Replacement Procedure

1. Open hood and fit fender protector covers.

2. Open luggage compartment lid and remove battery cover.

3. Disconnect battery.

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

4. On supercharged engines, remove supercharger drive belt (see Workshop Manual, JTIS CD ROM, section: 303-12, SRO 18.50.08 except 2001 MY XKR vehicles see Workshop Manual, JTIS CD ROM, section: 303-05).

5. On all engines, remove FEAD belt and tensioner (see Workshop Manual, JTIS CD ROM, section: 303-05, SRO 12.10.41).

6. On V8 XJ Series vehicles, remove front undertray (see Workshop Manual, JTIS CD ROM, section: 501-02, SRO 76.22.90).

7. On all vehicles, loosen and reposition A/C compressor upper securing bolts.

8. Loosen the lower securing bolts of the A/C compressor by approximately 10 mm to allow A/C compressor to be levered clear of upper dowel.

Note:
A/C compressor lower securing bolts are to remain engaged in threads to keep the upper securing bolt aligned with the dowel.

9. Using suitable lever, reposition A/C compressor from upper dowel.





10. Place suitable piece of metal stock across A/C compressor upper dowel (Illustration 1).

Note:
A short steel engineers rule can be used as an alternative to a flat metal stock.

11. Trap metal stock against dowel end using finger pressure on A/C compressor upper securing bolt head.





12. Using the shank of a new 3.2 mm (1/8 in.) twist drill, ensure gap between A/C compressor/ PAS pump bracket and flat metal stock is 3.2 mm (1/8 in.) or greater (Illustration 2).

13. Remove 3.2 mm (1/8 in.) twist drill.

14. Remove flat metal stock.

Note:
If the gap between A/C compressor bracket and flat metal stock is within specification continue from step 41. If gap is less than 3.2 mm (1/8 in.) continue from step 15.

15. Recover A/C refrigerant (see Workshop Manual, JTIS CD ROM, section: 412-00, General Procedures, Recover/Reclaim).

16. Place special tool 303-D055 on the PAS pump pulley and tighten tool belt.

17. Remove the PAS pump pulley securing screws.

18. Remove special tool 303-D055 from the PAS pump pulley.

19. Remove the PAS pump pulley.

20. Remove the A/C compressor (see Workshop Manual, JTIS CD ROM, section: 412-03, SRO 82.10.20).





21. Remove the screw securing the engine dipstick tube retaining bracket to the PAS pump (Illustration 3).

22. Remove the rear bolt securing the A/C compressor/PAS pump mounting bracket to the engine.

23. Reposition crank sensor harness support clip.

24. Remove the front bolt securing the A/C compressor/PAS pump mounting bracket to the engine.

25. Remove the A/C compressor/PAS pump mounting bracket.

26. Place new A/C compressor/PAS pump mounting bracket to front.





27. Install three new dowels to A/C compressor/PAS pump mounting bracket (Illustration 4).

Note:
Using suitable vernier caliper, check that the two dowels locating the A/C compressor/PAS pump mounting bracket to the engine (see 1, Illustration 4) protrude 4.2-4.8 mm and that the dowel locating the A/C compressor to the bracket (see 2, Illustration 4) protrudes 3.2-3.8 mm.

28. Seat A/C compressor/PAS pump mounting bracket on the engine.

29. Install and tighten the upper front bolt securing the A/C compressor/PAS pump mounting bracket to the engine.

30. Align crank sensor harness support clip to A/C compressor/PAS pump mounting bracket upper rear fixing hole.

31. Install and tighten the upper rear bolt securing the A/C compressor/PAS pump mounting bracket to the engine.

32. Reposition and align PAS pump to mounting bracket.





33. Install and tighten PAS pump securing bolts to 16-20 Nm (Illustration 5).

34. Install and tighten engine dipstick tube retaining bracket to PAS pump securing bolt to 8-12 Nm.

35. Position PAS pump pulley and align fixing holes.

36. Install, but do not tighten, PAS pump pulley securing bolts.

37. Position special tool 303-D055 on PAS pump pulley and tighten tool belt.

38. Final tighten PAS pump pulley securing bolts to 18-24 Nm.

39. Remove special tool 303-D055 from PAS pump pulley and place aside.





40. Inspect A/C compressor dowel location hole to ensure it is not worn out-of-round (Illustration 6).

Note:
If the A/C compressor dowel hole is out of round, install a new A/C compressor.

41. Install A/C compressor (see Workshop Manual, JTIS CD ROM, section: 412-03, SRO 82.10.20).

42. Install new FEAD belt and tensioner (see Workshop Manual, JTIS CD ROM, section: 303-05, SRO 12.10.41).

43. If fitted, install supercharger drive belt (see Workshop Manual, JTIS CD ROM, ,section: 303-12, SRO 18.50.08 except 2001 MY XKR vehicles see Workshop Manual, JTIS CD ROM, section: 303-05).

44. If required, recharge A/C system (see Workshop Manual, JTIS CD ROM, section: 412-00).

45. Reconnect battery.

46. Install battery cover and close luggage compartment lid.

47. Remove fender protectors and close hood.