2003 Jaguar S-Type (X200) V6-3.0L Intake Manifold Removal and Installation
Intake Manifold Removal
- Disconnect the battery ground cable.
WARNING: 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.
WARNING: 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.
Release the cooling system pressure.
- Remove the coolant expansion tank pressure cap.
Diagram Description: Illustration shows a hand holding a cloth over the coolant expansion tank pressure cap, indicating a slow loosening procedure to release pressure.
- Remove the cowl vent screen.
- Remove the engine compartment support.
- Remove the air cleaner outlet pipe.
Diagram Description: Illustration of the throttle body area. An arrow points to the air cleaner outlet pipe connection.
- Disconnect the throttle motor electrical connector.
Diagram Description: Illustration of the throttle body. An arrow points to the throttle motor electrical connector.
- Disconnect the throttle position sensor.
Diagram Description: Illustration of the throttle body area. An arrow points to the throttle position sensor connector.
- Disconnect the Positive Crankcase Ventilation (PCV) hose.
Diagram Description: Illustration showing the PCV hose connection. Arrows point to the hose clamp and connection point.
- NOTE: Cap the coolant hoses to minimize coolant loss.
- Detach the coolant hoses from the throttle body.
Diagram Description: Illustration of the throttle body. An arrow points to a coolant hose connection on the throttle body.
- NOTE: Left-hand Intake Manifold Tuning (IMT) valve shown, right-hand IMT similar.Disconnect the IMT valves electrical connectors.
Diagram Description: Illustration of an Intake Manifold Tuning (IMT) valve. An arrow points to the electrical connector.
- Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
Diagram Description: Illustration of the intake manifold area. An arrow points to the MAP sensor electrical connector.
- Disconnect the fuel pressure regulator vacuum hose.
Diagram Description: Illustration showing a vacuum hose connection. An arrow points to the fuel pressure regulator vacuum hose connection.
- NOTE: The brake booster vacuum hose is attached to the induction manifold by a quick release coupling.Detach the brake booster vacuum hose from the induction manifold.
Diagram Description: Illustration of the induction manifold area. An arrow points to the brake booster vacuum hose connection, noting a quick release coupling.
- Detach the intake manifold front retaining bracket.
Diagram Description: Illustration showing the front of the intake manifold. An arrow points to the retaining bracket.
- Detach the engine wiring harness from the intake manifold rear retaining bracket.
Diagram Description: Illustration of the rear of the intake manifold. An arrow points to the engine wiring harness attached to a retaining bracket.
- Detach the intake manifold rear retaining bracket.
Diagram Description: Illustration of the rear of the intake manifold. An arrow points to the rear retaining bracket.
- NOTE: The evaporative emission canister purge valve transfer pipe is attached to the induction manifold by a quick release coupling.Disconnect the evaporative emission canister purge valve transfer pipe.
Diagram Description: Illustration of the evaporative emission canister purge valve transfer pipe connection. An arrow points to the connection, noting a quick release coupling.
- Remove the fuel pressure regulator bracket retaining bolt.
Diagram Description: Illustration showing the fuel pressure regulator bracket. Arrows point to the retaining bolt.
- Remove the fuel pressure regulator bracket.
Diagram Description: Illustration showing the fuel pressure regulator bracket attached to the intake manifold. Arrows point to the bracket mounting bolts.
- Remove the intake manifold.
Diagram Description: Illustration of the intake manifold with numbered bolts (1-6) indicating removal sequence. Arrows point to the bolts.
Installation
- NOTE: The intake manifold retaining bolts in position 1,2,3 are longer than the retaining bolts in position 4,5 and 6.To install, reverse the removal procedure.
- Install new intake manifold gaskets.
- Tighten to 10 Nm.
Diagram Description: Illustration shows a bolt location on the intake manifold, likely indicating where torque is applied during installation.
- Tighten to 10 Nm.
Diagram Description: Illustration shows a bolt location, likely related to bracket installation.
- Install the intake manifold front retaining bracket.
- Tighten to 10 Nm.
