1994 JAGUAR XJ engine

AJ16 Engine Service Manual
SERVICE OPERATIONS
4.1 Camshaft, Renew
SRO 12.13.01
Remove camshaft cover, see Section 4.2.
Drain the cooling system, see Section 4.1 in the appropri
- ate Vehicle Service Manual.
1 Rotate the engine and set No. 1 cylinder at TDC using Ser- viceTool 18G 1433 (1 Fig. 1).
Push back the lock tabs (1 Fig.2) from the camshaft
sprocket securing bolts (2 Fig. 2). and slacken off the bolts.
Remove the upper chain tensioner valve clamp bolt
(3 Fig.
2), remove the clamp (4 Fig. 2) and remove the
valve (5 Fig. 2).
1 Using a 3 mm Allen key, wind backthe tensioner (6 Fig. 2) (turn clockwise) until the snail engages in the park posi- tion. Remove the tensioner housing securing bolt (7 Fig. 2) and withdraw the tensioner assembly (8, 9 Fig. 2).
1 Remove and discard the '0' ring (9 Fig. 2) and gasket (10 Fig. 2).
. Remove the camshaft sprocket securing bolts and tab
washers (1,2 Fig. 2) and remove the sprockets (11 Fig. 2) (ensure that neither the bolts nor the tab washer drop into
the timing case).
CAUTION: Do not rotate the engine while the camshaft is
disconnected.
. Remove the cylinder head bolt from No. 2 cap, left-hand
1 Remove No. 2 cap from the left-hand camshaft.
1 Fit spacer tool 18G 1435 (2 Fig. 3) to the head.
Fit and torque tighten the cylinder head bolt.
Repeat the procedure for Nos 3,4,5 and 6 caps, left-hand
camshaft (3 Fig. 3).
Remove the cylinder head bolt from
No. 7 cap, left-hand
camshaft.
Loosen in sequence the securing bolts from Nos 1 and 7 caps, until theleft-handcamshaft isfree. Liftthecamshaft
from the cylinder head and fit spacer tool 18G 1435 to No. 7 cylinder head bolt position (5 Fig. 3). Fit and torque
tighten the bolt.
Clean
all components and examine for wear and damage.
Renew all worn or damaged components.
Lubricate the new left
-hand camshaft.
Fit the camshaft at approximately TDC.
Lubricate Nos 1 and 7 caps.
Fit No. 1 cap but do not tighten the securing bolts. Remove No. 7 cap cylinder head bolt.
1 Remove the spacer tool. Fit No. 7 cap but do not tighten
the securing bolts.
1 Finally tighten Nos 1 and 7 cap securing bolts in sequence.
Remove No. 4 cap cylinder head bolt and remove the
spacer tool. Lubricate and fit No. 4 cap.
CAUTION: The cylinder head bolts MUST be renewed dur- ing assembly and torque tightened as de- scribed in Section 2.1, SPS Joint Control System.
camshaft
(1 Fig. 3).
1 Repeat
the procedure for the right-hand camshaft.
1
Fia. 1
Fia. 2
Fig. 3
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AJ16 Engine Service Manual
. Fit and tighten No. 4 cap securing bolts.
. Fit and tighten No. 4 cap cylinder head bolt.
CAUTION: The cylinder head bolts MUST be renewed dur- ing assembly and torque tightened as de- scribed in Section 2.1, SPS Joint Control
System.
. Repeat the procedure for Nos 2,3,5 and 6 caps, left-hand
Set the left-hand camshaft to TDC.
. Repeat the procedure for the right-hand camshaft.
. Check and adjust valve clearances see Section 4.3.
Refit the camshaft cover, see Section 4.2.
camshaft. ~~
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AJ16 Engine Service Manual
4.2 Camshaft Cover Gasket, Renew
SRO 12.29.39
1 Remove the top cover and disconnect the on-plug coils
from the spark plugs.
. Disconnect the camshaft cover breather hose.
1 Remove the camshaft cover to cylinder head securing
Screws (1 Fig. 11, and remove the camshaft cover (2 Fig. 1).
. Remove and discard the camshaft cover gasket (3 Fig. 1).
. Clean the camshaft cover and cylinder head mating faces.
1 Fit a new gasket to the camshaft cover.
. Refit the camshaft cover.
1 Fit and tighten the camshaft cover securing screws.
. Reconnect the breather hose.
1 Reconnect the on-plug coils to the spark plugs and fit the
top cover.
I Fia. I
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AJ16 Engine Service Manual
4.3
SRO 12.29.48
1 Remove camshaft cover, see Section 4.2.
1 Rotate the engine as necessary to measurethevalve clear- ances between the heel of the cam and the cam follower
(Fig.
1). See Service Data in the Preliminary Pages for the
correct valve clearances.
1 Make a note of each clearance measurement.
1 Should the clearances be incorrect, proceed as follows:
1 Rotate the engine and set No. 1 cylinder at TDC using Ser- viceTool 18G 1433 (1 Fig. 2).
Push back the lock tabs (1 Fig. 3) from the camshaft
sprocket securing bolts (2 Fig. 3).
1 Slacken off the bolts and tab washers.
1 Remove the upper chain tensioner valve clamp bolt
(3 Fig. 3), remove the clamp (4 Fig. 3) and remove the
valve (5 Fig. 3).
1 Using a 3 mm Allen key, wind back the tensioner (turn
clockwise) until the snail engages in the park position.
1 Remove the tensioner housing securing bolt (7 Fig. 3) and
remove the tensioner assembly (8,9 Fig. 3).
1 Remove and discard the '0' ring (9 Fig. 3) and gasket (10 Fig. 3).
1 Remove the camshaft sprocket securing bolts/tab washers (1,2 Fig. 3) and remove the sprockets (1 1 Fig. 3).
1 Remove the cylinder head bolt from No. 2 cap, left-hand
camshaft (1 Fig. 4).
1 Remove the cap securing bolts from No. 2 cap, left-hand
cams haft.
. Remove No. 2 cap from the left-hand camshaft.
1 Fit spacer tool 18G 1435 (2 Fig. 4) to the head.
1 Fit and torque tighten the cylinder head bolt.
1 Repeat the procedure for Nos 3,4,5 and 6 caps, left-hand
camshaft
(3 Fig. 4).
1 Remove the cylinder head bolt from No. 7 cap, left-hand
camshaft.
1 Loosen in sequence the securing bolts from Nos 1 and 7 caps, until the left-hand camshaft is free. Lift the camshaft
from the cylinder head and fit spacer tool 18G 1435 to No. 7 cylinder head bolt position (5 Fig. 4). Fit and torque
tighten the bolt.
Valve Clearance, Check and Aa'just
1 Repeat the procedure for the right-hand camshaft.
CAUTION: The cylinder head bolts
MUST be renewed dur- ing assembly and torque tightened as de- scribed in Section 2.1, SPS Joint Control
System.
111 ...
Fig. 1
1
Fig. 2
Fig. 3
Fig. 4
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1.
Remove all the valve shims or only those requiring adjust- ment, check the size of the existing shims with a micrometer
and note the reading. Calculate the size of the
shim required
following the examples shown below:
VALVE CLEARANCES
For valve clearances see Service Data in the Preliminarv
I Pages
Excessive Clearance inches
Size of existing shim
Plus the actual clearance noted
Less the specified valve clearance
I
00.100
0.019
0.119
0.013
Required shim size = 0.106
Insufficient Clearance inches
Size of existing shim
0.107
Plus the actual clearance noted o.010
0.117
Less the specified valve clearance 0.013
Required shim size = 0.104
I
Fit the relevant shims to the cylinder head.
Note:
. Fit the left-hand camshaft at approximately TDC.
. Lubricate Nos 1 and 7 caps.
1 Fit No 1 cap. Fit but do not tighten the cap securing bolts.
. Remove No 7 cap cylinder head bolt.
. Remove the spacer tool.
1 Fit No. 7 cap. Fit but do not tighten the cap securing bolts.
. Finally tighten Nos 1 and 7 cap securing bolts in sequence.
. Remove No. 4 cap cylinder head bolt and remove the
. Lubricate and fit No. 4 cap.
. Fit and tighten No. 4 cap securing bolts.
. Fit and tighten No. 4 cap cylinder head bolt.
9 Repeat the procedure for Nos 2,3,5 and 6 caps, left-hand
CAUTION: The cylinder head bolts MUST be renewed dur- ing assembly and torque tightened as de- scribed in Section 2.1, SPS Joint Control
System.
See
Service Data in the Preliminary Pages for
avail- able valve shim sizes.
I
3
spacer tool.
camshaft.
1 Set the left-hand camshaft to TDC.
. Repeat the procedure for the right-hand camshaft.
Fit and align the camshaft sprockets to the chain and the
camshafts
AJ16 Engine Service Manual
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AJ16 Engine Service Manual
1 Move all the slack in the chain to the tensioner side.
1 Fit upper chain tensioner tool 18G 14361A (2 Fig. 1). Fit and
tighten the tool securing bolts (1 Fig. 1).
1 Tension the cam chain.
1 Remove the camshaft coupling (12 Fig.2) from the
sprocket (11 Fig. 2) and align the securing bolt holes. Fit
the bolts (2 Fig. 2) and tab washers (1 Fig. 2), tighten the
securing bolts and lock over the tabs.
1 Repeat the procedure for the other sprocket.
1 Slacken off the chain tensioner tool securing bolts
1 Remove the tensioner tool.
1 Clean the tensioner assembly and gasket faces.
= Fit a new housing gasket (10 Fig. 2). Fit and lubricate a
new ‘0’ ring (9 Fig. 2).
1 Fitthetensionerassembly (8,9 Fig. 2)tothecylinderhead.
Fit andtighten thetensioner assembly securing bolt (3 Fig.
2).
(1 Fig. 1).
1 Fit but do not tighten the valve clamp bolt.
1 Clean the valve assembly and fit new ‘0‘ rings (13 Fig. 2).
Lubricate the tensionervalve (5 Fig. 2). Using an Allen key,
release the tensioner, by turning the
Allen key anti-clock- wise.
1 Fit the tensioner valve (5 Fig. 2). Position the clamp (4 Fig. 2) over the valve.
1 Tighten the clamp bolt (3 Fig. 2).
1 Refit the camshaft cover, see Section 4.2. Fig.
1
I Fia. 2
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AJ16 Engine Service Manual
4.4 Cylinder Head Gasket, Renew
SRO 12.29.01
Drain the cooling system, see Section 4.1 and depressurize
the fuel system,see Section 5.1 (thesesections are in the ap- propriate Vehicle Service Manual). Disconnect the exhaust
system with the vehicle supported on axle stands. Remove
components as required for access to the cylinder head and
proceed as follows.
1 Rotate the engine to TDC No. 1 cylinder.
1 Remove the camshaft cover, see Section 4.2.
1 Push backthe lock tabs and remove the camshaft sprocket
securing bolts (2 Fig. 1). Remove the tab washers (1 Fig. 1).
1 Remove the upper chain tensioner valve clamp bolt (1 Fig. 2), remove the clamp (2 Fig. 2) and remove the
valve (3 Fig. 2).
1 Using a 3 mm Allen key, wind back the tensioner (turn
clockwise) until the snail engages in the park position.
1 Remove the tensioner housing securing bolt (4 Fig. 2) and
withdraw the tensioner assembly.
1 Re-position thetiming chain between the upper dampers.
1 Remove the cylinder head front securing bolts.
1 Remove the remaining cylinder head securing bolts/ nuts.
Remove the upper static damper pedestal assembly and
remove the cylinder head.
0 1 Fit an elastic band to retain the dampers and chain.
. Remove and discard the head gasket.
1 Remove and discard the exhaust manifold sealing rings.
1 Place the cylinder head on suitable blocks on a bench.
Clean the cylinder head thoroughly and check the cylinder
head and cylinder block for warping, bowing or cracks.
Renew if defective.
1 Fit a new cylinder head gasket.
1 Fit the cylinder head assembly to the engine, ensure no
hoses or cables are trapped.
A2616
Fig. 1
Fin. 2
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AJ16 Engine Service Manual
= Refit the upper static damper assembly.
lighten the cylinder head bolts with reference to the se- quence shown in Fig. 1.
CAUTION: The cylinder head bolts MUST be renewed dur- ing assembly and torque tightened as de-
scribed in Section 2.1, SPS Joint Control
System.
Ensure that the camshaft is still on TDC using Ser
-
vice Tool 18G 1433 (1 Fig. 2).
Fit the harness clip and hose bracket to the cylinder head
front securing bolts.
Fit and tighten the front securing bolts.
1433 (1 Fig. 2).
b:
= Check the camshafts are set atTDC using Service Tool 18G
= Raise the timing chain from between the upper dampers.
Remove the elastic band.
= Fit and engage the sprockets to the chain and camshafts.
. Move all the chain free play to the tensioner side.
Fit upper chain tensioner tool 18G 1436/A (2 Fig. 3).
Fit and tighten the tool securing bolts (1 Fig. 3).
Tension the timing chain.
sprocket
(1 1 Fig. 4) and align the securing bolt holes.
bolts
(2 Fig. 4). Lock over the tabs.
Release the tension on the timing chain.
Re
-position the
chain over the camshafts.
. Remove the camshaft coupling (12 Fig. 4) from the
. Fit the tab washers (1 Fig. 4). Fit and tighten the securing
. Slacken off the upper chain tensioner tool securing bolts.
Remove the upper chain tensioner tool 18G 14361A (2 Fig.
Clean the tensioner assembly and gasket faces.
3).
Fit a new housing gasket (10 Fig. 4). Lubricate andfita new '0' ring (9 Fig. 4).
. Fit the tensioner to the cylinder head.
. Fit and tighten the tensioner assembly securing bolt
Clean the valve assembly and fit new '0' rings.
Using an Allen key, release the tensioner, ie turn the Allen
(4 Fig. 3).
Lubricate the tensioner valve.
key
anti-clockwise.
I
104 2 5 7 I l2
I Fig. 1
1
Fig. 2
Fig. 3
Fig. 4
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