Removing & Reinstalling XK8 Engine

1. Park the vehicle on a 4 post lift; select "neutral"; lower both windows at least 25 mm (1 inch) before switching the ignition "off"; release the hood latch. Depress the switch to release the trunk lid latch. Leave the handbrake "off". Chock one wheel using wedges to prevent unnecessary movement of the vehicle.

The engine hoist should be rated at 500 kg Safe Working Load minimum, and should be capable of fore and aft movement along the longitudinal axis of the vehicle. Depending on the working environment, side to side movement to allow the engine & transmission assembly to be traversed clear of the vehicle may also be appropriate.

2. Open the hood and install fender covers.

3. Disconnect the negative cable at the battery.

4. Apply masking tape to protect the front edge of the hood. With an assistant, support the hood while disconnecting the gas struts. After removing the 6 bolts that retain the hood, lift the hood clear.

5. Remove the LH and RH engine covers.

6. Discharge the refrigerant from the air conditioning system using recycling equipment. (As for 1995 MY On Sedan range).

7. Use Special Tool set JD-209 or similar proprietary equipment to depressurize the fuel system. Use Special Tool JD-182 to disconnect the fuel feed and return pipes from the fuel rail. Plug the feed and return pipes. Disconnect the fuel return hose from the fuel feed hose securing clip.

8. Drain the cooling system into a clean container. Save as much of the original coolant as possible, for reuse on reassembly.

9. Loosen the union nuts of the transmission fluid upper and lower cooling pipes from the radiator, position a drain tray and disconnect the pipes. Discard the drained-off transmission fluid. Plug the pipes and the radiator connections.

10. Drain the engine oil into a suitable container; discard the oil.

11. Lower the vehicle.

12. Disconnect the convoluted breather pipe from the stub on the "A" bank cam cover. Retain the O-ring.

13. Disconnect the multiplug from the mass air flow (MAF) sensor; cut and discard the tie strap which secures the throttle body vacuum pipe to the induction elbow. Remove the two bolts and disconnect the intake tube from the throttle body, discarding the rubber seal. Release the 6 clips at the air cleaner, and remove the air intake tube/MAF sensor/air cleaner cover assembly.

14. Remove the cooling system expansion tank and disconnect the top hose from the engine. Disconnect the bottom hose at the thermostat housing.

15. Disconnect the high speed and low speed fan multiplugs, release their harnesses from the clips on the fan cowl and move the harnesses clear.

16. Remove the 5 bolts and remove the radiator top closing panel and radiator top mounting rubbers. Release and move the air conditioning refrigerant pipe from the clip on the fan cowl. Remove the bolt securing the hose from the receiver/drier to the air conditioning condenser, disconnect the hose from the receiver/drier. Plug the hose and the receiver/drier. With an assistant, lift out the radiator assembly.

17. Prom the bracket at the rear, release the heated oxygen sensor connectors and disconnect the multiplugs.

18. Disconnect the 57-way connector of the Engine Management harness. Remove the multiplug from its bracket.

19. Disconnect the fuel injection harness multiplug from the Engine Management harness.

20. Disconnect the multiplugs of the EGR and Transmission Rotary Switch harnesses.

21. Rotate the throttle actuating cam and disconnect the throttle cable. Loosen the cable adjusting locknut and disconnect the outer cable from the bracket.

22. Disconnect the heater return hose. Release the connector lock lever and disconnect the heater feed hose.

23. Release and relocate the protective sleeve on the brake servo vacuum hose and disconnect the hose connector.

24. On each side of the cylinder block install an engine rear lifting eye - Special Tool JD 222. Tighten the captive securing bolts.

25. Remove the nuts which secure each downpipe catalytic converter to its exhaust manifold.

26. Release the filler cap of the PAS reservoir.

27. After raising the vehicle, position a drain tray, loosen the PAS pump high pressure hose union nut, disconnect the hose, drain off and discard the fluid. Insert suitable plugs in both the hose and the PAS pump outlet. Discard the O-ring seal.

28. Remove the engine oil dipstick tube. Plug the opening in the crankcase. Release the clip and disconnect the PAS pump feed hose; plug the hose and pump ports.

29. Loosen the nuts of the front muffler to downpipe catalytic converter clamps on both sides of the vehicle; move the front muffler rearward off the catalytic converter outlet stubs. Loosen the nuts of the clamps of the intermediate mufflers on both sides; move the intermediate mufflers to the rear, allowing the front muffler assembly to be disconnected and removed.

30. Loosen the handbrake cable adjuster nut; remove the 4 handbrake assembly retaining bolts, displace the handbrake assembly from the body, allowing it to hang down.

31. Remove the three nuts and bolts from each coupling flange of the drive shaft, turning the drive shaft as necessary to obtain access. Temporarily leave one bolt in place at the rear coupling to support the shaft.

32. Place a transmission jack under the rear mounting of the transmission and adjust it to take the weight of the rear of the engine/transmission assembly; remove the four bolts which retain the transmission mounting to the body.

33. Remove the last bolt from the rear coupling and move the shaft away, allowing the rear end of the shaft to be supported on the handbrake cable. Lower the transmission jack until the shaft can be disengaged from the transmission spigot and removed clear of the vehicle.

34. Remove the two bolts that secure each downpipe catalytic converter to its mounting bracket; remove the two converters, placing them in a safe location where they will not be damaged and where there will be no contaminants will enter the catalyst.

35. On the RH side of the engine compartment, disconnect the ground strap from the body.

36. Disconnect the multiplug of the generator suppression module. Displace the fuel injection harness below the suppression module; identify and disconnect the multiplug of the Engine Management harness to starter motor.

37. Disconnect the starter power cable from the power stud, pull it through the heatshield into the engine compartment.

38. Release the lock and disconnect the transmission harness from the rear of the transmission.

39. Remove the nut from the transmission selector cross shaft; remove the selector cable abutment bolts and disconnect the cable from the cross shaft.

40. From above, align an overhead engine hoist equipped with 4 chains and hooks off a common ring. Connect the longer chains and hooks to the engine rear lifting eyes, the shorter chains to the engine front lifting points. Adjust the chains until they all are taking equal weight, permitting the transmission jack to be lowered and removed without the transmission moving away from the body.

CAUTION!
Do not allow the rear of the engine to drop. Damage will occur to components on the rear of the engine and on the bulkhead.

41. Remove the nuts from the engine mounts (Hydramounts.)

42. Remove the bolt through the rear mounting rubber and remove the rear mounting cross member.

43. With an assistant operating the engine hoist controls, very carefully lower the vehicle lift and engine hoist SIMULTANEOUSLY to a convenient working height.

44. Move the engine and transmission assembly forwards and upwards until the assembly can be lifted clear of the vehicle.

45. Move the engine hoist clear of the vehicle, until the engine and transmission assembly can be lowered to a convenient working height.

46. Disconnect the transmission oil cooler feed pipe, discarding the O-ring seal. Remove the securing bolt of the pipe bracket to the engine sump, release the air conditioning pipe from the bracket and remove the cooler pipes. Insert suitable blanking plugs in the transmission connection and in the pipes.

47. Remove the access cover, on the underside of the bell housing, to the torque converter. Turn the crankshaft, using a drive socket on the crankshaft damper securing bolt, to obtain access to the first bolt securing the torque converter to the drive plate and remove the bolt. (Rotate the engine clockwise only, viewed from the front). Suitably wedge the starter ring gear to prevent the crankshaft turning when loosening the bolt.

48. Rotate the engine 120° to remove the second bolt, and an additional 1200 to remove the third bolt.

49. Adjust a transmission jack to support the transmission, installing or adjusting any additional brackets as required, and securing the transmission to the jack using the safety chain.

50. Remove the 10 bolts that secure the bell housing to the engine.

51. Carefully separate the engine from the transmission. Make sure that the torque converter does not stick to the drive plate, but stays completely in the transmission at all times. Once separated, secure the torque converter to the transmission so that it is not accidentally dislodged.

52. Lower the engine to the floor and position a piece of wood under the oil sump to support the unit. If the accessories need to transferred to another engine, place the engine on an engine stand. Disconnect the lifting chains and hooks, and remove the engine rear lifting eyes.

53. Reassemble the transmission on the engine and reinstall the assembly in the vehicle in reverse order of the removal and dismantling procedure, noting:

^ Clean all pipe and hose joint faces and fit new seals/O-rings as appropriate at all joints, as shown in the included parts requirements.

^ Tighten all fasteners to the torque wrench settings as tabulated below.

^ Fill or top-up (as appropriate) the engine oil sump, ensuring that the oil level is at the "FULL" mark an the dipstick before attempting to start the engine.

Engine oil specification: API SG/CD, or preferably: API SH where available. Viscosity: 5W-30

^ When filling the cooling system, refer to COOLANT SYSTEM REFILLING PROCEDURE.

^ When refilling the PAS System, refer to the procedure in the XK8 Diagnostic and Test Manual, Section 211-02. Use DEXRON 3 Fluid.

IMPORTANT - THE FOLLOWING TWO OPERATIONS ARE CRITICAL

During reconnection of the throttle cable, it is critical that the cable adjustment is carried out as described in the XK8 On-Board Diagnostics Manual, Section 303-12, using that part of SRO 19-70-04 which refers to Throttle Cable Adjustment.

After reconnecting the battery and before starting the engine, carry out the continuation of the above SRO which refers to Kickdown Setting.

^ Before starting the engine, remove the transmission filler/level plug. Top up to the level of the plug. Reinstall the plug. After running the engine, top up the transmission as necessary, as described in XK8 Diagnostic & Test Manual, Section 307-01. Use only ESSO ATF LT 71141 fluid.

^ It may be found convenient, on initially starting the engine, that the Air Conditioning refrigeration system is not yet recharged with R134A refrigerant. Ensure that the controls are set such that the Air Conditioning compressor clutch does not become engaged until initial engine running is completed and the system has been charged with refrigerant and, where applicable, an appropriate quantity of the recommended refrigerant oil. For information, refer to XK8 Diagnostics and Test Manual, Section 412-03.

^ Adjust the handbrake cable - refer to HANDBRAKE CABLE ADJUSTMENT.

^ Reset the clock, the radio code (where applicable) and carry out the windows set-up procedure, following reconnection of the battery,

^ After completion of all items above and visual checks that no fluid leaks etc. are apparent, and all fluids have been correctly topped up, the vehicle may be driven to a storage area- The vehicle should be allowed to cool overnight,

^ A Test Drive must then be undertaken, which will allow ECM adaptation to occur. This test drive MUST include:

Cold start Some idling Heavy acceleration

Steady state cruising up to achievement of normal engine temperature as described in XK8 On-Board Diagnostics Manual, Section 303-14, Pinpoint Test P0603, P1609, Item A3.





TORQUE DATA