Jaguar 2000-06

Exhaust Manifold

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Removal & Installation



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust front pipes
     
    Air intake assembly
     
    Rack and pinion steering gear
     
    Exhaust Gas Recirculation (EGR) tube
     
    Exhaust manifolds
     

  4.  

To install:

  1. Install or connect the following:

    Exhaust manifolds using new gaskets. Tighten the bolts to 18-25 ft. lbs. (24-34 Nm).
     
    EGR tube
     
    Rack and pinion steering gear. Tighten the bolts to 30-37 ft. lbs. (40-50 Nm).
     
    Air intake assembly
     
    Exhaust front pipes
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Left and right catalytic converters
     
    Air intake assembly
     
    Rack and pinion steering gear
     
    Exhaust Gas Recirculation (EGR) tube
     
    Exhaust manifolds

    Click image to see an enlarged view

    Fig. Exhaust manifold bolts-V8

     

  4.  

To install:


NOTE
Use new exhaust manifold bolts.

  1. Install or connect the following:

    Exhaust manifolds
     
    EGR tube
     
    Rack and pinion steering gear
     
    Air intake assembly
     
    Left and right catalytic converters
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

  1. Remove the exhaust system.
  2.  
  3. Remove the right-hand exhaust manifold heat shield.
  4.  
  5. Detach the exhaust gas recirculation valve.
  6.  
  7. Remove and discard the retaining nuts and gasket.
  8.  
  9. Remove the exhaust manifold heat shield/gasket retaining bolt.
    NOTE
    New exhaust manifold retaining studs must be fitted if the old studs are removed.

  10.  
  11. Remove the exhaust manifold.
  12.  
  13. Remove and discard the retaining nuts and heat shield/gasket.
  14.  

To install


NOTE
Ensure exhaust manifold and heat shield/gasket is correctly aligned to cylinder head and studs.

  1. Install the exhaust manifold.
    NOTE
    When all retaining nuts have been torqued, re-torque all retaining nuts to 18 ft. lbs. (25 Nm).

  2.  
  3. Install new retaining nuts and a new heat shield/gasket. Tighten to 18 ft. lbs. (25 Nm).
  4.  
  5. Install the exhaust manifold heat shield/gasket retaining bolt. Tighten to 37 ft. lbs. (50 Nm).
  6.  
  7. Attach the exhaust gas recirculation valve. Install new retaining nuts and a new gasket. Tighten to 16 ft. lbs. (22 Nm).
  8.  
  9. Install the exhaust manifold heat shield. Tighten to 26 inch lbs. (3 Nm).
  10.  
  11. Install the exhaust system.
  12.  

  1. Remove the air cleaner assembly.
  2.  
  3. Remove the front silencer.
  4.  
  5. Remove the down pipe catalytic converter, right hand side.
  6.  
  7. From above the vehicle, disconnect the EGR pipe from the exhaust manifold.
  8.  
  9. Remove the two nuts which secure the EGR flange to the right hand exhaust manifold.
  10.  
  11. Reposition the EGR pipe from the manifold.
  12.  
  13. Remove the bolts which secure the front section of the exhaust manifold to the cylinder head.
  14.  
  15. Working from below the vehicle, remove the manifold bolts.
    1. Remove the bolts which secure the rear section of the exhaust manifold to the cylinder head.
    2.  
    3. Remove the manifold and the manifold gasket from the cylinder head.
    4.  

  16.  
  17. Remove the gasket from the EGR flange.
  18.  
  19. If fitting a new manifold, remove the two studs from the EGR flange of the manifold, and transfer them to the new manifold.
  20.  
  21. Clean the manifold faces (if refitting) and the mating faces on the cylinder head.
  22.  
  23. Use a thread tap (plug) to clean out the threads of the manifold securing bolt holes, in the cylinder head.
  24.  
  25. Install a spacer to each new manifold securing bolt (8 bolts).
  26.  
  27. Install the manifold and manifold gasket.
  28.  
  29. Install and align the new gasket to the cylinder head.
  30.  
  31. Install and align the manifold to the cylinder head.

    Click image to see an enlarged view

    Fig. Right side exhaust manifold bolt locations-2002 XR Range

  32.  
  33. Install the rear four bolts which secure the manifold, but do not tighten.
  34.  
  35. Working from above the vehicle, fit and tighten the remaining manifold securing bolts.
  36.  
  37. Working from below the vehicle, fully tighten the rear bolts on each manifold.
  38.  
  39. From above the vehicle, connect the EGR pipe to the exhaust manifold.
  40.  
  41. Install a new EGR gasket to the manifold.
  42.  
  43. Reposition the EGR pipe to the manifold.
  44.  
  45. Install the two nuts which secure the EGR flange to the exhaust manifold.
  46.  
  47. Install the down pipe catalytic converter, right hand side.
  48.  
  49. Install the front silencer.
  50.  
  51. Install the air cleaner assembly.
  52.  

  1. Remove the right-hand catalytic converter.
  2.  
  3. Remove and discard the retaining nuts.
  4.  
  5. Lower the vehicle.
  6.  
  7. Remove the air cleaner.
  8.  
  9. Remove the exhaust manifold to EGR valve tube retaining nuts.
  10.  
  11. Remove and discard the retaining nuts and gasket.
    NOTE
    New exhaust manifold retaining studs must be fitted if the old retaining studs are removed.

  12.  
  13. Remove the exhaust manifold. Remove and discard the retaining nuts and heat shield/gasket.
  14.  

To install:

Click image to see an enlarged view

Fig. Right side exhaust manifold nut locations-2003-04 XK Range

  1. Make sure exhaust manifold and heat shield/gasket is correctly aligned to cylinder head and studs.
    NOTE
    When all retaining nuts have been torqued, re-torque all retaining nuts to 18 ft. lbs. (25 Nm).

  2.  
  3. Install the exhaust manifold. Install new retaining nuts and a new heat shield/gasket. Tighten to 18 ft. lbs. (25 Nm).
  4.  
  5. Attach the exhaust manifold to EGR valve tube retaining nuts. Install new retaining nuts and a new gasket. Tighten to 16 ft. lbs. (22 Nm).
  6.  
  7. Install the air cleaner.
  8.  
  9. Raise the vehicle.
  10.  
  11. Install the right-hand catalytic converter.
  12.  

4.0L Engine
Left Side


Click image to see an enlarged view

Fig. Left exhaust manifold bolt torque sequence-2002 S-Type 4.0L

  1. Detach the power assisted steering reservoir.
  2.  
  3. Remove the air cleaner. Remove the oil deposit tube.
  4.  
  5. Remove the left-hand three way catalytic converter.
  6.  
  7. Remove the exhaust manifold.
  8.  
  9. To install, reverse the removal procedure.
  10.  

Right Side


Click image to see an enlarged view

Fig. Right exhaust manifold bolt torque sequence-2002 S-Type 4.0L

  1. Remove the air intake tube.
  2.  
  3. Remove the right-hand three way catalytic converter.
  4.  
  5. Remove the exhaust manifold.
  6.  

3.0L Engine
  1. Remove the catalytic converter.
  2.  
  3. Lower the vehicle.
  4.  
  5. Detach the valve cover wiring harness.
  6.  
  7. Remove the dipstick tube retaining bolt.
  8.  
  9. Reposition the dipstick tube (left side).
  10.  
  11. Remove the exhaust manifold heat shield.
  12.  
  13. Raise the vehicle.
  14.  
  15. Remove the exhaust manifold lower retaining nuts.
  16.  
  17. Lower the vehicle.
  18.  
  19. Remove the exhaust manifold.
  20.  
  21. Remove and discard the exhaust gasket.
  22.  
  23. To install, reverse the removal procedure.
  24.  
  25. Install a new gasket. Tighten to 15 ft. lbs. (25 Nm).
  26.  

Left Manifold


Click image to see an enlarged view

Fig. Left side exhaust manifold torque sequence-2001 S-Type 3.0L engine

  1. Remove the three way catalytic converter (TWC).
  2.  
  3. Lower the vehicle.
  4.  
  5. Remove the exhaust manifold heat shield.
  6.  
  7. Remove the exhaust manifold.
  8.  
  9. Discard the gasket.
  10.  

To install:

  1. Install the exhaust manifold with a new gasket.
  2.  
  3. Tighten the nuts and the bolts in the sequence shown.
  4.  
  5. Install the exhaust manifold heat shield.
  6.  
  7. Install the three way catalytic converter (TWC).
  8.  



Click image to see an enlarged view

Fig. Left side exhaust manifold torque sequence-S-Type 3.0L engine

  1. Remove the three way catalytic converter (TWC).
  2.  
  3. Lower the vehicle.
  4.  
  5. Remove the exhaust manifold heat shield.
  6.  
  7. Remove the exhaust manifold.
  8.  
  9. Discard the gasket.
  10.  

To install:

  1. Install the exhaust manifold with a new gasket.
  2.  
  3. Tighten the nuts and the bolts in the sequence shown.
  4.  
  5. Install the exhaust manifold heat shield.
  6.  
  7. Install the three way catalytic converter (TWC).
  8.  

Right Manifold


Click image to see an enlarged view

Fig. Right side exhaust manifold torque sequence-2001 S-Type 3.0L engine

  1. Remove the three way catalytic converter (TWC).
  2.  
  3. Lower the vehicle.
  4.  
  5. Detach the EGR valve tube.
  6.  
  7. Remove the exhaust manifold heat shield.
  8.  
  9. Remove the exhaust manifold.
  10.  
  11. Discard the gasket.
  12.  

To install:

  1. Install the exhaust manifold with a new gasket.
  2.  
  3. Tighten the nuts and the bolts in the sequence shown.
  4.  
  5. Install the exhaust manifold heat shield.
  6.  
  7. Attach the EGR valve tube.
  8.  
  9. Install the three way catalytic converter (TWC).
  10.  



Click image to see an enlarged view

Fig. Right side exhaust manifold torque sequence-S-Type 3.0L engine

  1. Remove the three way catalytic converter (TWC).
  2.  
  3. Lower the vehicle.
  4.  
  5. Detach the EGR valve tube.
  6.  
  7. Remove the exhaust manifold heat shield.
  8.  
  9. Remove the exhaust manifold.
  10.  
  11. Discard the gasket.
  12.  

To install:

  1. Install the exhaust manifold with a new gasket.
  2.  
  3. Tighten the nuts and the bolts in the sequence shown.
  4.  
  5. Install the exhaust manifold heat shield.
  6.  
  7. Attach the EGR valve tube.
  8.  
  9. Install the three way catalytic converter (TWC).
  10.  

2.5L And 3.0L Engines
Left Side
  1. Drain the cooling system.
  2.  
  3. Remove the cooling fan motor and shroud.
  4.  
  5. Lower the vehicle.
  6.  
  7. Remove the air filter intake pipe.
  8.  
  9. Detach the generator wiring harness.
  10.  
  11. Remove the air filter retaining bracket.
  12.  
  13. Detach the coolant pipe.
  14.  
  15. Detach the coolant hose.
  16.  
  17. Raise the vehicle.
  18.  
  19. Remove the coolant hose.
  20.  
  21. Disconnect the heated oxygen sensor electrical connector.
  22.  
  23. Remove the exhaust manifold heat shield retaining bolt.
  24.  
  25. Lower the vehicle.
  26.  
  27. Remove the exhaust manifold heat shield.
  28.  
  29. Detach the catalytic converter. Discard the retaining nuts.
  30.  
  31. Remove and discard the retaining studs. Using a suitable tool remove the HO 2 S.
  32.  
  33. Remove the exhaust manifold.
  34.  
  35. Remove and discard the exhaust manifold gasket.
  36.  

To install:

Click image to see an enlarged view

Fig. Left side exhaust manifold torque sequence-X-Type 2.5L and 3.0L engine

  1. Install the new exhaust manifold gasket.
  2.  
  3. Install the exhaust manifold. Complete the tightening sequence. Tighten to 15 ft. lbs. (20 Nm).
  4.  
  5. Install the H0 2 S. Tighten to 30 ft. lbs. (40 Nm).
    NOTE
    Make sure that the catalytic converter retaining nuts are tightened twice in the sequence shown.



    Click image to see an enlarged view

    Fig. Catalytic converter torque sequence-2.5L and 3.0L

  6.  
  7. Attach the catalytic converter. Install new retaining nuts and studs. Tighten to 80 inch lbs. (9 Nm). Tighten in the sequence shown to 19 ft. lbs. (25 Nm).
  8.  
  9. Install the exhaust manifold heat shield. Tighten to 98 inch lbs. (11 Nm).
  10.  
  11. Connect the heated oxygen sensor electrical connector.
  12.  
  13. Install the coolant hose.
  14.  
  15. Lower the vehicle.
  16.  
  17. Attach the coolant hose.
  18.  
  19. Install the coolant pipe retaining bracket. Tighten to 89 inch lbs. (10 Nm). Attach the coolant pipe. Attach the coolant hose.
  20.  
  21. Install the air filter retaining bracket.
  22.  
  23. Attach the generator wiring harness.
  24.  
  25. Install the air filter intake pipe.
  26.  
  27. Install the cooling fan motor and shroud.
  28.  
  29. Fill and bleed the cooling system.
  30.  

Right Side
  1. Disconnect the heated oxygen sensor electrical connector. Remove the three way catalytic converter (TWC).
  2.  
  3. Using a suitable tool remove the H0 2 S.
  4.  
  5. Remove the exhaust manifold.
  6.  
  7. Remove and discard the exhaust manifold gasket.
  8.  

To install:

Click image to see an enlarged view

Fig. Right side exhaust manifold torque sequence-X-Type 2.5L and 3.0L engine

  1. Install the exhaust manifold.
  2.  
  3. Install the new exhaust manifold gasket. Complete the tightening sequence. Tighten to 15 ft. lbs. (20 Nm).
  4.  
  5. Install the three way catalytic converter (TWC). Tighten to 30 ft. lbs. (40 Nm).
  6.  

Left Rear
  1. Remove the front silencer.
  2.  
  3. Remove the down pipe catalytic converter, left hand side.
  4.  
  5. Working from above the vehicle, remove the bolts which secure the front section of the exhaust manifold to the cylinder head.

    Click image to see an enlarged view

    Fig. Steering rack bolt locations-XK Range



    Click image to see an enlarged view

    Fig. Exhaust manifold bolt locations-XK Range

  6.  
  7. Working from below the vehicle, reposition the steering rack for access.
    1. Remove the two bolts which secure the steering rack at the driver's side.
    2.  
    3. Loosen, but do not remove, the two bolts which secure the steering rack at the passenger side.
    4.  
    5. Reposition the steering rack for access.
    6.  

  8.  
  9. Working from below the vehicle, remove the manifold.
    1. Remove the bolts which secure the rear section of the exhaust manifold to the cylinder head.
    2.  
    3. Remove the manifold and the manifold gasket.
    4.  

  10.  
  11. Clean the manifold faces (if refitting) and the mating faces on the cylinder head.
  12.  
  13. Use a thread tap (plug) to clean out the threads of the manifold securing bolt holes, in the cylinder head.
  14.  
  15. Installation is the reverse of removal. Use new gaskets and new securing bolts for the manifold.
  16.  

4.2L Engines
  1. Remove the exhaust system.
  2.  
  3. Remove the exhaust manifold heat shield.
  4.  
  5. Detach the exhaust gas recirculation (EGR) valve.
  6.  
  7. Remove and discard the retaining nuts and gasket.
  8.  
  9. Remove the exhaust manifold heat shield/gasket retaining bolt.
    NOTE
    New exhaust manifold retaining studs must be fitted if the old studs are removed.

  10.  
  11. Remove the exhaust manifold.
  12.  
  13. Remove and discard the retaining nuts and heat shield/gasket.
  14.  

To install:


NOTE
When all retaining nuts have been torqued, re-torque all retaining nuts to 18 ft. lbs. (25 Nm).


NOTE
Ensure exhaust manifold and heat shield/gasket is correctly aligned to cylinder head and studs.

  1. Install the exhaust manifold.
  2.  
  3. Install new retaining nuts and a new heat shield/gasket. Tighten to 18 ft. lbs. (25 Nm).
  4.  
  5. Install the exhaust manifold heat shield/gasket retaining bolt. Tighten to 50 Nm.
  6.  
  7. Attach the exhaust gas recirculation (EGR) valve.
  8.  
  9. Install new retaining nuts and a new gasket. Tighten to 16 ft. lbs. (22 Nm).
  10.  
  11. Install the exhaust manifold heat shield. Tighten to 27 inch lbs. (3 Nm).
  12.  
  13. Install the exhaust system.
  14.  

Right Side
  1. Remove the air cleaner assembly.
  2.  
  3. Remove the front silencer.
  4.  
  5. Remove the down pipe catalytic converter, right hand side.
  6.  
  7. From above the vehicle, disconnect the EGR pipe from the exhaust manifold.
  8.  
  9. Remove the two nuts which secure the EGR flange to the right hand exhaust manifold.
  10.  
  11. Reposition the EGR pipe from the manifold.
  12.  
  13. Remove the bolts which secure the front section of the exhaust manifold to the cylinder head.
  14.  
  15. Working from below the vehicle, remove the manifold bolts.
    1. Remove the bolts which secure the rear section of the exhaust manifold to the cylinder head.
    2.  
    3. Remove the manifold and the manifold gasket from the cylinder head.
    4.  

  16.  
  17. Remove the gasket from the EGR flange.
  18.  
  19. If fitting a new manifold, remove the two studs from the EGR flange of the manifold, and transfer them to the new manifold.
  20.  
  21. Clean the manifold faces (if refitting) and the mating faces on the cylinder head.
  22.  
  23. Use a thread tap (plug) to clean out the threads of the manifold securing bolt holes, in the cylinder head.
  24.  
  25. Install a spacer to each new manifold securing bolt (8 bolts).
  26.  
  27. Install the manifold and manifold gasket.
  28.  
  29. Install and align the new gasket to the cylinder head.
  30.  
  31. Install and align the manifold to the cylinder head.
  32.  
  33. Install the rear four bolts which secure the manifold, but do not tighten.
  34.  
  35. Working from above the vehicle, fit and tighten the remaining manifold securing bolts.
  36.  
  37. Working from below the vehicle, fully tighten the rear bolts on each manifold.
  38.  
  39. From above the vehicle, connect the EGR pipe to the exhaust manifold.
  40.  
  41. Install a new EGR gasket to the manifold.
  42.  
  43. Reposition the EGR pipe to the manifold.
  44.  
  45. Install the two nuts which secure the EGR flange to the exhaust manifold.
  46.  
  47. Install the down pipe catalytic converter, right hand side.
  48.  
  49. Install the front silencer.
  50.  
  51. Install the air cleaner assembly.
  52.  


    Click image to see an enlarged view

    Fig. Right side exhaust manifold bolt locations-2001-02 XR Range


 
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