1994 JAGUAR XJ engine

AJ16 Engine Service Manual
Cylinder Block
Adapter to cylinder block
Bearing cap to cylinder block
Blanking plate to cylinder block
Manual transmission to engine
(4,O liter supercharged automatic)
Oil drilling blanking plug
Oil gallery blanking setscrew
Oil pressure sensor
Oil pressure sensor plug
Oil seal adapter to cylinder block
Transmission adapter to cylinder block
Water drain plug
Windage tray to cylinder block
Cylinder Head and Camshaft Cover
Bearing cap to cylinder head
Camshaft coupling bolt
(Nm)
43 - 57
136
- 142 (SPS
System)
21,5 - 28,5
43 - 57
29
- 39
21,5 - 28,5
23 - 27
8,5- 11,5
21,5 - 28,5
44.5 - 59,5
64.5 - 79.5
21.5
- 28,5
17 - 23
22
- 28
Camshaft cover to cylinder head
- - . ~. Cylinder head to cylinder block
Cylinder head to timing cover -
______ ____ Exhaust manifold to cylinder head
On
-plug coil cover to camshaft cover
Rear cover to cylinder head
4-5
59 - 61 (SPS System) ~~ -. . - 21,5 - 28,5
22 - 28
_. . -.. ___ Dipstick
Tube
Dipstick tube assembly nut
Dipstick tube attachment to tube support bracket
(4,O liter supercharged)
__ Dipstick tube bracket (4,O liter supercharged)
Dipstick tube to bracket
Drive Chain System
Dipstick tube bracket screw
Auxiliary shaft assembly setscrew
Coupling to intermediate shaft
Damper to cylinder block (bolt)
Damper to cylinder block (screw)
Damper to distance piece
Damper to saddle
Distance piece to cylinder block
Endplate to damper
Housing to cylinder block (bolt)
Housing to cylinder block
(capscrew)
Pivot bracket to cylinder block
Pivot plate to cylinder block
Sprocket to hub setscrew
Engine Mounting
Engine mounting bracket to engine
Issue 1 August 1994 viii
81 -99
15.5 - 20,5
5-7
9,5
- 12,5
5%: 7.8
30,5 - 37,5
12-16
21,5 - 28,5
21.5 - 28,5
21,5 - 28,5
21,5 - 28,5
21,5 - 28,5
21.5 - 28,5
21,5 - 28,5
21,5 - 28,5
21,5 - 28,5
2 1,5 - 28,5
9,5 - 12,5
445 - 59,5

AJ16 Engine Service Manual
Exhaust Manifold
Exhaust manifold to cylinder head
Heatshield to exhaust manifold
Lifting eye setscrew (slave item only)
.~ Fuel System
Fuel pressure regulator to bracket
Fuel rail connecting nut
. i------
44,5 - 59.5
21.5
- 28,5
21.5 - 28,5
~- 30.5 - 41,5
12,5 - 15,5
Fixing
- Adjuster bracket to oil pan
Adjuster sleeve
to generator
Generator mounting bracket pivot bolt
Sleeve to adjuster bolt
21,5 - 28,5
17 - 23
34
- 46
11 - 15
__~___.___ 21.5 - 28,5 __ ~~ ~ Generator
Mounting
bdjuskr bolt to timing cover
Intake Manifold
Blanking plate to intake manifold (in place of adapter) 9,5 - 12,5
8,5- 11,5
9,5 - 12,5
36 - 44
14.5
- 19.5
LBreather adapter to intake manifold (4,O liter normally aspirated)
l EGR adapter to intake manifold
EGR pipe to adapter
EGR sensor to intake manifold 1
1 Intake manifold steady screw (4,O liter supercharged)
Intake manifold
to cylinder head
Pedestal to throttle body
22 - 28
21,5 - 28,5
9,5 - 12,5
Pressure regulator to intake manifold
Pressure regulator to intake manifold
(4.0 liter supercharged)
9,5 - 12,5
5-7
Throttle linkage baseplate to pedestal
assembly nut
Purge adapter
to intake manifold
Throttle body to intake manifold
9,5 - 12,5
21,5 - 28,5
9,5 - 12.5
1.8 - 2,2
'Throttle cable abutment to intake manifold
Throttle linkage actuator nut
9,5 - 12,5
Throttle stop screw locknut
Miscellaneous Hoses
Hose clamp, breather hose to restrictor
Hose clamp, heater return hose to throttle body
4,3 - 5,7
1.5
- 2,5
1,5
- 2.5
Hose clamp, hose to cam cover 2,5 - 3.5
' Hose clamp, restrictor to throttle body
I Oil cooler clamp screw 5-7
1.5
- 2,5
Oil
cooler pipe bracket screw 1.5 - 2.5
l Hose clamp, thermostat housing to restrictor ~
Hose
clamp, water pump
Oil Cooler (4.0 Liter Supercharged)
Hose clamp, oil cooler hose to radiator cradle
..
Oil cooler pipes to engine 14-18
1,5
- 2,5
2,5
- 3.5
7
-10
Oil cooler to body
Tube nut, all except those shown below 17 - 23
17
- 23
16 - 20 ,Tube nut, transmission pipes to transmission
Issue 1 August 1994 ix

AJ16 Engine Service Manual
0 Fixing
Oil Pump, Filter and Oil Pan
Baffle tray to oil pan
Drain plug to oil pan
Pick
-up to carrier
Filter head to cylinder block
Front cover to body
Oil filter canister
Oil pan to cylinder block
Oil pan to timing cover
Oil pump and oil pump carrier to cylinder block
Rear cover to body
Relief valve plug Tightening
Torque
(Nm)
21,5 - 28,5
64.8 - 79,2
9,5 - 12,5
21.5 - 28.5
9,5
- 12,5
12-15
21,5 - 28,5
21,5 - 28,5
21,5 - 28.5
9.5
- 12,5
35,7 - 48,3
Power Steering
Adapter to housing 21,5 - 28,5
Power steering pump to adapter
Power steering pump to engine
spark Plug
Starter Motor
Starter motor to adapter
Transmission to starter motor
Supercharger-
Spark plug
--
44.5 - 59,5
22 - 28
22
- 28
43
- 57
43
- 57 -___
Adapter to timing cover
Air duct clamp to intercooler
Air duct hoses
Air duct lower to intercooler 22 - 28
2,5
- 3,5
2,5
- 3,5
2,5 - 3,5
Air duct upper casting to lower
Bypass valve to throttle body
Elbow to intercooler
Idler bracket
/ timing cover to cylinder block
Idler bracket to water pump
X Issue 1 August 1994
2,5 - 3,5
8,5
- 11,5
22 - 28
22
- 28
22
- 28
Idler mounting bracket
Intercooler water pipes
Outlet elbow to supercharger
Pulley to carrier
Supercharger mounting bracket to engine
Supercharger mounting stud 22 - 28
22
- 28
22
- 28
22
- 28
43
- 57
22
- 28
Supercharger to mounting bracket 43 - 57
Tensioner bracket / timing cover to cylinder block 22 - 28
Tensioner bracket to adapter
Throttle body adapter to bypass actuator 22 - 28
8,5
- 11.5

AJ16 Engine Service Manual
~- Fixing Tightening
Torque
r- (Nm)
____ liming Cover L 1 Auxiliary shaft blanking plate to timing cover 9,5 - 12,5
Generator adjuster to timing cover 8,5 - 11,5 ~ __ ____ ~ t Intermediate shaft blanking
plate to timing cover 1 21,5-28,5
I Sensor to timing cover
l Timing cover to cylinder block b+-- 21,5 - 28,5
21,5 - 28,5 _. ______
xi Issue 1 August 1994

AJ16 Engine Service Manual
Description
Hylosil 102 sealant
111. SERVICE MATERIALS
UseS Notes
Oil pick-up strainer to transfer housing
Thermostat housing to extension
I jThermostat outer housing to inner housing
Loctite
501 sealant
~. Xming cover to cylinder block
t Transmission adapter to cylinder block
drive
-plate bolt
Oil pump front cover to body
[Oil pump rear cover to body
1 Oil filter threaded insert to housing
Loctite 542 sealant
__ __ Loctite 573 sealant to
cylinder block
Issue 1 August 1994 xii

AJ16 Engine Service Manual
SERVICE DATA
Engine Data
Application Item
Number of cylinders
Bore
Specification
Seneral 6
91
mm
Stroke 3,2 liter: 83 mm
4,O liter: 102 mm
3.2 liter: 3239 cm3
4.0 liter: 3980 cm3
Cubic capacity
Compression ratio
3.2 liter: 1O:l
4,O liter: 1O:l (normally aspirated)
4,O liter: 8,51 (supercharged)
1,5,3,6,2,4 (No. 1 cylinder at
crankshaft pulley end)
Fully mapped Lucas engine
management system with digital
ignition
Firing
order
gnition timing
0
0
0
Jalve clearance
Intake and exhaust 0,30 to 0,36 mm
Champion RCSYCC (except North
America, normally aspirated
engines)
Champion
RC12YCC (North
America, for normally aspirated
engines only)
__ ~ ~
--__ ~~
Spark
plug
0,9 mm
On-plug ignition coil
Diamond
Number per vehicle
Primary winding resistance
Current consumption ~ ~~
6
0,75 ohm
Oto6A
Clockwise
(viewed from above)
1,5,3,6,2,4 (No. 1 cylinder at
crankshaft pulley end)
-
Engine position sensor
Fuel injection equipment
Exhaust Emission Rotation
Firing order
Micro
-processor controlled engine
management system
Fuel pressure
Exhaust gas analyzer reading (at
engine idle speed, normal operating
temperature and with catalytic
converter fitted)
3 bar
0,5% CO maximum.
For Swiss market only:
0,02% CO
maximum,
70 ppm HC maximum
Idle speed (engine at normal
operating temperature) Manual transmission 700 RPM
Automatic
transmission 700 RPM (gear selector in neutral)
11,O to 11,7 bar (with all spark plugs
removed, throttle fully open, engine
at operating temperature and
a
minimum cranking speed of 300
RPM)
0,7 bar (maximum)
Compression pressure
Cylinder pressure
Differential pressure between
cylinders
Aluminum alloy
Cylinder block
. ___ Material
xiii
Issue 1 August 1994

AJ16 Engine Service Manual
kern
For piston grade F
Application
alinder block bore diameter after
boning
Specification
90,990 to 90,998
mm
zylinder head For
piston grade
G
For piston grade H
t0.020 in.
:rankshaft
90,999 to 91,007 mm
91,008 to 91,016 mm
91,513 to 91,526 mm
:onnecting rod To
within 15
gm cm (imbalance to
be corrected by drilling up to four
holes in each balance weight
9,5
mm diameter x 29 mm deep
' maximum)
'iston
'iston diameter Length
between centers
Bore for connecting rod bearing
Connecting rod bearing diametrical
clearance
Connecting rod bearing side
clearance
Bore for small end bushing
Type
Skirt clearance
Grade
F
Grade G
Grade
H
+0.020 in.
Number
of compression rings
'iston ring
____ Blue: 52,990 to 53,000 mm
3,2 liter: 175785 to 175,285 mm
4,O liter: 166,320 to 166,420 mm
56,731 mm
0,023 to 0,059 mm
0,132 to 0,233 mm
26,975 to 27,000 mm
AE413P/PD (BS 1490-198SLM 13TF)
phosphorus treated
0,Ol to 0,026 mm
90,972 to 90,980 mm
90,980 to 90,989 mm
90,990 to 90,998 mm
91,480 to 91,506 mm
2
Material
I Aluminum
alloy
Material
I3,2 liter: cast iron
Number of main bearings
Main bearing type
Journal diameter
Thrust washer thickness
Permissible end float
Balancing
Diametrical clearance
Crankpin diameter
4,O liter: forged steel
7
Vandervell
VP2C
Pink 76,210 to 76,220 mm
White: 76.220 to 76,230 mm
Green: 76,230 to 76,240 mm
2.57 to 2,62 mm
0,lO to 0,28 mm
Number of oil control rings
Gap when fitted in bore 1
Top compression ring:
0,40 to 0,65
mm
Second compression ring: 0,40 to
0,65 mm
Oil control ring: 0.30 to 0,55 mm
Issue 1 August 1994 xiv

AJ16 Engine Service Manual
Item
Type
Length
Outside diameter
Inside diameter
Material ~
Application
Specification
Chamfer locking
3,2
liter: 68,37 to 68,50 mm
4,O liter: 77,12 to 77,25 mm
23,807 to 23,812 mm
14,30 to 14.81 mm
Cast iron
'iston pin
2amshaft
dalve
Number of journals
Nominal
lift
Permissible end float
4djustment of valve clearance 7
9,95 mm
0.13 mm
rlalve Guide
Valve
stem diameter
Valve clearance
Jalve seat Intake
and exhaust: 6,947 to 6,960
mm
Intake and exhaust: 0,30 to 0,36 mm
Jalve seat insert outside diameter Outside
diameter
rappet
lalve spring Standard
- no
groove: 10,993 to
11,005 mm
1st oversize - 1 groove: 11,043 to
11,055
mm (production only)
2nd oversize
- 2 grooves: 1 1,143 to
11,155 mm
:amshaft sprocket
:rankshaft sprocket Diametrical
clearance
Free length
Number
of teeth
ntermediate sprocket
0,02 to 0,05 mm
43,5 mm
30
xv Issue 1 August 1994