1994 JAGUAR XJ check engine

AJ16 Engine Service Manual
4.22
SRO 12.65.30
. Remove the timing cover.
. Remove the upper timing chain (6 Fig. 1) and remove the
flanged bolts
(3 Fig. 1) securing the tensioner pedestal.
= Remove the pedestal / tensioner assembly and chain
damper (1 Fig. 1).
. Remove the tensioner pivot pin (2 Fig. 1) and remove the
tensioner from the pedestal.
. Remove the bolts (11 Fig. 1) securing the lower timing
chain tensioner, and remove the tensioner assembly (10 Fig. 1).
Timing Chain Tensioner, Lower, Renew
. Remove the lower timing chain (8 Fig. 1).
. Clean the lower tensioner assembly, remove the ball valve (1 Fig. 2) and ensure that the base of the housing (2 Fig. 2) is clean.
. Check that the ball valve is free by shaking the assembly
to ensure it rattles. If it does not, renew the valve assem- bly. If it does, renew and lubricatethe 'O'ring (3Fig. 2) and
press the valve back into the housing. The ball free move-
ment is 0,45-0,74 mm.
. Inspect the housing and the hydraulictensioner piston (4
Fig. 2) for excessive wear or scoring. Also check that the
oil hole (5 Fig. 2) is clear in the end of the piston.
. Lubricate the component parts with clean engine oil. As-
semble the tensioner by pressing and twisting the snail
clockwise until the pawl locks in the 'parK position. Fit the
tensioner assembly to the cylinder block with the guide
facing downwards.
. Fit but do not tighten the tensioner upper securing bolt,
push the guide into the housing to release the base and
align with the damper.
Align the damper with the lower bolt hole, fit and tighten
the lower bolt.
. Tighten the upper bolt, fill the tensioner oil reservoir with
oil and work the tensioner to prime with oil.
. Fit the upper tensioner to the pedestal and fit the tensioner
pivot pin, and secure with the flanged bolts
(6 Fig. 2).
m Fit the lower static damper, and secure with the flanged
bolts.
17 i3 is ii
Fig. 1
6
112 7; I
Fig. 2
42 Issue 1 August 1994

AJ16 Engine Service Manual
4.24 Auxiliary Shaft, Renew
SRO 12.10.30
Remove the timing cover.
. Remove the pulley woodruff key and remove the oil seal
spacer from the crankshaft.
. Remove the flanged bolts (3 Fig. 1) securing the tensioner
pedestal.
Remove the pedestal / tensioner assembly and chain
damper (1 Fig. 1).
. Remove the tensioner pivot pin (2 Fig. 1) and remove the
tensioner from the pedestal. Clean the pivot pin.
. Remove the flanged bolts (5 Fig. 1) securing the upper
static damper. Remove the damper (4 Fig. 1) and upper
timing chain (6 Fig. 1).
Remove the bolts (11 Fig. 1) securing the chain tensioner
and remove the assembly (17 Fig. 1).
Remove the power assisted steering pump assembly, see
Section 10 in the appropriate Vehicle Service manual
. Remove the pump drive coupling.
. Remove the flanged bolt (1 Fig.2) and the drive-plate (2 Fig. 2).
Using Service Tool JD 118, remove the auxiliary shaft rear
oil seal (3 Fig. 2) from its housing.
. Using right-angled snap-ring pliers remove the snap-ring (5 Fig. 2) securing the drive shaft (4 Fig.2).
. Lift the timing chain (8 Fig. 1) from the sprocket (7 Fig. 11, remove the shaft / sprocket assembly and retrieve the
thrust washer.
. Clean all component parts and checkfor wear or damage.
Renew worn or damaged parts as necessary. Clean the auxiliary bearing housing.
. Check for wear and if necessarychangethe auxiliaryshaft bushes.
. Refit the housing with new gasket. Fit and tighten the se-
curing bolts.
. Lubricate the shaft and refit the to the housing, engaging
the chain with the gear as it is fitted. Lubricate and fit the
thrust washer and secure with the snap-ring.
. Renew the auxiliary shaft rear oil seal, see Section 4.25.
. Refitthe power assisted steering pump assembly, see Sec-
. Refit the lower chain tensioner, see Section 4.22.
Refit the upper chain tensioner, see Section 4.21.
. Renew the oil seal (1 Fig. 3) and refit the timing cover.
tion
10 in
the appropriate Vehicle Service manual.
Fig. 1
Fig. 2
Fig. 3
Issue 1 August 1994 44

AJ16 Engine Service Manual
4.30
SRO 12.60.56
Remove the oil pan, see Section 4.27.
Remove oil pressure relief valve screw cap (1 Fig. 1) and
collect spring (2 Fig.
I), valve (4 Fig. I), and mandrel (3 Fig. 1).
Check the valve spring and mandrel for wear, scoring or pitting, renew if damaged.
Measure the components against the specifications listed in Service Data in the Preliminary Pages.
If any of the components are suspect, they must be re- newed.
. Lubricate and assemble the mandrel, spring and valve.
Fit and tighten the relief valve screw cap.
. Refit the oil pan, see Section 4.27.
Oil Pressure ReYief Valve AssemblB Renew
1116.1
Fig. 1
Issue 1 August 1994 50

AJ16 Engine Service Manual
4.31 Oil Pump, Renew
SRO 12.60.26
Remove the oil pan, see Section 4.27.
1 Place a drain tray under the transfer housing. Remove the
housing bolts and housing
(1,2 Fig. 1).
. Remove the pick-up pipes (3 Fig. l), push back the lock
tabs (1 Fig. 2) and remove the pump sprocket bolts (2 Fig. 2).
. Remove the oil pump drive sprocket (3 Fig. 2), tab washer (4 Fig. 2) and shims.
. Remove the oil pump securing bolts and remove the
pump.
. Removethe pressure relief valve cap, spring, mandrel and
valve
(1-4 Fig. 3).
1 Clean the mating face in the cylinder block, the relief valve
assembly, sprocket and shims.
. Lubricate the relief valve assembly, assemble into new
pump, tighten the cap.
. Fitthe new oil pump tothe engine and tighten thesecuring
bolts.
1 Movethedrivechain asfar rearward aspossible,fit a shim
pack of 0.015 in. thickness to the oil pump flange (3 Fig. 4), align the bolt holes, fit the drive sprocket and two securing
bolts. Using
a straight edge (2 Fig. 41, check the alignment
of the oil pump drive sprocket (1 Fig. 4) and crankshaft
sprocket (4 Fig. 4).
1 Remove and refit the pump drive sprocket and adjust the
value of shim thickness as required in order to align the
sprockets.
. When the alignment is satisfactory, remove the pump
sprocket. Fit the chain and shims to the sprocket,fit to the
oil pump. Fit the tab washer and securing bolts. Tighten
the bolts and lock over the tabs.
. Ensure that the tension of the oil pump drive chain is cor- rect, see Service Data in the Preliminary Pages. Adjust by
slackening the tensioner securing screws, tapping the
tensioner inwards to increase the tension, and securing in
position when the tension is correct.
1 Fit new ‘0 rings to the oil pump pick-up pipes.
. Lubricate and refit the pipes to the pump.
1 Fit and seat the transfer housing. Fit and tighten the secur-
. Refit the oil pan, see Section 4.27.
ing bolts.
Fig. 3
Fig. 4
Issue 1 August 1994 51

AJ16 Engine Service Manual
4.32 Oil Pump, Overhaul
SRO 12.60.32
8 Remove the oil pump, see Section 4.31.
1 Remove the bolts securing the pump body.
1 Remove the pump body, pump outer rotor, backplate se-
1 Clean all component parts of the pump.
1 Check all the clearance and components for undue wear
(Fig.
1) and (Fig. 2). Check tolerances, see Service Data in
the Preliminary Pages.
curing
bolts, the backplate and the bearing shell.
. Fit the bearing shell to the housing.
1 Apply sealantto the backplate gasketface,fitthe backplate
and securing bolts. See Service Materials in the Prelimi- nary Pages.
1 Fit the outer rotor.
a Lubricate the relief valve assembly and assemble into the
1 Tighten the relief valve cap.
1 Refit the oil pump, see Section 4.31.
pump.
Fia. 1
Fin. 2
Issue 1 August 1994 52

D
Drive belt tensions, xvi
F
Fau It diagnosis
Diagnostic procedures, 3
Introduction, 3
Foreword, iii
General description
Construction, 1
Cooling system, 2
Crankcase breather, 1
Cylinder head, 1
Lubrication system, 1
Supercharger, 2
S
Service data, xiii
Service materials, xii
Service operations
Check & adjust
Crankshaft end
-float, 27
Valve clearances, 10
Cylinder head, 16
Engine assy., 33
Oil pump, 52
Auxiliary shaft, 44
Auxiliary shaf? rear seal, 45
Camshaft, 7
Camshaft cover gasket, 9
Connecting rod bearings, 22
Crankshaft, 24
Crankshaft damper /pulley assy., 26
Crankshaft front oil seal, 28
Crankshaft rear oil seal, 29
Cylinder head casting, 19
Cylinder head gasket, 13
Drive-plate, 31
Flywheel, 30
Main bearings, 23
Oil filter head gasket, 46
Oil pan gasket, 47
Oil pick-up strainer, 49
Oil pressure relief valve, 50
Oil pump, 51
Oil pump pipe ‘0’ ring, 48
Pistons &connecting rods, 20
Timing chain damper, 40
Timing chain tensioner
Overhaul
Renew
Lower,
42
Upper, 41
Timing chain, gear & tensioner, 37
Timing sprocket, Intermediate, 43
Transmission adapter plate, 32
Service procedures
Sealants, 2
SPS joint control system, 2
Service tools & equipment iv
T
Torque tightening specifications,
53