AJ16 Engine Service Manual
b:
1 Secure with new snap-rings, never re-use old ones.
1 Fit the rings to the pistons ensuring that gaps are posi-
tioned as shown in Fig. 1.
1 Lubricate and compress the rings using Service Tool 18G 55A (Fig. 2).
1 Insert the piston skirt into the bore and using a suitable im- plement such as a wooden hammer shaft, gently tap the
piston into
the cylinder bore.
1 Ensure that the connecting rod does not foul either the cyl-
inder block or camshaft.
Lubricate (using clean engine oil) and fit the bearing shells
to the connecting rod and the connecting rod bearing cap.
Fit the rod to the crankshaft, and fit the connecting rod
bearing cap to the connecting rod.
CAUTION: The connecting rod bearing nuts and bolts
MUST be renewed during assembly and torque
tightened asdescribed in Section2.1, SPS Joint
Control System.
Pistons are marked
'FRONT'. Ensure
that the mark- ing faces the front of the engine.
1 Fit and tighten the connecting rod bearing nuts.
1 Repeat the operation for the remaining pistons.
1 Ensure crankshaft rotation during assembly.
1 Clean and fit the windage trays. Fit and tighten the secur- ing bolts.
1 Removethe oil pumpandoverhau1,seeSection 4.32. Refit
when serviceable.
1 Lubricate the lower timing chain. Fit the chain to the inter- mediate sprocket, fit the chain to the lower sprocket and
then assemble the intermediate sprocket and chain to the
cylinder block.
= Should the intermediate sprocket be worn or damaged,
the assembly must be renewed.
= Fit the spacers to the lower pivoting damper and fit the as-
sembly to the cylinder block.
1 Fit the tab washer and securing bolts.
1 Tighten the bolts and lock over the tabs.
1 Renew the lower tensioner assembly, see Section 4.22.
Fit a dial gauge to the top of the cylinder block and turn the
1 Lubricate the upper chain with clean engine oil and fit to
1 Fit an elastic band around the upper dampers tosecurethe
1 Renew the crankshaft front oil seal, see Section 4.13.
1 Refit the timing cover.
= Lubricate and fit the oil seal distance spacer. Fit and seat
1 Renew the rear housing oil seal, see Section 4.14.
1 Refit the oil pan, see Section 4.27.
1 Refit the cylinder head, see Section 4.4.
1 Remove the engine from the stand.
1 Refit the transmission unit to the engine.
1 Refit the engine/ transmission unit to the vehicle, see Sec-
engine over until No.1 piston is at TDC (Fig. 3).
the intermediate sprocket.
chain.
the crankshaft pulley woodruff key.
tion 3.1 in the appropriate Vehicle Service Manual.
V'
ill'.,
Fia. 1
Fig.
2
Fig. 3
Issue 1 August 1994 36
AJ16 Engine Service Manual
@ 4.27 Oil Pan Gasket, Renew
SRO 12.60.38
Remove components as required for access and proceed as
follows.
. Drain the engine oil, see Section 3.1 in the appropriate Ve-
= Remove all but two oil pan bolts (1 Fig. 1).
= Remove the bell housing to oil pan bolts.
. Remove the two remaining oil pan bolts and lower the oil
pan (2 Fig. 1).
. Clean all components and examine for damage and wear.
Renew any damaged components. Discard the oil pan
gasket.
&&: If renewing the oil pan, transfer all components to
the new oil pan.
Clean the gasket face on the cylinder block.
. Fit new oil pan gasket.
. Lift the oil pan into position, fit and torque tighten these-
hicle Service Manual.
curing bolts.
in the appropriate Vehicle Service Manual.
. Fill the engine with oil to the correct level, see Section 3.1
Replace the components removed for access.
112-83L
Fig. 1
Issue 1 August 1994 47
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
