Jaguar V8-V6 Engine Workshop Manual-352 Pgs.

ENGINE REFERENCE MATERIAL
Jaguar V6/V8 Engine Workshop Manuals
GENERIC PROCEDURES - ENGINE

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303-00-1 Engine System - General Information 303-00-1
.
SECTION 303-00 GENERIC PROCEDURES - ENGINE

VEHICLE APPLICATION: ALL
CONTENTS PAGE
GENERAL PROCEDURES
Bearing Inspection.............................................................................................................. 303-00-2
Camshaft Bearing Journal Clearance................................................................................. 303-00-3
Camshaft Bearing Journal Diameter.................................................................................. 303-00-4
Camshaft End Play............................................................................................................. 303-00-5
Camshaft Lobe Lift.............................................................................................................. 303-00-6
Camshaft Surface Inspection............................................................................................. 303-00-7
Connecting Rod Cleaning................................................................................................... 303-00-8
Connecting Rod Large End Bore........................................................................................ 303-00-9
Crankshaft End Play........................................................................................................... 303-00-10
Crankshaft Main Bearing Journal Clearance...................................................................... 303-00-11
Cylinder Bore Out-of-Round............................................................................................... 303-00-12
Cylinder Head Distortion..................................................................................................... 303-00-13
Exhaust Manifold Cleaning and Inspection........................................................................ 303-00-14
Piston Inspection................................................................................................................ 303-00-15
Piston Pin Diameter............................................................................................................ 303-00-16
Piston Pin to Bore Diameter............................................................................................... 303-00-17
Piston Ring End Gap.......................................................................................................... 303-00-18
Piston Ring-to-Groove Clearance....................................................................................... 303-00-19
Valve Spring Free Length................................................................................................... 303-00-20
Valve Stem Diameter.......................................................................................................... 303-00-21
Page 1
GENERAL PROCEDURES
Bearing Inspection
1. Inspect bearings for the following defects.
1. Cratering - fatigue failure
2. Spot polishing - incorrect seating.
3. Imbedded dirt engine oil.
4. Scratching - dirty engine oil.
5. Base exposed - poor lubrication.
6. Both edges worn - journal damaged.
7. One edge worn - journal tapered or bearing
not seated.
1 2
3 4 5
6 7
VUJ0002219
G61255en
Page 2 4/2005 2004.50 X200
GENERAL PROCEDURES
Camshaft Bearing Journal Clearance

• If the values are not to specification install a
1. NOTE: Make sure that the following stages
new camshaft.
are followed exactly. The tappets or followers
must be removed to carry out this
measurement.
NOTE: Make sure that the camshaft is to
specification.
NOTE: The bearing caps and journals should be
free from engine oil and dirt.
Position on a length of plastigage on the
bearing cap.
• Insert the camshaft, without lubrication, into
the cylinder head. VUJ0001697
• Position a plastigage strip, which should be
equal to the width of the bearing cap, on the
bearing journal.
VUJ0001696
2. Install the camshaft bearing caps.

• Follow the relevant tightening sequence.
3. NOTE: Do not strike the bearing caps.
Remove the camshaft bearing caps.
• Follow the relevant loosening sequence.
4. Using the special tool, read off the
measurement.
• Compare the width of plastigage with the
plastigage scale.
• The value that is read off is the bearing
clearance.
2004.50 X200 4/2005 Page 3 G61235en

GENERAL PROCEDURES
Camshaft Bearing Journal Diameter

1. Determine the diameter of the camshaft
journals.
• Using a micrometer measure the diameter
at 90 degrees intervals to determine if the
journals are out-of-round.
• Measure at two different points on the journal
to determine if there is any tapering.
• If the measurements are out of the specified
range, install a new camshaft.
VUJ0001695
G61234en
Page 4 4/2005 2004.50 X200
GENERAL PROCEDURES
Camshaft End Play

1. NOTE: Make sure that the camshaft is to
specification.
Using the special tool, measure the end play.
• Slide the camshaft in both directions. Read
and note the maximum and minimum values
on the dial indicator gauge.
• End play = maximum value minus minimum
value.
• If the measurement is out of specification,
install new components.
VUJ0001698
2004.50 X200 4/2005 Page 5 G61236en

GENERAL PROCEDURES
Camshaft Lobe Lift

1. Measure the diameter (1) and diameter (2)
with a vernier caliper. The difference in
measurements is the lobe lift.
1
VUJ0001699
G61238en
Page 6 4/2005 2004.50 X200
GENERAL PROCEDURES
Camshaft Surface Inspection

1. Inspect camshaft lobes for pitting or damage
in the active area. Minor pitting is acceptable
outside the active area.
VUJ0001700
2004.50 X200 4/2005 Page 7 G61237en

GENERAL PROCEDURES
Connecting Rod Cleaning

1.
CAUTION: Do not use a caustic cleaning
solution or damage to connecting rods may
occur.
Mark and separate the parts and clean with
solvent. Clean the oil passages.
VUJ0002224
G61251en
Page 8 4/2005 2004.50 X200
GENERAL PROCEDURES
Connecting Rod Large End Bore

1. Measure the bearing bore in two directions.
The difference is the connecting rod bore
out-of-round. Verify the out-of-round is within
specification.
VUJ0002223
2. Measure the bearing bore diameter in two

directions. Verify the bearing bore is within
specification.
VUJ0002222
2004.50 X200 4/2005 Page 9 G61252en

GENERAL PROCEDURES
Crankshaft End Play

1. Using the Dial Indicator Gauge with Brackets,
measure the end play.
• Measure the end play by lifting the crankshaft
using a lever.
• If the value is out of the specification, install
new thrust half rings to take up the end float
and repeat the measurement.
VUJ0002235
G61242en
Page 10 4/2005 2004.50 X200
GENERAL PROCEDURES
Crankshaft Main Bearing Journal Clearance

• If the measurement is out of the specified
1. NOTE: Verify that the following stages are
range, change the bearing shells and repeat
followed exactly. The crankshaft must be to
the measurement.
specification.
NOTE: The bearing shells and journals must be
free from engine oil and dirt.
NOTE: The measuring point should be near to the
center.
Position on a length of Plastigage on the
bearing journal.
• Insert the associated bearing shells, without
lubrication, into the cylinder block.
• Insert the crankshaft, without lubrication, into
the cylinder block. VUJ0002237
• Position a strip of Plastigage, equal to the
width of the bearing, on the bearing journal.
VUJ0002236
2. NOTE: Measure all the bearings at the same

time.
Carry out the measurement.
• Install the lower crankcase with bearing
shells following the relevant tightening
sequence.
3. NOTE: Do not hit the lower crankcase.
Remove the lower crankcase with bearing
shells.
4. Read off the measurement.
• Compare the length of plastigage with the
Plastigage scale.
• The value that is read off is the bearing
clearance.
2004.50 X200 4/2005 Page 11 G61241en

GENERAL PROCEDURES
Cylinder Bore Out-of-Round

1. NOTE: The main bearing caps or lower
crankcase must be in place and tightened to
the specified torque; however, the bearing
shells should not be installed.
Measure the cylinder bore with an internal
micrometer.
• Carry out the measurements in different
directions and at different heights to
determine if there is any out-of-roundness or
tapering.
• If the measurement is out of the specified
range, hone out the cylinder block or install
a new block.
10 mm
10 mm
VUJ0002234
G61243en
Page 12 4/2005 2004.50 X200
GENERAL PROCEDURES
Cylinder Head Distortion

1. Measure the cylinder block/cylinder head
distortion.
• Using the special tool, measure the mating
face distortion.
• If the value is not to specification rework the
mating face.
VUJ0001701
2004.50 X200 4/2005 Page 13 G61239en

GENERAL PROCEDURES
Exhaust Manifold Cleaning and Inspection

1. Inspect the cylinder head joining flanges of
the exhaust manifold for evidence of exhaust
gas leaks.
2. Inspect the exhaust manifold for cracks,
damaged gasket surfaces, or other damage
that would make it unfit for further use.
G61240en
Page 14 4/2005 2004.50 X200
GENERAL PROCEDURES
Piston Inspection
1.
CAUTION: Do not use any aggressive
cleaning fluid or a wire brush to clean the
piston.
Carry out a visual inspection.
• Clean the piston skirt, pin bush, ring grooves
and crown and check for wear or cracks.
• If there are signs of wear on the piston skirt,
check whether the connecting rod is twisted
or bent.
VUJ0002233
2004.50 X200 4/2005 Page 15 G61244en

GENERAL PROCEDURES
Piston Pin Diameter

1. NOTE: The piston and piston pin are a
matched pair. Do not mix up the
components.
Measure the piston pin diameter.
• Measure the diameter in two directions.
• If the values are not to specification, install
a new piston and a new piston pin.
VUJ0002225
G61250en
Page 16 4/2005 2004.50 X200
GENERAL PROCEDURES
Piston Pin to Bore Diameter

1. NOTE: The piston and piston pin form a
matched pair. Do not mix up the
components.
Measure the diameter of the piston pin bore.
• Measure the diameter in two directions.
• If the values are not to specification, install
both a new piston and a new piston pin.
VUJ0002232
2004.50 X200 4/2005 Page 17 G61245en

GENERAL PROCEDURES
Piston Ring End Gap

1.
CAUTION: Do not mix up the piston rings.
Install the piston rings in the same position
and location.
Using the Feeler Gauge, measure the piston
ring gap.
• The values given in the specification refer to
a gauge ring used during production.
VUJ0002227
G61248en
Page 18 4/2005 2004.50 X200
GENERAL PROCEDURES
Piston Ring-to-Groove Clearance

1. NOTE: The piston ring must protrude from
the piston groove. To determine the piston
ring clearance, insert the Feeler Gauge right
to the back of the groove, behind the wear
ridge.
Using the Feeler Gauge, measure the piston
ring clearance.
VUJ0002226
2004.50 X200 4/2005 Page 19 G61249en

GENERAL PROCEDURES
Valve Spring Free Length

1. Using a vernier gauge, measure the free
length of each valve spring. Verify the length
is within specification.
VUJ0002221
G61254en
Page 20 4/2005 2004.50 X200
GENERAL PROCEDURES
Valve Stem Diameter

1. Using a micrometer measure the diameter
of the valve stems.
• If the measurements are not to specification,
install a new valve.
VUJ0002220
2004.50 X200 4/2005 Page 21 G61253en

Page 22

303-01B-1 Engine — 4.0L 303-01B-1
.
SECTION 303-01B Engine — 4.0L

VEHICLE APPLICATION: 2000.0 X200
CONTENTS PAGE
DISASSEMBLY
Engine. 303-01B-2
Page 23
303-01B-2 Engine — 4.0L 303-01B-2
DISASSEMBLY
Engine
Special Tool(s) Special Tool(s)
Crankshaft locking, main tool Cylinder Bore Protectors
303-191 303-535
303-191 303535
Adapter
303-191-02 Disassembly
1. Disconnect the oil cooler hoses.
303-191-02
Crankshaft pulley/damper
remover
303-588
303-588
Crankshaft setting, main tool VUJ0001553

303-645
2. Remove the coolant hose.
303-645
Camshaft setting
303-530
303-530
Timing chain tensioning tool VUJ0001552
303-532
3. Release the accessory drive belt tension.
303-532
G95948en
Page 24 4/2005 2000.0 X200
303-01B-3 Engine — 4.0L 303-01B-3
DISASSEMBLY
• Detach the accessory drive belt. 6. Remove the generator.
VUJ0001554
VUJ0001557
4. Remove the accessory drive belt tensioner. 7. Remove the generator mounting bracket.
• Remove the accessory drive belt.
VUJ0001558
VUJ0001555
8. Remove the right-hand exhaust manifold.

5. Disconnect the generator electrical
connector. • Remove and discard the gasket.
VUJ0001559
VUJ0001556
2000.0 X200 4/2005 Page 25 G95948en

303-01B-4 Engine — 4.0L 303-01B-4
DISASSEMBLY
9. Remove the right-hand engine mount. 12. Remove the starter motor.
VUJ0001560 VUJ0001563
10. Remove the right-hand engine mounting 13. Remove the oil deposit and tube
bracket.
• Remove and discard the 'O' ring seal.
VUJ0001561
VUJ0001565
11. Remove the wiring harness support 14. Remove the left-hand exhaust manifold.
bracket.
• Remove and discard the gasket.
VUJ0001562 VUJ0001566
G95948en
Page 26 4/2005 2000.0 X200
303-01B-5 Engine — 4.0L 303-01B-5
DISASSEMBLY
15. Remove the left-hand engine mount. 18. Disconnect the air conditioning compressor
electrical connector.
VUJ0001567
VUJ0001570
16. Remove the left-hand engine mounting

bracket. 19. Remove the air conditioning compressor.
VUJ0001568
VUJ0001571
17. Detach the power assisted steering tube. 20. Remove the air conditioning compressor
mounting bracket.
VUJ0001569
VUJ0001572
2000.0 X200 4/2005 Page 27 G95948en

303-01B-6 Engine — 4.0L 303-01B-6
DISASSEMBLY
21. Remove the power assisted steering tube. Remove the oil filter element.
VUJ0001573 VUJ0001576
22. Remove the power assisted steering pump. 25. Remove the oil cooler.
VUJ0001574 VUJ0001577
23. Remove the power assisted steering pump 26. Disconnect the oil pressure switch and oil
mounting bracket. temperature switch electrical connectors.
VUJ0001575 VUJ0001578
24. NOTE: Place a suitable container 27. Remove the oil filter housing.
underneath filter to prevent oil spillage.
G95948en
Page 28 4/2005 2000.0 X200
303-01B-7 Engine — 4.0L 303-01B-7
DISASSEMBLY
• Remove and discard the 'O' ring seal. 30. Detach the engine harness conduit.
VUJ0001579 VUJ0001582
28. Detach the left-hand oxygen sensor. 31. Detach the engine harness.
1. Disconnect the variable valve timing (VVT)
solenoid electrical connector.
2. Detach the engine harness.
VUJ0001580
2
29. Detach the engine harness retaining clips.
• Disconnect the crankshaft position sensor VUJ0002375
(CPS) electrical connector.

32. Detach the right-hand oxygen sensor.
VUJ0001581
VUJ0001584
2000.0 X200 4/2005 Page 29 G95948en

303-01B-8 Engine — 4.0L 303-01B-8
DISASSEMBLY
33. Detach the engine harness retaining clips. 2. Detach the engine harness.
VUJ0001585 VUJ0002376
34. Detach the engine harness conduit. 37. Detach the engine harness.
1. Disconnect the knock sensor electrical
connector.
2
VUJ0001586
35. Remove the engine cover bracket.

VUJ0001589
38. Disconnect the idle air control valve

VUJ0001588

1. Disconnect the variable valve timing (VVT) VUJ0001590
G95948en
Page 30 4/2005 2000.0 X200
303-01B-9 Engine — 4.0L 303-01B-9
DISASSEMBLY
39. Disconnect the fuel pressure regulator 42. Disconnect the left-hand bank fuel injector
electrical connector. electrical connectors.
VUJ0001591 VUJ0001594
40. Remove the engine harness bracket. 43. Remove the left-hand bank engine cover.
VUJ0001592 VUJ0001595
41. Disconnect the left-hand bank camshaft 44. Disconnect the left-hand bank ignition coil
position sensor electrical connector. electrical connector.
VUJ0001593 VUJ0001596
2000.0 X200 4/2005 Page 31 G95948en

303-01B-10 Engine — 4.0L 303-01B-10
DISASSEMBLY
45. Detach the camshaft position sensor (CPS) 48. Disconnect the left-hand bank knock sensor
electrical connector. electrical connector.
VUJ0002380 VUJ0002381
46. Detach the engine harness. 49. Detach the left-hand bank knock sensor
VUJ0001597
VUJ0002377
47. Disconnect the coolant temperature sensor

and the right-hand bank knock sensor 50. Remove the left-hand bank knock sensor
electrical connectors. bracket.
VUJ0001598 VUJ0002378
G95948en
Page 32 4/2005 2000.0 X200
303-01B-11 Engine — 4.0L 303-01B-11
DISASSEMBLY
51. Detach the crankcase ventilation breather 54. Disconnect the throttle position sensor
hose and disconnect the throttle body electrical connector.
VUJ0001603
VUJ0001600
55. Remove the throttle body.

52. Detach the throttle body bracket.
VUJ0001601 VUJ0001604
53. Remove the throttle body bracket. 56. Disconnect the right-hand bank camshaft
position sensor electrical connector.
VUJ0001602
VUJ0001605
2000.0 X200 4/2005 Page 33 G95948en

303-01B-12 Engine — 4.0L 303-01B-12
DISASSEMBLY
57. Disconnect the right-hand bank fuel injector 60. Remove the engine harness bracket.
electrical connectors.
VUJ0001609
VUJ0001606
61. Disconnect the fuel temperature sensor

58. Remove the right-hand bank engine cover. electrical connector.
VUJ0001607 VUJ0002379
59. Disconnect the right-hand bank ignition coil 62. Remove the engine wiring harness.
VUJ0002382
VUJ0001608
G95948en
Page 34 4/2005 2000.0 X200
303-01B-13 Engine — 4.0L 303-01B-13
DISASSEMBLY
63. Disconnect the intake manifold heater • Remove and discard the 'O' ring seals.
coolant hose.
VUJ0002385
VUJ0001613
67. Remove the noise and vibration insulating
64. Disconnect the intake manifold heater pad.
coolant hose.
VUJ0001615
VUJ0001614
68. Remove the intake manifold heater coolant
65. Remove the intake manifold rear plate. hose.
1. Remove the knock sensors.
2. Remove the intake manifold heater coolant
hose.
2
VUJ0002386
66. Remove the intake manifold assembly.

VUJ0002444
2000.0 X200 4/2005 Page 35 G95948en

303-01B-14 Engine — 4.0L 303-01B-14
DISASSEMBLY
69. Remove the water pump pulley. • Remove and discard the 'O' ring seals.
VUJ0002388
VUJ0001617
70. Remove the water pump. 73. Remove the accessory drive belt idler
pulley.
VUJ0002389
VUJ0001618
74. Remove the engine block insulation
grommet.
71. Remove the thermostat housing retaining
bolts.
VUJ0002390
VUJ0002387
72. Remove the thermostat housing and outlet

tube assembly.
G95948en
Page 36 4/2005 2000.0 X200
303-01B-15 Engine — 4.0L 303-01B-15
DISASSEMBLY
75. Remove the right-hand ignition coils. • Remove and discard the 'O' ring seal.
VUJ0002394
VUJ0002391
76. Remove the left-hand ignition coils. 79.

CAUTION: Under no circumstances
should the crankshaft setting peg 303645
be used in the following operations, to lock
the crankshaft.
Install the crankshaft locking tool to the
damper.
1. Install adaptor 30319102 to the main locking
tool 303191.
2. Reposition the crankshaft/damper to align
the mounting holes and install the locking
tool using the bolts provided.
VUJ0002392
3. Remove the damper securing bolt from the
crankshaft.
77. Remove the right-hand camshaft position

(CMP) sensor.
• Remove and discard the 'O' ring seal. 2
2
D303540
80. Remove the damper from the crankshaft.
VUJ0002393
1. Transfer the adaptor 30319102 from the
crankshaft locking tool to the damper
extractor tool 303588 (it is not secured to this
78. Remove the left-hand camshaft position puller by the bolts).
(CMP) sensor. 2. Locate the thrust button into the end of the
crankshaft,` the 'O' ring holds it in place.
• Assemble the puller to the damper.
2000.0 X200 4/2005 Page 37 G95948en

303-01B-16 Engine — 4.0L 303-01B-16
DISASSEMBLY
• Extract the damper from the crankshaft. 82.
CAUTION: Remove the spark plugs to
enable the engine to rotate freely.
2 Rotate the crankshaft clockwise to position the
engine to top dead center (TDC) No. 1 cylinder
1 prior to the removal and installation of the
camshafts.
Install the crankshaft setting peg 303645 to
the crankshaft position sensor location.
• Do not rotate the crankshaft
counterclockwise. The timing chains may
bind causing engine damage.
D303542
• Position the crankshaft so that the setting
peg engages fully into the timing slot.
81. Remove the crankshaft position (CKP) • Install the setting peg bolt.
sensor.
303-645
VUJ0002400
VUJ0002399
83. Remove the right-hand valve cover.

• Discard the valve cover gaskets.
VUJ0002395

84. Remove the left-hand valve cover.
G95948en
Page 38 4/2005 2000.0 X200
303-01B-17 Engine — 4.0L 303-01B-17
DISASSEMBLY
VUJ0002396
85. Remove the engine front cover.
2000.0 X200 4/2005 Page 39 G95948en

303-01B-18 Engine — 4.0L 303-01B-18
DISASSEMBLY
VUJ0002398
• Remove and discard the 'O' ring seals.

86. Remove the right-hand variable valve timing
(VVT) solenoid and bush carrier assembly.
VUJ0002401
G95948en
Page 40 4/2005 2000.0 X200
303-01B-19 Engine — 4.0L 303-01B-19
DISASSEMBLY
87. Install the camshaft locking tool 303530 to 90. Remove the primary timing chain.
the right hand camshafts, aligning the
shafts as necessary.
303-530
VUJ0002404
VUJ0002402
91. Remove the crankshaft sprocket.
88. Remove the tensioner assembly.

1. Remove the tensioner.
2. Remove the tensioner back-plate.
VUJ0002414
1
92. Remove the timing chain guide.
D303720
89. Remove the timing chain tensioner blade.
VUJ0002405
93. Remove the variable valve timing (VVT)

unit, exhaust camshaft sprocket and
VUJ0002403 secondary timing chain assembly.
2000.0 X200 4/2005 Page 41 G95948en

303-01B-20 Engine — 4.0L 303-01B-20
DISASSEMBLY
• Remove the variable valve timing (VVT) unit 96. Install the camshaft locking tool 303530 to
and exhaust camshaft sprocket retaining the left hand camshafts, aligning the shafts
bolts. as necessary.
303-530
VUJ0002406
VUJ0002409
94. Remove the secondary timing chain 97. Remove the left-hand variable valve timing
tensioner. (VVT) solenoid and bush carrier assembly.
• Remove and discard the 'O' ring seals.
VUJ0002407
VUJ0002410
95. Remove the camshaft setting tool.
98. Remove the tensioner assembly.
1. Remove the tensioner.
2. Remove the tensioner back-plate.
1
VUJ0002408
D.303.1099
G95948en
Page 42 4/2005 2000.0 X200
303-01B-21 Engine — 4.0L 303-01B-21
DISASSEMBLY
99. Remove the timing chain tensioner blade. 102. Remove the timing chain guide.
VUJ0002412 VUJ0002416
100. Remove the primary timing chain. 103. Remove the variable valve timing (VVT)
unit, exhaust camshaft sprocket and
secondary timing chain assembly.
• Remove the variable valve timing (VVT) unit
and exhaust camshaft sprocket retaining
bolts.
VUJ0002413
VUJ0002417
104. Remove the secondary timing chain

tensioner.
VUJ0002415
VUJ0002418
2000.0 X200 4/2005 Page 43 G95948en

303-01B-22 Engine — 4.0L 303-01B-22
DISASSEMBLY
105. Remove the camshaft setting tool. • Remove the camshaft bearing caps. Note
their orientation and markings, each is
marked with its position (a number) and
orientation (an arrow).
VUJ0002419
106. Remove the camshaft bearing caps. VUJ0002422
• Remove the camshaft bearing cap retaining

bolts evenly and in stages. 109. Remove the right-hand inlet camshaft.
• Remove the camshaft bearing caps. Note
VUJ0002423
110. Remove the camshaft bearing caps.

VUJ0002420 • Remove the camshaft bearing cap retaining
bolts evenly and in stages.
107. Remove the right-hand exhaust camshaft. • Remove the camshaft bearing caps. Note
VUJ0002421
108. Remove the camshaft bearing caps. VUJ0002424

G95948en
Page 44 4/2005 2000.0 X200
303-01B-23 Engine — 4.0L 303-01B-23
DISASSEMBLY
111. Remove the left-hand exhaust camshaft. • Remove and discard the gasket.
11 7 3 5 9 1
10 6 4 2
8 12
2
VUJ0002428
VUJ0002425
112. Remove the camshaft bearing caps. 115. Remove the left-hand cylinder head.
• Remove the camshaft bearing cap retaining • Remove the bolts in the indicated sequence.
bolts evenly and in stages. • Remove and discard the gasket.
2 12 8 4 6 10
9 5 3 7 11
VUJ0002429
116. Remove the crankshaft setting peg 303645

from the crankshaft position sensor
VUJ0002426
location.
113. Remove the left-hand inlet camshaft.

303-645
VUJ0002400
VUJ0002427 117. Remove the drive plate.

1. Remove the drive plate retaining bolts.
114. Remove the right-hand cylinder head.
• Remove the bolts in the indicated sequence.
2000.0 X200 4/2005 Page 45 G95948en

303-01B-24 Engine — 4.0L 303-01B-24
DISASSEMBLY
2. Remove the drive plate. 119. Remove the oil strainer.
1
1
VUJ0002432
VUJ0002434
118. Remove the lower oil pan.
• Remove and discard the gasket. 120. Remove the upper oil pan.
VUJ0002433
G95948en
Page 46 4/2005 2000.0 X200
303-01B-25 Engine — 4.0L 303-01B-25
DISASSEMBLY
VUJ0002435
Remove the connecting rod bolts, the

121. Remove the oil pump.
connecting rod caps and the lower
• Remove and discard the gasket. connecting rod bearings.
VUJ0002436
VUJ0002437
122.
CAUTION: Pistons, connecting rods and 123. Inspect the tops of the cylinder bores. As
connecting rod bearings should be necessary remove ridge and carbon build
numbered to make sure they are up from each cylinder.
reassembled in the same position. 124.
CAUTION: Use appropriate protection
NOTE: Mark the position of the connecting rod
to prevent damage to the crankshaft
caps to the connecting rods to make sure of correct
bearing journals and cylinder bore
installation.
surfaces.
NOTE: Discard the connecting rod bolts after
removal.
2000.0 X200 4/2005 Page 47 G95948en

303-01B-26 Engine — 4.0L 303-01B-26
DISASSEMBLY
Install special tools to the connecting rods. • Rotate the crankshaft to locate pistons at the
bottom of travel.
• Push the piston, connecting rod and upper
bearing through the top of the cylinder.
303 535
VUJ0002285
125.
CAUTION: Care should not be taken not VUJ0002438
to damage the connecting rod and cap joint
face surfaces or possible engine damage 126. NOTE: Remove the lower cylinder block
may occur. Avoid contaminating the bolts in the indicated sequence.
fractured joint surfaces with dirt or grease.
NOTE: Mark the position of the upper and lower
NOTE: Reattach the connecting rods and caps crankshaft main bearings for reassembly.
after removal to avoid mismatch.
Remove the lower cylinder block.
Remove the pistons.
• Remove the lower cylinder block retaining
bolts in the indicated sequence.
G95948en
Page 48 4/2005 2000.0 X200
303-01B-27 Engine — 4.0L 303-01B-27
DISASSEMBLY
6 10 14 12 8 4
15 19 24 22 18
25 29 34 32 28
27 31 33 30 26
17 21 23 20 16
3 7 11 13 9 5
VUJ0002439
2000.0 X200 4/2005 Page 49 G95948en

303-01B-28 Engine — 4.0L 303-01B-28
DISASSEMBLY
127. Discard the crankshaft rear main oil seal. 130. Clean the cylinder block with a soap and
water solution. Dry the cylinder block
completely with compressed air.
VUJ0002440
128.
CAUTION: Avoid damage to any
crankshaft bearing surfaces.
NOTE: Never remove any pipe plugs or dowels
unless they are to be newly installed or the cylinder
block is to be washed.
Remove the crankshaft.
VUJ0002441
129. Remove the upper crankshaft main

bearings.
1. Remove the upper crankshaft thrust washers.
2. Remove the upper crankshaft main bearings.
VUJ0002445
G95948en
Page 50 4/2005 2000.0 X200
303-01B-1 Engine — 4.0L 303-01B-1
.

CONTENTS PAGE
ASSEMBLY
Engine. 303-01B-2
Page 51
303-01B-2 Engine — 4.0L 303-01B-2
ASSEMBLY
Engine
Crankshaft locking, main tool Variable camshaft timing oil
303-191 control unit setting tool
303-654
303-191 303-654
Adapter Wedges, primary chain

303-191-02 303-533
303533
303-191-02
Crankshaft pulley/damper Cylinder Bore Protectors

remover 303-535
303-588
303-588
303535
Crankshaft setting, main tool Piston Ring Compressor

303-645 303-372
303372
303-645
Camshaft setting Crankshaft rear oil seal

303-530 remover/replacer
303-538
303-530
303-538
Timing chain tensioning tool

303-532 Assembly
1.
CAUTION: Use only a plastic scraper
when removing old gasket material.
303-532
Clean all the mating faces and reusable parts
thoroughly and check for damage.
• If gasket material remains on the cylinder
head after cleaning, use a plastic tipped
scraper to remove remaining material.
2. NOTE: Never remove pipe plugs or alignment
dowels unless they are to be serviced.
G95951en
Page 52 4/2005 2000.0 X200
303-01B-3 Engine — 4.0L 303-01B-3
ASSEMBLY
Reseal oil passage blanking plugs, as 5. NOTE: The main bearings are precision
necessary. selective fit. For additional information, refer
to: Crankshaft Main Bearing Journal
3. NOTE: The main bearings are precision
Clearance (303-00 Engine System - General
selective fit. For additional information, refer
Information, General Procedures).
Clearance (303-00 Engine System - General NOTE: Install lower cylinder block and tighten bolts
Information, General Procedures). to specification within twenty minutes of applying
sealer.
NOTE: Lubricate the upper crankshaft main
bearings and thrust washers. Apply a bead of sealant to the cylinder block
housing.
Install the upper crankshaft main bearings.
• Use silicone gasket and sealant.
1. Install the upper crankshaft thrust washers.
2. Install the upper crankshaft main bearings.
VUJ0002449
VUJ0002445
6.
CAUTION: Make sure all dowels are fully
4. seated into lower cylinder block prior to
CAUTION: Avoid damage to any tightening the bolts.
NOTE: Do not lubricate the lower cylinder block
Install the crankshaft. bolts.
NOTE: Do not rotate crankshaft until all bolts are
tightened to specification.
NOTE: Bolts must be tightened within twenty
minutes of applying sealer.
NOTE: Tighten the bolt in the indicated sequence
Install the lower cylinder block to the upper
cylinder block.
1. Tighten bolts 21 through 32 to 15 Nm
VUJ0002441 3. Tighten bolts 1 through 10 to 25 Nm
5. Tighten bolts 1 through 10 to 35 Nm +135°
2000.0 X200 4/2005 Page 53 G95951en

303-01B-4 Engine — 4.0L 303-01B-4
ASSEMBLY
33
29 25 21 23 27 31
20 16 11 13 17
10 6 1 3 7
8 4 2 5 9
18 14 12 15 19
32 28 24 22 26 30
34
VUJ0002450
7. Remove excess sealant which may squeeze

out at the front cover sealing surfaces.
8. Rotate the crankshaft to check correct
operation.
9. Using the special tool, install the crankshaft
rear oil seal.
• Make sure that the center bolt is unscrewed
to below the face which is to fit to the
crankshaft and position the tool to the
crankshaft.
G95951en
Page 54 4/2005 2000.0 X200
303-01B-5 Engine — 4.0L 303-01B-5
ASSEMBLY
• Check that the nuts are fully unscrewed and 12. Remove the special tool from the
install the two bolts to the crankshaft threads crankshaft.
and lightly tighten.
• Check that the seal is located correctly.
13.
surfaces.
Install special tools to the connecting rods.
• Position the crankshaft journal at the bottom
of the stroke.
• Make sure the piston rings are positioned at
different positions opposite the thrust side of
J3031302 the piston before installation.
14. NOTE: Install pistons with arrow to front of
10. Tighten the nuts, finger tight, to hold the engine.
tool assembly against the seal. Check that
the seal and the tool are approximately Using the special tool compress the rings
parallel to the rear of the engine. and install the piston and connecting rod.
• Lubricate all piston components.
303 372
J3031300
VUJ0002278
11. Press the seal into the housing.

15. CAUTIONS:
• Hold each bolt stationary, in turn, and tighten
its nut a small amount (approximately two to When assembling the connecting rods
three flats) in turn, to press the seal fully into and connecting rod caps it is imperative
the housing, until the tool is in contact with that bearing slots and tangs be located on
the cylinder block. the same side of the connecting rods.
Connecting rod bolts are torqued to yield

and must be replaced.
NOTE: Remove the special tools from the
connecting rods.
NOTE: Tighten the bolts in the indicated sequence.
Position the connecting rod cap on the
appropriate connecting rod.
1. Tighten to 10 Nm
2. Tighten to 30 Nm
J3031305
2000.0 X200 4/2005 Page 55 G95951en

303-01B-6 Engine — 4.0L 303-01B-6
ASSEMBLY
3. Tighten to 90° Using a suitable torque wrench, measure the
torque required to rotate the crankshaft. If
the torque exceeds 20 Nm, investigate and
rectify the cause, and then repeat the test.
18. Install the oil pump.
• Install a new gasket.
• Tighten to 12 Nm.
VUJ0002437

operation.
17.
CAUTION: The torque required to turn
the crankshaft must not exceed 20 Nm.
VUJ0002436
Failure to follow this instruction may result
in damage to the vehicle.
19. Install the upper oil pan.
VUJ0002435
20. Install the oil separator.

• Install a new 'O' ring seal.
G95951en
Page 56 4/2005 2000.0 X200
303-01B-7 Engine — 4.0L 303-01B-7
ASSEMBLY
• Tighten to 12 Nm. • Install the crankshaft setting peg 303-645 to
the crankshaft position sensor location.
303-645
VUJ0002434
VUJ0002400
21. Install the lower oil pan.

24. Install a new left-hand cylinder head gasket.
• Tighten to 12 Nm. 1. Install a new left-hand cylinder head gasket.
2. Make sure the cylinder head dowels are
correctly located.
VUJ0002433
2
VUJ0002431
22. Install the drive plate.
1. Install the drive plate.
25. NOTE: Tighten the bolts 1 through 10 in the
2. Install the drive plate retaining bolts. indicated sequence.
• Tighten to 110 Nm. Install the left-hand cylinder head.
1. Tighten bolts 1 through 10 to 20 Nm.
2 3. Tighten bolts 1 through 10 to 90°.
4. Tighten bolts 1 through 10 to 90°.
1 5. Tighten bolts 11 through 12 to 25 Nm.
12 7 5 1 3 10
2
VUJ0002451
11
23. Position the crankshaft.
9 4 2 6 8
VUJ0002452
2000.0 X200 4/2005 Page 57 G95951en

303-01B-8 Engine — 4.0L 303-01B-8
ASSEMBLY
26. Install a new right-hand cylinder head 29. Install the camshaft bearing cap bolts
gasket. evenly.
1. Make sure the cylinder head dowels are • Install the camshaft bearing caps.
correctly located. • Tighten to 10 Nm.
2. Install a new right-hand cylinder head gasket.
2 VUJ0002426
VUJ0002430
30. Install the left-hand exhaust camshaft.

27. NOTE: Tighten the bolts 1 through 10 in the
indicated sequence.
Install the right-hand cylinder head.
10 3 1 5 7 12
VUJ0002425
31. Install the camshaft bearing cap bolts

11 evenly.
• Install the camshaft bearing caps.
8 6 2 2
4 2
9
VUJ0002453
28. Install the left-hand inlet camshaft.
VUJ0002424
VUJ0002427
G95951en
Page 58 4/2005 2000.0 X200
303-01B-9 Engine — 4.0L 303-01B-9
ASSEMBLY
32. Install the right-hand inlet camshaft. • Tighten to 10 Nm.
VUJ0002420
VUJ0002423
33. Install the camshaft bearing cap bolts 36. Install the camshaft setting tool to the
evenly. left-hand cylinder head.

VUJ0002419
VUJ0002422 37. Install the secondary timing chain

tensioner.
34. Install the right-hand exhaust camshaft. • Tighten to 12 Nm.
VUJ0002418
VUJ0002421
38. Install the variable valve timing (VVT) unit,

35. Install the camshaft bearing cap bolts
exhaust camshaft sprocket and secondary
evenly.
timing chain assembly.
2000.0 X200 4/2005 Page 59 G95951en

303-01B-10 Engine — 4.0L 303-01B-10
ASSEMBLY
• Install the variable valve timing (VVT) unit • Remove the tool.
bolts but do not fully tighten.
E34040
VUJ0002417
42. Install the primary timing chain.
• Install the primary chain over the crankshaft
39. Install the timing chain guide.
sprocket and the VVT unit sprocket. There
• Tighten to 12 Nm. must be no slack on the drive side of the
primary chain and the VVT unit must not be
rotated on the camshaft.
VUJ0002416
VUJ0002413
40. Install the crankshaft sprocket.
43. Install the timing chain tensioner blade.

VUJ0002415
41. Install the chain tensioning tool 303-532 to

the exhaust camshaft sprocket. VUJ0002412
• Reposition the sprocket (and the VVT unit)

for the most advantageous position for use 44. Install the primary chain tensioner
of the tool. assembly.
G95951en
Page 60 4/2005 2000.0 X200
303-01B-11 Engine — 4.0L 303-01B-11
ASSEMBLY
• Use a wedge 303-533 (or two if required) 2. Rotate the variable camshaft timing oil control
between the primary chain tensioner and unit fully anti-clockwise to the fully retarded
tensioner blade, to take up the slack in the position.
chain.
1 303-654
VUJ0004924
D303844 47. Tighten the VVT unit bolt.

1. While still applying the opposing force to the
45. Tighten the exhaust camshaft sprocket sprocket and chain (using 303-532), check
securing bolt. that the wedges are still in place, carry out
1. Install the chain tensioner tool 303-532 to the the variable camshaft timing oil control unit
sprocket holes. retaining bolt tightening sequence.
• Apply force to the tool in an anti-clockwise • Tighten to 40 Nm + 90°.
direction to tension the chain on its drive • Remove the chain tensioning tool and the
side. wedge(s).
2. While applying the opposing force to sprocket
and chain, tighten the sprocket bolt to 120
Nm.
1
1
2
E34042
48. NOTE: Make sure the bush carrier oil inlet

E34041 filter screen is clean.
Install the left-hand variable valve timing
46. Rotate the variable camshaft timing oil (VVT) solenoid and bush carrier assembly.
control unit fully counter-clockwise to the
fully retarded position. • Install new 'O' ring seals.
1. Install the variable camshaft timing oil control
unit setting tool 303-654.
2000.0 X200 4/2005 Page 61 G95951en

303-01B-12 Engine — 4.0L 303-01B-12
ASSEMBLY
• Tighten to 21 Nm. • Tighten to 12 Nm.
VUJ0002410 VUJ0002407
49. Remove the camshaft setting tool. 52. Install the variable valve timing (VVT) unit,
exhaust camshaft sprocket and secondary
timing chain assembly.
• Install the variable valve timing (VVT) unit
303-530
bolts but do not fully tighten.
VUJ0002409
50. Install the camshaft setting tool to the

right-hand cylinder head.
VUJ0002406
53. Install the timing chain guide.

VUJ0002408
51. Install the secondary timing chain

tensioner.
VUJ0002405
G95951en
Page 62 4/2005 2000.0 X200
303-01B-13 Engine — 4.0L 303-01B-13
ASSEMBLY
54. Install the crankshaft sprocket. 57. Install the timing chain tensioner blade.
VUJ0002414
VUJ0002403
55. Install the chain tensioning tool 303-532 to

the exhaust camshaft sprocket. 58. Install the primary chain tensioner
• Reposition the sprocket (and the VVT unit) assembly.
for the most advantageous position for use • Use a wedge 303-533 (or two if required)
of the tool. between the primary chain tensioner and
• Remove the tool. tensioner blade, to take up the slack in the
chain.
E32656
56. Install the primary timing chain. J303532

sprocket and the VVT unit sprocket. There 59. Tighten the exhaust camshaft sprocket
must be no slack on the drive side of the securing bolt.
primary chain and the VVT unit must not be 1. Install the chain tensioner tool 303-532 to the
rotated on the camshaft. sprocket holes.
• Apply force to the tool in an anti-clockwise
direction to tension the chain on its drive
side.
VUJ0002404
2000.0 X200 4/2005 Page 63 G95951en

303-01B-14 Engine — 4.0L 303-01B-14
ASSEMBLY
2. While applying the opposing force to sprocket • Remove the chain tensioning tool and the
and chain, tighten the sprocket bolt to 120 wedge(s).
Nm.
1 2 120 Nm 1
VUJ0003396
E32658

60. Rotate the variable camshaft timing oil
control unit fully counter-clockwise to the
fully retarded position.
303-530
1. Install the variable camshaft timing oil control
unit setting tool 303-654.
2. Rotate the variable camshaft timing oil control
unit fully anti-clockwise to the fully retarded
position.
VUJ0002402
63. NOTE: Make sure the bush carrier oil inlet

filter screen is clean.
Install the right-hand variable valve timing
1 303-654 (VVT) solenoid and bush carrier assembly.
• Install new 'O' ring seals.
VUJ0004913 • Tighten to 21 Nm.
61. Tighten the VVT unit bolt.

1. While still applying the opposing force to the
sprocket and chain (using 303-532), check
that the wedges are still in place, carry out
the variable camshaft timing oil control unit
retaining bolt tightening sequence.
• Tighten to 40 Nm + 90°.
VUJ0002401
G95951en
Page 64 4/2005 2000.0 X200
303-01B-15 Engine — 4.0L 303-01B-15
ASSEMBLY
64. Remove the crankshaft setting peg 303-645 3. Install and fully locate, a new seal for the idler
from the crankshaft position sensor pulley.
location.
303-645 1
J3031230
VUJ0002400
68. Apply sealant to the eight joints on the
65. Carry out a valve clearance check. For engine face.
additional information, refer to: Valve • Sealant beads to be 3 mm diameter and 12
Clearance Check (303-01B Engine - 4.0L, mm long. Cut the nozzle of the sealant tube
General Procedures). to produce a 3 mm (0.12 in) bead. (Install
66. Install the crankshaft position (CKP) and tighten the securing bolts within twenty
sensor. minutes of sealant application).
• Tighten to 7 Nm
D303669
VUJ0002399
67. Install new seals to the timing cover.

1. Install the new seal to the inner groove on
the face of the timing cover.
2. Install the new seal to the outer groove on
• Remove the transit ring and check that the
oil seal is not damaged.
2000.0 X200 4/2005 Page 65 G95951en

303-01B-16 Engine — 4.0L 303-01B-16
ASSEMBLY
69. Install the timing cover. • Install new valve cover gaskets.
12 Nm
12 8 4 6 10 14
22 18 19 23
14 15
2
21 24 1
9 10
11 7 3 5 9 13
VUJ0001979
72.
17 20 CAUTION: Under no circumstances
should the crankshaft setting peg 303-645
13 16 be used in the following operations, to lock
the crankshaft.
7 6 Install the crankshaft locking tool to the
damper.
1 2
1. Install adaptor 303-191-02 to the main
5 8 locking tool 303-191.
11 4 12 2. Reposition the crankshaft/damper to align
VUJ0002003 the mounting holes and install the locking
tool using the bolts provided.
3. Install the damper securing bolt to the
70. NOTE: Apply an 8 mm diameter bead of crankshaft.
silicone gasket sealant on the two places
where the cylinder head and front cover
join.
Install the left-hand valve cover.
2
• Install new valve cover gaskets.
1
14 10 6 4 8 12
3
2
1 2
D303540
73. Install the spark plugs.
13 9 5 3 7 11
VUJ0001977 74. Install the left-hand camshaft position
(CMP) sensor.
71. NOTE: Apply an 8 mm diameter bead of • Install a new 'O' ring seal.
join.
Install the right-hand valve cover.
G95951en
Page 66 4/2005 2000.0 X200
303-01B-17 Engine — 4.0L 303-01B-17
ASSEMBLY
VUJ0002394 VUJ0002391
75. Install the right-hand camshaft position 78. Install the engine block insulation grommet.
(CMP) sensor.
VUJ0002390
79. Install the accessory drive belt idler pulley.

VUJ0002393
76. Install the left-hand ignition coils.

VUJ0002389
80. Install the thermostat housing retaining

VUJ0002392 bolts.
77. Install the right-hand ignition coils.
2000.0 X200 4/2005 Page 67 G95951en

303-01B-18 Engine — 4.0L 303-01B-18
ASSEMBLY
• Tighten to 10 Nm. 83. Install the water pump pulley.
10 Nm
10 Nm
VUJ0002387
VUJ0001997
81. Install the thermostat housing and outlet 84. Install the water pump pulley (continued).
tube assembly.
• Tighten bolts to 45°.
45
45
VUJ0001998
VUJ0002388
85. Install the intake manifold heater coolant
hose.
82. Install the water pump.
1. Install the knock sensors.
• Install a new gasket and 'O' ring seal. 2. Install the intake manifold heater coolant
hose.
12 Nm
20 Nm 1
2
12 Nm
VUJ0001996
VUJ0001616
G95951en
Page 68 4/2005 2000.0 X200
303-01B-19 Engine — 4.0L 303-01B-19
ASSEMBLY
86. Install the noise and vibration insulating 89. Connect the intake manifold heater coolant
pad. hose.
VUJ0001615 VUJ0001614
87. Install the intake manifold. 90. Connect the intake manifold heater coolant
hose.
VUJ0001613
VUJ0002385
91. Attach the engine wiring harness to the
88. Install the intake manifold rear plate. engine.
VUJ0002386 VUJ0002382
2000.0 X200 4/2005 Page 69 G95951en

303-01B-20 Engine — 4.0L 303-01B-20
ASSEMBLY
92. Connect the fuel temperature sensor 95. Install the right-hand bank engine cover.
VUJ0001607
VUJ0002379
96. Connect the right-hand bank fuel injector

93. Install the engine harness bracket. electrical connectors.
VUJ0001609 VUJ0001606
94. Connect the right-hand bank ignition coil 97. Connect the right-hand bank camshaft
electrical connectors. position sensor electrical connector.
VUJ0001608 VUJ0001605
98. Install the throttle body.

G95951en
Page 70 4/2005 2000.0 X200
303-01B-21 Engine — 4.0L 303-01B-21
ASSEMBLY
• Tighten to 10 Nm. 101. Attach the throttle body bracket.
VUJ0001604
VUJ0001601
99. Connect the throttle position sensor 102. Attach crankcase ventilation breather hose
electrical connector. and the throttle body electrical connector.
VUJ0001603
VUJ0001600
100. Install the throttle body bracket. 103. Install the left-hand bank knock sensor
bracket.
VUJ0001602
VUJ0002378
2000.0 X200 4/2005 Page 71 G95951en

303-01B-22 Engine — 4.0L 303-01B-22
ASSEMBLY
104. Attach the left-hand bank knock sensor 107. Attach the engine harness.
VUJ0001597
VUJ0002454
108. Attach the camshaft position sensor (CPS)

105. Connect the left-hand bank knock sensor electrical connector.
VUJ0002380
VUJ0002381
109. Connect the left-hand bank ignition coil

106. Connect the coolant temperature sensor electrical connector.
and the right-hand bank knock sensor
VUJ0001596
VUJ0001598
G95951en
Page 72 4/2005 2000.0 X200
303-01B-23 Engine — 4.0L 303-01B-23
ASSEMBLY
110. Install the left-hand bank engine cover. 113. Install the engine harness bracket.
VUJ0001595 VUJ0001592
111. Connect the left-hand bank fuel injector 114. Connect the fuel pressure regulator
electrical connectors. electrical connector.
VUJ0001594 VUJ0001591
112. Connect the left-hand bank camshaft 115. Connect the idle air control valve electrical
position sensor electrical connector. connector.
VUJ0001593 VUJ0001590
116. Attach the engine harness.

1. Connect the knock sensor electrical
connector.
2000.0 X200 4/2005 Page 73 G95951en

303-01B-24 Engine — 4.0L 303-01B-24
ASSEMBLY
2. Attach the engine harness. 119. Attach the engine harness conduit.
VUJ0001589
VUJ0001586
117. Attach the engine harness. 120. Attach the engine harness.
1. Connect the variable valve timing (VVT)
2
VUJ0001585
121. Attach the right-hand oxygen sensor.

VUJ0002376
118. Install the engine cover bracket.
VUJ0001584
VUJ0001588
G95951en
Page 74 4/2005 2000.0 X200
303-01B-25 Engine — 4.0L 303-01B-25
ASSEMBLY
2. Attach the engine harness. 125. Attach the left-hand oxygen sensor.
VUJ0002375
VUJ0001580
123. Attach the engine harness conduit. 126. Install the oil filter housing.
21 Nm
VUJ0001582
VUJ0001651
• Connect the crankshaft position sensor 127. Connect the oil pressure switch and oil
(CPS) electrical connector. temperature switch electrical connectors.
VUJ0001581
VUJ0001578
2000.0 X200 4/2005 Page 75 G95951en

303-01B-26 Engine — 4.0L 303-01B-26
ASSEMBLY
128. Install the oil cooler. 131. Install the power assisted steering pump.
58 Nm 25 Nm
25 Nm
VUJ0001650 VUJ0001648
129. Install the oil filter element. 132. Install the power assisted steering tube.
VUJ0001576 VUJ0001573
130. Install the power assisted steering pump 133. Install the air conditioning compressor
mounting bracket. mounting bracket.
25 Nm 25 Nm
24 Nm
VUJ0001649 VUJ0001647
G95951en
Page 76 4/2005 2000.0 X200
303-01B-27 Engine — 4.0L 303-01B-27
ASSEMBLY
134. Install the air conditioning compressor. • Tighten to 25 Nm.
25 Nm 25 Nm
VUJ0001644
VUJ0001646
135. Connect the air conditioning compressor 138. Install the left-hand engine mount.
43 Nm
VUJ0001643
VUJ0001570
139. Install the left-hand exhaust manifold.
136. Install the power assisted steering tube. • Install a new gasket.
18 Nm 1 3 5 7
10 Nm
2 4 6 8
VUJ0001645 VUJ0001642
137. Install the left-hand engine mounting 140. Install the oil level indicator and tube.
bracket.
2000.0 X200 4/2005 Page 77 G95951en

303-01B-28 Engine — 4.0L 303-01B-28
ASSEMBLY
• Install a new 'O' ring seal. 143. Install the right-hand engine mounting
bracket.
25 Nm 25 Nm
VUJ0001565
VUJ0001638
141. Install the starter motor.

144. Install the right-hand engine mounting
25 Nm
43 Nm
25 Nm
VUJ0001640
VUJ0001637
142. Install the wiring harness support bracket.
145. Install the right-hand exhaust manifold.
7 5 3 1 18 Nm
VUJ0001562
8 6 4 2
VUJ0001636
G95951en
Page 78 4/2005 2000.0 X200
303-01B-29 Engine — 4.0L 303-01B-29
ASSEMBLY
146. Install the generator mounting bracket. • Tighten to 40 Nm.
43 Nm 43 Nm
VUJ0001555
VUJ0001635
147. Install the generator. 150. Rotate the accessory drive belt tensioner
counterclockwise
21 Nm • Attach the accessory drive belt.

• Release the accessory drive belt tension.
40 Nm
VUJ0001634
148. Connect the generator electrical connector.

VUJ0001554
151. Install the coolant hose.

• Install the coolant hose retaining bolts.
• Install the coolant hose.
VUJ0001556
149. Install the accessory drive belt tensioner.

• Install the accessory drive belt.
VUJ0001552
2000.0 X200 4/2005 Page 79 G95951en

303-01B-30 Engine — 4.0L 303-01B-30
ASSEMBLY
152. Connect the oil cooler hoses.
VUJ0001553
G95951en
Page 80 4/2005 2000.0 X200
303-01B-1 Engine — 4.0L 303-01B-1
.

CONTENTS PAGE
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

Cylinder Head..................................................................................................................... 303-01B-2
Piston.. 303-01B-5
Page 81
303-01B-2 Engine — 4.0L 303-01B-2
Cylinder Head ()
Special Tool(s) 3. Using the special tool, compress the valve
springs.
Valve Spring Compressor
303-252 • Remove the valve collets.
303-252
303252
Disassembly
1. CAUTIONS:
Do not use a magnet to remove shims.
Failure to follow these instructions may VUJ0002447
result in damage to the vehicle.
If the cylinder head valve components 4. Remove the valve spring retainers and valve
are to be reused, mark the position of the springs.
valve components to make sure they are 1. Remove the valve spring retainers.
reassembled in the same position. 2. Remove the valve springs.
Remove the bucket tappet and shim 3. Remove the valve stem oil seals.
assemblies.
1
VUJ0002334
VUJ0002442
5. Remove the valves from the cylinder head.
2. Remove the camshaft position (CMP) sensor. 1. Remove the intake valves.
• Remove and discard the 'O' ring seal. 2. Remove the exhaust valves.
1
VUJ0002448
VUJ0002446
G95949en
Page 82 4/2005 2000.0 X200
303-01B-3 Engine — 4.0L 303-01B-3
6. Inspect the cylinder heads and related 3. Install the valve spring retainers.
components. For additional information, refer
to Section 303-00 [Engine System - General
Information] 3
7. Remove the pipe plugs and alignment dowels

as necessary to clean the cylinder heads. 1
Assembly
2
1.
WARNING: Eye protection is required
during use of compressed air. Failure to
follow these instructions may result in VUJ0002304
personal injury.
CAUTION: The cylinder head surface finish 5. Using the special tool, compress the valve
is measured in microns. For correct head springs.
gasket sealing, avoid any contact of finish
• Install the valve collets.
with metallic objects.
Clean gasket material, dirt and foreign
material from cylinder heads. Wash with a 303-252
suitable soap and water solution and dry the
cylinder head completely using compressed
air if pipe plugs have been removed.
2. Install the pipe plugs and alignment dowels
to cylinder heads.
• Apply pipe sealant to plugs prior to
installation.
3. NOTE: Lubricate the valve stems before VUJ0002447
assembly.
Install the valves into the cylinder heads. 6. Install the camshaft position (CMP) sensor.
1. Install the intake valves. • Install a new 'O' ring seal.
2. Install the exhaust valves. • Tighten to 7 Nm.
1
VUJ0002448 VUJ0002446
4. Install the valve spring retainers and valve 7.

CAUTION: Do not use a magnet to install
springs. shims. Failure to follow these instructions
1. Install the valve stem oil seals. may result in damage to the vehicle.
2. Install the valve springs.
2000.0 X200 4/2005 Page 83 G95949en

303-01B-4 Engine — 4.0L 303-01B-4
Install the bucket tappet and shim
assemblies.
VUJ0002442
G95949en
Page 84 4/2005 2000.0 X200
303-01B-5 Engine — 4.0L 303-01B-5
Piston ()
Disassembly 4. Remove the oil control spacer ring.
1. NOTE: Mark the pistons to the original

connecting rods to make sure correct
installation in the same cylinders from which
they were removed.
Remove the top compression ring.
A0006862
5. Remove the second oil control ring.
A0006859
2. Remove the second compression ring.
A0006863
6.
WARNING: The retaining rings have a
tendency to spring out during removal. Cover
the end of the pin bore with a hand or a rag
when removing the retaining ring. Eye
A0006860
protection should be worn. Failure to follow
these instructions may result in personal
3. Remove the first oil control ring. injury.
Remove the retaining clips.
A0006861
A0006864
2000.0 X200 4/2005 Page 85 G95950en

303-01B-6 Engine — 4.0L 303-01B-6
7. Remove the piston pin and the connecting 3. Check the piston ring end gap. For additional
rod from the piston. information, refer to Section 303-00 [Engine
System - General Information]
4. Lubricate the piston and piston rings.
5. Install the second oil control ring.
A0006866
8. Clean and inspect the connecting rod and

the piston. For additional information, refer
A0006867
Information]
6. Install the oil control spacer ring.
Assembly
1. Install the piston pin.
• Lubricate the piston pin and piston bore.
A0006856
7. Install the first oil control ring.
A0006866
2. Install the retaining clips.
A0006857
8. Install the second compression ring.
A0006864
G95950en
Page 86 4/2005 2000.0 X200
303-01B-7 Engine — 4.0L 303-01B-7
• The top of the second compression ring has
a "Of" marked on it. Position this side of the
ring towards the top of the piston.
A0006858
9. Install the top compression ring.

• The top compression ring can be installed
either side up.
A0006859
2000.0 X200 4/2005 Page 87 G95950en

303-01B-1 Engine — 4.0L 303-01B-1
.

CONTENTS PAGE
GENERAL PROCEDURES
Valve Clearance Adjustment............................................................................................... 303-01B-2
Valve Clearance Check...................................................................................................... 303-01B-4
Page 88
303-01B-2 Engine — 4.0L 303-01B-2
GENERAL PROCEDURES
Valve Clearance Adjustment ()

Special Tool(s) 3. Tighten the retaining screws to secure the
attachment to the base plate.
Tappet hold down tool
303-540 3
2
DWST024
1
Fan nozzle, air gun
303-590
J.303.705
DWST074
5. NOTE: Use a mirror to help locating the

1. Use a cloth to wipe away as much oil as fingers of the special tool as access is
possible from the tappet and shim. restricted.
2. Rotate the engine clockwise to position the Position the fingers on the outer edges of
camshaft lobe away from the shim surface. the tappet. Make sure the recessed step on
each finger locates on the edge of the tappet.
3. Install the base plate of the valve clearance
adjusting tool 303540 to the relevant cylinder
head using the bolts supplied
• Secure the tool to the valve cover retaining
holes.
X X
J.303.530
6. Tighten the special tool to compress the

valve springs.
J.303.704
4.
CAUTION: Do not rotate the crankshaft
while the attachment is installed to the base
plate.
Install the attachment of the tool 303540 to
the base plate to remove the relevant shims.
1. Adjust the fingers of the attachment to the
highest position.
2. Install the attachment to the base plate. J.303.706
G61304en
Page 89 4/2005 2000.0 X200
303-01B-3 Engine — 4.0L 303-01B-3
GENERAL PROCEDURES
7. 11. Using the feeler gauge set, measure the
WARNING: The following operations
clearance between the camshaft and the
require the use of compressed air. Always
shim surface. Record and check the
wear suitable eye protection.
readings. For additional information, refer
Remove, clean and measure the shim. toSection 303-00 [Engine System - General
1. Surround the immediate working area with Information].
a cloth to retain any loose shims displaced 12. When the valve clearance is correct,
by the compressed air. remove the attachment from the base plate
2. Use special tool 303590 (with a fan nozzle) and repeat the procedure for the following
aimed at the edge of the shim to lift it from two valves to be adjusted.
the tappet. Remove the shim from each 13. Install the right-hand valve cover. For
tappet, noting the position of each one. additional information, refer toValve
Cover—RH
2
1 14. Install the left-hand valve cover. For
additional information, refer toValve
Cover—LH
J.303.707
8. NOTE: Two shims within each procedure are

possible to be replaced using the special
tool.
Use the following formula to calculate the
required shim thickness.
• Original shim thickness + measured shim
clearance - desired clearance = required
shim thickness.
9. NOTE: Shims must be fitted with the size
markings facing the tappet, not the camshaft.
Apply a light coat of engine oil to the
replacement shim (s) and install.
10. Loosen the special tool to allow the valve
springs to return to their normal position.
J.303.706
2000.0 X200 4/2005 Page 90 G61304en

303-01B-4 Engine — 4.0L 303-01B-4
GENERAL PROCEDURES
Valve Clearance Check ()

1. Remove the left-hand valve cover. For
Cover—LH
2. Remove the right-hand valve cover. For
Cover—RH
3. CAUTIONS:
Rotating the crankshaft in a
counterclockwise direction may cause
engine damage. Crankshaft journals are
directionally machined. Rotating the
crankshaft counterclockwise Can raise burrs
on bearing surfaces, reducing engine life.
Camshaft lobes must be 180 degrees

away from each valve tappet or valve
clearance will be incorrect.
Rotate the engine clockwise to position the
camshaft lobe away from the shim surface.
4. Using the feeler gauge set, measure the
readings. For additional information, refer to
Section 303-00 [Engine System - General
Information]. Adjust the clearances as
necessary. For additional information, refer
to Valve—Clearance Adjustment
VUJ0002259
5. Install the right-hand valve cover. For

Cover—RH
6. Install the left-hand valve cover. For
Cover—LH
G61303en
Page 91 4/2005 2000.0 X200
303-01B-1 Engine — 4.0L 303-01B-1
.

CONTENTS PAGE
IN-VEHICLE REPAIR
Camshaft LH....................................................................................................................... 303-01B-2
Crankshaft Front Seal......................................................................................................... 303-01B-4
Crankshaft Pulley................................................................................................................ 303-01B-5
Crankshaft Rear Seal......................................................................................................... 303-01B-9
Cylinder Head RH............................................................................................................... 303-01B-12
Engine Front Cover............................................................................................................. 303-01B-21
Engine Mount LH................................................................................................................ 303-01B-27
Engine Mount RH............................................................................................................... 303-01B-28
Exhaust Manifold LH........................................................................................................... 303-01B-29
Exhaust Manifold RH.......................................................................................................... 303-01B-30
Flexplate............................................................................................................................. 303-01B-31
Intake Manifold................................................................................................................... 303-01B-32
Oil Cooler............................................................................................................................ 303-01B-36
Oil Pan 303-01B-38
Oil Pump............................................................................................................................. 303-01B-39
Primary Timing Chain LH.................................................................................................... 303-01B-40
Primary Timing Chain RH................................................................................................... 303-01B-44
Secondary Timing Chain LH............................................................................................... 303-01B-49
Secondary Timing Chain RH.............................................................................................. 303-01B-50
Valve Cover LH................................................................................................................... 303-01B-51
Valve Cover RH.................................................................................................................. 303-01B-54
Page 92
303-01B-2 Engine — 4.0L 303-01B-2
IN-VEHICLE REPAIR
Camshaft LH ()
Removal 3. Remove the camshaft from the engine.
Intake Camshaft 1
1. NOTE: Left-hand bank shown, right-hand 2
similar.
Remove the timing cover. For additional
information, refer to Engine Front Cover
2. Remove the VVT unit from the left-hand bank.
For additional information refer to Timing
Chain—Secondary, Left-Hand Bank
3
3. Remove the camshaft. D303769
1. Remove the bolts which secure the
camshafts caps; loosen them evenly, in
stages. Installation
2. Remove the camshaft caps. Note their
orientation and markings - each is marked Intake Camshaft
with its position (a number) and orientation 1. NOTE: Left-hand bank shown, right-hand
(an arrow). similar.
3. Remove the camshaft from the engine. NOTE: Make sure all components are clean.
1 3 Apply oil (EP-90) to the camshaft and bearing
surfaces, as follows:
2 • To the upper face of each bearing surface in
the cylinder head.
• To the upper face of each bearing surface in
each bearing cap.
• On the cam lobes ONLY, not on the base
circle area.
D303775
Exhaust Camshaft
4. NOTE: Left-hand bank shown, right-hand
similar.
NOTE: Make sure all components are clean.
Remove the exhaust camshaft sprocket. For
additional information refer to Timing
D303776
5. Remove the camshaft.
2. Install the camshaft.
1. Remove the bolts which secure the
camshafts caps; loosen them evenly, in 1. Install the camshaft to position in the cylinder
stages. head, with the timing flats uppermost.
2. Remove the camshaft caps. Note their 2. Install the camshaft caps to their respective
orientation and markings - each is marked locations (5 to 9 from the front) and in the
with its position (a number) and orientation correct orientation (arrow to front of engine).
(an arrow).
G61288en
Page 93 4/2005 1999.25 X200
303-01B-3 Engine — 4.0L 303-01B-3
IN-VEHICLE REPAIR
3. Install and tighten the cap retaining bolts. 3. Install and tighten the cap retaining bolts
evenly.
10 Nm 3 1
10 Nm 3
2
2
1
VUJ0001980
VUJ0001981
3. Install the camshaft locking tool, align

camshaft as necessary. 9. Install the camshaft locking tool, align
camshaft as necessary.
4. Install the VVT unit to left-hand bank. For
additional information, refer to Timing 10. Install the exhaust camshaft sprocket. For
Chain—Secondary, Left-Hand Bank additional information, refer to Timing
5. Remove the camshaft and crankshaft setting
tools, check and adjust the valve clearances 11. Remove the camshaft and crankshaft
on the intake camshaft as necessary. setting tools, check and adjust the valve
clearances on the intake camshaft as
6. Install the engine front cover. For additional
necessary.
Exhaust Camshaft
7. NOTE: Left-hand bank shown, right-hand
similar.
Apply oil (EP-90) to the camshaft and bearing
the cylinder head.
each bearing cap.
circle area.
8. Install the camshaft.
1. Install the camshaft to position in the cylinder
head, with the timing flats uppermost.
2. Install the camshaft caps to their respective
locations (5 to 9 from the front) and in the
correct orientation (arrow to front of engine).
1999.25 X200 4/2005 Page 94 G61288en

303-01B-4 Engine — 4.0L 303-01B-4
IN-VEHICLE REPAIR
Crankshaft Front Seal ()

Special Tool(s) 2. Using the special tool, remove the crankshaft
front oil seal.
Crankshaft locking, main tool
303-191
DWST038
Adapter
303-191-02
VUJ0001550
DWST075
Installation
remover 1. Using the special tool, install the crankshaft
303-588 front oil seal.
WST090
Crankshaft front seal remover

303-541
JWST082
VUJ0001551
Crankshaft front seal replacer
303-542
2. Install the crankshaft pulley. For additional
information, refer to Crankshaft Pulley
JWST083
Removal
1. Remove the crankshaft pulley. For additional
information, refer to Crankshaft Pulley
G61286en
Page 95 4/2005 1999.25 X200
303-01B-5 Engine — 4.0L 303-01B-5
IN-VEHICLE REPAIR
Crankshaft Pulley ()
Special Tool(s) 3. Raise and support the vehicle. For additional
information, refer toSection 100-02 [Jacking
Locking Tool, Crankshaft
and Lifting].
Pulley
303-191 4. Remove the radiator lower splash shield.
DWST038
Adapter for 303-191/303-588

303-191-02
DWST075
VUJ0000409
Remover, Crankshaft Pulley
303-588
5. Detach and reposition the air conditioning
pipe.
WST090
Removal
1. Remove the air cleaner outlet tube. For
additional information, refer to
Section 303-12A [Intake Air Distribution and
Filtering -- 3.0L] / 303-12B [Intake Air
Distribution and Filtering -- 4.0L].
VUJ0003168
2. Detach the accessory drive belt from the
crankshaft pulley.
6. NOTE: Place a suitable container underneath
1. Rotate the accessory drive belt tensioner the oil filter and the oil cooler to prevent oil
counter-clockwise. spillage.
2. Detach the accessory drive belt from the Remove and discard the oil filter.
crankshaft pulley.
2
VUJ0003167 VUJ0003169
1999.25 X200 4/2005 Page 96 G61285en

303-01B-6 Engine — 4.0L 303-01B-6
IN-VEHICLE REPAIR
7. Detach and reposition the oil cooler. 2. Install the thrust button to the end of the
crankshaft, install the crankshaft pulley
remover and adapter to the crankshaft pulley
and remove the crankshaft pulley.
VUJ0003170
8. D303542
should the crankshaft setting peg 303645 be
used in the following operations to lock the 10. Remove the thrust button from the end of
crankshaft. the crankshaft.
Using the special tools, remove and discard 11. Remove the crankshaft pulley remover and
the crankshaft pulley retaining bolt. adapter from the crankshaft pulley.
1. Install the adaptor 30319102 to the 12. Remove the split locking ring.
crankshaft pulley locking tool 303191.
2. Reposition the crankshaft pulley to align the
crankshaft pulley locking tool and adapter
mounting holes and install the crankshaft
pulley locking tool and adapter using the
retaining bolts provided.
3. Remove and discard the crankshaft pulley
retaining bolt.
2
D303700
1
Installation
3
1. NOTE: Apply a suitable amount of clean
engine oil to lubricate the crankshaft pulley
bore and the crankshaft front oil seal.
2
D303540 Install, but do not tighten, a new crankshaft
pulley retaining bolt.
9. Using the special tools, remove the 1. Install the crankshaft pulley.
crankshaft pulley.
2. Install the split locking ring.
1. Remove the adaptor 30319102 from the
crankshaft pulley locking tool and install it to
the crankshaft pulley remover 303588 (it is
not retained to the crankshaft pulley remover
by the retaining bolts).
G61285en
Page 97 4/2005 1999.25 X200
303-01B-7 Engine — 4.0L 303-01B-7
IN-VEHICLE REPAIR
3. Install, but do not tighten, a new crankshaft • Tighten to 58 Nm.
pulley retaining bolt.
VUJ0003170
J.303.1502

2. engine oil to lubricate the oil filter O-ring
seal.
should the crankshaft setting peg 303645 be
used in the following operations to lock the Install a new oil filter.
crankshaft.
Tighten the crankshaft pulley retaining bolt
to 375 Nm.
1. Install the adaptor 30319102 to the
crankshaft pulley locking tool 303191.
2. Reposition the crankshaft pulley to align the
crankshaft pulley locking tool and adapter
mounting holes and install the crankshaft
pulley locking tool and adapter using the
retaining bolts provided.
3. Tighten the crankshaft pulley retaining bolt
VUJ0003169
to 375 Nm.
6. Attach the air conditioning pipe.

2
2
D303540
3. Remove the crankshaft pulley locking tool

and adapter from the crankshaft pulley. VUJ0003168
4. Attach the oil cooler.
1999.25 X200 4/2005 Page 98 G61285en

303-01B-8 Engine — 4.0L 303-01B-8
IN-VEHICLE REPAIR
7. Install the radiator lower splash shield.
VUJ0000409
8. Lower the vehicle.

9. Attach the accessory drive belt to the
crankshaft pulley.
1. Rotate the accessory drive belt tensioner
counter-clockwise.
2. Attach the accessory drive belt to the
crankshaft pulley.
2
VUJ0003167
10. Install the air cleaner outlet tube. For

Section 303-12A [Intake Air Distribution and
Filtering -- 3.0L] / 303-12B [Intake Air
Distribution and Filtering -- 4.0L].
11. Check the engine oil level, and if necessary,
fill the engine with oil to the oil level
indicator 'MAX' mark.
12. Start the engine to allow the oil cooler and
the new oil filter to fill with oil.
13. Turn the engine off and allow the engine oil
level to settle.
14. Check the engine oil level, and if necessary,
fill the engine with oil to the oil level
indicator 'MAX' mark.
G61285en
Page 99 4/2005 1999.25 X200
303-01B-9 Engine — 4.0L 303-01B-9
IN-VEHICLE REPAIR
Crankshaft Rear Seal ()

Special Tool(s) 4. Hold the tool against the crankshaft and
lightly and evenly tighten the two nuts to the
Crankshaft rear oil seal
face of the tool; to secure the tool and to
remover/replacer
hold it parallel to the face of the crankshaft.
303-538
303-538
Removal
1. Remove the automatic transmission. For
additional information, refer toSection 307-01
[Automatic Transmission/Transaxle]
2. Remove the flexplate. For additional J3031300
information, refer to Flexplate—Automatic
Transmission 5. Secure the oil seal to the tool using the three
3. Install the seal removal tool 303538 to the self-tapping screws spaced evenly around
crankshaft. the face of the tool.
1. Unscrew the two nuts towards the head of • Use the punch (provided) and a hammer to
each bolt to allow the bolts to install fully into pierce the seal face and provide a pilot hole
the crankshaft. for one of the self-tapping screws provided.
2. Unscrew the center bolt until it is below the • Install a self-tapping screw and tighten by
face of the main tool and position the tool to 1.5 turns only. DO NOT TIGHTEN BY MORE
the rear of the crankshaft. THAN TWO TURNS OR THE SCREW MAY
3. Lightly tighten the two bolts so that they fully BREAK.
locate in the crankshaft. • Repeat the above steps for the other two
screws.
1
3
1
J3031299
J3031301
1999.25 X200 4/2005 Page 100 G61296en

303-01B-10 Engine — 4.0L 303-01B-10
IN-VEHICLE REPAIR
6. Hold the two bolts stationary and loosen fully Make sure the transit sleeve is correctly in
the two nuts. place and install the new seal over the
crankshaft. Do not use any lubricant on the
seal, the transit sleeve or the crankshaft.
2. Carefully remove the transit sleeve, leaving
the seal in place.
3. Install the tool to the crankshaft.
• Make sure that the center bolt is unscrewed
to below the face which is to fit to the
crankshaft and position the tool to the
crankshaft.
• Check that the nuts are fully unscrewed and
J3031302 install the two bolts to the crankshaft threads
and lightly tighten.
7. Remove the oil seal.
• Tighten the center bolt.
J3031302
4. Tighten the nuts, finger tight, to hold the tool

J3031303
assembly against the seal. Check that the
seal and the tool are approximately parallel
8. Remove the two bolts to release the tool and to the rear of the engine.
seal assembly from the crankshaft.
• Remove the three self-tapping screws.
• Remove and discard the seal.
• Unscrew the center bolt until it is below the
face of the tool.
J3031300
5. Press the seal into the housing.
J3031304
Installation
1. NOTE: Make sure all components are clean.
G61296en
Page 101 4/2005 1999.25 X200
303-01B-11 Engine — 4.0L 303-01B-11
IN-VEHICLE REPAIR
• Hold each bolt stationary, in turn, and tighten
its nut a small amount (approximately two to
three flats) in turn, to press the seal fully into
the housing, until the tool is in contact with
the cylinder block.
J3031305
6. Remove the tool from the crankshaft.

7. Install the flexplate. For additional
Transmission
8. Install the automatic transmission. For
1999.25 X200 4/2005 Page 102 G61296en

303-01B-12 Engine — 4.0L 303-01B-12
IN-VEHICLE REPAIR
Cylinder Head RH ()
Special Tool(s) 3. Detach the knock sensor electrical
connector.
Camshaft setting
303-530
303-530

303-532
VUJ0001528
DWST021

Wedges, primary chain connector.
303-533
DWST031
Crankshaft setting, main tool

303-645
VUJ0001529
DWST032
5. Remove the engine harness bracket.

Removal
1. Remove the engine front cover. For
additional information, refer to Engine Front
Cover
2. Disconnect the idle air control valve
VUJ0001609
VUJ0001276
G61291en
Page 103 4/2005 1999.25 X200
303-01B-13 Engine — 4.0L 303-01B-13
IN-VEHICLE REPAIR
6. Disconnect the intake manifold heater 9. Detach the engine harness conduit.
coolant hose.
VUJ0001534
VUJ0001520
10. Detach the engine harness conduit.

7. Detach the intake manifold.
VUJ0001535
VUJ0001532
11. Detach the exhaust downpipe from the

8. Remove the intake manifold. exhaust manifold.
VUJ0001533 VUJ0000576
12. Remove the VVT unit from the right-hand

bank. For additional information, refer to
Timing Chain—Secondary, Right-Hand
Bank
13. Remove the exhaust camshaft sprocket.
For additional information, refer to Timing
Chain—Secondary, Right-Hand Bank
14. Remove the secondary chain tensioner.
1999.25 X200 4/2005 Page 104 G61291en

303-01B-14 Engine — 4.0L 303-01B-14
IN-VEHICLE REPAIR
1. Remove the chain tensioner retaining bolts. • Mark the inside face of each tappet in pencil
2. Remove the chain tensioner. or felt tipped pen, with its original position
within the cylinder head.
1
1
2
D303834
D303779
15. NOTE: Note the orientation of the chain

guide and remove it from the upper 19. Place a suitable drain tray under the engine.
retaining pin. 20. Remove the cylinder head.
Remove the primary timing chain guide. 1. Place a cloth around the area of the cylinder
1. Remove the primary timing chain guide head to absorb spillage, when removing the
retaining bolt. head.
2. Remove the primary timing chain guide. 2. Remove the cylinder head bolts.
3. Remove the cylinder head.
2 3
2
1
D303733
16. Remove the intake camshaft. For additional

information, refer to Camshafts
17. Remove the exhaust camshaft. For
additional information, refer to Camshafts
18. Remove the tappets and shims.
1. Note the position of each tappet, for
reassembly, and remove each tappet and
shim assembly - retain each shim with its
original tappet.
1
J.303.855
21. Remove the cylinder head gasket.

1. Note how the gasket is fitted and remove it.
G61291en
Page 105 4/2005 1999.25 X200
303-01B-15 Engine — 4.0L 303-01B-15
IN-VEHICLE REPAIR
2. Remove and discard the cloth, placed 2. Install the cylinder head.
previously to absorb coolant spillage.
• Wipe up any leaked coolant.
2
D303782
22. Remove the coolant drain tray from under

the vehicle.
23. Clean cylinder head and cylinder block
gasket faces.
• Make sure that all threaded holes in the
cylinder block face are clean and free from
oil.
• Clean and inspect the cylinder head bolts.
They may be re-used on two occasions. D303846
When re-used, each bolt head should be
marked with one dot from an automatic
centre punch. 3. Install the cylinder head bolts, do not fully
tighten.
Installation
1. Install a new cylinder head gasket to the
cylinder block face.
D303845
1999.25 X200 4/2005 Page 106 G61291en

303-01B-16 Engine — 4.0L 303-01B-16
IN-VEHICLE REPAIR
4. Stage 1 - tighten bolts in sequence, to 20 Nm. 5. Stage 2 - tighten bolts in sequence, to 35 Nm.
20 Nm
8 10
4 6
2 1
5 3
9 7
T303784
T.303.783
G61291en
Page 107 4/2005 1999.25 X200
303-01B-17 Engine — 4.0L 303-01B-17
IN-VEHICLE REPAIR
6. Stage 3 - tighten bolts in sequence by 90°. 7. Stage 4 - tighten all M10 bolts in sequence
by 90°.
90 o
90 o
8 10
8 10
4 6
4 6
2 1
2 1
5 3
5 3
9 7
9 7
A
A
T.303.785
T.303.785
1999.25 X200 4/2005 Page 108 G61291en

303-01B-18 Engine — 4.0L 303-01B-18
IN-VEHICLE REPAIR
8. Stage 5 - tighten the bolts at the front of the 12. NOTE: The chain guide must be fitted so
cylinder head. that the slotted hole is towards the top, and
the raised shoulder to the cylinder block.
23-27 Nm Install the chain guide.
1. Install the chain guide to the block and locate
it onto the upper retaining pin.
2. Install the retaining bolt.
1
2 12 Nm
VUJ0002020
13. Push the secondary chain tensioner piston

into the body to provide clearance for fitting
the chain.
1. Insert a thin rigid rod through the hole in the
A end of the tensioner piston to move the ball
from the non return valve seat.
T.303.787
2. With the wire in position, press the piston
fully into the tensioner body.
9. NOTE: Lubricate each tappet assembly. • Remove the wire.
Install the tappet and shim assemblies.
1. Install each tappet and shim assembly to its
previously identified position in the cylinder
head. 2
1
1
VUJ0002007
14. Install the secondary chain tensioner

1. Install the tensioner in to the cylinder head.
D303779
10. Install the exhaust camshaft. For additional

11. Install the intake camshaft. For additional
G61291en
Page 109 4/2005 1999.25 X200
303-01B-19 Engine — 4.0L 303-01B-19
IN-VEHICLE REPAIR
2. Install the tensioner bolts. 19. Attach the engine harness conduit.
2 12 Nm
VUJ0002008
VUJ0001534
15. Install the exhaust camshaft sprocket. For 20. Install the intake manifold.
additional information, refer to Timing
Chain—Secondary, Right-Hand Bank
16. Install the VVT unit from the right-hand
bank. For additional information, refer to
Timing Chain—Secondary, Right-Hand 21 Nm 21 Nm
Bank
17. Install the exhaust downpipe retaining nuts.
VUJ0001994
21. Install the intake manifold bolts.
40 Nm
VUJ0000595
21 Nm 21 Nm
18. Attach the engine harness conduit.
VUJ0001995
VUJ0001535
1999.25 X200 4/2005 Page 110 G61291en

303-01B-20 Engine — 4.0L 303-01B-20
IN-VEHICLE REPAIR
22. Install the engine harness bracket. 25. Connect the idle air control valve electrical
connector.
VUJ0001609
VUJ0001276
23. Reconnect the knock sensor electrical

connector. 26. Reconnect the intake manifold heater
coolant pipe.
VUJ0001529
VUJ0001520
24. Attach the knock sensor electrical

connector. 27. Install the engine front cover. For additional
VUJ0001528
G61291en
Page 111 4/2005 1999.25 X200
303-01B-31 Engine — 4.0L 303-01B-31
IN-VEHICLE REPAIR
Flexplate ()
Removal Tighten to 15 Nm.
1. Remove the automatic transmission. For

[Automatic Transmission/Transaxle] 15 Nm 15 Nm
2. NOTE: Prevent the flexplate from rotating.
Remove the flexplate.
15 Nm 15 Nm
VUJ0001641
3. NOTE: Tighten the retaining bolts working

diagonally.
Tighten to 110 Nm.
J.303.1295
110 Nm 110 Nm
Installation
1. NOTE: Make sure the crankshaft and
flexplate mating faces are clean before
installation.
NOTE: The flexplate will only locate in one position.
110 Nm 110 Nm
NOTE: Install, but do not tighten, the flexplate
retaining bolts. VUJ0002026
Install the flexplate.
• Prevent the flexplate from rotating. 4. Install the automatic transmission. For
J.303.1296
2. NOTE: Tighten the retaining bolts working

diagonally.
1999.25 X200 4/2005 Page 112 G61295en

303-01B-38 Engine — 4.0L 303-01B-38
IN-VEHICLE REPAIR
Oil Pan
Removal
2. Install the oil pan to the oil pan body
1. Raise and support the vehicle. For additional
assembly.
information, refer toSection 100-02 [Jacking
and Lifting] • Install, but do not fully tighten the retaining
bolts.
2. Drain the engine oil.
3. Tighten the oil pan bolts to the correct torque
• Place suitable container under the vehicle.
figure 11-13 Nm, in the sequence indicated.
• Remove the drain plug and drain the engine
oil. • A new oil pan is supplied with the drain plug
installed. Check that the drain plug is
3. Remove the oil pan. tightened to the correct torque figure.
1. Remove the seventeen retaining bolts.
15 17 9 1 5 13
2. Remove the oil pan. 12 Nm
3. Remove the gasket. 11 7
1
3 12
8 4
3
2 14 6 2 10 16
VUJ0002017
VUJ0002015
Installation
1. NOTE: Make sure all surfaces are clean.
Install the oil pan gasket to the oil pan body
assembly.
• Insert the seal into the locating positions in
the groove, working around from a corner.
• Press in the remainder of the seal, following
the same procedure.
VUJ0002016
G61293en
Page 113 4/2005 1999.25 X200
Page 114

303-01B-1 Engine — 3.5L/4.2L 303-01B-1
.
SECTION 303-01B Engine — 3.5L/4.2L

CONTENTS PAGE
DISASSEMBLY
Engine. 303-01B-2
Page 115
303-01B-2 Engine — 3.5L/4.2L 303-01B-2
DISASSEMBLY
Engine
Crankshaft locking, main tool Cylinder Bore Protectors
303-191 303-535
303-191 303535
Adapter
303-191-02 Disassembly
Vehicles without supercharger
1. Disconnect the oil cooler hoses.
303-191-02
remover
303-588
303-588
Crankshaft setting, main tool

303-645
VUJ0001553
Vehicles with supercharger

303-645 2. Detach the supercharger belt.
• Use a 1/2 inch square drive bar to rotate the
Camshaft setting supercharger belt tensioner.
303-530 • Detach the supercharger belt.
303-530
Crankshaft damper holding

tool
303-D055
303D055 VUJ0005600
All vehicles
3. Release the accessory drive belt tension.
drive belt tensioner.
G215935en
Page 116 4/2005 2003.50 X300
303-01B-3 Engine — 3.5L/4.2L 303-01B-3
DISASSEMBLY
• Detach the accessory drive belt. 6. Detach the wiring harness.
VUJ0001554
E31033
4. Remove the accessory drive belt tensioner. 7. Detach the generator battery positive cable
• Remove the accessory drive belt. protective cover.
VUJ0001555 E36730
5. Remove the accessory drive belt idler pulley. 8. Disconnect the generator battery positive
cable.
VUJ0005594
E36731
2003.50 X300 4/2005 Page 117 G215935en

303-01B-4 Engine — 3.5L/4.2L 303-01B-4
DISASSEMBLY
9. Disconnect the generator electrical 12. Remove the generator mounting bracket.
connector.
E30628
E36732
13. Detach the right-hand oxygen sensor

10. Remove the generator. retaining bracket.
E36733 VUJ0001584
11. Detach the engine wiring harness. 14. Detach the engine wiring harness.
E30627 E30661
G215935en
Page 118 4/2005 2003.50 X300
303-01B-5 Engine — 3.5L/4.2L 303-01B-5
DISASSEMBLY
15. Remove the starter motor. 18. Remove the heat shield retaining bolt.
E30139 E30641
16. Remove the oil level indicator and tube. 19. Remove the left-hand exhaust manifold.
• Remove and discard the O-ring seal. • Remove and discard the gasket.
E30639 E30642
17. Remove the heat shield. 20. Remove the left-hand engine mount.
E30640 E30637
2003.50 X300 4/2005 Page 119 G215935en

303-01B-6 Engine — 3.5L/4.2L 303-01B-6
DISASSEMBLY
21. Remove the left-hand engine mounting 24. Remove the air conditioning compressor
bracket. mounting bracket.
VUJ0001561
E37389
22. Disconnect the A/C compressor electrical 25. Remove the power steering pump.
connector.
E30644
E37253
26. Remove the power steering pump mounting

23. Remove the A/C compressor. bracket.
E37256 E30645
G215935en
Page 120 4/2005 2003.50 X300
303-01B-7 Engine — 3.5L/4.2L 303-01B-7
DISASSEMBLY
27. Disconnect the crankshaft position sensor 30. Detach the engine wiring harness.
E30647
E30646
31. Detach the engine wiring harness.

28. Remove the crankshaft position sensor.
E30648
E30694

VUJ0001580
VUJ0002375
2003.50 X300 4/2005 Page 121 G215935en

303-01B-8 Engine — 3.5L/4.2L 303-01B-8
DISASSEMBLY
33. Disconnect the coolant temperature sensor • Cap the coolant ports.
E30237
E30649
37.
CAUTION: Make sure no foreign matter
Vehicles with supercharger enters the supercharger.
34. Detach the engine wiring harness. Remove the supercharger outlet pipe
E36700 E30238
35. Detach the hoses. 38. Remove and discard the supercharger
• Reposition the hose retaining clip. outlet pipe gasket.
39. Remove and discard the supercharger
outlet pipe retaining bolt seals.
40. Remove and discard the supercharger
outlet pipe to charge air coolers ducts.
E30236
36. Detach the supercharger outlet pipe coolant

hose.
E30239
G215935en
Page 122 4/2005 2003.50 X300
303-01B-9 Engine — 3.5L/4.2L 303-01B-9
DISASSEMBLY
41. Disconnect the thermostat housing hoses 44. Disconnect the hose.
E30412 E30411
42. Disconnect the coolant temperature sensor 45. Disconnect the hose.
E30415
E30413
46. Disconnect the hose.

43. Reposition the thermostat housing hose
retaining clip.
E30416
E30414
2003.50 X300 4/2005 Page 123 G215935en

303-01B-10 Engine — 3.5L/4.2L 303-01B-10
DISASSEMBLY
47. Disconnect the hose. 50. Disconnect the charge air cooler coolant
pipes.
E30417
E30241
48. Remove the thermostat housing retaining

bolts. 51. Disconnect the intake air temperature (IAT)
sensor electrical connector.
E30418
E30242
49. Remove the thermostat housing.

52. Disconnect the electrical connectors.
• Remove and discard the thermostat housing
O-ring seals.
E31194
E30419
53. NOTE: Cap the exposed ports.
G215935en
Page 124 4/2005 2003.50 X300
303-01B-11 Engine — 3.5L/4.2L 303-01B-11
DISASSEMBLY
Detach the coolant hose from the throttle Disconnect the coolant hoses.
body.
E31339
E31195
57. Remove the EGR valve and the exhaust

54. Remove the throttle body. manifold to EGR valve tube.
• Remove and discard the gasket. • Remove the retaining bolts.
• Remove and discard the exhaust manifold
to EGR valve tube gasket.
• Remove and discard the EGR valve to air
intake elbow gasket.
E31196
55. Disconnect the exhaust gas recirculation

(EGR) valve electrical connector.
E30634
58. Disconnect the air intake elbow pipes.
E30257
56. NOTE: Cap the exposed ports.

E30243
59. NOTE: Make sure correct location of the

ground strap is noted.
2003.50 X300 4/2005 Page 125 G215935en

303-01B-12 Engine — 3.5L/4.2L 303-01B-12
DISASSEMBLY
Remove the air intake elbow retaining 62. Remove the supercharger.
bracket lower retaining bolts.
E30248
E30245
63.
60. Detach the air intake elbow.
enters the cylinder head ports.
NOTE: Right-hand shown, left-hand similar.
• Remove and discard the retaining bolt seals.
Remove the charge air coolers.
• Remove and discard the charge air cooler
gasket.
E30246
61. Remove the air intake elbow.

E30240
• Disconnect the manifold absolute pressure
(MAP) sensor.
All vehicles
connectors.
E30247
E30652
65. NOTE: Left-hand shown, right-hand similar.
G215935en
Page 126 4/2005 2003.50 X300
303-01B-13 Engine — 3.5L/4.2L 303-01B-13
DISASSEMBLY
Remove the ignition coil cover. Detach the engine wiring harness.
E30653 E30668
Vehicles without supercharger 69. NOTE: Right-hand shown, left-hand similar.

66. Remove the engine cover retaining bracket. Disconnect the fuel injector electrical
connectors.
E30654
E30669
67. Remove the engine cover retaining bracket.

70. Disconnect the ignition on-plug coil
E30663
E30657
All vehicles
68. NOTE: Right-hand shown, left-hand similar.
2003.50 X300 4/2005 Page 127 G215935en

303-01B-14 Engine — 3.5L/4.2L 303-01B-14
DISASSEMBLY
3
2
E30662
E30658
72. Detach the engine wiring harness. Vehicles with supercharger

• Remove the retaining bolt.
E30674
73. Disconnect the camshaft position sensor E37437

E30660
E37438
1. Detach the ground cable.
G215935en
Page 128 4/2005 2003.50 X300
303-01B-15 Engine — 3.5L/4.2L 303-01B-15
DISASSEMBLY
Vehicles without supercharger 80. Disconnect the exhaust gas recirculation
valve coolant hose.
77. Disconnect the positive crankcase
ventilation pipe.
E30667
E30664
All vehicles
78. Disconnect the fuel pressure regulator 81. Detach the engine wiring harness.
E30668
E30665
82. Disconnect the fuel injector electrical

79. Disconnect the exhaust gas recirculation connectors.
valve electrical connector.
E30669
E30666
2003.50 X300 4/2005 Page 129 G215935en

303-01B-16 Engine — 3.5L/4.2L 303-01B-16
DISASSEMBLY
83. Detach the engine wiring harness. 86. Disconnect the camshaft position sensor
E30671
E30673
84. Disconnect the ignition on-plug coil

electrical connectors. 87. Detach the engine wiring harness
E30670 E30674
85. Disconnect the fuel temperature sensor Vehicles without supercharger

E30672
E30676
G215935en
Page 130 4/2005 2003.50 X300
303-01B-17 Engine — 3.5L/4.2L 303-01B-17
DISASSEMBLY
89. Remove the intake manifold. • Remove and discard the O-ring seal.
E30678 VUJ0001577
Vehicles with supercharger All vehicles

90. Remove the lower intake manifold. 93. Disconnect the oil pressure switch and oil
temperature sensor electrical connectors.
E36707
VUJ0001578
All vehicles
94. Remove the oil filter housing.
91. NOTE: Place a suitable container
underneath the filter to prevent oil spillage. • Remove and discard the O-ring seal.
Remove the oil filter element.
VUJ0001579
VUJ0001576

92. Remove the oil cooler.
2003.50 X300 4/2005 Page 131 G215935en

303-01B-18 Engine — 3.5L/4.2L 303-01B-18
DISASSEMBLY
95. Detach the right-hand oxygen sensor. 2. Remove the intake manifold heater coolant
hose.
VUJ0001584
E30679
96. Detach the engine wiring harness retaining

clips. 100. Remove the engine block insulation
grommet.
E30661
VUJ0002390
97. Remove the engine wiring harness

101. Remove the water pump pulley.
98. Remove the noise and vibration insulating
pad. • Using the special tool, retain the water pump
pulley.
VUJ0001615 E30680
99. Remove the intake manifold heater coolant 102. Remove the water pump.
hose.
1. Remove the knock sensors.
G215935en
Page 132 4/2005 2003.50 X300
303-01B-19 Engine — 3.5L/4.2L 303-01B-19
DISASSEMBLY
• Remove and discard the O-ring seal. • Remove and discard the O-ring seal.
E30681 E30692
Vehicles without supercharger 107. Remove the left-hand camshaft position

(CMP) sensor.
103. Remove the thermostat housing.
• Remove and discard the O-ring seal.
• Remove and discard the O-ring seals.
E30693
E30682
108.
All vehicles CAUTION: Under no circumstances
104. NOTE: Left-hand shown, right-hand similar should the crankshaft setting peg 303-645
be used in the following operations to lock
Remove the ignition coils. the crankshaft.
NOTE: The crankshaft retaining bolt will be very
tight.
Using special tools, retain the crankshaft
pulley.
• Remove and discard the crankshaft pulley
bolt.
303-191-02
E30685
105. Remove the spark plugs. 303-191

106. Remove the right-hand camshaft position
(CMP) sensor.
E31149
2003.50 X300 4/2005 Page 133 G215935en

303-01B-20 Engine — 3.5L/4.2L 303-01B-20
DISASSEMBLY
109. Remove the special tools. Install the special tool 303-645.
110. NOTE: The crankshaft pulley will be very
tight.
Using special tools, remove the crankshaft 303-645
pulley.
• Collect the locking ring.
VUJ0002400
113. Remove the right-hand valve cover.

303-588
E31150
111. Remove the crankshaft position (CKP)

sensor.
E30696
114. Remove the left-hand valve cover.

E30694
112. CAUTIONS:
Make sure the spark plugs are removed
to enable the engine to rotate freely.
Do not rotate the crankshaft

counterclockwise. The timing chains may E30697

Rotate the crankshaft clockwise to
position the engine to top dead center (TDC) 115. Remove the engine front cover.
No. 1 cylinder.
G215935en
Page 134 4/2005 2003.50 X300
303-01B-21 Engine — 3.5L/4.2L 303-01B-21
DISASSEMBLY
VUJ0002398
Vehicles without supercharger • Remove and discard the O-ring seals.

116. Remove the right-hand variable camshaft
timing oil control unit housing.
E30699
2003.50 X300 4/2005 Page 135 G215935en

303-01B-22 Engine — 3.5L/4.2L 303-01B-22
DISASSEMBLY
117. Remove the left-hand variable camshaft 120. Remove the primary timing chain tensioner
timing oil control unit housing. assembly.
E30701
E30708
121. Remove the primary timing chain tensioner

All vehicles guide.
118. Install the special tool to the left-hand
cylinder head.
303-530
E30702
E31337 122. Remove the primary timing chain.
119. Install the special tool to the right-hand

cylinder head.
303-530
E30703
E30700
G215935en
Page 136 4/2005 2003.50 X300
303-01B-23 Engine — 3.5L/4.2L 303-01B-23
DISASSEMBLY
123. Remove the primary timing chain guide. 126. Remove the primary timing chain tensioner
assembly.
E30704
E30709

tensioner retaining bolts. 127. Remove the primary timing chain tensioner
guide.
E30715
VUJ0002412
125. Remove the camshaft sprockets.

128. Remove the primary timing chain.
• Remove the secondary timing chain
tensioner and secondary timing chain from
the camshaft sprockets.
E30710
E30705
2003.50 X300 4/2005 Page 137 G215935en

303-01B-24 Engine — 3.5L/4.2L 303-01B-24
DISASSEMBLY
129. Remove the crankshaft sprocket. • Remove the secondary timing chain
tensioner and secondary timing chain from
the camshaft sprockets.
E30711
E30714
130. Remove the primary timing chain tensioner
guide.
E30713
VUJ0002419

tensioner retaining bolts. 134. Remove the camshaft setting tool.
VUJ0002408
E30706
132. Remove the camshaft sprockets. 135. Remove the camshaft bearing caps.
G215935en
Page 138 4/2005 2003.50 X300
303-01B-25 Engine — 3.5L/4.2L 303-01B-25
DISASSEMBLY
• Remove the camshaft bearing caps. Note 138. Remove the right-hand intake camshaft.
VUJ0002423
VUJ0002420 139. Remove the camshaft bearing caps.

136. Remove the right-hand exhaust camshaft. bolts evenly and in stages.
VUJ0002421
137. Remove the camshaft bearing caps.

• Remove the camshaft bearing cap retaining VUJ0002424

• Remove the camshaft bearing caps. Note 140. Remove the left-hand exhaust camshaft.
VUJ0002425
VUJ0002422 141. Remove the camshaft bearing caps.

2003.50 X300 4/2005 Page 139 G215935en

303-01B-26 Engine — 3.5L/4.2L 303-01B-26
DISASSEMBLY
• Remove the camshaft bearing caps. Note • Remove and discard the gasket.
orientation (an arrow). 2 12 8 4 6 10
9 5 3 7 11
VUJ0002429
VUJ0002426
145. Remove the crankshaft setting peg 303-645
from the crankshaft position sensor
location.
142. Remove the left-hand inlet camshaft.
303-645
VUJ0002400
VUJ0002427
146. Remove the flexplate.

143. Remove the right-hand cylinder head.
1. Remove the flexplate retaining bolts.
• Remove the bolts in the indicated sequence. 2. Remove the flexplate.
1
11 7 3 5 9 1
1
10 6 4 2
8 12
2 VUJ0002432
VUJ0002428
147. Remove the lower oil pan.

144. Remove the left-hand cylinder head.
• Remove the bolts in the indicated sequence.
G215935en
Page 140 4/2005 2003.50 X300
303-01B-27 Engine — 3.5L/4.2L 303-01B-27
DISASSEMBLY
• Remove and discard the gasket. • Remove and discard the O-ring seal.
VUJ0002433 E30738
148. Remove the oil strainer. 149. Remove the upper oil pan.
VUJ0002435
2003.50 X300 4/2005 Page 141 G215935en

303-01B-28 Engine — 3.5L/4.2L 303-01B-28
DISASSEMBLY
• Remove and discard the gasket. Install special tools to the connecting rods.
303 535
E30739
VUJ0002285
151. Inspect the tops of the cylinder bores. As 155.

necessary remove ridge and carbon build CAUTION: Care should be taken not to
up from each cylinder. damage the connecting rod and cap joint
face surfaces or possible engine damage
Vehicles with supercharger may occur. Avoid contaminating the
fractured joint surfaces with dirt or grease.
152. Remove the piston cooling jets.
NOTE: Attach the connecting rods and caps after
removal to avoid mismatch.
All vehicles
Remove the pistons.
153.
CAUTION: Pistons, connecting rods and
• Rotate the crankshaft to locate pistons at the
connecting rod bearings should be
bottom of travel.
numbered to make sure they are
reassembled in the same position. • Push the piston, connecting rod and upper
caps to the connecting rods to make sure of correct
installation.
removal.
Remove the connecting rod bolts, the
connecting rod bearings.
VUJ0002438
156. NOTE: Remove the lower cylinder block

NOTE: Mark the position of the upper and lower
crankshaft main bearings for reassembly.
VUJ0002437 • Remove the lower cylinder block retaining
154.
surfaces.
G215935en
Page 142 4/2005 2003.50 X300
303-01B-29 Engine — 3.5L/4.2L 303-01B-29
DISASSEMBLY
6 10 14 12 8 4
15 19 24 22 18
25 29 34 32 28
27 31 33 30 26
17 21 23 20 16
3 7 11 13 9 5
VUJ0002439
2003.50 X300 4/2005 Page 143 G215935en

303-01B-30 Engine — 3.5L/4.2L 303-01B-30
DISASSEMBLY
157. Discard the crankshaft rear main oil seal. 160. Clean the cylinder block with a soap and
VUJ0002440
158.
NOTE: Never remove any pipe, plugs or dowels
VUJ0002441

bearings.
1. Remove the upper crankshaft thrust washers.
2. Remove the upper crankshaft main bearings.
VUJ0002445
G215935en
Page 144 4/2005 2003.50 X300
303-01B-1 Engine — 3.5L/4.2L 303-01B-1
.

CONTENTS PAGE
ASSEMBLY
Engine. 303-01B-2
Page 145
303-01B-2 Engine — 3.5L/4.2L 303-01B-2
ASSEMBLY
Engine
Crankshaft locking, main tool Piston Ring Compressor
303-191 303-372
303-191 303372
Adapter Crankshaft rear oil seal

303-191-02 remover/replacer
303-538
303-191-02 303-538
Crankshaft setting, main tool Crankshaft front seal installer

303-645 303-538
303-645 303-750
Camshaft setting Crankshaft damper holding

303-530 tool
303-D055
303-530
303D055

303-532 Assembly
All vehicles
1.
303-532 CAUTION: Use only a plastic scraper
when removing old gasket material.
Cylinder Bore Protectors Clean all the mating faces and reusable parts
303-535 thoroughly and check for damage.
303535 2. NOTE: Never remove pipe plugs or alignment

Reseal oil passage blanking plugs, as
necessary.
G215936en
Page 146 4/2005 2003.50 X300
303-01B-3 Engine — 3.5L/4.2L 303-01B-3
ASSEMBLY
3. NOTE: The main bearings are precision NOTE: Install lower cylinder block and tighten bolts
selective fit. For additional information, refer to specification within twenty minutes of applying
to Section 303-00 [Engine System - General sealer.
Information].
Apply a bead of sealant to the cylinder block
NOTE: Lubricate the upper crankshaft main housing.
bearings and thrust washers.
• Use WSS-M4G320-A3-RTV sealant.
Install the upper crankshaft main bearings.
1. Install the upper crankshaft thrust washers.
2
VUJ0002449
6. CAUTIONS:
VUJ0002445
Make sure all dowels are fully seated into
lower cylinder block prior to tightening the
4. bolts.
crankshaft bearing surfaces. Do not lubricate the lower cylinder block
Install the crankshaft. bolts.
Do not rotate crankshaft until all bolts are
tightened to specification.
Bolts must be tightened within twenty
minutes of applying sealer.
Tighten the bolts in the sequence shown.
Install the lower cylinder block to the upper
cylinder block.
1. Tighten bolts 21 to 32 to 15 Nm
VUJ0002441 3. Tighten bolts 1 to 10 to 25 Nm
5. NOTE: The main bearings are precision 5. Tighten bolts 1 to 10 to 35 Nm +135°
selective fit. For additional information, refer 6. Tighten bolts 11 to 20 to 20 Nm +150°
to Section 303-00 [Engine System - General 7. Tighten bolts 21 to 32 to 20 Nm +90°
Information]. 8. Tighten bolts 33 to 34 to 20 Nm +150°
2003.50 X300 4/2005 Page 147 G215936en

303-01B-4 Engine — 3.5L/4.2L 303-01B-4
ASSEMBLY
33
29 25 21 23 27 31
20 16 11 13 17
10 6 1 3 7
8 4 2 5 9
18 14 12 15 19
32 28 24 22 26 30
34
VUJ0002450
7. Rotate the crankshaft to check correct Make sure the transit sleeve is correctly in
operation. place and install the new seal over the
crankshaft.
out at the front cover sealing surfaces. 10. Carefully remove the transit sleeve, leaving
the seal in place.
9. CAUTIONS:
Do not use any lubricant on the seal, the
transit sleeve or the crankshaft.
Make sure all components are clean and

dry.
G215936en
Page 148 4/2005 2003.50 X300
303-01B-5 Engine — 3.5L/4.2L 303-01B-5
ASSEMBLY
11. Install the special tool to the crankshaft. 15.
303-538 surfaces.
of the stroke.
16. CAUTIONS:
Make sure the piston rings are
positioned at different positions opposite
E31176
the thrust side of the piston before
installation.
12. Reposition the nuts to hold the special tool Install pistons with arrow to front of
against the crankshaft rear seal. Check that engine.
the crankshaft rear seal and the special tool
are parallel to the rear of the engine. Using the special tool compress the rings
and install the piston and connecting rod.
303-538
303 372
E31177
VUJ0002278
13.
CAUTION: Alternate nut tightening to
correctly seat the crankshaft rear seal. 17. CAUTIONS:
Using the special tool, install the crankshaft When assembling the connecting rods
rear seal. and connecting rod caps it is imperative
that bearing slots and tangs be located on
the same side of the connecting rods.
303-538
Bolts must be tightened equally.
connecting rods.
E31177
1. Tighten to 10 Nm
2. Tighten to 30 Nm
14. Remove the special tool from the
crankshaft.
2003.50 X300 4/2005 Page 149 G215936en

303-01B-6 Engine — 3.5L/4.2L 303-01B-6
ASSEMBLY
3. Tighten to 90° All vehicles
VUJ0002437

operation.
E30739

21. Install the upper oil pan.
19. Install the piston cooling jets.
• Tighten to 9 Nm
VUJ0002435
22. Install the oil strainer.

• Install a new O-ring seal.
G215936en
Page 150 4/2005 2003.50 X300
303-01B-7 Engine — 3.5L/4.2L 303-01B-7
ASSEMBLY
• Tighten to 12 Nm. • Install, but do not fully tighten the retaining
bolts.
E30738
VUJ0002433
23. Install the oil pan.

24. Tighten to 12 Nm.
• Tighten in the sequence shown.
• A new oil pan is supplied with the drain plug
installed. Check that the drain plug is
tightened to 25 Nm.
15 17 9 1 5 13
11 7
3 12
8 4
14 6 2 10 16
E36705
25. Install the flexplate.

1. Install the flexplate.
2. Install the flexplate retaining bolts.
2003.50 X300 4/2005 Page 151 G215936en

303-01B-8 Engine — 3.5L/4.2L 303-01B-8
ASSEMBLY
• Tighten to 110 Nm. 3. Tighten bolts 1 to 10 to 90°.
4. Tighten bolts 1 to 10 to 90°.
5. Tighten bolts 11 to 12 to 25 Nm.
2
12 7 5 1 3 10
1
11
2
VUJ0002451
9 4 2 6 8
26. Reposition the crankshaft. VUJ0002452
• Install the crankshaft setting peg 303-645 to

the crankshaft position sensor location. 29. Install a new right-hand cylinder head
gasket.
• Make sure the cylinder head dowels are
303-645 correctly located.
VUJ0002400
27. Install a new left-hand cylinder head gasket.

E31267
• Make sure the cylinder head dowels are
correctly located.
30.
CAUTION: Tighten the bolts 1 to 10 in
the sequence shown.
Install the right-hand cylinder head.
E31267
28.
CAUTION: Tighten the bolts 1 to 10 in
the sequence shown.
Install the left-hand cylinder head.
G215936en
Page 152 4/2005 2003.50 X300
303-01B-9 Engine — 3.5L/4.2L 303-01B-9
ASSEMBLY
5. Tighten bolts 11 to 12 to 25 Nm. Install the camshaft bearing cap bolts evenly.
10 3 1 5 7 12
11
8 6 2 2
4 2
9
VUJ0002453
VUJ0002426
Apply oil (EP-90) to the camshaft and bearing 34. NOTE: Make sure all components are clean.
• To the upper face of each bearing surface in surfaces, as follows:
the cylinder head.
• To the upper face of each bearing surface in the cylinder head.
each bearing cap.
• On the cam lobes ONLY, not on the base each bearing cap.
circle area.
circle area.
E36723
E36723
32. Install the left-hand inlet camshaft.
35. Install the left-hand exhaust camshaft.
VUJ0002427
VUJ0002425
33.
CAUTION: Alternate bolt tightening to
correctly seat the camshaft bearing caps.
2003.50 X300 4/2005 Page 153 G215936en

303-01B-10 Engine — 3.5L/4.2L 303-01B-10
ASSEMBLY
36. 38. Install the right-hand inlet camshaft.
correctly seat the camshaft bearing caps.
Install the camshaft bearing cap bolts evenly.
VUJ0002423
39.
VUJ0002424 correctly seat the camshaft bearing caps.
37. NOTE: Make sure all components are clean. • Tighten to 10 Nm.
the cylinder head.
each bearing cap.
circle area.
VUJ0002422

the cylinder head.
E36723
each bearing cap.
G215936en
Page 154 4/2005 2003.50 X300
303-01B-11 Engine — 3.5L/4.2L 303-01B-11
ASSEMBLY
• On the cam lobes ONLY, not on the base 43. Install the camshaft setting tool.
circle area.
VUJ0002408
E36723
44. Install the camshaft setting tool.

41. Install the right-hand exhaust camshaft.
VUJ0002419
VUJ0002421
45. CAUTIONS:
42.
CAUTION: Alternate bolt tightening to Do not tighten the camshaft sprocket
correctly seat the camshaft bearing caps. retaining bolts.
Make sure the secondary timing chain
• Tighten to 10 Nm. and camshaft sprockets are free to rotate.
Install the camshaft sprockets.
• Install the secondary timing chain tensioner
and secondary timing chain to the camshaft
sprockets.
VUJ0002420
E30714
2003.50 X300 4/2005 Page 155 G215936en

303-01B-12 Engine — 3.5L/4.2L 303-01B-12
ASSEMBLY
46. Using a suitable tool, retain the left-hand 50. Install the primary timing chain tensioner
timing chain tensioner piston. guide.
E36694
E30713
47. Release the tension in the left-hand timing

chain tensioner. 51. Install the crankshaft sprocket.
• Remove the retaining tool.
48. Install the secondary timing chain
tensioner.
E30711
52.
CAUTION: Make sure the timing chain
slack is on the tensioned side of the timing
E30706 chain.
Install the primary timing chain.
49. Install the timing chain tensioning tool
303-532 to the exhaust camshaft sprocket.
sprocket and the intake sprocket.
• Reposition the camshaft sprockets for the
most advantageous position for use of the
tool.
303-532
E30710
53. Install the primary timing chain tensioner

E31268
guide.
G215936en
Page 156 4/2005 2003.50 X300
303-01B-13 Engine — 3.5L/4.2L 303-01B-13
ASSEMBLY
• Tighten to 12 Nm. Using a suitable tool, retain the left-hand
timing chain tensioner piston.
VUJ0002412
E36693
54.
CAUTION: During timing chain tensioner
compression, do not release the ratchet 57. Install the primary timing chain tensioner
stem until the timing chain tensioner piston assembly.
is fully bottomed in its bore or damage to • Tighten to 12 Nm.
the ratchet stem will result.
Using a suitable tool, hold the left-hand
timing chain tensioner ratchet lock
mechanism away from the ratchet stem.
E30709

chain tensioner.
E36693
59.
55. NOTE: The timing chain tensioner piston CAUTION: While applying the opposing
should retract with minimal force. If binding force to sprocket and chain, tighten the
occurs, reposition the timing chain sprocket bolt.
tensioner to eliminate side loading. Using the special tool apply force to the tool
Slowly compress the left-hand timing chain in an anti-clockwise direction to tension the
tensioner. primary timing chain on its drive side.
56. NOTE: The retaining tool must remain in
the timing chain tensioner until the timing
chain tensioner is installed to the engine
with the piston bottomed in the bore.
2003.50 X300 4/2005 Page 157 G215936en

303-01B-14 Engine — 3.5L/4.2L 303-01B-14
ASSEMBLY
• Tighten to 120 Nm. • Install the secondary timing chain tensioner
and secondary timing chain to the camshaft
303-532 sprockets.
E31269
E30705
60.
CAUTION: While applying the opposing
force to sprocket and chain, tighten the
62. Using a suitable tool, retain the right-hand
sprocket bolt.
Using the special tool apply force to the tool
in an anti-clockwise direction.
303-532
E36694
63. Install the secondary timing chain tensioner

E31270
retaining bolts.
61. CAUTIONS:
Do not tighten the camshaft sprocket
retaining bolts.
Make sure the secondary timing chain

and camshaft sprockets are free to rotate.
Install the camshaft sprockets.
E30715
64. Release the tension in the right-hand timing

chain tensioner.
65. Install the timing chain tensioning tool
303-532 to the exhaust camshaft sprocket.
G215936en
Page 158 4/2005 2003.50 X300
303-01B-15 Engine — 3.5L/4.2L 303-01B-15
ASSEMBLY
• Reposition the camshaft sprockets for the • Tighten to 12 Nm.
most advantageous position for use of the
tool.
303-532
E30702
E31274
69.
compression, do not release the ratchet
66. Install the primary timing chain guide.
stem until the timing chain tensioner piston
• Tighten to 12 Nm. is fully bottomed in its bore or damage to
Using a suitable tool, hold the right-hand
E30704
67.
CAUTION: Make sure the timing chain
slack is on the tensioned side of the timing
chain. E36693
Install the primary timing chain.

70. NOTE: The timing chain tensioner piston
• Install the primary chain over the crankshaft should retract with minimal force. If binding
sprocket and the intake sprocket. occurs, reposition the timing chain
tensioner to eliminate side loading.
Slowly compress the right-hand timing chain
tensioner.
E30703
68. Install the primary timing chain tensioner

guide.
2003.50 X300 4/2005 Page 159 G215936en

303-01B-16 Engine — 3.5L/4.2L 303-01B-16
ASSEMBLY
Using a suitable tool, retain the right-hand • Tighten to 120 Nm.
303-532
E31271
E36693
75.
72. Install the primary timing chain tensioner force to sprocket and chain, tighten the
assembly. sprocket bolt.
• Tighten to 12 Nm. Using the special tool apply force to the tool
in an anti-clockwise direction.
303-532
E30701
73. Release the tension in the right-hand timing E37392

chain tensioner.
• Remove the retaining tool. 76. Remove the special tool from the right-hand
74. cylinder head.
force to sprocket and chain, tighten the
sprocket bolt.
303-530
Using the special tool apply force to the tool
in an anti-clockwise direction to tension the
primary timing chain on its drive side.
E30700
G215936en
Page 160 4/2005 2003.50 X300
303-01B-17 Engine — 3.5L/4.2L 303-01B-17
ASSEMBLY
77. Remove the special tool from the left-hand All vehicles
cylinder head.
80. Remove the special tool.
303-530 303-645
E31337
VUJ0002400
Vehicles without supercharger 81. Install the crankshaft position sensor.

78. Install the left-hand variable camshaft
• Install new O-ring seals.
E30694
82. Install new seals to the timing cover.

E30708
1. Install the new seal to the inner groove on
79. Install the right-hand variable camshaft
2. Install the new seal to the outer groove on
E36698
E30699 83. Apply sealant to the eight joints on the

engine face.
2003.50 X300 4/2005 Page 161 G215936en

303-01B-18 Engine — 3.5L/4.2L 303-01B-18
ASSEMBLY
• Sealant beads to be 3mm diameter and
Do not remove the crankshaft front seal
12mm long. Cut the nozzle of the sealant
protector.
tube to produce a 3 mm bead. (Install and
tighten the securing bolts within twenty Using the special tool, install a new
minutes of sealant application). crankshaft front seal.
303-750
E36699 E31173
84. Install the timing cover. 86. Remove the crankshaft seal protector.
22 18 19 23
14 15
21 9 10 24
3
E31172
87. Install a new O-ring seal to the crankshaft

pulley.
17 20 • Lubricate the new O-ring.
88. CAUTIONS:
13 16
The screw thread in the crankshaft must
7 6
be cleaned out before a new crankshaft
pulley bolt is installed.
1 2
A new crankshaft pulley bolt must be
5 8 used.
11 4 12 Install, but do not tighten, a new crankshaft
E31273 pulley retaining bolt.
85. CAUTIONS:
Make sure the crankshaft front seal
mating faces are clean and dry.
G215936en
Page 162 4/2005 2003.50 X300
303-01B-19 Engine — 3.5L/4.2L 303-01B-19
ASSEMBLY
• Install the crankshaft pulley and locking ring • Tighten to 10 Nm.
to the crankshaft.
14 10 6 4 8 12
2
1
13 9 5 3 7 11
VUJ0001977
E31152
93. NOTE: Apply an 8mm diameter bead of

89. silicone gasket sealant on the two places
should the crankshaft setting peg 303-645
join.
be used in the following operations to lock
the crankshaft. Install the right-hand valve cover.
Using special tools, retain the crankshaft • Install new valve cover gaskets.
pulley. • Tighten in the sequence shown.
• Tighten the crankshaft pulley retaining bolt • Tighten to 10 Nm.
to 375 Nm.
12 8 4 6 10 14
303-191-02
2
1
303-191
11 7 3 5 9 13
VUJ0001979
E31149
90. Remove the special tools. • Tighten to 27 Nm.
91. Carry out a valve clearance check. For 95. Install the left-hand camshaft position
additional information, refer to: Valve (CMP) sensor.
Clearance Check - VIN Range:
G00442->G45170 (303-01B Engine - • Install a new O-ring seal.
3.5L/4.2L, General Procedures).
92. NOTE: Apply an 8mm diameter bead of
join.
Install the left-hand valve cover.
2003.50 X300 4/2005 Page 163 G215936en

303-01B-20 Engine — 3.5L/4.2L 303-01B-20
ASSEMBLY
E30693 E30682
96. Install the right-hand camshaft position All vehicles

(CMP) sensor.
99. Install the water pump.
• Install new O-ring seals and gaskets.
E30692
E30681
97. NOTE: Left-hand shown, right-hand similar

100. Install the water pump pulley.
Install the ignition coils.
• Using special tool, retain the water pump
• Tighten to 5 Nm. pulley.
• Tighten to 10 Nm + 45°.
E30685
E30680

98. Install the thermostat housing.
G215936en
Page 164 4/2005 2003.50 X300
303-01B-21 Engine — 3.5L/4.2L 303-01B-21
ASSEMBLY
101. Install the engine block insulation grommet. 105. Attach the engine wiring harness retaining
clips.
VUJ0002390
E30661

hose. 106. Attach the right-hand oxygen sensor.
1. Install the knock sensors. • Tighten to 10 Nm.
hose.
2 VUJ0001584
107. Install the oil filter housing.

E30679
103. Install the noise and vibration insulating
pad.
VUJ0001579
VUJ0001615
104. Install the engine wiring harness.
2003.50 X300 4/2005 Page 165 G215936en

303-01B-22 Engine — 3.5L/4.2L 303-01B-22
ASSEMBLY
108. Connect the oil pressure switch and oil Vehicles with supercharger
temperature sensor electrical connectors.
111.

112. Install the intake manifold.
VUJ0001578

109. Install the oil cooler.
• Install a new O-ring seal. E30678
113. Attach the engine wiring harness.
VUJ0001577
All vehicles E30676

engine oil to lubricate the oil filter O-ring Vehicles with supercharger
seal.
114. NOTE: Left-hand shown, right-hand simular.
Install a new oil filter.
Install the lower intake manifold.
VUJ0001576
E36707
G215936en
Page 166 4/2005 2003.50 X300
303-01B-23 Engine — 3.5L/4.2L 303-01B-23
ASSEMBLY
All vehicles 118. Connect the ignition on-plug coil electrical
connectors.
E30670
E30674

116. Connect the camshaft position sensor
E30671
E30673
120. Connect the fuel injector electrical
connectors.
117. Connect the fuel temperature sensor
E30669
E30672
2003.50 X300 4/2005 Page 167 G215936en

303-01B-24 Engine — 3.5L/4.2L 303-01B-24
ASSEMBLY
Vehicles without supercharger 124. Connect the fuel pressure regulator
E30665
E30668
125. Connect the positive crankcase ventilation

122. Connect the exhaust gas recirculation valve
pipe.
coolant hose.
E30664
E30667
123. Connect the exhaust gas recirculation valve Vehicles with supercharger
electrical connector. 126. Attach the engine wiring harness.
E30666 E37438
G215936en
Page 168 4/2005 2003.50 X300
303-01B-25 Engine — 3.5L/4.2L 303-01B-25
ASSEMBLY
127. Attach the engine wiring harness. 130. Attach the engine wiring harness.
E37437 E30674
All vehicles 131. Attach the engine wiring harness.

1. Connect the earth wire.
3
E30658
2
132. Connect the ignition on-plug coil electrical

1 connectors.
E30662
129. Connect the camshaft position sensor

E30657
133. NOTE: Left-hand shown, right hand similar.
E30660
2003.50 X300 4/2005 Page 169 G215936en

303-01B-26 Engine — 3.5L/4.2L 303-01B-26
ASSEMBLY
Connect the fuel injector electrical 136. Install the engine cover retaining bracket.
connectors.
E30654
E30656
All vehicles
Install the ignition coil cover.
E30655
E30653
135. Install the engine cover retaining bracket.
connectors.
E30663
E30652

Install the charge air coolers.
• Install a new charge air cooler gasket.
G215936en
Page 170 4/2005 2003.50 X300
303-01B-27 Engine — 3.5L/4.2L 303-01B-27
ASSEMBLY
E30240 E30246
140. Install the supercharger. 143. NOTE: Make sure ground strap is correctly
installed to the location noted.
Install the air intake elbow retaining bracket
lower retaining bolts.
E30248
141. Connect the manifold absolute pressure

(MAP) sensor. E30245
144. Connect the air intake elbow pipes.
E30247
142. Install the air intake elbow. E30243

• Install new retaining bolt seals. 145.
CAUTION: Do not attempt to clean the
throttle body. The bore and the throttle
plate has a special coating applied during
manufacture which should not be removed.
Install the throttle body.
2003.50 X300 4/2005 Page 171 G215936en

303-01B-28 Engine — 3.5L/4.2L 303-01B-28
ASSEMBLY
• Install a new throttle body gasket. • Tighten to 10 Nm.
E30634
E31196

146. NOTE: Un-cap the coolant hose.
Attach the coolant hose to the throttle body.
E30635
E31195 150. NOTE: Un-cap the exposed ports.

Connect the coolant hoses.
147. Connect the electrical connectors.
E31339
E31194
148. Install the EGR valve and the exhaust

manifold to EGR valve tube.
• Install a new exhaust manifold to EGR valve
tube gasket.
• Install a new EGR valve to air intake elbow
gasket.
G215936en
Page 172 4/2005 2003.50 X300
303-01B-29 Engine — 3.5L/4.2L 303-01B-29
ASSEMBLY
151. Connect the exhaust gas recirculation 156. Tighten to 10 Nm.
(EGR) valve electrical connector.
E30419
E30257

152. Connect the IAT sensor electrical
connector.
E30418
E30242
158. Connect the hose.
153. Connect the charge air cooler coolant

pipes.
E30417
E30241
154. Install new O-ring seals to the thermostat

housing.
155. Install thermostat housing.
2003.50 X300 4/2005 Page 173 G215936en

303-01B-30 Engine — 3.5L/4.2L 303-01B-30
ASSEMBLY
159. Connect the hose. 162. Reposition the thermostat housing hose
retaining clip.
E30416
E30414

163. Connect the coolant temperature sensor
E30415
E30413
164. Connect the thermostat housing hoses
E30411
E30412
165. Install new supercharger outlet pipe to

charge air coolers ducts.
G215936en
Page 174 4/2005 2003.50 X300
303-01B-31 Engine — 3.5L/4.2L 303-01B-31
ASSEMBLY
• Tighten to 8 Nm. • Reposition the hose retaining clip.
E30239 E30236
166. Install a new supercharger outlet pipe 171. Attach the engine wiring harness.
gasket.
167. Install new seals to the supercharger outlet
pipe retaining bolts
168.
enters the supercharger.
Install the supercharger outlet pipe
E36700

172. Connect the coolant temperature sensor
E30238
169. NOTE: Un-cap the coolant ports.

Attach the supercharger outlet pipe coolant
hose.
E30649
All vehicles
E30237
170. Attach the hoses.
2003.50 X300 4/2005 Page 175 G215936en

303-01B-32 Engine — 3.5L/4.2L 303-01B-32
ASSEMBLY
2. Attach the engine wiring harness. 176. Attach the engine wiring harness.
VUJ0002375
VUJ0001580
174. Attach the engine wiring harness. 177. Connect the crankshaft position sensor
E30648
E30646
178. Install the power steering pump mounting
bracket.
E30647
E30645
179. Install the power steering pump.
G215936en
Page 176 4/2005 2003.50 X300
303-01B-33 Engine — 3.5L/4.2L 303-01B-33
ASSEMBLY
• Tighten to 25 Nm. 182. Connect the air conditioning compressor
E30644
E37253
180. Install the air conditioning compressor
mounting bracket. 183. Install the left-hand engine mounting
• Tighten to 25 Nm. bracket.
E37389
VUJ0001561
181. Install the A/C compressor.

• Tighten to 25 Nm. 184. Install the left-hand engine mount.
E37256
E30637
185. CAUTIONS:
Make sure the exhaust manifold and
gasket are correctly aligned to the cylinder
head.
2003.50 X300 4/2005 Page 177 G215936en

303-01B-34 Engine — 3.5L/4.2L 303-01B-34
ASSEMBLY
Make sure the exhaust manifold torque
is checked after initial tighten.
Install the left-hand exhaust manifold.
E30639
189. Install the starter motor.

E30642
186. Install the heat shield retaining bolt.

E30139
E30641
187. Install the heat shield.

E30661
E30640
188. Install the oil level indicator and tube.

G215936en
Page 178 4/2005 2003.50 X300
303-01B-35 Engine — 3.5L/4.2L 303-01B-35
ASSEMBLY
191. Attach the right hand oxygen sensor • Tighten the generator lower retaining bolt to
retaining bracket. 40 Nm.
E36733
VUJ0001584
192. Install the generator mounting bracket. 195. Attach the wiring harness.
E31033
E30628
E36732
E30627
197. Attach the generator battery positive cable.
194. Install the generator.
• Tighten the generator upper retaining bolt to
21 Nm.
2003.50 X300 4/2005 Page 179 G215936en

303-01B-36 Engine — 3.5L/4.2L 303-01B-36
ASSEMBLY
• Tighten to 12 Nm • Tighten to 45 Nm.
E36731 VUJ0001555
198. Attach the generator battery positive cable 201. Attach the accessory drive belt.
protective cover.
drive belt tensioner.
• Attach the accessory drive belt.
E36730
199. Install the accessory drive belt idler pulley. VUJ0001554
202. Install the supercharger belt.
supercharger belt tensioner.
VUJ0005594
200. Install the accessory drive belt tensioner.

• Install the accessory drive belt.
VUJ0005600
G215936en
Page 180 4/2005 2003.50 X300
303-01B-37 Engine — 3.5L/4.2L 303-01B-37
ASSEMBLY
203. Connect the oil cooler hoses.
VUJ0001553
2003.50 X300 4/2005 Page 181 G215936en

303-01B-1 Engine — 3.5L/4.2L 303-01B-1
.

CONTENTS PAGE

Cylinder Head..................................................................................................................... 303-01B-2
Page 182
303-01B-2 Engine — 3.5L/4.2L 303-01B-2
Cylinder Head ()
Special Tool(s) 3. Using the special tool, compress the valve
springs.
303-252 • Remove the valve collets.
303-252
303252
Disassembly
1. CAUTIONS:
Do not use a magnet to remove shims.
Failure to follow these instructions may VUJ0002447
result in damage to the vehicle.
If the cylinder head valve components 4. Remove the valve spring retainers and valve
are to be reused, mark the position of the springs.
valve components to make sure they are 1. Remove the valve spring retainers.
reassembled in the same position. 2. Remove the valve springs.
Remove the bucket tappet and shim 3. Remove the valve stem oil seals.
assemblies.
1
VUJ0002334
VUJ0002442
5. Remove the valves from the cylinder head.
2. Remove the camshaft position (CMP) sensor. 1. Remove the intake valves.
• Remove and discard the 'O' ring seal. 2. Remove the exhaust valves.
1
VUJ0002448
VUJ0002446
G95949en
Page 183 4/2005 2003.50 X300
303-01B-3 Engine — 3.5L/4.2L 303-01B-3
6. Inspect the cylinder heads and related 3. Install the valve spring retainers.
components. For additional information, refer
Information] 3

as necessary to clean the cylinder heads. 1
Assembly
2
1.
follow these instructions may result in VUJ0002304
personal injury.
CAUTION: The cylinder head surface finish 5. Using the special tool, compress the valve
is measured in microns. For correct head springs.
• Install the valve collets.
Clean gasket material, dirt and foreign
material from cylinder heads. Wash with a 303-252
suitable soap and water solution and dry the
cylinder head completely using compressed
air if pipe plugs have been removed.
to cylinder heads.
installation.
3. NOTE: Lubricate the valve stems before VUJ0002447
assembly.
Install the valves into the cylinder heads. 6. Install the camshaft position (CMP) sensor.
1. Install the intake valves. • Install a new 'O' ring seal.
2. Install the exhaust valves. • Tighten to 7 Nm.
1
VUJ0002448 VUJ0002446
4. Install the valve spring retainers and valve 7.

springs. shims. Failure to follow these instructions
1. Install the valve stem oil seals. may result in damage to the vehicle.
2003.50 X300 4/2005 Page 184 G95949en

303-01B-4 Engine — 3.5L/4.2L 303-01B-4
Install the bucket tappet and shim
assemblies.
VUJ0002442
G95949en
Page 185 4/2005 2003.50 X300
303-01B-1 Engine — 3.5L/4.2L 303-01B-1
.

CONTENTS PAGE
GENERAL PROCEDURES
Valve Clearance Adjustment — VIN Range: G00442->G45170........................................ 303-01B-2
Valve Clearance Adjustment — VIN Range: G45171->G99999........................................ 303-01B-4
Valve Clearance Check — VIN Range: G00442->G45170................................................ 303-01B-6
Valve Clearance Check — VIN Range: G45171->G99999................................................ 303-01B-7
Page 186
303-01B-2 Engine — 3.5L/4.2L 303-01B-2
GENERAL PROCEDURES
Valve Clearance Adjustment — VIN Range: G00442->G45170 ()

Special Tool(s) Install the attachment of the tool to the base
plate to remove the relevant shims.
303-540 1. Adjust the fingers of the attachment to the
highest position.
2. Install the attachment to the base plate.
DWST024 3. Tighten the retaining screws to secure the
3
Fan nozzle, air gun 303-540
303-590
2
DWST074
1. Remove the Left-hand valve cover. For

additional information, refer to Valve Cover
LH in this section. E31418
2. Remove the Right-hand valve cover. For

additional information, refer to Valve Cover 7. NOTE: Use a mirror to help locating the
RH in this section. fingers of the special tool as access is
restricted.
3. Use a cloth to wipe away as much oil as
possible from the tappet and shim. Position the fingers on the outer edges of
the tappet. Make sure the recessed step on
4. Rotate the engine clockwise to position the each finger locates on the edge of the tappet.
adjusting tool to the relevant cylinder head
using the bolts supplied.
X X
holes.
303-540
J.303.530
E31417
6.
plate.
G187607en
Page 187 4/2005 2003.50 X300
303-01B-3 Engine — 3.5L/4.2L 303-01B-3
GENERAL PROCEDURES
8. Tighten the special tool to compress the 11.
valve springs.
shims. Failure to follow these instructions
may result in damage to the vehicle.
NOTE: Shims must be fitted with the size markings
303540
facing the tappet, not the camshaft.
replacement shim(s) and install.
E31419
303540
9.
CAUTION: Do not use a magnet to remove
E31419
Remove, clean and measure the shim.
1. Surround the immediate working area with 13. Using the feeler gauge set, measure the
a cloth to retain any loose shims displaced clearance between the camshaft and the
by the compressed air. shim surface. Record and check the
2. Use special tool aimed at the edge of the readings. For additional information, refer
shim to lift it from the tappet. Remove the to Section 303-00 [Engine System - General
shim from each tappet, noting the position of Information].
each one. 14. When the valve clearance is correct,
remove the attachment from the base plate
2 303-540 and repeat the procedure for the following
1
two valves to be adjusted.
15. Install the Right-hand valve cover. For
RH in this section.
16. Install the Left-hand valve cover. For
303-590 LH in this section.
E31420
10. NOTE: Two shims within each procedure

are possible to be replaced using the
special tool.
shim thickness.
2003.50 X300 4/2005 Page 188 G187607en

303-01B-4 Engine — 3.5L/4.2L 303-01B-4
GENERAL PROCEDURES
Valve Clearance Adjustment — VIN Range: G45171->G99999 ()

Special Tool(s) Install the attachment of the tool to the base
plate to remove the relevant shims.
303-540 1. Adjust the fingers of the attachment to the
highest position.
2. Install the attachment to the base plate.
DWST024 3. Tighten the retaining screws to secure the
3
Fan nozzle, air gun 303-540
303-590
2
DWST074
1. Remove the Left-hand valve cover. For

LH in this section. E31418
2. Remove the Right-hand valve cover. For

additional information, refer to Valve Cover 7. NOTE: Use a mirror to help locating the
RH in this section. fingers of the special tool as access is
restricted.
3. Use a cloth to wipe away as much oil as
possible from the tappet and shim. Position the fingers on the outer edges of
the tappet. Make sure the recessed step on
4. Rotate the engine clockwise to position the each finger locates on the edge of the tappet.
adjusting tool to the relevant cylinder head
using the bolts supplied.
X X
holes.
303-540
J.303.530
E31417
6.
plate.
G532049en
Page 189 4/2005 2003.50 X300
303-01B-5 Engine — 3.5L/4.2L 303-01B-5
GENERAL PROCEDURES
8. Tighten the special tool to compress the 11.
valve springs.
NOTE: Shims must be fitted with the size markings
303540
facing the tappet, not the camshaft.
E31419
303540
9.
CAUTION: Do not use a magnet to remove
E31419
Remove, clean and measure the shim.
1. Surround the immediate working area with 13. Using the feeler gauge set, measure the
a cloth to retain any loose shims displaced clearance between the camshaft and the
by the compressed air. shim surface. Record and check the
2. Use special tool aimed at the edge of the readings. For additional information, refer
shim to lift it from the tappet. Remove the to Section 303-00 [Engine System - General
shim from each tappet, noting the position of Information].
each one. 14. When the valve clearance is correct,
remove the attachment from the base plate
2 303-540 and repeat the procedure for the following
1
two valves to be adjusted.
15. Install the Right-hand valve cover. For
RH in this section.
16. Install the Left-hand valve cover. For
303-590 LH in this section.
E31420
10. NOTE: Two shims within each procedure

are possible to be replaced using the
special tool.
shim thickness.
2003.50 X300 4/2005 Page 190 G532049en

303-01B-6 Engine — 3.5L/4.2L 303-01B-6
GENERAL PROCEDURES
Valve Clearance Check — VIN Range: G00442->G45170 ()

LH in this section.
RH in this section.
3. CAUTIONS:

Information]. . Adjust the clearances as
to: Valve Clearance Adjustment - VIN Range:
G00442->G45170 (303-01B Engine - 3.5L/4.2L,
General Procedures).
VUJ0002259

RH in this section.
LH in this section.
G187606en
Page 191 4/2005 2003.50 X300
303-01B-7 Engine — 3.5L/4.2L 303-01B-7
GENERAL PROCEDURES
Valve Clearance Check — VIN Range: G45171->G99999

LH in this section.
RH in this section.
3. CAUTIONS:

Information]. . Adjust the clearances as
to: Valve Clearance Adjustment - VIN Range:
G00442->G45170 (303-01B Engine - 3.5L/4.2L,
VUJ0002259

RH in this section.
LH in this section.
2003.50 X300 4/2005 Page 192 G532051en

303-01B-18 Engine — 3.5L/4.2L 303-01B-18
IN-VEHICLE REPAIR
Crankshaft Front Seal — VIN Range: G00442->G45170 ()

Special Tool(s) Using the special tool, install the crankshaft
Installer, crankshaft front seal front seal.
303-750
303-750
Remover, crankshaft front

seal
303-751
303-750
E31173
303-751
2. Remove the crankshaft seal protector.

Removal
information, refer to Crankshaft Pulley in this
section.
2. Using the special tool, remove the crankshaft
front seal.
E31172

information, refer to Crankshaft Pulley in this
section.
303-751
E31171
Installation
1. CAUTIONS:

protector.
G205551en 5/2005 2003.50 X300

303-01B-19 Engine — 3.5L/4.2L 303-01B-19
IN-VEHICLE REPAIR
Crankshaft Front Seal — VIN Range: G45171->G99999 ()

Special Tool(s) Using the special tool, install the crankshaft
Installer, crankshaft front seal front seal.
303-750
303-750
Remover, crankshaft front

seal
303-751
303-750
E31173
303-751
2. Remove the crankshaft seal protector.

Removal
information, refer to: Crankshaft Pulley - VIN
Range: G45171->G99999 (303-01B, In-vehicle
Repair).
front seal.
E31172

information, refer to: Crankshaft Pulley - VIN
Range: G45171->G99999 (303-01B, In-vehicle
Repair).
303-751
E31171
Installation
1. CAUTIONS:

protector.
2003.50 X300 5/2005 G531103en


303-01A-1 Engine — 3.0L 303-01A-1
.
SECTION 303-01A Engine — 3.0L

CONTENTS PAGE
DISASSEMBLY
Engine. 303-01A-2
Page 193
303-01A-1 Engine — 3.0L 303-01A-1
.

CONTENTS PAGE
DISASSEMBLY
Engine. 303-01A-2
Page 194
303-01A-2 Engine — 3.0L 303-01A-2
DISASSEMBLY
Engine
Special Tool(s) 2. Disconnect the throttle position (TP) sensor
Crankshaft Damper Holding
Tool
303-D055
303D055
Crankshaft Damper Remover

303-D121
E43695
303D121
3. NOTE: Reposition the throttle motor
Cylinder Bore Protector electrical connector insulation.
303-535
Disconnect the throttle motor electrical
connector.
303535
E43694
Disassembly
4. Detach the throttle body.
1. Remove the intake manifold tuning (IMT)
valve cover.
1. Disconnect the electrical connector.
2. Remove the IMT valve cover.
VUJ0000124
1
VUJ0000170
G95943en
Page 195 4/2005 2000.0 X200
303-01A-3 Engine — 3.0L 303-01A-3
DISASSEMBLY
5. Remove and discard the throttle body gasket. 8. Disconnect the engine breather hose.
VUJ0000126 E43693
6. Remove the throttle body. 9. Remove the evaporative emission purge

valve vacuum tube.
• Disconnect the coolant hoses.
VUJ0000125 E43690
7. Disconnect the coolant hose. 10. Disconnect the IMT valve.
E43692 E43691
2000.0 X200 4/2005 Page 196 G95943en

303-01A-4 Engine — 3.0L 303-01A-4
DISASSEMBLY
11. Remove the fuel rail pressure (FRP) sensor 2. Detach the engine wiring harness.
cover.
2
VUJ0001026
E43689
15. Disconnect the crankshaft position (CKP)
12. Remove the intake manifold. sensor electrical connector.
E43696 VUJ0001028
1. Disconnect the knock sensor electrical 1. Disconnect the knock sensor electrical
connector. connector.
2. Disconnect the air conditioning (A/C) 2. Detach the oxygen sensor electrical
compressor electrical connector. connector.
3
1
3
2
1
2 VUJ0001029
VUJ0001027
1. Disconnect the oil pressure switch and the 1. Disconnect the generator electrical
oil temperature sensor electrical connector. connector.
G95943en
Page 197 4/2005 2000.0 X200
303-01A-5 Engine — 3.0L 303-01A-5
DISASSEMBLY
2. Detach the engine wiring harness. 20. Remove the coolant hose.
1
2
VUJ0001030 E30572
18. Remove the rear knock sensor. 21. Remove the coolant hose.
1. Detach the knock sensor wiring harness.
2. Remove the rear knock sensor.
E30573
VUJ0001018
22. Detach the fuel injector wiring harness.
19. Disconnect the oil cooler coolant hoses.
VUJ0001025
E30571
2000.0 X200 4/2005 Page 198 G95943en

303-01A-6 Engine — 3.0L 303-01A-6
DISASSEMBLY
23. Disconnect the FRP sensor vacuum hose 26. Remove the crankcase tube bracket
and electrical connector. retaining nut.
VUJ0001115 VUJ0001858
24. Disconnect the electrical connectors. 27. Disconnect the electrical connectors.
E43697 E43699
25. Detach the cylinder head earth strap. 28. Detach the throttle body wiring harness
from the left-hand valve cover.
E43698
VUJ0001063
G95943en
Page 199 4/2005 2000.0 X200
303-01A-7 Engine — 3.0L 303-01A-7
DISASSEMBLY
29. Detach the engine wiring harness from the 32. Detach the engine wiring harness from the
left-hand valve cover. right-hand valve cover.
VUJ0001024 VUJ0001137
30. Detach the engine wiring harness from the 33. Remove the engine wiring harness from
left-hand valve cover. the engine.
VUJ0001133 VUJ0001138
31. Detach the engine wiring harness from the 34. Remove the ignition coils.
right-hand valve cover.
VUJ0001022
VUJ0001797
2000.0 X200 4/2005 Page 200 G95943en

303-01A-8 Engine — 3.0L 303-01A-8
DISASSEMBLY
35. Remove the fuel injection supply manifold 38. Remove the engine mount retaining
and lower intake manifold. bracket.
VUJ0001021 VUJ0001012
36. Remove and discard the gaskets. 39. Remove the exhaust manifold heat shield.
VUJ0001020 VUJ0001013
37. Remove the accessory drive belt. 40. Remove the flywheel.
1. Rotate the belt tensioner counter-clockwise. • Prevent the engine from rotating.
• Use a 3/8 inch square drive bar to rotate
the belt tensioner.
2. Remove the accessory drive belt.
1
VUJ0001014
VUJ0001019
G95943en
Page 201 4/2005 2000.0 X200
303-01A-9 Engine — 3.0L 303-01A-9
DISASSEMBLY
41. Remove the engine rear backing plate. • Remove the crankshaft pulley retaining bolt.
VUJ0001015
VUJ0001064
42. Install the special tool and loosen the 45. Remove the accessory drive belt idler
crankshaft pulley retaining bolt. pulley and bracket.
303-D055
E30933 VUJ0001010
43. Using the special tool, detach the 46. Remove the generator.
crankshaft pulley.
303-D121
VUJ0001011
VUJ0001016
44. Remove the crankshaft pulley.
2000.0 X200 4/2005 Page 202 G95943en

303-01A-10 Engine — 3.0L 303-01A-10
DISASSEMBLY
47. Remove the exhaust manifold. • Remove and discard the O-ring seals.
E30761
VUJ0001200
48. Remove the power steering pump. 51. Remove the A/C compressor.
VUJ0001006
VUJ0001008
49. Remove the exhaust manifold heat shield. 52. Remove the A/C compressor mounting
bracket.
VUJ0001009
VUJ001006A
50. Remove the oil filter housing.
G95943en
Page 203 4/2005 2000.0 X200
303-01A-11 Engine — 3.0L 303-01A-11
DISASSEMBLY
53. Remove the front knock sensor. 2. Remove the water pump and coolant hose
assembly.
2
VUJ0001004
VUJ0001002
54. Remove the coolant crossover tube.

57. Remove the oil level indicator tube.
VUJ0001005
VUJ0001000
55. Remove the accessory drive belt tensioner

and accessory drive belt idler pulley. 58. Remove the exhaust manifold.
VUJ0001199
VUJ0001003
56. Remove the water pump and coolant hose

assembly.
1. Detach the hose.
2000.0 X200 4/2005 Page 204 G95943en

303-01A-12 Engine — 3.0L 303-01A-12
DISASSEMBLY
59. Remove the cylinder head temperature • Remove and discard the valve cover gaskets.
(CHT) sensor.
VUJ0002239
VUJ0001134
62. Remove the RH valve cover.

60. Remove the engine oil pressure and oil • Remove and discard the valve cover gaskets.
temperature sensors.
VUJ0002241
VUJ0002229
63. Remove the oil pan.
61. Remove the LH valve cover. • Remove the retaining bolts.
• Clean and inspect the oil pan and cylinder
block sealing surfaces using Metal surface
cleaner or equivalent meeting Jaguar
specification WSE-M5B392-A.
G95943en
Page 205 4/2005 2000.0 X200
303-01A-13 Engine — 3.0L 303-01A-13
DISASSEMBLY
VUJ0002243
65. Remove the CKP sensor pulse wheel.

64. Remove the engine front cover.
• Remove and discard the engine front cover
gaskets.
VUJ0002248
VUJ0002245 66. Install the crankshaft pulley bolt and

washer.
Rotate the crankshaft clockwise until the
colored timing chains align with the marks on
the camshaft sprockets and crankshaft
sprocket, to position the engine to top dead
center (TDC) No. 1 cylinder prior to the removal
and installation of the camshafts.
2000.0 X200 4/2005 Page 206 G95943en

303-01A-14 Engine — 3.0L 303-01A-14
DISASSEMBLY
Do not rotate the crankshaft 69. Remove the RH timing chain.
• Remove the crankshaft pulley bolt and
washer.
VUJ0002253
70. Remove the RH timing chain guide.

VUJ0002249
67. Remove the RH chain tensioner.
VUJ0002254
71. Remove the LH chain tensioner.
VUJ0002250
68. Remove the RH chain tensioner arm.
VUJ0001186
VUJ0002252
G95943en
Page 207 4/2005 2000.0 X200
303-01A-15 Engine — 3.0L 303-01A-15
DISASSEMBLY
72. Remove the LH chain tensioner arm. 75. Remove the crankshaft sprocket.
VUJ0002256 VUJ0002260
73. Remove the LH timing chain. 76. Remove the RH exhaust camshaft bearing
cap retaining bolts evenly.
• Remove the exhaust camshaft bearing caps.
VUJ0002257
74. Remove the LH timing chain guide. VUJ0002261
77. Remove the RH exhaust camshaft.
VUJ0002258
VUJ0002263
78. Remove the RH inlet camshaft bearing cap

retaining bolts evenly.
2000.0 X200 4/2005 Page 208 G95943en

303-01A-16 Engine — 3.0L 303-01A-16
DISASSEMBLY
• Remove the inlet camshaft bearing caps. 81. Remove the LH exhaust camshaft.
VUJ0002264
VUJ0002269
79. Remove the RH inlet camshaft. 82. Remove the LH inlet camshaft bearing cap
• Remove the inlet camshaft bearing caps.
VUJ0002266
80. Remove the LH exhaust camshaft bearing VUJ0002270

• Remove the exhaust camshaft bearing caps. 83. Remove the LH inlet camshaft.
VUJ0002267
VUJ0002272
84. NOTE: Remove the retaining bolts in the

indicated sequence.
Remove the RH cylinder head.
G95943en
Page 209 4/2005 2000.0 X200
303-01A-17 Engine — 3.0L 303-01A-17
DISASSEMBLY
• Remove and discard the gasket. • Remove and discard the O-ring seal.
4 6 8 2
3 7 5 1
VUJ0002273 VUJ0002279
85. NOTE: Remove the retaining bolts in the 88. Remove the oil pan baffle.
indicated sequence.
Remove the LH cylinder head.
2 8 6 4
VUJ0002281
1 5 7 3
VUJ0002275
86. Remove the engine oil separator and

coolant housing.
VUJ0002282
90.
CAUTION: Pistons, connecting rods and
connecting rod bearings should be
numbered to make sure they are
VUJ0002277
reassembled in the same position.
87. Remove the oil intake tube. caps to the connecting rods to make sure they are
installed in the correct position.
removal.
2000.0 X200 4/2005 Page 210 G95943en

303-01A-18 Engine — 3.0L 303-01A-18
DISASSEMBLY
Remove the connecting rod retaining bolts, 93.
CAUTION: Care should be taken not to
the connecting rod caps and the lower
damage the connecting rod and cap joint
face surfaces or possible engine damage
may occur. Avoid contaminating the
fracture joint surfaces with dirt or grease.
NOTE: Reattach the connecting rods and caps
after removal to avoid mismatch.
Remove the pistons.
bottom of travel.
VUJ0002284
91. Inspect the tops of the cylinder bores. As

necessary remove ridge and carbon build
up from each cylinder.
92.
surfaces.
Install special tools to the connecting rods. VUJ0002286
94. NOTE: Remove the lower cylinder block

retaining bolts in the indicated sequence.
303 535
VUJ0002285
G95943en
Page 211 4/2005 2000.0 X200
303-01A-19 Engine — 3.0L 303-01A-19
DISASSEMBLY
4 22 14 6 20 12 2 16 8 11 7
15
19
18
10
1
17 13 21 3 5
VUJ0002312

95. NOTE: Mark the position of the upper and
lower crankshaft main bearing and the • Remove and discard the crankshaft rear main
crankshaft thrust bearing for reassembly. oil seal.
Remove the lower crankshaft bearings.
1. Remove the lower crankshaft thrust main
bearing.
2. Remove the lower crankshaft main bearings.
VUJ0002289
1
2
2
VUJ0002293
96.
2000.0 X200 4/2005 Page 212 G95943en

303-01A-20 Engine — 3.0L 303-01A-20
DISASSEMBLY
bearings.
VUJ0002290
98. Clean the cylinder block with a soap and

G95943en
Page 213 4/2005 2000.0 X200
303-01A-1 Engine — 3.0L 303-01A-1
.

CONTENTS PAGE
ASSEMBLY
Engine. 303-01A-2
Page 214
303-01A-2 Engine — 3.0L 303-01A-2
ASSEMBLY
Engine
Special Tool(s) Reseal oil passage blanking plugs, as
necessary.
Wrench Strap-Universal
303-D055 3. NOTE: The main bearings are precision
Clearance (303-00 Engine System - General
Information, General Procedures).
303D055
Install the upper crankshaft thrust washer.
Crankshaft Rear Seal • Align assembly tab on thrust bearing to
Installer machining spot face on cylinder block.
303-178
303178
Crankshaft Rear Seal

Installer Adapter Bolts
303-384
303384 VUJ0002291
Piston Ring Compressor

303-372
• Lubricate the bearings and thrust washer.
303372
Cylinder Bore Protector

303-535
303535
VUJ0002290
Assembly 5.
1. crankshaft journal bearing surfaces.
CAUTION: Use only plastic scraper when
removing old gasket material.
G95946en
Page 215 4/2005 2000.0 X200
303-01A-3 Engine — 3.0L 303-01A-3
ASSEMBLY
Install the crankshaft. 7. NOTE: Sealant application must stop 6 mm
from the rear crankshaft bore on each side.
NOTE: Install lower cylinder block and tighten all
bolts to specification within four minutes of applying
sealer.
housing.
• Use Silicone gasket and sealant.
VUJ0002289
6. NOTE: Push the crankshaft rearward prior

to installation of upper thrust bearings.
NOTE: Visually inspect the bearings to verify that
the bearing oiling holes align with cylinder block
oil feed holes.
Install the lower crankshaft bearings into the VUJ0002294
cylinder block.
1. Install the lower crankshaft thrust main 8.
bearing into lower cylinder block. seated into lower cylinder block prior to
2. Install the lower crankshaft main bearings tightening the retaining bolts.
into lower cylinder block.
NOTE: Before installing the retaining bolts lightly
• Lubricate the bearings and thrust washer. seat the crankshaft forward.
retaining bolts.
NOTE: Loosely install the lower cylinder block
retaining bolts.
NOTE: Do not rotate crankshaft until all retaining
1 bolts are tightened to specification.
2
NOTE: Retaining bolts must be tightened within 4
2
minutes of applying sealant.
Install the lower cylinder block on the
VUJ0002293 cylinder block.
• Push crankshaft rearward to seat the
crankshaft thrust washer.
2000.0 X200 4/2005 Page 216 G95946en

303-01A-4 Engine — 3.0L 303-01A-4
ASSEMBLY
VUJ0002287
• Stage 1: Bolts 1-8, 25 Nm

9.
CAUTION: The retaining bolts 1 through • Stage 2: Bolts 9-16, 40 Nm
16 are tighten-to-yield and must be replaced. • Stage 3: Bolts 1-16, 90°
NOTE: Tighten the retaining bolts in the indicated • Stage 4: Bolts 17-22, 25 Nm
sequence in four stages. • Verify the crankshaft rotates freely.
Complete the tightening sequence.
G95946en
Page 217 4/2005 2000.0 X200
303-01A-5 Engine — 3.0L 303-01A-5
ASSEMBLY
19 1 9 17 3 11 21 7 15 12 16
13
22
14
6 10 2 20 18
VUJ0002288

of the stroke.
out at the front cover sealing surface.
13. NOTE: Make sure the piston ring gaps are
11. NOTE: Alternate retaining bolt tightening
positioned at different locations opposite
to correctly seat the crankshaft rear oil seal
until it is flush with the cylinder block.
installation.
Using the special tools, install the crankshaft
NOTE: Install pistons with arrow to front of engine.
rear oil seal.
Using the special tool compress the rings
303 178
303 384
303 372
VUJ0002329
12.
CAUTION: Use appropriate protection VUJ0002278
surfaces. 14. CAUTIONS:
2000.0 X200 4/2005 Page 218 G95946en

303-01A-6 Engine — 3.0L 303-01A-6
ASSEMBLY
NOTE: Tighten the retaining bolts in the indicated
When assembling the connecting rods
sequence in two stages.
and connecting rod caps, it is imperative
that bearing slots and tangs be located on Install the oil pan baffle.
the same side of the connecting rods. • Stage 1: 5 Nm
Connecting rod retaining bolts are • Stage 2: 45°
torqued to yield and must be replaced.
connecting rods.
NOTE: Tighten the retaining bolts in the indicated
sequence in three stages.
• Stage 1: 23 Nm
• Stage 2: 43 Nm
• Stage 3: 105° VUJ0002281
18. NOTE: Lubricate a new O-ring seal before

installation.
Install the oil intake tube.
1. Tighten to 10 Nm
VUJ0002284

operation.
• Tighten to 10 Nm. VUJ0002279
19. Install the engine oil separator and coolant

housing.
VUJ0002282
17.
CAUTION: Oil pan baffle retaining nuts
are tightened to yield and must not be
reused.
VUJ0002277
G95946en
Page 219 4/2005 2000.0 X200
303-01A-7 Engine — 3.0L 303-01A-7
ASSEMBLY
20. Position the crankshaft. • Tighten 90°
• Turn the crankshaft until the key is in the 11
o'clock position. 7 1 3 5
• Remove the crankshaft pulley retaining bolt
and washer.
8 4 2 6
VUJ0002276
23. NOTE: Install the retaining bolts in the

indicated sequence.
VUJ0002295
Install the RH cylinder head.
• Tighten to 30 Nm
• Tighten 90°
Install a new cylinder head gasket. • Loosen 360°
1. Make sure the cylinder head dowels are • Tighten to 30 Nm
correctly located. • Tighten 90°
2. Install a new cylinder head gasket. • Tighten 90°
5 3 1 7
1
6 2 4 8
2
VUJ0002335
VUJ0002274
22. NOTE: Install the retaining bolts in the 24. Install the LH inlet camshaft.
indicated sequence.
Install the LH cylinder head.
• Tighten 90°
• Loosen 360°
• Tighten 90°
VUJ0002272
25. Install the LH inlet camshaft bearing cap

2000.0 X200 4/2005 Page 220 G95946en

303-01A-8 Engine — 3.0L 303-01A-8
ASSEMBLY
• Install the inlet camshaft bearing caps. 28. Align the timing marks on the rear of the
sprockets.
2 4 6 8
1 3 5 7
VUJ0002271
VUJ0002255
26. Install the LH exhaust camshaft.
29. Install the crankshaft sprocket.
VUJ0002269
VUJ0002260
27. Install the LH exhaust camshaft bearing
cap retaining bolts evenly. 30. Install the LH timing chain guide.
• Install the exhaust camshaft bearing caps. • Tighten to 25Nm.
2 4 6 8
1 3 5 7
VUJ0002268
VUJ0002258
31.
CAUTION: Make sure the colored timing
chain links align with the marks on the
camshaft sprockets and the crankshaft
sprocket.
G95946en
Page 221 4/2005 2000.0 X200
303-01A-9 Engine — 3.0L 303-01A-9
ASSEMBLY
Install the LH timing chain. Hold the LH timing chain tensioner ratchet
lock mechanism away from the ratchet stem
with a small pick.
VUJ0002257
GA3139-B
32. Install the LH chain tensioner arm.
35. NOTE: Piston should retract with minimal

force. If binding occurs, reposition the
Slowly compress the LH timing chain
tensioner.
36. NOTE: Wire must remain in the timing chain
tensioner until the tensioner is installed
onto the engine with the piston bottomed
in the bore.
VUJ0002256 Retain the tensioner piston using a suitable

tool.
33. Position the LH timing chain tensioner in a
vise with jaw protectors.
GA3140-A
GA3138-B 37. Install the LH chain tensioner.

• Tighten to 25Nm.
34.
CAUTION: During tensioner
compression, do not release ratchet stem
until tensioner piston is fully bottomed in
its bore or damage to the ratchet stem will
result.
2000.0 X200 4/2005 Page 222 G95946en

303-01A-10 Engine — 3.0L 303-01A-10
ASSEMBLY
• Release the tension in the tensioner. 40. Install the RH exhaust camshaft.
VUJ0001186
VUJ0002263
38. Install the RH inlet camshaft. 41. Install the RH exhaust camshaft bearing
• Install the exhaust camshaft bearing caps.
8 6 4 2
VUJ0002266
7 5 3 1
39. Install the RH inlet camshaft bearing cap VUJ0002262
• Install the inlet camshaft bearing caps. 42. Align the timing marks on the rear of the
sprockets.
8 6 4 2
7 5 3 1
VUJ0002265
VUJ0002280
43. Install the RH timing chain guide.
G95946en
Page 223 4/2005 2000.0 X200
303-01A-11 Engine — 3.0L 303-01A-11
ASSEMBLY
• Tighten to 25Nm. 46. Position the RH timing chain tensioner in
a vise with jaw protectors.
VUJ0002254
GA3138-B
44.
CAUTION: Make sure the colored timing
chain links align with the marks on the 47.
CAUTION: During tensioner
camshaft sprockets and the crankshaft compression, do not release ratchet stem
sprocket. until tensioner piston is fully bottomed in
Install the RH timing chain. its bore or damage to the ratchet stem will
result.
Hold the RH timing chain tensioner ratchet
lock mechanism away from the ratchet stem
with a small pick.
VUJ0002253
45. Install the RH chain tensioner arm.
GA3139-B
48. NOTE: Piston should retract with minimal

force. If binding occurs, reposition the
Slowly compress the RH timing chain
tensioner.
49. NOTE: Wire must remain in the timing chain
tensioner until the tensioner is installed
onto the engine with the piston bottomed
VUJ0002252
in the bore.
2000.0 X200 4/2005 Page 224 G95946en

303-01A-12 Engine — 3.0L 303-01A-12
ASSEMBLY
Retain the tensioner piston using a suitable Do not rotate the crankshaft
tool. counterclockwise. The timing chains may
GA3140-A
VUJ0001179
50. Install the RH chain tensioner.

52. Carry out a valve clearance check. For
additional information, refer to For
• Release the tension in the tensioner. additional information, refer to: Valve
Clearance Check (303-01A Engine - 3.0L,
53. Remove the crankshaft pulley retaining bolt
and washer.
54. Install the crankshaft position (CKP) sensor
pulse wheel.
VUJ0002250
51. Install the crankshaft pulley retaining bolt

and washer.
Rotate the crankshaft clockwise until the VUJ0002248
colored timing chains align with the marks on
the camshaft sprockets and crankshaft
sprocket, to position the engine to top dead 55. Install new engine front cover gaskets.
center (TDC) No. 1 cylinder prior to the removal
and installation of the camshafts.
VUJ0002336
G95946en
Page 225 4/2005 2000.0 X200
303-01A-13 Engine — 3.0L 303-01A-13
ASSEMBLY
56. NOTE: Prior to applying sealer clean the 57. NOTE: Tighten the retaining nuts in the
engine front cover to engine block and indicated sequence.
cylinder head sealing surfaces with metal
Install the engine front cover.
surface cleaner.
Apply silicone sealant meeting Jaguar
specification to the indicated locations.
GA3187-A
3 2 6
5
4
9
8
10 16 11 13 12 15 14
VUJ0002247
1. Apply an 8mm dot of silicone gasket and

58. NOTE: Install the oil pan and tighten the
sealant or equivalent meeting Jaguar
retaining bolts within six minutes of
specification to the sealing surface on the
applying sealer.
engine block and front cover joint.
Install the oil pan. • Install a new gasket.
• Install the retaining bolts.
2000.0 X200 4/2005 Page 226 G95946en

303-01A-14 Engine — 3.0L 303-01A-14
ASSEMBLY
VUJ0002243
To install, reverse the removal procedure.

59. NOTE: Apply a 5mm diameter bead of
silicone gasket sealant on the valve cover • Install new valve cover gaskets.
caps and apply an 8mm diameter on the • Tighten to 10Nm.
two places where the cylinder head and
front cover join.
VUJ0002241
61. Install the engine oil pressure and oil

temperature sensors.
VUJ0002239

silicone gasket sealant on the valve cover
caps and apply an 8mm diameter on the
two places where the cylinder head and
front cover join.
G95946en
Page 227 4/2005 2000.0 X200
303-01A-15 Engine — 3.0L 303-01A-15
ASSEMBLY
• Tighten to 14Nm. • Install a new O-ring seal.
10 Nm
VUJ0002229 VUJ0001037
62. Install the cylinder head temperature (CHT) 65. Install the water pump and coolant hose
sensor. assembly.
25 Nm
14 Nm
252Nm
VUJ0001230
VUJ0001039
63. Install the exhaust manifold. 66. Install the accessory drive belt tensioner
and accessory drive belt idler pulley.
6 1 20 Nm 3
25 Nm
4 2 5
48 Nm
VUJ0001206
VUJ0001040
64. Install the oil level indicator tube.

67. Install the coolant crossover tube.
2000.0 X200 4/2005 Page 228 G95946en

303-01A-16 Engine — 3.0L 303-01A-16
ASSEMBLY
• Install new O-ring seals. 70. Install the A/C compressor.
10 Nm
25 Nm 25 Nm
VUJ0001041 VUJ0001044
68. Install the front knock sensor. 71. NOTE: Install new O-ring seals.
Install the oil filter housing.
• Tighten all oil filter housing retaining bolts to
25 Nm 25 Nm.
VUJ0001042
69. Install the air conditioning (A/C)

compressor mounting bracket.
E30761
72. Tighten the retaining bolts in sequence.

2. Tighten to 40 Nm + 90 degrees.
25 Nm
VUJ0001043
2
2
1
E31387
G95946en
Page 229 4/2005 2000.0 X200
303-01A-17 Engine — 3.0L 303-01A-17
ASSEMBLY
73. Install the exhaust manifold heat shield. 76. Install the generator.
10 Nm 48 Nm
10 Nm
VUJ0001047 VUJ0001049
74. Install the power steering pump. 77. Install the accessory drive belt idler pulley
and bracket.
25 Nm 25 Nm
VUJ0001046
VUJ0001048
75. Install the exhaust manifold.

pulley.
3 1 20 Nm 6
• Coat the crankshaft pulley keyway with
silicone gasket sealant meeting Jaguar
specification.
• Coat the sealing surfaces of the crankshaft
pulley with silicone gasket sealant meeting
Jaguar specification.
5 2 4 303-335/2
VUJ0001207
303-102
VUJ0001017
2000.0 X200 4/2005 Page 230 G95946en

303-01A-18 Engine — 3.0L 303-01A-18
ASSEMBLY
79. Using the special tool, hold the crankshaft 82. Install the exhaust manifold heat shield.
pulley and install the crankshaft vibration
damper retaining bolt.
10 Nm
• Torque to 120 Nm.
• Loosen the retaining bolt (minimum 1 turn).
• Angle Torque to 90°.
303-D055 VUJ0001051
83. Install the engine mount bracket.
E30933
40 Nm
80. Install the engine rear backing plate.
VUJ0001050
84. Install the accessory drive belt.

1. Rotate the belt tensioner counter-clockwise.
the belt tensioner.
VUJ0001064
2. Install the belt.
81. NOTE: The flywheel will only locate in one

position.
Install the flywheel.
2
• Prevent the engine from rotating.
• Tighten the retaining bolts working
diagonally.
1
80 Nm 80 Nm
VUJ0001019
80 Nm
VUJ0001052
G95946en
Page 231 4/2005 2000.0 X200
303-01A-19 Engine — 3.0L 303-01A-19
ASSEMBLY
85. Install new gaskets. 88. Attach the engine wiring harness to the
engine.
VUJ0001020
VUJ0001138
86. Install the fuel injection supply manifold

and lower intake manifold. 89. Attach the engine wiring harness to the
10 Nm
10 Nm
10 Nm
VUJ0001055
VUJ0001137
87. Install the ignition coils.

90. Attach the engine wiring harness to the
6 Nm 6 Nm
6 Nm
VUJ0001056
VUJ0001798
2000.0 X200 4/2005 Page 232 G95946en

303-01A-20 Engine — 3.0L 303-01A-20
ASSEMBLY
91. Attach the engine wiring harness to the 94. Connect the electrical connectors.
left-hand valve cover.
6 Nm
E43699
VUJ0001229
95. Install the crankcase tube bracket retaining

92. Attach the engine wiring harness to the nut.
left-hand valve cover.
10 Nm
VUJ0001874
VUJ0001024
96. Attach the cylinder head earth strap.

93. Attach the throttle body wiring harness to
the left-hand valve cover.
E43698
VUJ0001063
G95946en
Page 233 4/2005 2000.0 X200
303-01A-21 Engine — 3.0L 303-01A-21
ASSEMBLY
97. Connect the electrical connectors. 100. Install the coolant hose.
E43697 E30573
98. Connect the fuel rail pressure (FRP) sensor 101. Install the coolant hose.
vacuum hose and electrical connector.
E30572
VUJ0001115
102. Connect the oil cooler coolant hoses.

99. Attach the fuel injector wiring harness.
E30571
VUJ0001025
2000.0 X200 4/2005 Page 234 G95946en

303-01A-22 Engine — 3.0L 303-01A-22
ASSEMBLY
103. Install the rear knock sensor. 106. Connect the crankshaft position (CKP)
sensor electrical connector.
25 Nm
VUJ0001054
VUJ0001028

2. Attach the engine wiring harness. 1. Connect the oil pressure switch and oil
temperature sensor electrical connector.
1
1
2
VUJ0001030
2
VUJ0001026
connector.
2. Attach the oxygen sensor electrical 1. Connect the knock sensor electrical
connector. connector.
3. Attach the engine wiring harness. 2. Connect the A/C compressor electrical
connector.
1 3
3
2
VUJ0001029
1
2
VUJ0001027
109. Install the intake manifold.
G95946en
Page 235 4/2005 2000.0 X200
303-01A-23 Engine — 3.0L 303-01A-23
ASSEMBLY
• Loosely install the intake manifold retaining • Tighten to 7 Nm.
bolts.
E43861
E43696
113. Connect the intake manifold tuning (IMT)

110. Install the FRP sensor cover. valve.
• Loosely install the FRP cover retaining bolts.
E43691
E43860
114. Install the evaporative emission purge valve

111. Tighten the intake manifold retaining bolts vacuum tube.
in sequence.
8 6 10 Nm 1 3
4 2 5 7
E43690
VUJ0001236
112. Install the FRP cover retaining nut.
2000.0 X200 4/2005 Page 236 G95946en

303-01A-24 Engine — 3.0L 303-01A-24
ASSEMBLY
115. Connect the engine breather hose. 118. Install a new throttle body gasket.
E43693 VUJ0000126
116. Connect the coolant hose. 119. Install the throttle body.
E43692
VUJ0000124
117. Attach the throttle body.

• Connect the coolant hoses. 120. NOTE: Reposition the throttle motor
electrical connector insulation.
Connect the throttle motor electrical
connector.
VUJ0000125
E43694
G95946en
Page 237 4/2005 2000.0 X200
303-01A-25 Engine — 3.0L 303-01A-25
ASSEMBLY
121. Connect the throttle position (TP) sensor
E43695
122. Connect the IMT valve electrical connector.

1. Install the IMT valve cover.
2. Connect the IMT valve electrical connector.
2
E43864
2000.0 X200 4/2005 Page 238 G95946en

303-01A-2 Engine — 3.0L 303-01A-2
Cylinder Head ()
Special Tool(s) • Discard the 'O' ring seal.
303-252
303252
Disassembly
1. VUJ0002330
CAUTION: If the cylinder head valve
components are to be reused, mark position
of the valve components to make sure they 4. Using the special tool, compress the valve
are reassembled in the same position. springs.
Remove the bucket tappet and shim • Remove the valve collets.
assemblies.
303 252
VUJ0002333
VUJ0002332
5. Remove the valve spring retainers and valve
2. Remove the variable camshaft timing control springs.
solonoid. 1. Remove the valve spring retainers.
2. Remove the valve springs.
3. Remove the valve stem oil seals.
2
VUJ0002328
VUJ0002334
3. Remove the camshaft position sensor and
suppressor.
6. Remove the valves from the cylinder heads.
1. Remove the intake valves.
G95944en
Page 239 4/2005 2000.0 X200
303-01A-3 Engine — 3.0L 303-01A-3
2. Remove the exhaust valves. 2. Install the exhaust valves.
2 2
1 1
VUJ0002337 VUJ0002337
7. Inspect the cylinder heads and the related 4. Install the valve spring retainers and valve
components. For additional information, refer springs.
1. Install the valve stem oil seals.
Information].
8. Remove the pipe plugs and alignment dowels 3. Install the valve spring retainers.
as necessary to clean the cylinder heads.
Assembly 3
1.
WARNING: Eye protection is required 1
follow these instructions may result in
personal injury. 2
CAUTION: The cylinder head surface finish
is measured in microns. For correct head
gasket sealing, avoid any contact of finish VUJ0002304
Clean gasket material, dirt and foreign 5. Using the special tool, compress the valve
material from cylinder heads. Wash with a springs.
suitable soap and water solution and dry
completely using compressed air if pipe • Install the valve collets.
plugs have been removed.
2. Install the pipe plugs and alignment dowels 303 252
to cylinder heads.
installation.
3. NOTE: Lubricate the valve stems before
assembly.
Install the valves into the cylinder heads.
1. Install the intake valves.
VUJ0002333
6. Install the camshaft position sensor and

suppressor.
2000.0 X200 4/2005 Page 240 G95944en

303-01A-4 Engine — 3.0L 303-01A-4
VUJ0002330
7. Install the variable camshaft timing control

solenoid.
VUJ0002328
8. Install the bucket tappet and shim

assemblies.
VUJ0002332
G95944en
Page 241 4/2005 2000.0 X200
303-01A-5 Engine — 3.0L 303-01A-5
Piston ()

they were removed.
A0006862
A0006859
A0006863
6.
A0006860
A0006861
A0006864
2000.0 X200 4/2005 Page 242 G95945en

303-01A-6 Engine — 3.0L 303-01A-6
System - General Information].
A0006865

A0006867
Information].
Assembly
A0006856
A0006866
A0006857
A0006864
G95945en
Page 243 4/2005 2000.0 X200
303-01A-7 Engine — 3.0L 303-01A-7
a "0" marked on it. Position this side of the
A0006858

with either side up.
A0006859
2000.0 X200 4/2005 Page 244 G95945en

303-01A-1 Engine — 3.0L 303-01A-1
.

CONTENTS PAGE
GENERAL PROCEDURES
Valve Clearance Adjustment............................................................................................... 303-01A-2
Valve Clearance Check...................................................................................................... 303-01A-3
Page 245
303-01A-2 Engine — 3.0L 303-01A-2
GENERAL PROCEDURES

1. Remove the camshafts. For additional
information, refer toCamshaft.
2. Use compressed air to remove the shims
that require replacing.
• Blow compressed air between the shim edge
and bucket to dislodge the shim.
3. Use the following formula to calculate the
• Original shim thickness + measured
shim thickness.
4. Apply a light coat of engine oil to the
5. Install the camshafts. For additional
information, refer toCamshaft.
G61278en
Page 246 4/2005 2000.0 X200
303-01A-3 Engine — 3.0L 303-01A-3
GENERAL PROCEDURES

additional information, refer to Valve
Cover—LH.
Cover—RH.
3. CAUTIONS:

Information].
Adjust the clearances as necessary. For
additional information, refer
toValve—Clearance Adjustment.
VUJ0002259

Cover—RH.
Cover—LH.
2000.0 X200 4/2005 Page 247 G61277en

303-01A-1 Engine — 3.0L 303-01A-1
.

CONTENTS PAGE
IN-VEHICLE REPAIR
Camshafts LH..................................................................................................................... 303-01A-2
Crankshaft Front Seal......................................................................................................... 303-01A-3
Crankshaft Pulley................................................................................................................ 303-01A-4
Crankshaft Rear Seal......................................................................................................... 303-01A-8
Cylinder Head..................................................................................................................... 303-01A-10
Engine Front Cover............................................................................................................. 303-01A-14
Engine Mount...................................................................................................................... 303-01A-18
Exhaust Manifold LH........................................................................................................... 303-01A-19
Exhaust Manifold RH.......................................................................................................... 303-01A-21
Flexplate............................................................................................................................. 303-01A-23
Flywheel.............................................................................................................................. 303-01A-25
Intake Manifold................................................................................................................... 303-01A-27
Oil Cooler............................................................................................................................ 303-01A-30
Oil Pan 303-01A-33
Oil Pump............................................................................................................................. 303-01A-36
Timing Drive Components.................................................................................................. 303-01A-38
Valve Cover LH................................................................................................................... 303-01A-46
Valve Cover RH.................................................................................................................. 303-01A-49
Page 248
303-01A-2 Engine — 3.0L 303-01A-2
IN-VEHICLE REPAIR
Camshafts LH ()
Removal Install the camshafts.
1. Remove the timing chains. For additional

information, refer to Timing Drive
Components.
2. Remove the camshaft bearing cap bolts
evenly.
• Remove the camshaft bearing caps.
VUJ0001196
2.
CAUTION: Do not install the cylinder head
camshaft journal thrust caps until the
camshaft journal caps are installed or
damage to the thrust caps may occur.
VUJ0001195 Install the camshaft bearing caps in their
original position.
3. Remove the camshafts. • Install the camshaft bearing cap bolts evenly.
1 10 Nm 3 5 7
2 4 6 8
10 12 14
9 11 13 15 16
VUJ0001211
VUJ0001196

Installation additional information, refer
toValve—Clearance Check.
1. NOTE: Lubricate the camshaft and the
camshaft bearing caps with oil 4. Install the timing chains. For additional
ESR-M99C80-A or equivalent meeting Jaguar information, refer to Timing Drive
specification prior to installation. Components.
G61266en
Page 249 5/2005 2001.0 X200
303-01A-3 Engine — 3.0L 303-01A-3
IN-VEHICLE REPAIR

Special Tool(s) • Lubricate the seal lip with clean engine oil.
Crankshaft Front Seal
Remover
303-409 303 335
303409

Installer
303-335
VUJ0001171
303335 2. Install the crankshaft vibration damper. For

additional information, refer to Crankshaft
Pulley.
Removal
1. Remove the crankshaft vibration damper.
For additional information, refer to
Crankshaft Pulley.
front oil seal.
303-409
VUJ0001170
Installation
front oil seal.
NOTE: Use tool 303-700 and the procedure described for the AJ61/AJ62 In-Vehicle Repair Section
2001.0 X200 5/2005 Page 250 G61263en

303-01A-4 Engine — 3.0L 303-01A-4
IN-VEHICLE REPAIR
Special Tool(s) 2. Remove the accessory drivebelt.
Wrench strap-universal
303-D055 1
303D055

303-D121
VUJ0000903
303D121
5. Remove the upper shield.
303102 Crankshaft Damper Installer
303-102
303102
Removal
1. Drain the cooling system. For additional
information, refer to Section 303-03 [Engine VUJ0000569
Cooling].
2. Remove and discard the drivebelt tensioner 6. Remove the throttle body. For additional
clip (if fitted). information, refer to Section 303-04A [Fuel
Charging and Controls -- 3.0L] / 303-04B
[Fuel Charging and Controls -- 4.0L].
7. Detach the coolant hose from the housing
assembly.
VUJ0000902
3. Remove the accessory drivebelt.

VUJ0001114
the belt tensioner.
G61262en
Page 251 5/2005 2001.0 X200
303-01A-5 Engine — 3.0L 303-01A-5
IN-VEHICLE REPAIR
8. Remove the upper radiator mounting bracket. 11. Using the special tool, hold the crankshaft
vibration damper.
303-D055
VUJ0002039
VUJ0001176
9. Detach the hose assembly from the water

pump and lower hose. 12. Loosen the crankshaft vibration damper
retaining bolt.
VUJ0000103
VUJ0001015
10. Remove the hose assembly.

13. Using the special tool, remove the
• Detach the hose clips.
crankshaft vibration damper.
303-D121
VUJ0000107
VUJ0001016
2001.0 X200 5/2005 Page 252 G61262en

303-01A-6 Engine — 3.0L 303-01A-6
IN-VEHICLE REPAIR
• Remove the crankshaft vibration damper 3. Install the crankshaft vibration damper bolt.
retaining bolt.
• Loosen the bolt (minimum 1 turn).
VUJ0001015
Installation
VUJ0001015
vibration damper.
4. Install the hose assembly.
• Coat the crankshaft damper keyway with
silicone gasket sealant WSE-M4G323-A6 or • Reposition the hose clips.
equivalent meeting Jaguar specification.
• Coat the sealing surfaces of the crankshaft
damper with silicone gasket sealant
WSE-M4G323-A6 motor oil or equivalent
meeting Jaguar specification.
303-335/2
303-102
VUJ0000107
5. Install the hose assembly to the water pump

and lower hose.
VUJ0001017
2. Using the special tool, hold the crankshaft

vibration damper.
303-D055
VUJ0000103
VUJ0001176
G61262en
Page 253 5/2005 2001.0 X200
303-01A-7 Engine — 3.0L 303-01A-7
IN-VEHICLE REPAIR
6. Install the upper radiator mounting bracket. • Use a 3/8 inch square drive bar to rotate
the belt tensioner.
2. Install the accessory drivebelt.
VUJ0002039
VUJ0000903
7. Install the coolant hose to the housing
assembly.
13. Fill and bleed the cooling system. For
Section 303-03 [Engine Cooling].
VUJ0001114
8. Install the throttle body. For additional

information, refer to Section 303-04A [Fuel
Charging and Controls -- 3.0L] / 303-04B
[Fuel Charging and Controls -- 4.0L].
9. Install the upper shield.
VUJ0000569
10. Raise the vehicle.

11. Install the accessory drivebelt.
2001.0 X200 5/2005 Page 254 G61262en

303-01A-8 Engine — 3.0L 303-01A-8
IN-VEHICLE REPAIR

Special Tool(s) Using the special tools, remove the
crankshaft rear main oil seal.
Remover
303-566
303 556
303566

Installer
303-178
VUJ0001120
303178
Installation
303-384
All Vehicles
1. Clean and inspect the crankshaft rear oil seal
sealing surfaces.
2. Lubricate the crankshaft flange, the
303384
crankshaft rear oil bore seal, and the oil seal
Crankshaft Rear Seal lip.
303102
Installer Draw Bolts • Use engine assembly lubricant or equivalent
303-102 meeting Jaguar specification
ESR-M99C80-A.
3. NOTE: Alternate bolt tightening to correctly
303102 seat the crankshaft rear oil seal until it is
flush with the cylinder block.
Removal rear oil seal.
Vehicles With Manual Transmission

1. Remove the flywheel. For additional 303 178
information, refer to Flywheel—Manual
Transmission.
Vehicles With Automatic Transmission

2. Remove the flexplate. For additional
information, refer to Flexplate—Automatic 303 384
Transmission.
VUJ0001848
All Vehicles
3.
CAUTION: Avoid scratching or damaging Vehicles With Automatic Transmission
the oil seal sealing surfaces on the
crankshaft and cylinder block. 4. Install the flexplate. For additional
Transmission.
G61275en
Page 255 5/2005 2001.0 X200
303-01A-9 Engine — 3.0L 303-01A-9
IN-VEHICLE REPAIR
5. Install the flywheel. For additional
Transmission.
2001.0 X200 5/2005 Page 256 G61275en

303-01A-38 Engine — 3.0L 303-01A-38
IN-VEHICLE REPAIR
Timing Drive Components

Removal
1 O'clock position and the alignment mark
1. Remove the engine front cover. For
on the right-hand exhaust camshaft sprocket
additional information, refer to Engine Front
is at the 8 O'clock position.
Cover.
2. Remove the spark plugs.
3. Remove the crankshaft position (CKP)
sensor pulse wheel.
VUJ0004246
6. Remove the right-hand timing chain

tensioner.
VUJ0001177
4.
Install the crankshaft pulley retaining bolt
and washer.
VUJ0001181
7. Remove the right-hand timing chain outer

guide.
VUJ0004259
5.
crankshaft keyway is at the 7 O'clock
VUJ0001182
position, the alignment mark on the
right-hand intake camshaft sprocket is at the
G61265en
Page 257 5/2005 2001.0 X200
303-01A-39 Engine — 3.0L 303-01A-39
IN-VEHICLE REPAIR
8. Remove the right-hand timing chain. 11.
Remove the crankshaft pulley retaining bolt
and washer.
12. Remove the left-hand timing chain
tensioner.
VUJ0001183
9. Remove the right-hand timing chain inner

guide.
VUJ0001186
13. Remove the left-hand timing chain inner

guide.
VUJ0001185
10.
crankshaft keyway is at the 11 O'clock VUJ0001188
position, the alignment mark on the left-hand
intake camshaft sprocket is at the 9 O'clock
14. Remove the left-hand timing chain.
position and the alignment mark on the
left-hand exhaust camshaft sprocket is at
the 2 O'clock position.
VUJ0001189
VUJ0004247
2001.0 X200 5/2005 Page 258 G61265en

303-01A-40 Engine — 3.0L 303-01A-40
IN-VEHICLE REPAIR
15. Remove the left-hand timing chain outer sprocket clockwise until the camshaft
guide. sprocket alignment mark is at the 12 O'clock
position.
VUJ0001193
VUJ0003137

3.
NOTE: Lubricate the camshafts and the camshaft
bearing caps with oil ESR-M99C80-A or equivalent
meeting Jaguar specification prior to installation.
Install the right-hand intake camshaft and
right-hand exhaust camshaft bearing caps
in their original position.
VUJ0001118 • Install the camshaft bearing cap retaining
bolts evenly.
Installation • Tighten the retaining bolts in the sequence
shown to 10 Nm.
1. Remove the right-hand intake camshaft and
right-hand exhaust camshaft bearing caps 1 10 Nm 3 5 7
evenly.
2 4 6 8
10 12 14
9 11 13 15 16
VUJ0001211
VUJ0001195
2. Rotate the right-hand intake camshaft

clockwise until the camshaft sprocket
alignment mark is at the 5 O'clock position
and rotate the right-hand exhaust camshaft
G61265en
Page 259 5/2005 2001.0 X200
303-01A-41 Engine — 3.0L 303-01A-41
IN-VEHICLE REPAIR
4. Install the crankshaft sprocket. Install the left-hand timing chain.
VUJ0001118 VUJ0004268
5. Install the left-hand timing chain outer guide. 7. Install the left-hand timing chain inner guide.
VUJ0001188
VUJ0001193
8.
CAUTION: Use suitable protective covers
6. CAUTIONS: on the vice jaws to protect the timing chain
Make sure the crankshaft keyway is at tensioner.
the 11 O'clock position, the alignment mark Secure the left-hand timing chain tensioner
on the left-hand intake camshaft sprocket is in the vice jaws.
at the 9 O'clock position and the alignment
mark on the left-hand exhaust camshaft
sprocket is at the 2 O'clock position.
Make sure the timing chain alignment

marks are correctly positioned to the
crankshaft sprocket and camshaft sprocket
alignment marks.
Make sure the timing chain slack is on
the tensioned side of the timing chain.
GA3138-B
9.
compression, do not release the ratchet stem
until the timing chain tensioner piston is fully
bottomed in its bore or damage to the ratchet
stem will result.
2001.0 X200 5/2005 Page 260 G61265en

303-01A-42 Engine — 3.0L 303-01A-42
IN-VEHICLE REPAIR
Using a suitable tool, hold the left-hand • Tighten to 25 Nm.
VUJ0004260
GA3139-B 13. Release the tension in the left-hand timing

chain tensioner.
10. NOTE: The timing chain tensioner piston • Remove the retaining tool.
should retract with minimal force. If binding
occurs, reposition the timing chain
Slowly compress the left-hand timing chain
tensioner.
Using a suitable tool, retain the left-hand
timing chain tensioner piston. VUJ0004248
14. Make sure the left-hand timing chain

alignment marks have remained correctly
positioned to the camshaft sprocket and
crankshaft sprocket alignment marks.
GA3140-A
12. Install the left-hand timing chain tensioner.
VUJ0004249
15.
and washer.
G61265en
Page 261 5/2005 2001.0 X200
303-01A-43 Engine — 3.0L 303-01A-43
IN-VEHICLE REPAIR
16. Install the right-hand timing chain.
position.
VUJ0003144
19. Install the right-hand timing chain outer

guide.
VUJ0003142
17. Install the right-hand timing chain inner

guide.
VUJ0001182
20.
CAUTION: Use suitable protective
covers on the vice jaws to protect the
timing chain tensioner.
Secure the right-hand timing chain tensioner
VUJ0001185 in the vice jaws.
18. CAUTIONS:
Make sure the crankshaft keyway is at
the 3 O'clock position, the alignment mark
on the right-hand intake camshaft sprocket
is at the 5 O'clock position and the
alignment mark on the right-hand exhaust
camshaft sprocket is at the 12 O'clock
position.

marks are correctly positioned to the GA3138-B
alignment marks.
2001.0 X200 5/2005 Page 262 G61265en

303-01A-44 Engine — 3.0L 303-01A-44
IN-VEHICLE REPAIR
21. • Tighten to 25 Nm.
is fully bottomed in its bore or damage to
VUJ0004261

chain tensioner.
GA3139-B

tensioner.
VUJ0004250
chain tensioner is installed to the engine 26.
CAUTION: Make sure the right-hand
timing chain alignment marks have
Using a suitable tool, retain the right-hand remained correctly positioned to the
timing chain tensioner piston. camshaft sprocket and crankshaft sprocket
alignment marks.
Make sure all the timing chain alignment
marks are in the positions shown.
GA3140-A
24. Install the right-hand timing chain

tensioner. VUJ0004251
G61265en
Page 263 5/2005 2001.0 X200
303-01A-45 Engine — 3.0L 303-01A-45
IN-VEHICLE REPAIR
27. Install the CKP sensor pulse wheel.
Check the engine valve timing is correctly
set.
• Rotate the crankshaft two complete turns
clockwise. Make sure the alignment marks
on the rear of the camshaft sprockets are in
line when the crankshaft keyway is at the 11
O'clock position.
VUJ0001177

31. Install the engine front cover. For additional
information, refer to Engine Front Cover.
VUJ0003147
28.
and washer.
VUJ0004259
29. NOTE: Make sure the CKP sensor pulse

wheel is correctly installed with the teeth
pointing outwards.
2001.0 X200 5/2005 Page 264 G61265en

303-01A-46 Engine — 3.0L 303-01A-46
IN-VEHICLE REPAIR
Valve Cover LH
Removal
5. Detach the wiring harness from the valve
1. Disconnect the battery ground cable.
cover.
2. Remove the engine cover.
VUJ0001024
VUJ0000140
6. Remove the ignition coils.

3. Detach the engine breather tube.
VUJ0001132
VUJ0001130

4. Detach the throttle body wiring harness. cover.
VUJ0001063 VUJ0001133
G61261en
Page 265 5/2005 2001.0 X200
303-01A-47 Engine — 3.0L 303-01A-47
IN-VEHICLE REPAIR
8. Remove the cylinder head temperature • Discard the valve cover gaskets.
sensor.
VUJ0001135
VUJ0001134
Installation
9. Remove the valve cover.
caps and apply an 8mm diameter on the two
places where the cylinder head and front
cover join.
7 11 1 10 Nm 14 10 6
15
5 3 13 4 12 2 8
VUJ0001231
2001.0 X200 5/2005 Page 266 G61261en

303-01A-48 Engine — 3.0L 303-01A-48
IN-VEHICLE REPAIR
14 Nm
VUJ0001230
6 Nm
VUJ0001229
6 Nm
6 Nm
VUJ0001228
2. NOTE: When the battery has been

disconnected and reconnected, some
abnormal drive symptoms may occur while
the vehicle relearns its adaptive strategy.
Connect the battery ground cable.
G61261en
Page 267 5/2005 2001.0 X200
303-01A-49 Engine — 3.0L 303-01A-49
IN-VEHICLE REPAIR
Valve Cover RH
Removal
• Remove the retaining nuts.
1. Remove the intake manifold. For additional
information, refer to Intake Manifold.
2. Remove the EGR valve tube.
VUJ0001138
6. Remove the ignition coils.

VUJ0001799
3. Detach the engine breather tube.
VUJ0001139

VUJ0001136 cover.
4. Detach the wiring harness.
VUJ0001797
VUJ0001137 8. Remove the valve cover.
5. Detach the wiring harness/bracket from the

valve cover.
2001.0 X200 5/2005 Page 268 G61260en

303-01A-50 Engine — 3.0L 303-01A-50
IN-VEHICLE REPAIR
• Discard the valve cover gaskets. Installation
caps and apply an 8mm diameter on the two
places where the cylinder head and front
cover join.
VUJ0001140
6 10 14 11 7
15
8 2 12 4 13 3 10 Nm 1
VUJ0001227
6 Nm
6 Nm
VUJ0001798 VUJ0001226
G61260en
Page 269 5/2005 2001.0 X200
303-01A-51 Engine — 3.0L 303-01A-51
IN-VEHICLE REPAIR
6 Nm
VUJ0001225
40 Nm
VUJ0001800
2001.0 X200 5/2005 Page 270 G61260en


303-01-1 Engine 303-01-1
.
SECTION 303-01 Engine

CONTENTS PAGE
DISASSEMBLY
Engine. 303-01-2
Page 271
303-01-2 Engine 303-01-2
DISASSEMBLY
Engine
Special Tool(s)
Wrench strap-universal Disassembly
303-D055
1. Disconnect the throttle motor electrical
connector.
303D055
Crankshaft Pulley Remover

303-D121
303D121
Crankshaft Pulley Installer E30763

303102
303-102
2. Disconnect the throttle position sensor.
303102
Trust Pad
303-D121-01
303D12101
E30764
Crankshaft pulley installer
303-335/2
3. Disconnect the positive crankcase ventilation
(PCV) hose.
303-335/2
E30558
G201914en
Page 272 4/2005 2004.0 X400
303-01-3 Engine 303-01-3
DISASSEMBLY
4. Disconnect the electrical connectors. 7. Detach the intake manifold front retaining
bracket.
E30559
E30563
5. Disconnect the fuel pressure regulator

vacuum hose. 8. Detach the engine wiring harness from the
intake manifold rear retaining bracket.
E30560
E30564
6. Remove the fuel pressure regulator bracket.

9. Detach the intake manifold rear retaining
bracket.
E30561
E30565
10. NOTE: The evaporative emission canister

purge valve transfer pipe is attached to the
induction manifold by a quick release
coupling.
2004.0 X400 4/2005 Page 273 G201914en

303-01-4 Engine 303-01-4
DISASSEMBLY
Disconnect the evaporative emission 13. Remove the engine breather hose.
canister purge valve transfer pipe.
E30569
E30566
14. Remove the evaporative emission purge

11. Remove the intake manifold. valve hose.
E30567 E30570
12. Remove and discard the intake manifold 15. Disconnect the oil cooler coolant hoses.
gaskets.
E30571
E30568
G201914en
Page 274 4/2005 2004.0 X400
303-01-5 Engine 303-01-5
DISASSEMBLY
16. Remove the coolant hose. 19. Detach the engine harness.
E30572 E30575
17. Remove the coolant hose. 20. Detach engine harness.
E30573 E30576
18. Disconnect the electrical connectors. 21. Remove the rear knock sensor.
1. Detach the knock sensor wiring harness.
2. Remove the rear knock sensor.
2
E30574
VUJ0001018
2004.0 X400 4/2005 Page 275 G201914en

303-01-6 Engine 303-01-6
DISASSEMBLY
22. Disconnect the right-hand camshaft 25. Disconnect the right-hand ignition coils.
position sensor.
E30580
VUJ0003995

23. Detach the engine harness retaining
bracket.
E30581
E30577
27. Disconnect the left-hand camshaft position
sensor.
E30582
E30578
G201914en
Page 276 4/2005 2004.0 X400
303-01-7 Engine 303-01-7
DISASSEMBLY
28. Disconnect the left-hand ignition coils. 31. Remove the ignition coils.
E30584 E30588
29. Disconnect the engine wiring harness 32. Remove the lower intake manifold and
electrical connectors. injector supply manifold.
E30585 E30589
30. Remove the engine wiring harness. 33. Remove and discard the lower intake
manifold gaskets.
E30586
E30590
2004.0 X400 4/2005 Page 277 G201914en

303-01-8 Engine 303-01-8
DISASSEMBLY
34. Remove the left-hand knock sensor. 37. Remove the generator.
E30434 VUJ0001011
35. Remove the accessory drive belt. 38. Remove the power steering pump.
1. Use a 3/8 inch drive bar to release the
accessory drive belt tensioner.
2. Remove the accessory drive belt.
1
E30593
39. Remove the air conditioning (A/C)

E30592 compressor.
36. Remove the right-hand idler pulley.
VUJ0001006
VUJ0001010
G201914en
Page 278 4/2005 2004.0 X400
303-01-9 Engine 303-01-9
DISASSEMBLY
40. Remove the A/C compressor mounting Remove the exhaust manifolds.
bracket.
VUJ0001200
E30594
44. Remove the flywheel.

1. Remove and discard the O-ring seal.
VUJ0001014
E30595
45. Remove the engine rear backing plate.

42. NOTE: Right-hand shown, Left-hand similar.
Remove the exhaust manifold heat shields.
VUJ0001064
VUJ0001013 46. Remove the oil filter housing assembly.
2004.0 X400 4/2005 Page 279 G201914en

303-01-10 Engine 303-01-10
DISASSEMBLY
• Remove and discard the O-ring seal. 2. Remove the water pump and coolant hose
assembly.
2
E30761
VUJ0001002
47. Remove the engine oil pressure and oil

temperature sensors. 50. Remove the accessory drive belt tensioner.
VUJ0002229 E30940
48. Remove the coolant crossover tube. 51. Install the special tool, loosen the
crankshaft pulley retaining bolt.
303-D055
VUJ0001005 E30933
49. Remove the water pump and coolant hose

assembly.
1. Detach the hose.
G201914en
Page 280 4/2005 2004.0 X400
303-01-11 Engine 303-01-11
DISASSEMBLY
52. Install the special tool. • Clean and inspect the oil pan and cylinder
block sealing surfaces using Metal surface
cleaner or equivalent meeting Jaguar
specification.
303-D121-01
E30934
53. Using the special tool, remove the E30925

Remove the valve covers.
303-D121
E30935
54. Remove the left-hand idler pulley.

VUJ0003858
57. Remove the engine front cover

• Remove and discard the engine front cover
gaskets.
VUJ0001172
55. Remove the oil pan.

• Remove and discard the oil pan gasket.
E30915
2004.0 X400 4/2005 Page 281 G201914en

303-01-12 Engine 303-01-12
DISASSEMBLY
58. Remove the crankshaft position (CKP) 1 O'clock position and the alignment mark
sensor pulse wheel. on the right-hand exhaust camshaft sprocket
VUJ0003443
VUJ0003971
59.
61.
counterclockwise. The timing chains may CAUTION: Do not rotate the crankshaft
bind causing engine damage. counterclockwise. The timing chains may
and washer. Remove the crankshaft pulley retaining bolt
and washer.
VUJ0003810
VUJ0003810
60.
62. Remove the right-hand timing chain
tensioner.
position, the alignment mark on the
right-hand intake camshaft sprocket is at the
VUJ0003441
G201914en
Page 282 4/2005 2004.0 X400
303-01-13 Engine 303-01-13
DISASSEMBLY
63. Remove the right-hand timing chain outer 66. Remove the crankshaft outer sprocket.
guide.
VUJ0003360
VUJ0003440
67.
64. Remove the right-hand timing chain.
and washer.
68.
position, the alignment mark on the left-hand
VUJ0003362
intake camshaft sprocket is at the 9 O'clock
position and the alignment mark on the
left-hand exhaust camshaft sprocket is at
65. Remove the right-hand timing chain inner the 2 O'clock position.
guide.
E31326
VUJ0003361
69.
and washer.
2004.0 X400 4/2005 Page 283 G201914en

303-01-14 Engine 303-01-14
DISASSEMBLY
70. Remove the left-hand timing chain 73. Remove the left-hand timing chain outer
tensioner. guide.
VUJ0003358 VUJ0003355
71. Remove the left-hand timing chain inner 74. Remove the crankshaft inner sprocket.
guide.
VUJ0003354
VUJ0003357
75. Remove the RH exhaust camshaft bearing

72. Remove the left-hand timing chain. cap bolts evenly.
• Remove the exhaust camshaft bearing caps.
VUJ0003356
VUJ0002261
G201914en
Page 284 4/2005 2004.0 X400
303-01-15 Engine 303-01-15
DISASSEMBLY
76. Remove the RH exhaust camshaft. • Remove the exhaust camshaft bearing caps.
VUJ0002267
VUJ0002263
77. Remove the RH inlet camshaft bearing cap 80. Remove the LH exhaust camshaft.
bolts evenly.
• Remove the inlet camshaft bearing caps.
VUJ0002269
VUJ0002264 81. Remove the LH inlet camshaft bearing cap

bolts evenly.
78. Remove the RH inlet camshaft. • Remove the inlet camshaft bearing caps.
VUJ0002270
VUJ0002266
79. Remove the LH exhaust camshaft bearing

cap bolts evenly.
2004.0 X400 4/2005 Page 285 G201914en

303-01-16 Engine 303-01-16
DISASSEMBLY
82. Remove the LH inlet camshaft. • Discard the 'O' ring seals.
E31346
VUJ0002272
83. NOTE: Remove the bolts in the indicated 86. NOTE: Engine inverted for clarity.
sequence. Remove the oil pump tube.
Remove the RH cylinder head.
• Discard the gasket.
4 6 8 2
VUJ0003458
3 7 5 1
VUJ0002273 87. Remove the oil pan baffle.
84. NOTE: Remove the bolts in the indicated

sequence.
Remove the LH cylinder head.
• Discard the gasket.
2 8 6 4
VUJ0002281

1 5 7 3 • Remove and discard the O-ring seal.
VUJ0002275
85. Remove the engine coolant housing.
G201914en
Page 286 4/2005 2004.0 X400
303-01-17 Engine 303-01-17
DISASSEMBLY
• Inspect the oil pump for damage and wear. Install special tools to the connecting rods.
303 535
VUJ0003838 VUJ0002285
89. 92.
CAUTION: Pistons, connecting rods and CAUTION: Care should be taken not to
connecting rod bearings should be damage the connecting rod and cap joint
numbered to make sure they are face surfaces or possible engine damage
reassembled in the same position. may occur. Avoid contaminating the
NOTE: Mark the position of the connecting rod fracture joint surfaces with dirt or grease.
caps to the connecting rods to make sure correct NOTE: Reattach the connecting rods and caps
insulation. after removal to avoid mismatch.
NOTE: Discard the connecting rod bolts after Remove the pistons.
removal.
Remove the connecting rod bolts, the bottom of travel.
VUJ0002284 VUJ0002286
90. Inspect the tops of the cylinder bores. As 93. NOTE: Remove the lower cylinder block
necessary remove ridge and carbon build bolts in the indicated sequence.
up from each cylinder.
91.
surfaces.
2004.0 X400 4/2005 Page 287 G201914en

303-01-18 Engine 303-01-18
DISASSEMBLY
4 22 14 6 20 12 2 16 8 11 7
15
19
18
10
1
17 13 21 3 5
VUJ0002312

94. NOTE: Mark the position of the upper and
lower crankshaft main bearing and the • Discard the crankshaft rear main oil seal.
crankshaft thrust bearing for reassembly.
Remove the lower crankshaft bearings.
1. Remove the lower crankshaft thrust main
bearing.
2. Remove the lower crankshaft main bearings.
VUJ0002289
1
2
2
VUJ0002293
95.
G201914en
Page 288 4/2005 2004.0 X400
303-01-19 Engine 303-01-19
DISASSEMBLY
bearings.
VUJ0002290
97. Clean the cylinder block with a soap and

2004.0 X400 4/2005 Page 289 G201914en

303-01-1 Engine 303-01-1
.

CONTENTS PAGE
ASSEMBLY
Engine. 303-01-2
Page 290
303-01-2 Engine 303-01-2
ASSEMBLY
Engine
Special Tool(s) Reseal oil passage blanking plugs, as
necessary.
Wrench Strap-Universal
303-D055 3. NOTE: The main bearings are precision
Information].
Install the upper crankshaft thrust washer.
303D055
• Align assembly tab on thrust bearing to
Crankshaft Rear Seal machining spot face on cylinder block.
Installer
303-178
303178

303-384
VUJ0002291
303384
Piston Ring Compressor
303-372 • Lubricate the bearings and thrust washer.
303372
Cylinder Bore Protector

303-535
VUJ0002290
303535
5.
Assembly CAUTION: Avoid damage to any
crankshaft journal bearing surfaces.
1.
CAUTION: Use only plastic scraper when
removing old gasket material.
G201916en
Page 291 4/2005 2004.0 X400
303-01-3 Engine 303-01-3
ASSEMBLY
Install the crankshaft. 7. NOTE: Sealant application must stop 6 mm
from the rear crankshaft bore on each side.
NOTE: Install lower cylinder block and tighten all
bolts to specification within four minutes of applying
sealer.
housing.
• Use Silicone gasket and sealant.
VUJ0002289
6. NOTE: Push the crankshaft rearward prior

to installation of upper thrust bearings.
NOTE: Visually inspect the bearings to verify that
the bearing oiling holes align with cylinder block
oil feed holes.
Install the lower crankshaft bearings into the VUJ0002294
cylinder block.
1. Install the lower crankshaft thrust main 8.
bearing into lower cylinder block. seated into lower cylinder block prior to
2. Install the lower crankshaft main bearings tightening the bolts.
into lower cylinder block.
NOTE: Before installing the bolts lightly seat the
• Lubricate the bearings and thrust washer. crankshaft forward.
bolts.
NOTE: Loosely install the lower cylinder block
bolts.
NOTE: Do not rotate crankshaft until all bolts are
1 tightened to specification.
2
NOTE: Bolts must be tightened within 4 minutes
2
of applying sealant.
Install the lower cylinder block on the
VUJ0002293 cylinder block.
• Push crankshaft rearward to seat the
crankshaft thrust washer.
2004.0 X400 4/2005 Page 292 G201916en

303-01-4 Engine 303-01-4
ASSEMBLY
VUJ0002287
• Stage 1: Bolts 1-8, 25 Nm

9.
CAUTION: Bolts 1 through 16 are • Stage 2: Bolts 9-16, 40 Nm
tighten-to-yield and must be replaced. • Stage 3: Bolts 1-16, 90°
NOTE: Tighten the bolts in the indicated sequence • Stage 4: Bolts 17-22, 25 Nm
in four stages. • Verify the crankshaft rotates freely.
Complete the tightening sequence.
G201916en
Page 293 4/2005 2004.0 X400
303-01-5 Engine 303-01-5
ASSEMBLY
19 1 9 17 3 11 21 7 15 12 16
13
22
14
6 10 2 20 18
VUJ0002288

of the stroke.
out at the front cover sealing surface.
13. NOTE: Make sure the piston ring gaps are
11. NOTE: Alternate bolt tightening to correctly
positioned at different locations opposite
seat the crankshaft rear oil seal until it is
installation.
NOTE: Install pistons with arrow to front of engine.
rear oil seal.
Using the special tool compress the rings
303 178
303 384
303 372
VUJ0002329
12.
CAUTION: Use appropriate protection VUJ0002278
surfaces. 14. CAUTIONS:
2004.0 X400 4/2005 Page 294 G201916en

303-01-6 Engine 303-01-6
ASSEMBLY
When assembling the connecting rods
and connecting rod caps, it is imperative
that bearing slots and tangs be located on
the same side of the connecting rods.

connecting rods.
NOTE: Tighten the bolts in the indicated sequence
in three stages.
VUJ0003838
17.
• Stage 1: 23 Nm CAUTION: Oil pan baffle nuts are
• Stage 2: 43 Nm tightened to yield and must not be reused.
• Stage 3: 105° NOTE: Tighten the bolts in the indicated sequence
in two stages.
Install the oil pan baffle.
• Stage 1: 5 Nm
• Stage 2: 45°
VUJ0002284

operation.
16. CAUTIONS: VUJ0002281
Install the oil pump flush to the cylinder
block for correct sealing. 18. NOTE: Engine inverted for clarity.
Rotate the inner rotor of the oil pump to Install the oil pump tube.
align with the flats on the crankshaft before • Install a new O-ring seal.
installation. • Tighten to 10 Nm.
Install the oil pump.
VUJ0003839
G201916en
Page 295 4/2005 2004.0 X400
303-01-7 Engine 303-01-7
ASSEMBLY
19. NOTE: Engine inverted for clarity. 1. Make sure the cylinder head dowels are
correctly located.
Tighten to 5 Nm + 45°.
2. Install a new cylinder head gasket.
2
VUJ0004058
VUJ0002335
20. Install the engine coolant housing. 23. NOTE: Install the bolts in the indicated
• Install new 'O' ring seals. sequence.
• Tighten to 25 Nm. Install the LH cylinder head.
• Tighten 90°.
• Loosen 360°.
• Tighten 90°.
• Tighten 90°.
7 1 3 5
E31346
21. Position the crankshaft.

• Turn the crankshaft until the key is in the 11
o'clock position. 8 4 2 6
• Remove the crankshaft pulley bolt and
washer. VUJ0002276
24. NOTE: Install the bolts in the indicated

sequence.
Install the RH cylinder head.
• Tighten 90°.
• Loosen 360°.
• Tighten 90°.
VUJ0002295
22. Install a new cylinder head gasket (LH

shown - RH similar).
2004.0 X400 4/2005 Page 296 G201916en

303-01-8 Engine 303-01-8
ASSEMBLY
• Tighten 90°. 27. Install the LH exhaust camshaft.
5 3 1 7
6 2 4 8
VUJ0002274
VUJ0002269
25. Install the LH inlet camshaft. 28.

CAUTION: Do not install the cylinder
head camshaft journal thrust caps until the
bearing caps with oil WSE-M2C908-A or equivalent
meeting Jaguar specification prior to installation.
Install the LH exhaust camshaft bearing cap
bolts evenly.
• Install the exhaust camshaft bearing caps.
VUJ0002272
2 4 6 8
26.
CAUTION: Do not install the cylinder
head camshaft journal thrust caps until the
bearing caps with oil WSE-M2C908-A or equivalent
meeting Jaguar specification prior to installation. 1 3 5 7
Install the LH inlet camshaft bearing cap VUJ0002268
bolts evenly.
• Install the inlet camshaft bearing caps. 29. Install the RH inlet camshaft.
2 4 6 8
1 3 5 7
VUJ0002266
VUJ0002271
G201916en
Page 297 4/2005 2004.0 X400
303-01-9 Engine 303-01-9
ASSEMBLY
30. Install the RH inlet camshaft bearing cap sprocket clockwise until the camshaft
bolts evenly. sprocket alignment mark is at the 12
O'clock position.
• Install the inlet camshaft bearing caps.
8 6 4 2
7 5 3 1
VUJ0002265 VUJ0004271
31. Install the RH exhaust camshaft. 34. Install the crankshaft inner sprocket.
VUJ0002263 VUJ0003354
32. Install the RH exhaust camshaft bearing 35. Install the left-hand timing chain outer
cap bolts evenly. guide.
• Install the exhaust camshaft bearing caps. • Tighten the retaining bolts in the sequence
shown in two stages.
• Stage 1: Tighten bolt 1 to 25 Nm.
8 6 4 2 • Stage 2: Tighten bolts 2 to 25 Nm.
7 5 3 1
2
VUJ0002262
2
33. Rotate the right-hand intake camshaft
clockwise until the camshaft sprocket VUJ0003807
alignment mark is at the 5 O'clock position

and rotate the right-hand exhaust camshaft 36. CAUTIONS:
2004.0 X400 4/2005 Page 298 G201916en

303-01-10 Engine 303-01-10
ASSEMBLY
Secure the left-hand timing chain tensioner
in the vice jaws.
on the left-hand intake camshaft sprocket
alignment mark on the left-hand exhaust
position.

alignment marks.
the tensioned side of the timing chain. GA3138-B
Install the left-hand timing chain.

39.
Using a suitable tool, hold the left-hand
VUJ0003356
37. Install the left-hand timing chain inner

guide.
GA3139-B

Slowly compress the left-hand timing chain
VUJ0003357
tensioner.
38.
CAUTION: Use suitable protective the timing chain tensioner until the timing
covers on the vice jaws to protect the chain tensioner is installed to the engine
timing chain tensioner. with the piston bottomed in the bore.
G201916en
Page 299 4/2005 2004.0 X400
303-01-11 Engine 303-01-11
ASSEMBLY
Using a suitable tool, retain the left-hand 44. Make sure the left-hand timing chain
timing chain tensioner piston. alignment marks have remained correctly
positioned to the camshaft sprocket and
crankshaft sprocket alignment marks.
GA3140-A
VUJ0003808
42. Install the left-hand timing chain tensioner.
45.
and washer.
46.
VUJ0003358
position.

chain tensioner.
VUJ0003142
47.
VUJ0003359 counterclockwise. The timing chains may
and washer.
2004.0 X400 4/2005 Page 300 G201916en

303-01-12 Engine 303-01-12
ASSEMBLY
48. Install the crankshaft outer sprocket. Install the right-hand timing chain.
VUJ0003360 VUJ0003362
49. Install the right-hand timing chain inner 51. Install the right-hand timing chain outer
guide. guide.
• Tighten the retaining bolts in the sequence
shown in two stages.
• Stage 1: Tighten bolt 1 to 25 Nm.
• Stage 2: Tighten bolts 2 to 25 Nm.
1 2
VUJ0003440
52.
CAUTION: Use suitable protective
covers on the vice jaws to protect the
VUJ0003991
timing chain tensioner.
50. CAUTIONS: Secure the right-hand timing chain tensioner

in the vice jaws.
on the right-hand intake camshaft sprocket
alignment mark on the right-hand exhaust
position.

alignment marks.
GA3138-B
G201916en
Page 301 4/2005 2004.0 X400
303-01-13 Engine 303-01-13
ASSEMBLY
53. • Tighten to 25 Nm.
VUJ0003441

chain tensioner.
GA3139-B

tensioner.
VUJ0003442
chain tensioner is installed to the engine 58.
CAUTION: Make sure the right-hand
timing chain alignment marks have
Using a suitable tool, retain the right-hand remained correctly positioned to the
timing chain tensioner piston. camshaft sprocket and crankshaft sprocket
alignment marks.
Make sure all the timing chain alignment
marks are in the positions shown.
GA3140-A
56. Install the right-hand timing chain

tensioner. VUJ0003809
2004.0 X400 4/2005 Page 302 G201916en

303-01-14 Engine 303-01-14
ASSEMBLY
59. Remove the crankshaft pulley retaining bolt
and washer.
and washer.
VUJ0003810
62. NOTE: Make sure the CKP sensor pulse

wheel is correctly installed with the teeth
VUJ0003810
pointing outwards.
Install the CKP sensor pulse wheel.
60.
Check the engine valve timing is correctly
set.
• Rotate the crankshaft two complete turns
clockwise. Make sure the alignment marks
on the camshaft sprockets are in the
positions shown when the crankshaft keyway
VUJ0003443

Clearance Check in this section.
64. Install new front timing cover gaskets.
VUJ0004272
61.
VUJ0002336
G201916en
Page 303 4/2005 2004.0 X400
303-01-15 Engine 303-01-15
ASSEMBLY
65. NOTE: Prior to applying sealer clean the • Complete the tightening sequence.
front cover to engine block and cylinder • Tighten to 25 Nm.
head sealing surfaces with metal surface
cleaner. 10 11 12
9
Apply a 6 mm diameter dot of silicone 13
8
sealant meeting Jaguar specification to the
14
indicated locations.
15
7
6 1
5 3 2
4
E30926

Install the valve covers.
VUJ0003672
• Complete the tightening sequence.
66. NOTE: The engine front cover retaining
bolts numbered 3,4,10 and 11 are longer
than the retaining bolts numbered
4 2 8 5
1,2,5,6,7,8,9,12,13,15 and 16. The retaining 12 1 9
bolt numbered 14 is a retaining bolt with a
stud head.
Install the engine front cover, completing the 6 10 3 7
11
tightening sequence .
VUJ0004139
14 15
16 69. Install the left-hand idler pulley.
12
11 • Tighten to 25 Nm.
9 10
5
6
7 8
13 1 3
4
E30916 2
67. NOTE: Apply an 10 mm dot of silicone

gasket and sealant meeting Jaguar
specification to the engine block and front
cover mating surface. VUJ0001172
NOTE: Loosely install the oil pan to transmission
housing bolts. 70. Using the special tools, install the
NOTE: Tighten all oil pan retaining bolts with in six crankshaft pulley.
minutes of applying the sealer. • Coat the crankshaft pulley keyway with
Install the oil pan rear retaining bolts. silicone gasket sealant meeting Jaguar
specification.
2004.0 X400 4/2005 Page 304 G201916en

303-01-16 Engine 303-01-16
ASSEMBLY
• Coat the sealing surfaces of the crankshaft 2. Install the water pump and coolant hose
pulley with silicone gasket sealant meeting assembly.
Jaguar specification. • Tighten to 25 Nm.
303-335/2
2
303-102
1
2
VUJ0001017
VUJ0001002
71. Install the crankshaft pulley retaining bolt. 74. NOTE: Install new coolant crossover O-ring
• Torque to 120 Nm. seals.
• Loosen the bolt (minimum 1 turn). Install the coolant crossover tube.
• Torque to 50 Nm. • Tighten to 10 Nm,
303-D055
VUJ0001005
E30933
75. Install the engine oil pressure and oil

72. Install the accessory drive belt tensioner. temperature sensors.
• Tighten 45 Nm. • Tighten to 14Nm.
E30940 VUJ0002229
73. Install the water pump and coolant hose 76. NOTE: Install new O-ring seals.
assembly.
Install the oil filter housing assembly.
1. Attach the hose.
G201916en
Page 305 4/2005 2004.0 X400
303-01-17 Engine 303-01-17
ASSEMBLY
• Tighten all oil filter housing retaining bolts to • Tighten to 80 Nm.
25 Nm.
VUJ0001014
E30761

77. Tighten the oil filter housing assembly
Install the exhaust manifolds.
retaining bolts in sequence.
2. Tighten to 40 Nm + 90 degrees.
2
2
1 VUJ0001200
E31387
78. Install the engine rear backing plate. Install the exhaust manifold heat shields.
VUJ0001064
VUJ0001013
79. Install the flywheel.

82. NOTE: Install a new O-ring seal.
2004.0 X400 4/2005 Page 306 G201916en

303-01-18 Engine 303-01-18
ASSEMBLY
Install the oil level indicator tube. • Tighten to 25 Nm.
E30593
E30595
83. Install the A/C compressor mounting 86. Install the generator.
bracket. • Tighten to 48 Nm.
VUJ0001011
E30594
87. Install the right-hand idler pulley.
84. Install the air conditioning (A/C) • Tighten to 25 Nm.
compressor.
VUJ0001010
VUJ0001006 88. Install the accessory drive belt.

1. Use a 3/8 inch drive bar to release the
85. Install the power steering pump. accessory drive belt tensioner.
G201916en
Page 307 4/2005 2004.0 X400
303-01-19 Engine 303-01-19
ASSEMBLY
2. Install the accessory drive belt. • Tighten to 10 Nm.
E30592 E30589
89. Install the left-hand knock sensor. 92. Install the ignition coils.
E30434 E30588
90. Install new lower intake manifold gaskets. 93. Install the engine wiring harness.
E30590
E30586
91. Install the lower intake manifold and

injector supply manifold.
2004.0 X400 4/2005 Page 308 G201916en

303-01-20 Engine 303-01-20
ASSEMBLY
94. Connect the engine wiring harness 97. Attach the engine harness.
E30581
E30585
98. Connect the right-hand ignition coils.

95. Connect the left-hand ignition coils.
E30580
E30584

96. Connect the left-hand camshaft position
sensor.
E30578
E30582
G201916en
Page 309 4/2005 2004.0 X400
303-01-21 Engine 303-01-21
ASSEMBLY
100. Attach the engine harness retaining 103. Attach engine harness.
bracket.
E30576
E30577

101. Disconnect the right-hand camshaft
position sensor.
E30575
VUJ0003995
105. Connect the electrical connectors.
102. Install the rear knock sensor.

1. Attach the knock sensor wiring harness.
2. Install the rear knock sensor.
E30574
VUJ0001018
2004.0 X400 4/2005 Page 310 G201916en

303-01-22 Engine 303-01-22
ASSEMBLY
106. Install the coolant hose. 109. Install the evaporative emission purge valve
hose.
E30573
E30570
107. Install the coolant hose.

110. Install the engine breather hose.
E30572
E30569
108. Connect the oil cooler coolant hoses.

111. Install new intake manifold gaskets.
E30571
E30568
112. NOTE: The intake manifold retaining bolts

in position 1,2,3 and are longer than the
retaining bolts in position 4,5 and 6.
• Install new intake manifold gaskets.
G201916en
Page 311 4/2005 2004.0 X400
303-01-23 Engine 303-01-23
ASSEMBLY
• Tighten to 10 Nm. 115. Attach the engine wiring harness from the
intake manifold rear retaining bracket.
3 4
1 2 6
5
E31284
E30564
113. Connect the evaporative emission canister
purge valve transfer pipe. 116. Attach the intake manifold front retaining
bracket.
E30566
114. Attach the intake manifold rear retaining E30563

bracket.
• Tighten to 10 Nm. 117. Install the fuel pressure regulator bracket.
E30565
E31388
2004.0 X400 4/2005 Page 312 G201916en

303-01-24 Engine 303-01-24
ASSEMBLY
118. Tighten to 7 Nm. 121. Connect the positive crankcase ventilation
(PCV) hose.
E31389
E30558
119. Connect the fuel pressure regulator vacuum

hose. 122. Connect the throttle position sensor.
E30764
E30560
120. Connect the electrical connectors. 123. Connect the throttle motor electrical
connector.
E30559
E30763
G201916en
Page 313 4/2005 2004.0 X400
303-01-1 Engine 303-01-1
.

CONTENTS PAGE

Cylinder Head..................................................................................................................... 303-01-2
Piston.. 303-01-4
Page 314
303-01-2 Engine 303-01-2
Cylinder Head ()
Special Tool(s) 2. Remove the valve springs.
Valve Spring Compressor 3. Remove the valve stem oil seals.
303-252
1
3
303252
2
Disassembly
1.
CAUTION: If the cylinder head valve
components are to be reused, mark position VUJ0002334
of the valve components to make sure they

are reassembled in the same position. 4. Remove the valves from the cylinder heads.
Remove the bucket tappet and shim 1. Remove the intake valves.
assemblies. 2. Remove the exhaust valves.
1
E30946 VUJ0002337
2. Using the special tool, compress the valve 5. Inspect the cylinder heads and the related
springs. components. For additional information, refer
• Remove the valve collets.
Information].
303 252 as necessary to clean the cylinder heads.
Assembly
1.
follow these instructions may result in
personal injury.
VUJ0002333 CAUTION: The cylinder head surface finish
is measured in microns. For correct head
3. Remove the valve spring retainers and valve with metallic objects.
springs.
1. Remove the valve spring retainers.
G201915en
Page 315 4/2005 2004.0 X400
303-01-3 Engine 303-01-3
Clean gasket material, dirt and foreign • Install the valve collets.
material from cylinder heads. Wash with a
suitable soap and water solution and dry
303 252
completely using compressed air if pipe
plugs have been removed.
to cylinder heads.
installation.
3. NOTE: Lubricate the valve stems before
assembly.
VUJ0002333
Install the valves into the cylinder heads.
1. Install the intake valves.
6. Install the bucket tappet and shim
2. Install the exhaust valves. assemblies.
1
VUJ0002337
E30946
4. Install the valve spring retainers and valve

springs.
1. Install the valve stem oil seals.
3. Install the valve spring retainers.
VUJ0002304
5. Using the special tool, compress the valve

springs.
2004.0 X400 4/2005 Page 316 G201915en

303-01-4 Engine 303-01-4
Piston ()

they were removed.
A0006862
A0006859
A0006863
6.
A0006860
A0006861
A0006864
G95945en
Page 317 4/2005 2004.0 X400
303-01-5 Engine 303-01-5
System - General Information].
A0006865

A0006867
Information].
Assembly
A0006856
A0006866
A0006857
A0006864
2004.0 X400 4/2005 Page 318 G95945en

303-01-6 Engine 303-01-6
a "0" marked on it. Position this side of the
A0006858

with either side up.
A0006859
G95945en
Page 319 4/2005 2004.0 X400
303-01-1 Engine 303-01-1
.

CONTENTS PAGE
GENERAL PROCEDURES
Valve Clearance Adjustment............................................................................................... 303-01-2
Valve Clearance Check...................................................................................................... 303-01-3
Page 320
303-01-2 Engine 303-01-2
GENERAL PROCEDURES

1. Remove the camshafts. For additional
information, refer toCamshaft
2. Use compressed air to remove the shims
that require replacing.
• Blow compressed air between the shim edge
and bucket to dislodge the shim.
3. Use the following formula to calculate the
• Original shim thickness + measured
shim thickness.
4. Apply a light coat of engine oil to the
5. Install the camshafts. For additional
information, refer toCamshaft
G92375en
Page 321 4/2005 2004.0 X400
303-01-3 Engine 303-01-3
GENERAL PROCEDURES

1. Remove the left hand valve cover. For
Cover—LH
2. Remove the right hand valve cover. For
Cover—RH
3. CAUTIONS:
crankshaft counterclockwise can raise burrs

away from each valve shim or valve
clearance measurement will be incorrect.
Information]. Adjust the clearances as
to Valve Clearance Adjustment
VUJ0002259
2004.0 X400 4/2005 Page 322 G92374en

303-01-1 Engine 303-01-1
.

CONTENTS PAGE
IN-VEHICLE REPAIR
Camshafts LH..................................................................................................................... 303-01-2
Crankshaft Front Seal......................................................................................................... 303-01-3
Crankshaft Pulley................................................................................................................ 303-01-4
Crankshaft Rear Seal......................................................................................................... 303-01-7
Cylinder Head LH............................................................................................................... 303-01-9
Engine Front Cover............................................................................................................. 303-01-14
Engine Front Mount............................................................................................................ 303-01-31
Exhaust Manifold LH........................................................................................................... 303-01-34
Exhaust Manifold RH.......................................................................................................... 303-01-39
Flexplate............................................................................................................................. 303-01-40
Flywheel.............................................................................................................................. 303-01-41
Intake Manifold................................................................................................................... 303-01-42
Oil Cooler............................................................................................................................ 303-01-51
Oil Pan 303-01-52
Oil Pressure Sender........................................................................................................... 303-01-57
Oil Pump............................................................................................................................. 303-01-58
Timing Drive Components.................................................................................................. 303-01-60
Valve Cover LH................................................................................................................... 303-01-69
Valve Cover RH.................................................................................................................. 303-01-72
Page 323
303-01-2 Engine 303-01-2
IN-VEHICLE REPAIR
Camshafts LH ()
Removal Install the camshafts.
1. Remove the timing chains. For additional

Components.
2. Remove the camshaft bearing caps evenly.
VUJ0003767
2.
VUJ0003766
3. Remove the camshafts. Install the camshaft bearing caps in their

original position.
• Install the camshaft bearing cap retaining
bolts evenly.
• Tighten the retaining bolts in the sequence
shown to 10 Nm.
2 4 5 6 8
7
1
9 3 11 13 15
VUJ0003767
10
Installation
12 14 16
1. NOTE: Lubricate the camshafts and the VUJ0004303
camshaft bearing caps with oil
WSE-M2C908-A or equivalent meeting Jaguar
specification prior to installation. 3. Carry out a valve clearance check. For
Clearance Check.
4. Install the timing chains. For additional
Components.
G92363en
Page 324 5/2005 2003.0 X400
303-01-3 Engine 303-01-3
IN-VEHICLE REPAIR

Special Tool(s) NOTE: Lubricate the seal lip with oil
WSE-M2C908-A or equivalent meeting Jaguar
specification.
Remover
303-700 Using the special tool, install the crankshaft
front oil seal.
303-700 303-542

Installer
303-542
303-102
303-542
303102 Crankshaft Damper Installer VUJ0003655

303-102
2. Install the crankshaft vibration damper. For
additional information, refer to Crankshaft
Pulley.
303102
Removal
For additional information, refer to
Crankshaft Pulley.
front oil seal.
303-700
VUJ0003653
Installation
1.
CAUTION: Make sure the seal and the tool
are approximately parallel to the front of the
engine.
2003.0 X400 5/2005 Page 325 G92360en

303-01-4 Engine 303-01-4
IN-VEHICLE REPAIR
Special Tool(s) 2. Remove the splash shield.
Wrench strap-universal
303-D055
303D055

303-D121
VUJ0004136
303D121 3. Disconnect the crankshaft position sensor

(CKP) electrical connector.
Thrust Pad
303-D121-01
303D12101
303102 Crankshaft Damper Installer

Draw Bolt
303-102
VUJ0003779
303102
4. Remove the CKP sensor.

Crankshaft Damper Installer
303-335/2
303-335/2
Accessory Belt Detensioner

303-703
VUJ0003780
303-703 5. Detach the accessory drivebelt.

1. Using the special tool, rotate the belt
Removal tensioner counter clockwise.
1. Remove the wheel and tire. For additional

information, refer to Section 204-04 [Wheels
and Tires].
G92359en
Page 326 5/2005 2003.0 X400
303-01-5 Engine 303-01-5
IN-VEHICLE REPAIR
2. Detach the accessory drivebelt. 8. Using the special tools, remove the
303-703
303-D121
VUJ0003647
VUJ0003650
vibration damper retaining bolt.
Installation
• Remove and discard the crankshaft vibration
damper retaining bolt. 1. NOTE: Coat the crankshaft damper keyway
with silicone gasket sealant WSE-M4G323-A6
or equivalent meeting Jaguar specification.
Using the special tool, install the crankshaft
vibration damper.
303-102
303-D055
VUJ0003648 303-335/2
7. Install the special tool.
VUJ0003651
2. Using the special tool, tighten the crankshaft

vibration damper retaining bolt.
• Install a new crankshaft vibration damper
retaining bolt.
303-121-01 • Complete the tightening sequence.
• Stage 1: Torque to 120 Nm.
• Stage 2: Loosen the bolt (minimum 1 turn).
VUJ0003649 • Stage 3: Torque to 50 Nm.
2003.0 X400 5/2005 Page 327 G92359en

303-01-6 Engine 303-01-6
IN-VEHICLE REPAIR
• Stage 4: Angle Torque to 90°. 5. Connect the CKP electrical connector.
303-D055
VUJ0003652
VUJ0003779
3. Attach the accessory drivebelt. 6. Install the splash shield.

1. Using the special tool, rotate the belt
tensioner counter-clockwise.
2. Attach the accessory drivebelt.
303-703
2
VUJ0004136
7. Install the wheel and tire. For additional

VUJ0003647
information, refer to Section 204-04 [Wheels
and Tires].
4. Install the CKP.
VUJ0003780
G92359en
Page 328 5/2005 2003.0 X400
303-01-7 Engine 303-01-7
IN-VEHICLE REPAIR

Special Tool(s) Using the special tool, remove the crankshaft
rear main oil seal.
Remover
303-566 303 566
303566

Installer
303-178
VUJ0003843
303178
Installation
303-384
All Vehicles
1. Clean and inspect the crankshaft rear oil seal
sealing surfaces.
2. NOTE: Use oil WSE-M2C908-A or equivalent
303384
meeting Jaguar specification.
303102 Crankshaft Rear Seal Lubricate the seal lip with oil.
Installer Draw Bolts
303-102 3. NOTE: Alternate bolt tightening to correctly
seat the crankshaft rear oil seal until it is
Using the special tool, install the crankshaft
303102
rear oil seal.
Removal 303-178

1. Remove the flywheel. For additional
Transmission.
Vehicles With Automatic Transmission 303 384

2. Remove the flexplate. For additional
information, refer to Flexplate—Automatic VUJ0003844
Transmission.
All Vehicles
4. Install the flywheel. For additional
3. information, refer to Flywheel—Manual
CAUTION: Avoid scratching or damaging
the oil seal sealing surfaces on the Transmission.
crankshaft and cylinder block.
2003.0 X400 5/2005 Page 329 G92372en

303-01-8 Engine 303-01-8
IN-VEHICLE REPAIR
Vehicles With Automatic Transmission
5. Install the flexplate. For additional
Transmission.
G92372en
Page 330 5/2005 2003.0 X400
303-01-9 Engine 303-01-9
IN-VEHICLE REPAIR
Cylinder Head LH ()
Removal Vehicles with 2.0L engine
4. Disconnect the coolant temperature (ECT)
Vehicles with 2.5L or 3.0L engine electrical connector.
1. Disconnect the engine coolant temperature
(ECT) and fuel temperature sensor (FTS)
E30522
All vehicles
VUJ0003067
5. Detach the fuel charging wiring harness.
2. Disconnect the electrical connector. • 2.5 and 3.0L shown, 2.0L similar.
VUJ0003070
VUJ0003068
6.
3. Detach fuel sensor vacuum line. WARNING: Fuel may still be present in
the fuel injection supply manifold, extreme
care must be taken as this could cause
personal injury.
Detach the fuel injection supply manifold,
lower intake manifold and place to one side.
• Remove and discard the lower intake
manifold seals.
VUJ0003069
2003.0 X400 5/2005 Page 331 G201975en

303-01-10 Engine 303-01-10
IN-VEHICLE REPAIR
• 2.5 and 3.0L shown, 2.0L similar. • Remove and discard the water pump outlet
pipe O-ring seals.
VUJ0003950
VUJ0003861
7. Remove the fuel injection supply manifold

and lower intake manifold. 10. Remove the coolant bypass tube.
• Disconnect the electrical connector. • Remove and discard the coolant bypass tube
O-ring seals.
VUJ0003869
VUJ0003862

11. Remove the exhaust manifold.
• Remove and discard the oil level indicator
tube O-ring seal. • Remove and discard the exhaust manifold
gasket.
VUJ0003462
VUJ0003863
9. Remove the water pump outlet pipe.

12. Remove the left-hand camshafts. For
additional information, refer to Camshaft.
13. NOTE: Remove the bolts in the indicated
sequence.
Remove the cylinder head.
G201975en
Page 332 5/2005 2003.0 X400
303-01-11 Engine 303-01-11
IN-VEHICLE REPAIR
• Remove and discard the cylinder head • Stage 6: Tighten 90 degrees.
gasket.
7 3 1 5
2 6 8 4
8 4 2 6
1 5 7 3
VUJ0003867
VUJ0003866
3. Install the left-hand camshafts. For additional

14. Clean and inspect the cylinder head and information, refer to Camshaft.
cylinder block. For additional information,
4. Install the exhaust manifold.
refer to Section 303-00 [Engine System -
General Information]. • Install the new exhaust manifold gasket.
Installation • Tighten to 20 Nm.
All vehicles 2
1. NOTE: The head gaskets must be installed
over the cylinder block dowels.
Install a new cylinder head gasket. 1
2. 4
CAUTION: Use care when installing the 5 3
cylinder head. Damage to the cylinder block, 6
cylinder head or the cylinder head gasket
may result.
VUJ0003762
NOTE: Make sure the cylinder head is installed in
its original position.
NOTE: Tighten the bolts in the indicated sequence 5. Install the coolant bypass tube.
in six stages. • Install the new coolant bypass tube O-ring
Position the cylinder head and install new seals.
cylinder head bolts and washers. • Tighten to 10 Nm.
• Stage 1: Tighten to 30 Nm.
• Stage 2: Tighten 90 degrees.
• Stage 3: Loosen 360 degrees (one full turn)
in reverse order.
• Stage 4: Tighten to 30 Nm.
• Stage 5: Tighten 90 degrees.
VUJ0003862
6. Install the water pump outlet pipe.
2003.0 X400 5/2005 Page 333 G201975en

303-01-12 Engine 303-01-12
IN-VEHICLE REPAIR
• Install the new water pump outlet pipe O-ring • Tighten in the sequence shown.
seals. • Tighten to 10 Nm.
2
1
E30813
VUJ0003861
10. Attach the fuel charging wiring harness.

7. Install the oil level indicator tube.
• 2.5 and 3.0L shown, 2.0L similar.
VUJ0003070
VUJ0003462
Vehicles with 2.0L engine
11. Connect the coolant temperature (ECT)
8. Attach the fuel injection supply manifold and electrical connector.
lower intake manifold.
• Connect the electrical connector.
E30522
VUJ0003869
9. Install the fuel injection supply manifold,

lower intake manifold.
• Install new lower intake manifold O-ring
seals.
G201975en
Page 334 5/2005 2003.0 X400
303-01-13 Engine 303-01-13
IN-VEHICLE REPAIR
Vehicles with 2.5L or 3.0L engine
12. Attach the fuel sensor vacuum line.
VUJ0003069
13. Connect the electrical connector.
VUJ0003068
14. Connect the engine coolant temperature

(ECT) and fuel temperature sensor (FTS)
VUJ0003067
2003.0 X400 5/2005 Page 335 G201975en

303-01-69 Engine 303-01-69
IN-VEHICLE REPAIR
Valve Cover LH
Removal
All vehicles • 2.5 and 3.0L shown, 2.0L similar.
1. Remove the ignition coils. For additional
information, refer to Section 303-07 [Engine
Ignition].
2. Remove the air filter intake pipe.
VUJ0003337
5. Detach the positive crank case ventilation

hose.
VUJ0002968

VUJ0003636
Vehicles with 2.0L engine

6. Detach the positive crank case ventilation
hose.
VUJ0003336
4. Remove the air filter retaining bracket.
VUJ0005738
2003.0 X400 5/2005 Page 336 G201973en

303-01-70 Engine 303-01-70
IN-VEHICLE REPAIR
7. Detach the heated positive crankcase • 2.5 and 3.0L shown, 2.0L similar.
ventilation valve coolant pipes.
VUJ0003771
E30542
Installation
All vehicles
1. NOTE: Apply a 5 mm diameter bead of
8. Disconnect the variable camshaft timing silicone gasket sealant WSE-M4G323-A6 or
(VCT) solenoid electrical connector. equivalent meeting Jaguar specification on
• 2.5 and 3.0L shown, 2.0L similar. the half round gaskets, apply an 8 mm
diameter bead of silicone gasket sealant on
the two places where the cylinder head and
front timing cover join and the twe places
wherethe cylindar head and the water pump
join.
NOTE: Make sure that the valve cover isolator
mounts are correctly installed to the new valve
cover gaskets.
• Install the new valve cover gaskets.
VUJ0003769 • Complete the tightening sequence.
9. Detach the coolant hose. • 2.5 and 3.0L shown, 2.0L similar.
12 8 4
1 2
5 13
9
7
3
11 10 6
VUJ0003772
VUJ0003770
2. Tighten to 6 Nm.
• Remove and discard the valve cover gaskets.
G201973en
Page 337 5/2005 2003.0 X400
303-01-71 Engine 303-01-71
IN-VEHICLE REPAIR
VUJ0003337
2003.0 X400 5/2005 Page 338 G201973en

303-01-72 Engine 303-01-72
IN-VEHICLE REPAIR
Valve Cover RH
Removal
5. Remove the intake manifold support bracket.
1. Remove the ignition coils. For additional
information, refer toSection 303-07 [Engine
Ignition].
VUJ0003776

VUJ0003773 • Remove and discard the valve cover gaskets.
3. Disconnect the variable camshaft timing

(VCT) solenoid electrical connector.
VUJ0003777
Installation
VUJ0003774
1. NOTE: Apply a 5 mm diameter bead of
silicone gasket sealant WSE-M4G323-A6 or
4. Remove the engine cover retaining bracket. equivalent meeting Jaguar specification on
the half round gaskets and apply an 8 mm
diameter bead of silicone gasket sealant on
the two places where the cylinder head and
front timing cover join.
NOTE: Make sure that the valve cover isolator
mounts are correctly installed to the new valve
cover gaskets.
• Install the new valve cover gaskets.
VUJ0003775
G92357en
Page 339 5/2005 2003.0 X400
303-01-73 Engine 303-01-73
IN-VEHICLE REPAIR
6 4
2
10 8
11 12
3 9
7 1
5
VUJ0003778
2. Tighten to 6 Nm.
VUJ0003776
3. Tighten to 6 Nm.
VUJ0003775
2003.0 X400 5/2005 Page 340 G92357en

Jaguar V8-V6 Engine Workshop Manual-352 Pgs.

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ENGINE REFERENCE MATERIAL

Jaguar V6/V8 Engine Workshop Manuals

GENERIC PROCEDURES - ENGINE

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SECTION 303-00 GENERIC PROCEDURES - ENGINE

Camshaft Bearing Journal Clearance

2. Install the camshaft bearing caps.

2004.50 X200 4/2005 Page 3 G61235en

Camshaft Bearing Journal Diameter

Camshaft End Play

2004.50 X200 4/2005 Page 5 G61236en

Camshaft Lobe Lift

Camshaft Surface Inspection

2004.50 X200 4/2005 Page 7 G61237en

Connecting Rod Cleaning

Connecting Rod Large End Bore

2. Measure the bearing bore diameter in two

2004.50 X200 4/2005 Page 9 G61252en

Crankshaft End Play

Crankshaft Main Bearing Journal Clearance

2. NOTE: Measure all the bearings at the same

2004.50 X200 4/2005 Page 11 G61241en

Cylinder Bore Out-of-Round

Cylinder Head Distortion

2004.50 X200 4/2005 Page 13 G61239en

Exhaust Manifold Cleaning and Inspection

2004.50 X200 4/2005 Page 15 G61244en

Piston Pin Diameter

Piston Pin to Bore Diameter

2004.50 X200 4/2005 Page 17 G61245en

Piston Ring End Gap

Piston Ring-to-Groove Clearance

2004.50 X200 4/2005 Page 19 G61249en

Valve Spring Free Length

Valve Stem Diameter

2004.50 X200 4/2005 Page 21 G61253en

GENERIC PROCEDURES - ENGINE

SECTION 303-01B Engine — 4.0L

Crankshaft setting, main tool VUJ0001553

Timing chain tensioning tool VUJ0001552

8. Remove the right-hand exhaust manifold.

2000.0 X200 4/2005 Page 25 G95948en

16. Remove the left-hand engine mounting

2000.0 X200 4/2005 Page 27 G95948en

(CPS) electrical connector.

2000.0 X200 4/2005 Page 29 G95948en

35. Remove the engine cover bracket.

38. Disconnect the idle air control valve

36. Detach the engine harness.

2000.0 X200 4/2005 Page 31 G95948en

47. Disconnect the coolant temperature sensor

55. Remove the throttle body.

2000.0 X200 4/2005 Page 33 G95948en

61. Disconnect the fuel temperature sensor

66. Remove the intake manifold assembly.

2000.0 X200 4/2005 Page 35 G95948en

72. Remove the thermostat housing and outlet

76. Remove the left-hand ignition coils. 79.

77. Remove the right-hand camshaft position

80. Remove the damper from the crankshaft.

2000.0 X200 4/2005 Page 37 G95948en

83. Remove the right-hand valve cover.

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