XKR Vehicles

1. Open hood and install fender protectors.

2. Open luggage compartment lid and remove battery cover.

3. Disconnect battery.

Note:
Ensure the radio code is available before disconnecting the battery.





4. Remove air intake tube/mass air flow sensor/air cleaner cover assembly (see Illustration 12).

WARNING:
NEVER REMOVE THE COOLANT EXPANSION TANK PRESSURE CAP WHILE THE ENGINE IS RUNNING. WHEN REMOVING THE CAP USE EXTREME CARE TO AVOID HOT COOLANT OR STEAM BLOWING OUT OF THE COOLING SYSTEM. WAIT UNTIL THE ENGINE HAS COOLED DOWN THEN INSULATE THE CAP USING A SUITABLE CLOTH AND SLOWLY LOOSEN THE CAP UNTIL THE PRESSURE IS RELEASED. WHEN ALL THE PRESSURE HAS BEEN RELEASED SLOWLY REMOVE THE CAP FROM THE TANK. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN PERSONAL INJURY.

5. Release cooling system pressure.





6. Disconnect throttle body electrical connectors (see Illustration 13).





7. Detach right-hand camshaft position sensor electrical harness (see Illustration 14).





8. Disconnect throttle body coolant hose (see Illustration 15).

Note:
Cap the coolant hose to minimize coolant loss.





9. Disconnect throttle body coolant hose (see Illustration 16).

Note:
Cap the coolant hose to minimize coolant loss.





10. Remove and discard cable tie and disconnect the accelerator outer cable (see Illustration 17).





11. Reposition the accelerator pulley to the full throttle position and disconnect accelerator inner cable (see Illustration 18).





12. Disconnect throttle body electrical connectors (see Illustration 19).





13. Detach left-hand camshaft position sensor electrical harness (see Illustration 20).





14. Remove throttle body securing screws and throttle body and discard the gasket (see Illustration 21).





15. Remove right hand catalytic converter heat shield upper securing screws (see Illustration 22).





16. Remove right hand catalytic converter heat shield to right hand exhaust manifold securing screws and remove heat shield from vehicle (see Illustration 23).





17. Remove EGR transfer pipe heat shield securing screw and remove heat shield from vehicle (see Illustration 24).





18. Remove EGR transfer pipe to EGR valve securing screws (see Illustration 25).

19. Reposition EGR transfer pipe for access to the gasket.

20. Remove and discard EGR transfer pipe to EGR valve gasket.





21. Remove EGR transfer pipe to right hand exhaust manifold securing nuts (see Illustration 26.).

22. Displace and remove EGR transfer pipe from the right hand exhaust manifold studs.

23. Remove gasket from the right hand exhaust manifold studs.

24. Clean the relevant components and mating faces.

25. Install a new gasket to the right hand exhaust manifold studs.

26. Install EGR transfer pipe to the right hand exhaust manifold studs.





27. Install, but do not fully tighten, EGR transfer pipe to right hand exhaust manifold securing nuts (see Illustration 27).

28. Adjust EGR transfer pipe (via convolutions) to align with the EGR valve.

29. Install a new gasket between the EGR transfer pipe flange and the EGR valve.

30. While maintaining the gasket in position, align the EGR transfer pipe flange to the EGR valve.





31. Install and tighten EGR transfer pipe to EGR valve securing screws to 21 Nm (see Illustration 28).





32. Final tighten EGR transfer pipe to right hand exhaust manifold securing nuts to 21 Nm (see Illustration 29).





33. Align EGR transfer pipe heat shield to vehicle and install but do not fully tighten securing screw (see Illustration 30).





34. Align right hand catalytic converter heat shield to vehicle and install but do not fully tighten securing screws (see Illustration 31).





35. Install and fully tighten right hand catalytic converter heat shield upper securing screws (see Illustration 32).

36. Final tighten EGR and right hand catalytic converter heat shields securing screws.





37. Install a new throttle body gasket and install throttle body. Tighten securing screws to 18-24 Nm (see Illustration 33).





38. Re-install left-hand camshaft position sensor electrical harness (see Illustration 34).





39. Connect throttle body electrical connectors (see Illustration 35).





40. Reposition accelerator pulley to the full throttle position and connect the accelerator inner cable (see Illustration 36).





41. Install accelerator outer cable to mounting bracket and secure using cable tie (see Illustration 37).





42. Connect throttle body coolant hose (see Illustration 38).

Note:
Uncap the coolant hose.





43. Connect throttle body coolant hose (see Illustration 39).

Note:
Uncap the coolant hose.





44. Re-install right-hand camshaft position sensor electrical harness (see Illustration 40).





45. Connect throttle body electrical connectors (see Illustration 41).

46. Re-fill cooling system to the correct level.

47. Install cooling system expansion tank pressure cap.

48. Check accelerator cable adjustment.





49. Install air intake/mass air flow sensor/air cleaner cover assembly (see Illustration 42).

50. Connect battery.

51. Re-align battery cover and close luggage compartment lid.

52. Remove fender protectors and close hood.