Intake Manifold: Removal

1. Disconnect the battery ground cable.
   • Refer to BATTERY DISCONNECTION PROCEDURE .
2. Release the fuel system pressure. Refer to FUEL SYSTEM PRESSURE RELEASE .
WARNING: Never remove the coolant expansion tank pressure cap under any circumstances while the engine is operating. Failure to follow this instruction may result in personal injury.
WARNING: To avoid hot coolant or steam blowing out of the cooling system, use extreme care when removing the coolant expansion tank pressure cap. Wait until the engine has cooled down, then insulate the coolant pressure cap with a suitable cloth and slowly loosen the coolant expansion tank pressure cap until the cooling system pressure is released. Do not remove the coolant expansion tank pressure cap. Step back while the pressure is released from the system. When all of the pressure has been released slowly remove the coolant expansion tank pressure cap (still with the suitable cloth in position) from the coolant expansion tank. Failure to follow this instruction may result in personal injury.
3. Release the cooling system pressure.
   • Remove the coolant expansion tank pressure cap.
4. Disconnect the intake tube from the throttle body.
   • Remove the two bolts which secure the intake tube to the throttle body. (1)
   • Disconnect the intake tube from the throttle body. (2)
   Fig 1: Disconnecting Intake Tube From Throttle Body

   Courtesy of JAGUAR CARS, INC.
5. Disconnect the air cleaner cover.
   • Release the five clips which secure the air cleaner cover.
   Fig 2: Disconnecting Air Cleaner Cover

   Courtesy of JAGUAR CARS, INC.
6. Disconnect the mass air flow meter electrical connector.
   • Disconnect the breather pipe from the camshaft cover. (1)
   • Disconnect the mass air flow meter electrical connector. (2)
   Fig 3: Disconnecting Mass Air Flow Meter Electrical Connector

   Courtesy of JAGUAR CARS, INC.
7. Remove the intake tube / air flow meter / air cleaner cover assembly.
   • Remove the intake tube / air flow meter / air cleaner cover assembly. (1)
   • Remove and discard the rubber seal; air intake tube to throttle body. (2)
   Fig 4: Removing Intake Tube / Air Flow Meter / Air Cleaner Cover Assembly

   Courtesy of JAGUAR CARS, INC.
8. Detach the coolant pipe.
   Fig 5: Detaching Coolant Pipe

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9. Remove the engine left-hand cover.
   Fig 6: Removing Engine Left-Hand Cover

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10. Disconnect the throttle body electrical connectors.
    Fig 7: Disconnecting Throttle Body Electrical Connectors

    Courtesy of JAGUAR CARS, INC.
11. Detach the right-hand camshaft position (CMP) sensor wiring harness.
    Fig 8: Detaching Right-Hand Camshaft Position (CMP) Sensor Wiring Harness

    Courtesy of JAGUAR CARS, INC.
12. Disconnect the brake booster vacuum pipe.
    Fig 9: Disconnecting Brake Booster Vacuum Pipe

    Courtesy of JAGUAR CARS, INC.
NOTE: Cap the coolant hoses to minimize coolant loss.
Fig 10: Disconnecting Throttle Body Coolant Hose
Courtesy of JAGUAR CARS, INC.
13. Disconnect the throttle body coolant hose.
NOTE: Right-hand shown, left-hand similar.
Fig 11: Removing Throttle Body Elbow Lower Retaining Bolts
Courtesy of JAGUAR CARS, INC.
14. Remove the throttle body elbow lower retaining bolts.
NOTE: Cap the coolant hoses to minimize coolant loss.
Fig 12: Disconnecting Throttle Body Coolant Hose
Courtesy of JAGUAR CARS, INC.
15. Disconnect the throttle body coolant hose.
16. Disconnect the accelerator inner cable.
    • Reposition the accelerator pulley to the full throttle position. (1)
    • Disconnect the accelerator inner cable. (2)
    Fig 13: Disconnecting Accelerator Inner Cable

    Courtesy of JAGUAR CARS, INC.
17. Disconnect the accelerator outer cable.
    • Remove and discard the retaining strap.1
    • Disconnect the accelerator outer cable. (2)
    Fig 14: Disconnecting Accelerator Outer Cable

    Courtesy of JAGUAR CARS, INC.
18. Disconnect the throttle body electrical connectors.
    Fig 15: Disconnecting Throttle Body Electrical Connectors

    Courtesy of JAGUAR CARS, INC.
19. Detach the left-hand CMP sensor wiring harness from the throttle body elbow.
    Fig 16: Detaching Left-Hand CMP Sensor Wiring Harness

    Courtesy of JAGUAR CARS, INC.
20. Disconnect the knock sensor (KS) electrical connectors.
    Fig 17: Disconnecting Knock Sensor (KS) Electrical Connectors

    Courtesy of JAGUAR CARS, INC.
NOTE: Left-hand shown, right-hand similar.
Fig 18: Disconnecting Fuel Injectors Electrical Connectors
Courtesy of JAGUAR CARS, INC.
21. Disconnect the fuel injectors electrical connectors.
NOTE: Place an absorbent cloth underneath fuel connection to absorb any spillages.
NOTE: Cap the fuel line and fuel injection supply manifold to prevent contamination.
Fig 19: Disconnecting Fuel Feed Hose
Courtesy of JAGUAR CARS, INC.
22. Disconnect the fuel feed hose.
    • Disconnect the fuel feed hose at the Quick Fit connector, using special tool 310 - 044.
NOTE: Place an absorbent cloth underneath fuel connection to absorb any spillages.
NOTE: Cap the fuel line and fuel injection supply manifold to prevent contamination.
Fig 20: Disconnecting Fuel Return Hose
Courtesy of JAGUAR CARS, INC.
23. Disconnect the fuel return hose.
    • Disconnect the fuel return hose at the Quick Fit connector, using special tool 310 -054.
24. Disconnect the engine breather hose from the throttle body elbow.
    • Disconnect the vacuum hose from the throttle body elbow.
    • Disconnect the engine breather hose from the throttle body elbow.
    Fig 21: Disconnecting Engine Breather & Vacuum Hoses

    Courtesy of JAGUAR CARS, INC.
25. Remove the intake manifold.
    Fig 22: Removing Intake Manifold

    Courtesy of JAGUAR CARS, INC.
26. Remove and discard the eight seals from the intake manifold ports.
    Fig 23: Removing Seals From Intake Manifold Ports

    Courtesy of JAGUAR CARS, INC.