the connecting rods to make sure of correct installation.
    NOTE: Discard the connecting rod bolts after removal.
  152. Remove the connecting rod bolts, the connecting rod caps and the lower connecting rod bearings.
    GJ0002185Courtesy of JAGUAR CARS, INC.
    153. CAUTION: Use appropriate protection to prevent damage to the crankshaft bearing journals and cylinder bore surfaces.
  153. Install special tools to the connecting rods.
    GJ0002186Courtesy of JAGUAR CARS, INC.
    154. CAUTION: Care should be taken not to damage the connecting rod and cap joint face surfaces or possible engine damage may occur. Avoid contaminating the fractured joint surfaces with dirt or grease.
    NOTE: Attach the connecting rods and caps after removal to avoid mismatch.
  154. Remove the pistons.
    • Rotate the crankshaft to locate pistons at the bottom of travel.
    • Push the piston, connecting rod and upper bearing through the top of the cylinder.
      GJ0002187Courtesy of JAGUAR CARS, INC.
    155. NOTE: Remove the lower cylinder block bolts in the indicated sequence.
    NOTE: Mark the position of the upper and lower crankshaft main bearings for reassembly.
  155. Remove the lower cylinder block.
    • Remove the lower cylinder block retaining bolts in the indicated sequence.
      GJ0002188Courtesy of JAGUAR CARS, INC.
  156. Discard the crankshaft rear main oil seal.
    GJ0002189Courtesy of JAGUAR CARS, INC.
    157. CAUTION: Avoid damage to any crankshaft bearing surfaces.
    NOTE: Never remove any pipe plugs or dowels unless they are to be newly installed or the cylinder block is to be washed.
  157. Remove the crankshaft.
    GJ0002190Courtesy of JAGUAR CARS, INC.
  158. Remove the upper crankshaft main bearings.
    1. Remove the upper crankshaft thrust washers.
    2. Remove the upper crankshaft main bearings.
      GJ0002191Courtesy of JAGUAR CARS, INC.
  159. Clean the cylinder block with a soap and water solution. Dry the cylinder block completely with compressed air.
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