Does anybody know what the lower and upper intake manifold gasket torque is supposed to be for an 03 XKR? Is there a bolt pattern to follow? I can't seem to find it in the JTIS...

Merry Christmas!

 

According to the workshop manual for the '99 model, the torque values are:

Charge air cooler gasket bolts (8 per bank) 11 to 13Nm, no specific pattern but in pairs is usual.

Inlet elbow, 4 bolts, 18 to 24Nm

Jack

 

Look in the engine assembly section of JTIS for the 2003. Everything associated with the intake is 22 nM. The lower manifold, charge air coolers to manifold and the supercharger. Start in the center and work your way outward alternating back and forth along the fasteners.
I normally torque to half value and then retrace the pattern to full value.
E..G. bolt down the center 2 and move to the next to towards the front and then go to the 2 towards the back. Repeat until they are all torqued.

 

Thanks guys! What is the torque supposed to be for the intake manifold/charge air cooler adapter on the XKR?

I see the charge air coolers in the 2003 XK JTIS are supposed to be 13Nm but I can't find anything on the adapter...

 

Are you talking about the 'charge cooler inlet assembly'?... the black rubber ducts and plates that connect the supercharger outlet plate to the two intercooler inlets? In the '99 Manual, they're 18-24Nm.

Or... the Supercharger outlet plate that sits on top of the supercharger with the integrated supercharger coolant port on top, with 4 mount bolts and a rubber gasket?... those bolts are at 9-11Nm. I would recommend that you DO NOT torque them to 22Nm or you risk them snapping off in their holes and needing to use ezyouts to drill out the bolt stubs.

Those numbers are for a 4.0 litre blower, from the '99 workshop manual but the 4.2 litre blower and connections are pretty much the same. I just did mine last week! Painfull process!

Quick warning...clean any bolts that you've removed and their threaded holes properly and don't over torque them. Remember that we're talking aluminium here, and the threads strip easily, and if they do, you're stuck with trying to put helicoils in there, which is painful. If the threads strip on the duct plates (which I've had happen)... you'll need to either get replacement plates, which cost a fortune new, or bodge up 'through bolts' with a nut and spring washer to get them up to torque and stop the rubber ducts from deforming into the plenum outlet. You don't want to go there... trust me, plus it looks messy.

Also, it's worth buying new supercharger outlet plate bolts (as recommended in the manual) if yours aren't in good condition as they are only 6mm x 1mm pitch bolts and they strip and break really easily.

Good luck.
Jack.

 

Here's the '99 manual excerpt.

Jack

 

I have attached a picture of the part I'm talking about, it has 5 bolts on both the left/right side, the fuel injectors connect to it and the charge air coolers sit on top. I found one reference of it in the JTIS that calls it the "charge air cooler adapter" but I can't find anything that gives me the torque number.

I'm guessing it is supposed to be torqued to the same number as the intake manifold on an XK8 at 21 Nm but I wanted to make sure...

 

This is from the pdf version of the workshop manual. (I believe its the same as the JTIS).
It calls it the lower intake manifold - JEPC calls it the Induction manifold adaptor

 

Thanks! It looks like my JTIS might be missing some information, I'm thinking it could be because some files got corrupted on my notebook recently.