How to replace timing belt on Jaguar XJ 3.0D V6 2010-

Replacement Interval Guide

• Jaguar recommend:
• Replace timing belt every 112,000 miles or 10 years.
• Replace high-pressure fuel pump drive belt every 144,000 miles or 9 years.
• The previous use and service history of the vehicle must always be taken into account.

Check For Engine Damage

CAUTION: This engine has been identified as an INTERFERENCE engine in which the possibility of valve-to-piston damage in the event of a timing belt failure is MOST LIKELY to occur. A compression check of all cylinders should be performed before removing the cylinder head(s).

Repair Times – hrs

Remove & install:
Timing belt	4,30
High-pressure fuel pump belt	2,30

Special Tools

• Camshaft sprocket timing pins – No.303-1126.
• Flywheel locking tool – No.303-1117.
• High-pressure fuel pump sprocket locking tool – No.310-212.

Special Precautions

• Disconnect battery earth lead.
• DO NOT turn crankshaft or camshaft when timing belt removed.
• Remove glow plugs to ease turning engine.
• Turn engine in normal direction of rotation (unless otherwise stated).
• DO NOT turn engine via camshaft or other sprockets.
• Observe all tightening torques.

Timing Belt

Removal

1. Raise and support front of vehicle.
2. Drain coolant.
3. Remove:
   • • Engine top cover.
   • • Coolant expansion tank.
4. Disconnect intercooler intake housing multi-plug.
5. Remove:
   • • Intercooler intake housing.
   • • Intercooler intake housing bracket.
   • • Air filter housing and hoses.
   • • Upper fan shroud.
   • • Engine undershields.
6. Unclip coolant hoses from lower fan shroud.
7. Remove:
   • • Lower fan shroud.
   • • Crankshaft pulley bolts [1] .
   • • Crankshaft pulley [2] .
   • • Coolant outlet hose from cylinder head.
   • • Auxiliary drive belt.NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.
   • • Auxiliary drive belt tensioner.
   • • Auxiliary drive belt guide pulley.
8. Disconnect inlet hose from exhaust gas recirculation (EGR) cooler.
9. Remove steering column lower joint bolt.
10. Disconnect steering angle sensor multi-plug.
11. Remove steering rack mounting bolts to gain access to starter motor.
12. Remove:
    • • Water pump pulley.
    • • Timing belt covers [3] .
    • • Starter motor.
    • • Blanking plug from cylinder block [4] .
13. Turn crankshaft to TDC on No.1 cylinder. Ensure TDC hole in flywheel aligned [5] .
14. Ensure camshaft sprocket timing holes correctly aligned [6] . If not: Turn crankshaft one turn clockwise.
15. Fit flywheel locking tool [7] . Tool No.303-1117.
16. Secure flywheel locking tool using starter motor bolt [8] .
17. Insert timing pins in camshaft sprockets [9] . Tool No.303-1126.
18. Slacken bolts of each camshaft sprocket [10] .
19. Remove:
    • • Tensioner pulley bolt [11] .
    • • Tensioner pulley [12] .
    • • Timing belt.

Installation

NOTE: Timing belt and tensioner pulley MUST be replaced.

1. Fit new tensioner pulley [12] .
2. Fit new tensioner pulley bolt [11] . Finger tighten bolt.
3. Ensure timing pins located correctly [9] .
4. Turn each camshaft sprocket fully clockwise in slotted holes [13] .
5. Fit timing belt in anti-clockwise direction, starting at crankshaft sprocket. Ensure belt is taut between sprockets.
6. Turn tensioner pulley anti-clockwise until mark aligned with notch [14] .
7. Tighten tensioner pulley bolt [11] . Tightening torque: 26 Nm.
8. Hold camshaft sprockets. Use suitable tool.NOTE: DO NOT use camshaft sprocket timing pins to counterhold camshafts.
9. Tighten bolts of each camshaft sprocket [10] . Tightening torque: 23 Nm.
10. Remove:
    • • Timing pins [9] .
    • • Flywheel locking tool [7] .
11. Turn crankshaft slowly two turns clockwise to TDC on No.1 cylinder.
12. Ensure TDC hole in flywheel aligned [5] .
13. Fit flywheel locking tool [7] .
14. Insert timing pins in camshaft sprockets CA1 and CA2 [9] . If timing pins cannot be inserted, repeat installation procedure.
15. Remove:
    • • Camshaft sprocket timing pins [9] .
    • • Flywheel locking tool [7] .
16. Fit blanking plug [4] .
17. Install components in reverse order of removal.
18. Tighten crankshaft pulley bolts [1] . Tightening torque: 25 Nm.
19. Refill cooling system.

High-Pressure Fuel Pump Belt

Removal

1. Raise and support front of vehicle.
2. Remove:
   • • Engine top cover.
   • • Turbocharger/intercooler air hoses.
   • • Rear engine cover.
   • • RH bulkhead cover.
3. Disconnect and seal off fuel pipes (if necessary).
4. Disconnect and seal off EGR coolant hoses.
5. Remove steering column lower joint bolt.
6. Disconnect steering angle sensor multi-plug.
7. Remove steering rack mounting bolts to gain access to starter motor.
8. Remove:
   • • High-pressure fuel pump belt cover [15] .
   • • Starter motor.
9. Turn crankshaft clockwise until timing marks aligned [16] .
10. Fit flywheel locking tool [7] .
11. Secure flywheel locking tool using starter motor bolt [8] .
12. Remove:
    • • Tensioner pulley bolt [17] .
    • • Tensioner pulley [18] .
    • • High-pressure fuel pump belt.

    NOTE: The high-pressure fuel pump rotates in an anti-clockwise direction when viewed from the rear of the engine.

Installation

NOTE: DO NOT remove tensioner pulley locking pin before fitting tensioner pulley to engine.

1. Fit new high-pressure fuel pump belt.
2. Ensure marks on belt aligned with marks on sprockets [16] & [19] .
3. Fit new tensioner pulley [18] .
4. Fit new tensioner pulley bolt [17] .NOTE: Ensure lug on rear of tensioner pulley located in groove in cylinder head [20] .
5. Fit high-pressure fuel pump sprocket locking tool [21] . Tool No.310-212.
6. Slacken camshaft rear sprocket bolts [22] .NOTE: Slacken bolts until sprocket can be moved within slotted holes.
7. Tighten tensioner pulley bolt [17] . Tightening torque: 23 Nm.
8. Remove tensioner pulley locking pin [23] .
9. Tighten camshaft rear sprocket bolts [22] . Tightening torque: 23 Nm.
10. Remove high-pressure fuel pump sprocket locking tool [21] .
11. Fit high-pressure fuel pump belt cover [15] . Tightening torque: 7 Nm.
12. Install components in reverse order of removal.