1994 JAGUAR XJ ABS

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
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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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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AJ16 Engine Service Manual
4.18 &;ne Assembly, Overhaul
SRO 12.41.05
. Remove the engine and transmission unit, see Section 3.1
. Remove the transmission unit from the engine.
. Fit the engine to a stand.
. Place a drain tray belowthe cylinder block drain plug and
Overhaul the cylinder head, see Section 4.5.
1 Remove the oil pan, see Section 4.27.
. Remove the oil pump, see Section 4.31.
. Remove the windage trays.
. Clean all components, check for damage and wear and
. Remove the rear oil seal housing, see Section 4.1 4.
. Remove the timing cover assembly.
1 Remove the pedestal bolts and tab washer.
. Remove the pedestal / tensioner assembly and damper.
Slacken off the oil pump drive chain damper securing
bolts and move the damper clear of the chain. Push back
the lock tabs
(1 Fig. 1) and remove the securing bolts (2
Fig. 1) from the oil pump drive sprocket (3 Fig. 1).
in the appropriate Vehicle Service Manual.
drain any remaining coolant from the engine.
renew as required.
. Remove the drive sprocket and shim pack.
. Remove the oil pump drive chain (5 Fig. l), remove the
elastic band from the upper dampers and remove the
upper timing chain.
1 Remove the lower tensioner securing bolts and remove
the tensioner.
. Push back the lower chain fixed damper securing bolt lock
tabs and remove the bolts.
. Remove the damper and tab washer.
. Repeat for the remaining fixed and pivot dampers and re- move the lower chain and intermediate sprocket.
Remove the crankshaft pulley spacer and the crankshaft
pulley woodruff key.
= Remove the drive sprockets and woodruff keys from the
crankshaft.
1 Checkall drive sprocketsforwear, distortion and damaged
teeth. Renew as required.
. Remove the power assisted steering pump assembly, see
Section 10 in the appropriate Vehicle Service Manual and
reposition away from the timing cover area.
. Renew the auxiliary shaft, see Section 4.24.
1 Renew the auxiliary shaft bushes, see Section 4.19.
1 Remove the oil pump drive chain damper.
. Remove the spacers from behind the damper.
. Remove the pistons and connecting rods and renew, see
Section 4.7.
. Refit the connecting rod bearing shells to one connecting
rod and cap and fit the rod to the crankshaft. Torque
tighten
the nuts and checkthe side clearance between the end face of the rod and the journal shoulder (Fig. 2) -see
Service Data in the Preliminary Pages.
Remove the connecting rod from the crankshaft.
. Repeat for the remaining five connecting rods. Fig.
1
Fig. 2
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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
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AJ16 Engine Service Manual
Clean all component parts and check for wear or damage,
renew worn or damaged components as necessary.
Check
forwear and renewtheauxiliaryshaft bushes (1 Fig.
1) using Service
Tool 18G 1434 (2 Fig. 1).
. Lubricate all bearing shells. Refit all shells using 18G 1434.
CAUTION: Ensure that the oil feed holes are lined up with the holes in the bearing shell (1 Fig. 2).
. Fit the timing cover blanking plate to the timing cover. Fit and tighten the securing bolts.
Lubricate and fit the auxiliary shaft to the housing.
Lubricate and fit the thrust washer.
. Refit the auxiliary shaft snap-ring.
Fit a new oil seal to the rear of the shaft.
Fit and align the oil pump drive-plate to the auxiliary shaft.
. Apply sealant to the bolt securing the driveplate, fit and
tighten the bolt. See Service Materials in the Preliminary
Pages.
Refit the power assisted steering pump, see Section 10 in
the appropriate Vehicle Service manual.
Fit the new sprocket to the crankshaft.
Using a straight edge (2 Fig. 3). check the alignment of the
oil pump drive sprocket (1 Fig. 3). and the crankshaft
sprocket (4 Fig. 3).
Push back the lock tabs from one bolt securing the oil
pump drive sprocket, and remove the bolt.
. Rotate the sprocket. Push back the locktabs from the sec- ond bolt, and remove the bolt.
m Rotate the sprocket, push back the lock tabs and remove the remaining bolt.
. Remove the tab washer and drive sprocket.
Remove the shims (3 Fig. 3). Calculate the thickness of
shim(s) required for correct sprocket alignment.
Fit and tighten a dummy stud to the oil pump drive flange. Fit and align the shims to the flange. Fit and align the
sprocket.
Fit and align the new tab washer.
Fit and tighten the first sprocket securing bolt. Do not lock
over the tab washer at this stage.
m Rotate the sprocket for access.
. Fit and tighten the second sprocket securing bolt. Lock
m Rotate the sprocket for access.
= Remove the dummy stud.
. Rotate the sprocket for access.
Re-tighten the first securing bolt.
. Re-check the sprocket alignment.
= Re-adjust as necessary.
m Lubricate the newtiming chain and position thechain over
. Lubricate the oil pump drive chain.
. Fit the drive chain to the oil pump sprocket.
* Engage the drive chain to the crank sprocket.
Ensure that the drive chain ends are on the damper side of
If the alignment is incorrect, proceed as follows:
over the
tab washer.
Fit and tighten the third
sprocket securing bolt. Lock over the tab washer.
Lock over the tab
washer.
the auxiliary drive shaft and crankshaft sprocket.
the sprockets.
Fia. 1
I I // , I,
Fia. 2
i Fig. 3
Issue 1 August 1994 38