Jaguar 2000-06

Intake Manifold

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Mass Air Flow (MAF) meter
     
    Air intake assembly
     
    Throttle body
     
    Fuel lines
     
    Fuel injector wiring connectors
     
    Intake manifold
     

  6.  

To install:

  1. Install or connect the following:

    Intake manifold with a new gasket. Tighten the mounting bolts to 13-18 ft. lbs. (18-24 Nm).
     
    Fuel injector wiring connectors
     
    Fuel lines
     
    Throttle body. Tighten the mounting bolts to 13-18 ft. lbs. (18-24 Nm).
     
    Air intake assembly
     
    MAF meter
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

  1. Remove the cowl vent screen.
  2.  
  3. Remove the air cleaner outlet pipe.
  4.  
  5. Remove the engine compartment support.
  6.  
  7. Remove the on-plug coil covers.
  8.  
  9. Disconnect the throttle potentiometer (TP) electrical connector.
  10.  
  11. Disconnect the throttle motor electrical connector.
    CAUTION
    To avoid having scalding hot coolant or steam blow out of the cooling system, use extreme care when removing the coolant pressure cap from a hot cooling system. Wait until the engine has cooled, then wrap a thick cloth around the coolant pressure cap and turn it slowly until the pressure begins to release. Step back while the pressure is released from the system. When certain all the pressure has been released (still with a cloth) turn and remove the coolant pressure cap from the coolant expansion tank. Failure to follow these instructions may result in personal injury.

  12.  
  13. Remove the coolant expansion tank cap. Cap the coolant hose.
  14.  
  15. Disconnect the throttle body coolant hose.
  16.  
  17. Disconnect the knock sensors (KS) electrical connectors.
  18.  
  19. Remove the left-hand engine cover bracket.
  20.  
  21. Detach the engine wiring harness.
  22.  
  23. Disconnect the fuel injector electrical connectors.
  24.  
  25. Detach the fuel line.
  26.  
  27. Detach the left-hand camshaft position sensor electrical connector.
  28.  
  29. Disconnect the coolant temperature sensor electrical connector.
  30.  
  31. Remove the right-hand engine cover bracket.
  32.  
  33. Remove the positive crankcase ventilation (PCV) valve.
  34.  
  35. Disconnect the fuel pressure regulator electrical connector.
  36.  
  37. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
  38.  
  39. Cap the coolant hose.
  40.  
  41. Disconnect the exhaust gas recirculation (EGR) valve coolant hose.
  42.  
  43. Detach the right-hand engine wiring harness.
  44.  
  45. Disconnect the right-hand fuel injector electrical connectors.
  46.  
  47. Disconnect the fuel temperature sensor electrical connector.
  48.  
  49. Disconnect the right-hand camshaft position (CMP) sensor.
  50.  
  51. Detach the brake booster vacuum pipe.
  52.  
  53. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
  54.  
  55. Detach the engine wiring harness.
  56.  
  57. Detach the exhaust gas recirculation (EGR) valve tube.
  58.  
  59. Remove and discard the gasket.
  60.  
  61. Remove the intake manifold.
  62.  
  63. Remove and discard the gaskets.
  64.  

To install:

  1. Make sure that all gasket mating faces are clean and dry.
  2.  
  3. Install the intake manifold.
  4.  
  5. Install new gaskets. Tighten to 16 ft. lbs. (22 Nm).
  6.  
  7. Attach the exhaust gas recirculation (EGR) valve tube. Install a new gasket. Tighten to 16 ft. lbs. (22 Nm).
  8.  
  9. Attach the engine wiring harness. Tighten to 10 Nm.
  10.  
  11. Connect the manifold absolute pressure (MAP) sensor electrical connector.
  12.  
  13. Connect the right-hand camshaft position (CMP) sensor.
  14.  
  15. Connect the fuel temperature sensor electrical connector.
  16.  
  17. Attach the brake booster vacuum pipe.
  18.  
  19. Connect the right-hand fuel injector electrical connectors.
  20.  
  21. Attach the engine wiring harness.
  22.  
  23. Remove the cap from the coolant hose.
  24.  
  25. Connect the exhaust gas recirculation (EGR) valve coolant hose.
  26.  
  27. Connect the exhaust gas recirculation (EGR) valve electrical connector.
  28.  
  29. Connect the fuel pressure regulator electrical connector.
  30.  
  31. Install the positive crankcase ventilation (PCV) pipe.
  32.  
  33. Install the right-hand engine cover bracket. Tighten to 50 inch lbs. (6 Nm).
  34.  
  35. Connect the coolant temperature sensor electrical connector.
  36.  
  37. Attach the left-hand camshaft position sensor electrical connector.
  38.  
  39. Connect the fuel line. Install new O-ring seals.
  40.  
  41. Attach the fuel line retaining clip.
  42.  
  43. Connect the fuel injector electrical connectors.
  44.  
  45. Attach the engine wiring harness.
  46.  
  47. Install the left-hand engine cover bracket. Tighten to 6 Nm.
  48.  
  49. Connect the knock sensor (KS) electrical connectors.
  50.  
  51. Remove the cap from the coolant hose.
  52.  
  53. Connect the throttle body coolant hose.
  54.  
  55. Connect the throttle motor electrical connector.
  56.  
  57. Connect the throttle potentiometer (TP) electrical connector.
  58.  
  59. Install the on-plug coil covers.
  60.  
  61. Install the engine compartment support. Tighten to 13 ft. lbs. (18 Nm).
  62.  
  63. Install the air cleaner outlet pipe.
  64.  
  65. Install the cowl vent screen.
  66.  
  67. Check and top up the cooling system.
  68.  

3.0L Engine


Click image to see an enlarged view

Fig. Intake manifold bolt identification-3.0L engine

  1. Disconnect the battery ground cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the throttle body.
  6.  
  7. Disconnect the EGR vacuum regulator (EVR) valve electrical connector.
  8.  
  9. Disconnect the vacuum hose connector from the EGR vacuum regulator valve.
  10.  
  11. Remove the intake manifold tuning valve cover.
  12.  
  13. Disconnect the electrical connector.
  14.  
  15. Remove the intake manifold tuning valve cover.
  16.  
  17. Disconnect the differential pressure feedback EGR sensor electrical connector.
  18.  
  19. Disconnect the hoses from the differential pressure feedback EGR sensor.
  20.  
  21. Disconnect the inlet and outlet intake manifold coolant hoses.
  22.  
  23. Disconnect the purge line tube.
  24.  
  25. Detach the EGR valve.
  26.  
  27. Remove the intake manifold bracket securing bolt.
  28.  
  29. Remove the intake manifold bracket securing bolt.
  30.  
  31. Remove the intake manifold securing bolts.
  32.  
  33. Remove the fuel pulse damper protective bracket.
  34.  
  35. Displace the intake manifold.
  36.  
  37. Disconnect the engine breather hose and the intake manifold tuning valve electrical connector.
  38.  
  39. Remove the intake manifold.
  40.  
  41. Discard the intake manifold gaskets.
  42.  


NOTE
The intake manifold retaining bolts in position 1,2,3 and 4 are longer than the retaining bolts in position 5,6,7 and 8.

  1. To install, reverse the removal procedure. Install new intake manifold gaskets. Install a new EGR valve gasket.
  2.  


NOTE
When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy.

  1. Connect the battery ground cable.
  2.  
  3. Fill and bleed the cooling system.
  4.  



Click image to see an enlarged view

Fig. Intake manifold bolt identification-3.0L engine

  1. Disconnect the battery ground cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the throttle body.
  6.  
  7. Disconnect the EGR vacuum regulator (EVR) valve electrical connector.
  8.  
  9. Disconnect the vacuum hose connector from the EGR vacuum regulator valve.
  10.  
  11. Remove the intake manifold tuning valve cover.
  12.  
  13. Disconnect the electrical connector.
  14.  
  15. Remove the intake manifold tuning valve cover.
  16.  
  17. Disconnect the differential pressure feedback EGR sensor electrical connector.
  18.  
  19. Disconnect the hoses from the differential pressure feedback EGR sensor.
  20.  
  21. Disconnect the inlet and outlet intake manifold coolant hoses.
  22.  
  23. Disconnect the purge line tube.
  24.  
  25. Detach the EGR valve.
  26.  
  27. Remove the intake manifold bracket securing bolt.
  28.  
  29. Remove the intake manifold bracket securing bolt.
  30.  
  31. Remove the intake manifold securing bolts.
  32.  
  33. Remove the fuel pulse damper protective bracket.
  34.  
  35. Displace the intake manifold.
  36.  
  37. Disconnect the engine breather hose and the intake manifold tuning valve electrical connector.
  38.  
  39. Remove the intake manifold.
  40.  
  41. Discard the intake manifold gaskets.
    NOTE
    The intake manifold retaining bolts in position 1,2,3 and 4 are longer than the retaining bolts in position 5,6,7 and 8.

  42.  
  43. To install, reverse the removal procedure. Install new intake manifold gaskets. Install a new EGR valve gasket.
    NOTE
    When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy.

  44.  
  45. Connect the battery ground cable.
  46.  
  47. Fill and bleed the cooling system.
  48.  

Upper Manifold


Click image to see an enlarged view

Fig. Upper intake manifold bolt identification-2003-06 S-Type 3.0L

  1. Release the cooling system pressure.
  2.  
  3. Remove the coolant expansion tank pressure cap.
  4.  
  5. Remove the air cleaner outlet pipe.
  6.  
  7. Remove the engine cover.
  8.  
  9. Disconnect the throttle motor electrical connector.
  10.  
  11. Disconnect the throttle position sensor (TPS) electrical connector.
  12.  
  13. Disconnect the positive crankcase ventilation (PCV) hose.
    NOTE
    Cap the coolant hoses to minimize coolant loss.

  14.  
  15. Detach the coolant hoses from the throttle body.
  16.  
  17. Detach the engine wiring harness from the intake manifold side retaining bracket.
  18.  
  19. Detach the intake manifold right-hand side retaining bracket.
  20.  
  21. Loosen the intake manifold right-hand side retaining bracket.
  22.  
  23. Detach the intake manifold front retaining bracket.
  24.  
  25. Loosen the intake manifold front retaining bracket.
  26.  
  27. Detach the coolant temperature sensor wiring harness.
  28.  
  29. Remove the engine cover front retaining bracket.
  30.  
  31. Detach the evaporative emission canister purge valve transfer pipe.
  32.  
  33. Remove the engine cover left-hand side retaining bracket.
  34.  
  35. Remove the fuel pressure sensor bracket retaining bolt.
  36.  
  37. Detach the fuel pressure sensor bracket.
  38.  
  39. Detach the intake manifold.
    NOTE
    The evaporative emission canister purge valve transfer pipe is attached to the induction manifold by a quick release coupling.

  40.  
  41. Disconnect the evaporative emission canister purge valve transfer pipe.
  42.  
  43. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
  44.  
  45. Disconnect the fuel pressure sensor vacuum hose.
  46.  
  47. Disconnect the IMT valves electrical connectors.
  48.  
  49. Disconnect the fuel pressure regulator vacuum hose.
  50.  
  51. Disconnect the brake booster vacuum hose.
  52.  
  53. Remove the intake manifold.
  54.  
  55. Install new intake manifold gaskets.
  56.  

To install


NOTE
The intake manifold retaining bolts in position 1, 4 and 5 are longer than the retaining bolts in position 2, 3 and 6. Do not fully tighten the retaining bolts.

  1. Install the intake manifold.
  2.  
  3. Connect the brake booster vacuum hose.
  4.  
  5. Connect the fuel pressure regulator vacuum hose.
  6.  
  7. Connect the IMT valves electrical connectors.
  8.  
  9. Disconnect the fuel pressure sensor vacuum hose
  10.  
  11. Connect the manifold absolute pressure (MAP) sensor electrical connector.
    NOTE
    The evaporative emission canister purge valve transfer pipe is attached to the induction manifold by a quick release coupling.

  12.  
  13. Connect the evaporative emission canister purge valve transfer pipe.
    NOTE
    The intake manifold retaining bolts in position 1, 4 and 5 are longer than the retaining bolts in position 2, 3 and 6.

  14.  
  15. Reposition the intake manifold. Tighten to 15 ft. lbs. Complete the tightening sequence.
  16.  
  17. Install the fuel pressure sensor bracket retaining bolt.
  18.  
  19. Attach the fuel pressure sensor bracket.
  20.  
  21. Install the engine cover left-hand side retaining bracket.
  22.  
  23. Attach the evaporative emission canister purge valve transfer pipe.
  24.  
  25. Install the engine cover front retaining bracket.
  26.  
  27. Attach the coolant temperature sensor wiring harness.
  28.  
  29. Attach the intake manifold front retaining bracket.
  30.  
  31. Fully tighten the intake manifold front retaining bracket.
  32.  
  33. Fully tighten the intake manifold right-hand side retaining bracket.
  34.  
  35. Fully tighten the intake manifold right-hand side retaining bracket.
  36.  
  37. Attach the engine wiring harness to the intake manifold side retaining bracket.
  38.  
  39. Attach the coolant hoses to the throttle body.
  40.  
  41. Connect the positive crankcase ventilation (PCV) hose.
  42.  
  43. Connect the throttle position sensor (TPS) electrical connector.
  44.  
  45. Connect the throttle motor electrical connector.
  46.  
  47. Install the engine cover.
  48.  
  49. Install the air cleaner outlet pipe.
  50.  
  51. Fill the cooling system up to the MAX mark on the coolant expansion tank using a fifty percent mixture of Jaguar Premium Cooling System Fluid or equivalent, meeting Jaguar specification WSS M97B44-D and fifty percent water.
  52.  

Lower Manifold
  1. Remove the intake manifold.
  2.  
  3. Disconnect the spring lock coupling.
  4.  
  5. Disconnect the fuel charging wiring harness.
  6.  
  7. Fuel may still be present in the fuel injection supply manifold.
  8.  
  9. Remove and discard the lower intake manifold O-ring seals.
  10.  
  11. Remove the lower intake manifold.
  12.  

To install:

Click image to see an enlarged view

Fig. Lower manifold torque sequence-3.0L engine

  1. Install new O-ring seals.
  2.  
  3. Tighten in the sequence shown.
  4.  
  5. To install, reverse the removal procedure.
  6.  
  7. Tighten the retaining bolts in the sequence shown. Tighten to 89 inch lbs. (10 Nm).
  8.  

4.2L Engine


Click image to see an enlarged view

Fig. Intake manifold bolt locations-S-Type 4.2L engine

  1. Remove the cowl vent screen.
  2.  
  3. Remove the air cleaner outlet pipe.
  4.  
  5. Remove the engine compartment brace.
  6.  
  7. Remove the on-plug coil covers.
  8.  
  9. Disconnect the throttle potentiometer (TP) electrical connector.
  10.  
  11. Disconnect the throttle motor electrical connector.
    NOTE
    Cap the coolant system hose to minimize coolant loss.

  12.  
  13. Disconnect the throttle body coolant hose.
  14.  
  15. Disconnect the knock sensors (KS) electrical connectors.
  16.  
  17. Remove the left-hand engine cover bracket.
  18.  
  19. Detach the left-hand engine wiring harness.
  20.  
  21. Disconnect the left-hand fuel injector electrical connectors.
  22.  
  23. Detach the fuel line.
  24.  
  25. Detach the left-hand camshaft position sensor electrical connector.
  26.  
  27. Disconnect the coolant temperature sensor electrical connector.
  28.  
  29. Remove the right-hand engine cover bracket.
  30.  
  31. Remove the positive crankcase ventilation (PCV) valve.
  32.  
  33. Disconnect the fuel pressure regulator electrical connector.
  34.  
  35. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
    NOTE
    Cap the coolant hose.

  36.  
  37. Disconnect the exhaust gas recirculation (EGR) valve coolant hose.
  38.  
  39. Detach the right-hand engine wiring harness.
  40.  
  41. Disconnect the right-hand fuel injector electrical connectors.
  42.  
  43. Disconnect the fuel temperature sensor electrical connector.
  44.  
  45. Disconnect the right-hand camshaft position (CMP) sensor.
  46.  
  47. Detach the brake booster vacuum pipe.
  48.  
  49. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
  50.  
  51. Detach the engine wiring harness.
  52.  
  53. Detach the exhaust gas recirculation (EGR) valve tube.
  54.  
  55. Remove and discard the gasket. Remove the intake manifold.
  56.  
  57. Remove and discard the gaskets.
  58.  

To install:

  1. Install the intake manifold. Install new gaskets. Tighten to 16 ft. lbs. (22 Nm).
  2.  
  3. Attach the exhaust gas recirculation (EGR) valve tube. Install a new gasket.
  4.  
  5. Attach the engine wiring harness. Tighten to 84 inch lbs. (10 Nm).
  6.  
  7. Connect the manifold absolute pressure (MAP) sensor electrical connector.
  8.  
  9. Connect the right-hand camshaft position (CMP) sensor.
  10.  
  11. Connect the fuel temperature sensor electrical connector.
  12.  
  13. Attach the brake booster vacuum pipe.
  14.  
  15. Connect the right-hand fuel injector electrical connectors.
  16.  
  17. Attach the right-hand engine wiring harness.
  18.  
  19. Remove the cap from the coolant hose.
  20.  
  21. Connect the exhaust gas recirculation (EGR) valve coolant hose.
  22.  
  23. Connect the exhaust gas recirculation (EGR) valve electrical connector.
  24.  
  25. Connect the fuel pressure regulator electrical connector.
  26.  
  27. Install the positive crankcase ventilation (PCV) pipe.
  28.  
  29. Install the right-hand engine cover bracket. Tighten to 50 inch lbs. (6 Nm).
  30.  
  31. Connect the coolant temperature sensor electrical connector.
  32.  
  33. Attach the left-hand camshaft position sensor electrical connector.
  34.  
  35. Connect the fuel line.
  36.  
  37. Install new O-ring seals.
  38.  
  39. Attach the fuel line retaining clip.
  40.  
  41. Connect the left-hand fuel injector electrical connectors.
  42.  
  43. Attach the left-hand engine wiring harness.
  44.  
  45. Install the left-hand engine cover bracket. Tighten to 50 inch lbs. (6 Nm).
  46.  
  47. Connect the knock sensor (KS) electrical connectors.
  48.  
  49. Remove the cap from the coolant hose.
  50.  
  51. Connect the throttle body coolant hose.
  52.  
  53. Connect the throttle motor electrical connector.
  54.  
  55. Connect the throttle potentiometer (TP) electrical connector.
  56.  
  57. Install the engine compartment brace. Tighten to 13 ft. lbs. (18 Nm).
  58.  
  59. Install the air cleaner outlet pipe.
  60.  
  61. Install the cowl vent screen.
  62.  
  63. Check and top up the cooling system.
  64.  



Click image to see an enlarged view

Fig. Intake manifold bolt locations-XK Range 4.2L engine

  1. Release the fuel system pressure.
  2.  
  3. Remove the air cleaner outlet pipe.
  4.  
  5. Remove the engine cover retaining brackets.
  6.  
  7. Detach the knock sensor (KS) electrical connectors.
  8.  
  9. Detach the engine wiring harness.
  10.  
  11. Disconnect the hose.
  12.  
  13. Disconnect the pipe.
  14.  
  15. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
  16.  
  17. Disconnect the fuel temperature sensor electrical connector.
  18.  
  19. Disconnect the right-hand camshaft position (CMP) sensor.
  20.  
  21. Detach the wiring harness.
  22.  
  23. Disconnect the electrical connectors.
  24.  
  25. Detach the wiring harness.
  26.  
  27. Disconnect the fuel pressure regulator electrical connector.
    CAUTION
    To avoid hot coolant or steam blowing out of the cooling system, use extreme care when removing the coolant expansion tank pressure cap. Wait until the engine has cooled down, then insulate the coolant pressure cap with a suitable cloth and slowly loosen the coolant expansion tank pressure cap until the cooling system pressure is released. Do not remove the coolant expansion tank pressure cap. Step back while the pressure is released from the system. When all of the pressure has been released slowly remove the coolant expansion tank pressure cap (still with the suitable cloth in position) from the coolant expansion tank. Failure to follow this instruction may result in personal injury.

  28.  
  29. Release the cooling system pressure.
  30.  
  31. Disconnect the coolant hose from the expansion tank.
  32.  
  33. Detach the wiring harness.
  34.  
  35. Disconnect the electrical connectors.
  36.  
  37. Detach the wiring harness.
  38.  
  39. Disconnect the electrical connector.
  40.  
  41. Disconnect the throttle body electrical connectors.
  42.  
  43. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
  44.  
  45. Disconnect the coolant hose.
  46.  
  47. Disconnect the coolant hose.
  48.  
  49. Disconnect the hose.
  50.  
  51. Remove the exhaust manifold to exhaust gas recirculation (EGR) valve tube heat shield retaining nut.
  52.  
  53. Remove the exhaust manifold to EGR valve tube heat shield.
  54.  
  55. Remove the exhaust manifold to EGR valve tube retaining bolts.
  56.  
  57. Remove and discard the gasket.
  58.  
  59. Remove the intake manifold.
  60.  
  61. Remove and discard the gaskets.
  62.  

To install:

  1. Install the intake manifold. Install new gaskets. Tighten to 16 ft. lbs. (22 Nm).
  2.  
  3. Install the exhaust manifold to EGR valve tube retaining bolts. Install a new gasket. Tighten to 16 ft. lbs. (21 Nm).
  4.  
  5. Install the exhaust manifold to EGR valve tube heat shield. Tighten to 80 inch lbs. (9 Nm).
  6.  
  7. Install the exhaust manifold to EGR valve tube heat shield retaining nut. Tighten to 44 ft. lbs. (60 Nm). Connect the hose.
  8.  
  9. Connect the coolant hose.
  10.  
  11. Connect the electrical connector.
  12.  
  13. Connect the manifold absolute pressure (MAP) sensor electrical connector.
  14.  
  15. Connect the throttle body electrical connectors.
  16.  
  17. Connect the CMP electrical connector.
  18.  
  19. Attach the wiring harness.
  20.  
  21. Connect the electrical connectors.
  22.  
  23. Attach the wiring harness.
  24.  
  25. Connect the hose to the expansion tank.
  26.  
  27. Connect the fuel pressure regulator electrical connector.
  28.  
  29. Attach the wiring harness.
  30.  
  31. Connect the electrical connectors.
  32.  
  33. Attach the wiring harness.
  34.  
  35. Connect the right-hand CMP sensor.
  36.  
  37. Disconnect the fuel temperature sensor electrical connector.
  38.  
  39. Connect the EGR valve electrical connector.
  40.  
  41. Connect the pipe. Connect the hose.
  42.  
  43. Attach the engine wiring harness.
  44.  
  45. Install the engine cover retaining brackets.
  46.  
  47. Detach the knock sensor (KS) electrical connectors. Tighten to 53 inch lbs. (6 Nm).
  48.  
  49. Install the air cleaner outlet pipe.
  50.  
  51. Check and top up the cooling system.
  52.  

2.5L And 3.0L Engines
  1. Remove the engine cover (if equipped).
  2.  
  3. Remove the air filter outlet pipe.
  4.  
  5. Remove the positive crankcase ventilation hose.
  6.  
  7. Remove the air cleaner resonator.
  8.  
  9. Disconnect the throttle body electrical connectors.
  10.  
  11. Disconnect the electrical connectors.
  12.  
  13. Detach the vacuum hoses. Press the retaining ring.
  14.  
  15. Detach the injector harness electrical connector from the intake manifold support bracket.
  16.  
  17. Remove the intake manifold support bracket.
  18.  
  19. Detach the wiring harness.
  20.  
  21. Detach the intake manifold support bracket.
  22.  
  23. Remove and discard the O-ring seal.
  24.  
  25. Detach the throttle body.
  26.  
  27. Remove the retaining bolts.
  28.  
  29. Remove the intake manifold.
  30.  
  31. Remove and discard the intake manifold gaskets.

    Click image to see an enlarged view

    Fig. Upper intake manifold torque sequence-2.5L and 3.0L engines

  32.  

To install:

  1. Install new intake manifold gaskets.
    NOTE
    The intake manifold retaining bolts in position 1, 4 and 5 are longer than the retaining bolts in position 2, 3 and 6.

  2.  
  3. Install the intake manifold. Do not fully tighten the retaining bolts.
  4.  
  5. Attach the intake manifold support bracket. Do not fully tighten the retaining bolts.
  6.  
  7. Install the intake manifold support bracket.
  8.  
  9. Install new intake manifold gaskets. Tighten to 10 Nm.
  10.  
  11. Attach the injector harness electrical connector to the intake manifold support bracket. Install a new O-ring seal.
  12.  
  13. Attach the throttle body. Install the retaining bolts.
  14.  
  15. Connect the vacuum hose. Attach the wiring harness. Tighten to 10 Nm.
  16.  
  17. Attach the vacuum hoses. Press the retaining ring.
  18.  
  19. Attach the vacuum hose.
  20.  
  21. Connect the throttle body electrical connectors.
  22.  
  23. Install the air cleaner resonator.
  24.  
  25. Install the positive crankcase ventilation hose.
  26.  
  27. Install the air filter outlet pipe.
  28.  
  29. Install the engine cover (if equipped).
  30.  

4.0L Engine


Click image to see an enlarged view

Fig. 4.0L engine intake manifold bolts-right side



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Fig. 4.0L engine intake manifold bolts-left side

  1. Remove the wiper arm nut covers.
  2.  
  3. Remove the wiper arm nuts.
  4.  
  5. Using special tool, detach the wiper arms.
  6.  
  7. Remove the wiper arms.
  8.  
  9. Remove the cowl grille.
  10.  
  11. Remove the engine compartment brace.
  12.  
  13. Remove the throttle body.
  14.  
  15. Disconnect the right-hand bank camshaft position sensor.
  16.  
  17. Disconnect the right-hand bank injector electrical connectors.
  18.  
  19. Disconnect the fuel temperature sensor electrical connector.
  20.  
  21. Detach the engine harness.
  22.  
  23. Disconnect the knock sensor electrical connector.
  24.  
  25. Detach the engine harness.
  26.  
  27. Disconnect the idle speed control valve electrical connector.
  28.  
  29. Disconnect the fuel pressure regulator electrical connector.
  30.  
  31. Remove the engine harness bracket.
  32.  
  33. Disconnect the camshaft position sensor electrical connector.
  34.  
  35. Disconnect the left-hand bank fuel injector electrical connectors.
  36.  
  37. Disconnect the brake booster vacuum supply hose.
  38.  
  39. Disconnect the evaporative emission canister purge valve vacuum supply hose.
  40.  
  41. Remove the engine harness bracket.
  42.  
  43. Disconnect the intake manifold heater coolant tube.
  44.  
  45. Detach the intake manifold.
  46.  
  47. Remove the intake manifold.
  48.  
  49. To install, reverse the removal procedure. Torque the manifold bolts to 13 ft. lbs. (18 Nm).
  50.  



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Fig. Intake manifold bolt locations-4.0L engine XK Range

  1. Disconnect the battery ground cable.
  2.  
  3. Remove the battery cover.
  4.  
  5. Release the fuel system pressure.
    CAUTION
    Never remove the coolant expansion tank pressure cap under any circumstances while the engine is operating. Failure to follow this instruction may result in personal injury. To avoid hot coolant or steam blowing out of the cooling system, use extreme care when removing the coolant expansion tank pressure cap. Wait until the engine has cooled down, then insulate the coolant pressure cap with a suitable cloth and slowly loosen the coolant expansion tank pressure cap until the cooling system pressure is released. Do not remove the coolant expansion tank pressure cap. Step back while the pressure is released from the system. When all of the pressure has been released slowly remove the coolant expansion tank pressure cap (still with the suitable cloth in position) from the coolant expansion tank. Failure to follow this instruction may result in personal injury.

  6.  
  7. Release the cooling system pressure.
  8.  
  9. Remove the coolant expansion tank pressure cap.
  10.  
  11. Disconnect the intake tube from the throttle body.
  12.  
  13. Remove the two bolts which secure the intake tube to the throttle body.
  14.  
  15. Disconnect the intake tube from the throttle body.
  16.  
  17. Disconnect the air cleaner cover.
  18.  
  19. Release the five clips which secure the air cleaner cover.
  20.  
  21. Disconnect the mass air flow meter electrical connector.
  22.  
  23. Disconnect the breather pipe from the camshaft cover.
  24.  
  25. Disconnect the mass air flow meter electrical connector.
  26.  
  27. Remove the intake tube/air flow meter/air cleaner cover assembly.
  28.  
  29. Remove the intake tube/air flow meter/air cleaner cover assembly.
  30.  
  31. Remove and discard the rubber seal; air intake tube to throttle body.
  32.  
  33. Detach the coolant pipe.
  34.  
  35. Remove the engine left-hand cover.
  36.  
  37. Disconnect the throttle body electrical connectors.
  38.  
  39. Detach the right-hand camshaft position (CMP) sensor wiring harness.
  40.  
  41. Disconnect the brake booster vacuum pipe.
    NOTE
    Cap the coolant hoses to minimize coolant loss.

  42.  
  43. Disconnect the throttle body coolant hose.
  44.  
  45. Remove the throttle body elbow lower retaining bolts.
    NOTE
    Cap the coolant hoses to minimize coolant loss.

  46.  
  47. Disconnect the throttle body coolant hose.
  48.  
  49. Disconnect the accelerator inner cable.
  50.  
  51. Reposition the accelerator pulley to the full throttle position.
  52.  
  53. Disconnect the accelerator inner cable.
  54.  
  55. Disconnect the accelerator outer cable.
  56.  
  57. Remove and discard the retaining strap.
  58.  
  59. Disconnect the accelerator outer cable.
  60.  
  61. Disconnect the throttle body electrical connectors.
  62.  
  63. Detach the left-hand CMP sensor wiring harness from the throttle body elbow.
  64.  
  65. Disconnect the knock sensor (KS) electrical connectors.
  66.  
  67. Disconnect the fuel injectors electrical connectors.
    NOTE
    Place an absorbent cloth underneath fuel connection to absorb any spillages.


    NOTE
    Cap the fuel line and fuel injection supply manifold to prevent contamination.

  68.  
  69. Disconnect the fuel feed hose.
  70.  
  71. Disconnect the fuel feed hose at the Quick Fit connector, using special tool 310-044, or equivalent.
    NOTE
    Place an absorbent cloth underneath fuel connection to absorb any spillages.


    NOTE
    Cap the fuel line and fuel injection supply manifold to prevent contamination.

  72.  
  73. Disconnect the fuel return hose.
  74.  
  75. Disconnect the fuel return hose at the Quick Fit connector, using special tool 310-054, or equivalent.
  76.  
  77. Disconnect the engine breather hose from the throttle body elbow.
  78.  
  79. Disconnect the vacuum hose from the throttle body elbow.
  80.  
  81. Disconnect the engine breather hose from the throttle body elbow.
  82.  
  83. Remove the intake manifold.
  84.  
  85. Remove and discard the eight seals from the intake manifold ports.
  86.  
  87. Clean all parts and relevant mating faces.
  88.  

To install

  1. Install eight new seals to the intake manifold ports.
  2.  
  3. Install the intake manifold. Tighten to 16 ft. lbs. (21 Nm).
  4.  
  5. Connect the engine breather hose to the throttle body elbow.
  6.  
  7. Connect the vacuum hose to the throttle body elbow.
  8.  
  9. Connect the engine breather hose from the throttle body elbow.
  10.  
  11. Uncap the fuel line and fuel injection supply manifold.
  12.  
  13. Connect the fuel feed hose.
  14.  
  15. Ensure that the hose is fully seated to the feed pipe.
  16.  
  17. Uncap the fuel line and fuel injection supply manifold.
  18.  
  19. Connect the fuel return hose.
  20.  
  21. Connect the fuel return hose at the Quick Fit connector. Ensure that the hose is fully seated to the feed pipe.
  22.  
  23. Connect the fuel injectors electrical connectors.
  24.  
  25. Connect the KS electrical connectors.
  26.  
  27. Attach the right-hand camshaft sensor wiring harness to the throttle body elbow.
  28.  
  29. Connect the throttle body electrical connectors.
  30.  
  31. Connect the accelerator inner cable.
  32.  
  33. Reposition the accelerator pulley to the full throttle position.
  34.  
  35. Connect the accelerator inner cable.
  36.  
  37. Uncap the coolant hose.
  38.  
  39. Connect the coolant hose to the throttle body.
  40.  
  41. Install the intake elbow lower retaining bolts. Tighten to 13 ft. lbs. (18 Nm).
  42.  
  43. Connect the coolant hose to the throttle body.
  44.  
  45. Attach the brake servo vacuum pipe to the throttle body elbow.
  46.  
  47. Attach the left-hand CMP sensor wiring harness to the throttle body elbow.
  48.  
  49. Connect the throttle body electrical connectors.
  50.  
  51. Install the engine right-hand cover.
  52.  
  53. Install the engine left-hand cover.
  54.  
  55. Attach the coolant pipe.
  56.  
  57. Install the intake tube/air flow meter/air cleaner cover assembly.
  58.  
  59. Install a new rubber seal; air intake tube to throttle body.
  60.  
  61. Install the intake tube/air flow meter/air cleaner cover assembly.
  62.  
  63. Connect the mass air flow meter electrical connector.
  64.  
  65. Connect the breather pipe from the camshaft cover.
  66.  
  67. Connect the mass air flow meter electrical connector.
  68.  
  69. Reconnect the air cleaner cover.
  70.  
  71. Install the five clips which secure the air cleaner cover.
  72.  
  73. Connect the intake tube to the throttle body.
  74.  
  75. Install the two bolts which secure the intake tube to the throttle body.
  76.  
  77. Connect the intake tube from the throttle body.
  78.  
  79. Fill the cooling system to the correct level.
  80.  
  81. Install the coolant expansion tank pressure cap.
  82.  
  83. Connect the battery.
  84.  
  85. Adjust the accelerator cable.
  86.  

 
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