1994 JAGUAR XJ cooling

AJ16 Engine Service Manual
CON TENTS
Section SRO Page
Foreword ........................................................................\
.. iii
I ................ Service Tools & Equipment ........................................................... iv
I1 ................ Torque Tightening Specifications ....................................................... vii
111 ............... Service Materials .................................................................... xii
1V ............... Service Data ...................................................................... xiii
1 ................ General Description .................................................................. 1
1.1 .............. Construction ........................................................................\
1
1.2 .............. Cylinder Head Design ................................................................ 7
1.3 .............. Crankcase Breather ................................................................... 7
1.4 .............. Lubrication System ................................................................... 1
1.5 .............. Cooling System ...................................................................... 2
1.6
.............. Supercharger ........................................................................\
2
2 ................ Service Procedures ................................................................... 2
2.1 .............. SPSloint ControlSystem .............................................................. 2
2.2 .............. Sealants ........................................................................\
.... 2
3 ................ Fault Diagnosis ...................................................................... 3
3.1
.............. Introduction ........................................................................\
. 3
3.2
.............. Diagnostic Procedures ................................................................ 3
4
................ Service Operations ................................................................... 7
4.1 .............. Camshaft, Renew .............................................. 12.13.01 ............. 7
4.2 .............. Camshaft Cover Gasket. Renew .................................. 12.29.39 ............. 9
4.3
.............. Valve Clearance, Checkand Adjust ............................... 12.29.48 ............ 10
4.4 .............. Cylinder Head Gasket, Renew ................................... 12.29.01 ............ 13
4.5
.............. Cylinder Head, Overhaul ........................................ 12.29.19 ............ 16
4.6
.............. Cylinder Head Casting, Renew ................................... 12.29.15 ............ 19
4.7
.............. Piston and Connecting Rod, Engine Set, Renew ..................... 12.17.10 ............ 20
4.8
.............. Connecting Rod Bearing, Engine Set, Renew ....................... 12.17.16 ............ 22
4.9
.............. Main Bearing, Engineset, Renew ................................. 12.21.39 ............ 23
4.10 ............. Crankshaft, Renew ............................................. 12.21.33 ............ 24
4.11
............. Crankshaft Damper/Pulley Assembly, Renew ...................... 12.21.09 ............ 26
4.12
............. Crankshaft End-float, Check andAdjust ........................... 12.21.26 ............ 27
4.13
............. Crankshaft Front Oil Seal, Renew ................................. 12.21.14 ............ 28
4.14
............. Crankshaft Rear Oil Seal, Renew ................................. 72.21.20 ............ 29
4.15
............. Engine Flywheel, Renew ........................................ 12.53.07 ............ 30
4.16
............. Engine Drive-plate, Renew ..................................... 12.53.13 ............ 31
4.17 ............. Engine Rear/ Transmission Adapter Plate, Renew ................... 12.53.03 ............ 32
4.18
............. Engine Assembly, Overhaul ...................................... 12.4 7 . 05 ............ 33
4.19
............. liming Chain, Gear and Tensioner, Engine Set, Renew ............... 12.65.13 ............ 37
4.20
............. Timing Chain Damper, Vehicle Set, Renew ......................... 12.65.48 ............ 40
4.21
............. liming Chain Tensioner, Upper, Renew ............................ 12.65.29 ............ 41
4.22
............. Timing Chain Tensioner, Lower, Renew ............................ 12.65.30 ............ 42
4.23
............. Timing Sprocket, Intermediate, Renew ............................ 12.65.26 ............ 43
4.24
............. Auxiliary Shaft, Renew ......................................... 12.10.30 ............ 44
4.25
............. Auxiliary Shaft Rear Seal. Renew ................................. 12.10.32 ............ 45
0
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AJ16 Engine Service Manual
FAULT DIAGNOSIS
3.1 Introduction
The following diagnostic procedures are provided to assist properly qualified persons to identify and rectify the faults
relating to the engine which are most likely to encountered. Reference is made to the Electrical Diagnostic Manual
(EDM), which should be consulted where necessary. Faults related to the cooling system are dealt with in Section 4.1
and to the fuel system in Section 5.1 in the appropriate Vehicle Service Manual (VSM).
3.2 Diagnostic Procedures
(fails to rotate)
I Engine rotates but 0 I will not fire
I
i
/Overheating
Overheating at tick-
Too cold
Loss of coolant Possible
Cause
Battery leads loose or ter
- minals corroded
Battery discharged
Starter motor inoperative
Starter motor speed too
low
Faulty ignition system
Fuel system defect
Oil requires changing
Worn crankshaft journals
Excessive crankshaft
end- float
Worn main bearing shells
Worn oil pump Oil pressure relief valve stick
- ing open
Oil pressure relief valve
spring too weak
Insufficient oil in oil pan
Engine overheating
Faulty gauge or sensor
Incorrect grade oil (viscosity
too low)
Water in oil Check
Check the condition of the
leads and terminals
Check condition of battery
with hydrometer
If the lights dim when ignition
switch is operated, the starter
may be jammed in starter
ring.
Check for loose and dirty con
- nections to the starter motor
Check battery leads and ter
- minals
Check state of battery charge
Refer to EDM
Remove the spark plugs
Check oil level and color
Listen for rumble or knock
Fit dial gauge and measure
Listen for rumble
Remove oil pump and check
the clearances
Remove valve and check for
sticking
Remove spring and check
spring rates
Check oil level
Refer to EDM
Check oil viscosity
Checkoil level and check if oil
is a milky white color
Check for leaking head gasket Remedy
Clean and tighten as necess
-
ary
Charge or renew battery as
necessary
Remove starter motor, free
off pinion and refit
Clean and tighten connec
- tions
Clean and tighten terminals
Charge or renew battery
as necessary
Rectify as required
Clean and re
-gap the spark
plugs, renew if worn out
Refer to Fuel System fault
finding in Section
5.1, VSM
Refer to Section
4.1, VSM
Refer to Section
4.1, VSM
Refer to Section
4.1, VSM
Refer to Section
4.1, VSM
Change oil and filter
Renew crankshaft
Renew thrust washers
Check crankshaft journals for
wear and renew shells
Renew oil pump
Renew valve
Renew spring
lop-up as required
Refer to Overheating fault
finding in Section
4.1, VSM
Rectify as required
Renew oil and filter
Renew oil and filter
Renew head gasket
Issue 1 August 1994 3

AJ16 Engine Service Manual
Symptom
Joisy chains
)etonation knock pinking)
.oss of power
Gugh running at iormal engine speed Possible
Cause
Low oil pressure
Tensioners not released
Chains worn
Sprockets worn
Tensioner worn
Ignition timing too far ad
- vanced
Head gasket leaking
Fuel
/ air mixture too weak
Engine running
too hot
Valve timing incorrect
Incorrect grade fuel
Burned valves Sticking valves
Poor engine tune
Insufficient valve clearance
Fuel injection fault
Lowcompression in cylinders
Ignition fault
Valve timing incorrect
Partial seizure of engine
Worn
camshaftb)
Incorrect grade fuel
Sticking valves Broken valve springs Piston fault
Leaking head gasket
Valve burned out
Valve seat burned out
Ignition fault
Fuel injection fault
Check
Take reading from oil pres- sure gauge when engine is
hot
Remove camshaft cover and
check tension of chain (top
chain). Remove timing cover
to check bottom chain tension
Visually check
/ remove and
check for wear
Visual check
Visual check
Refer to EDM
Check engine oil level and
checkfor contamination of oil
Pressure test cooling system
and check for contamination
of coolant in header tank
Refer to EDM
Check valve timing
If all other checks
OK, this
could be the cause
Check cylinder compressions
Check cylinder compressions
Refer to EDM
Check valve clearance
Check compressions
Refer to EDM
Check valve timing
Remove spark plugs and ro
- tate crankshaft
Remove
camshaft(s) and
check for wear
If all other checks OK this
could be the cause
Check cylinder compressions
Check cylinder compressions
and for bent valve stems
Check cylinder cornpressions
Check cylinder compressions
Check cylinder compressions
Refer to
EDM
Remedy
Refer to Insufficient Oil Pres- sure fault finding
Insert
3 mm Allen key and
turn tensioner anti-clock- wise, compress tensioner to
release bottom chain
Renew as necessary
Renew as necessary
Renew as necessary
Rectify as required
Renew head gasket
Rectify
as required
Refer
to Overheating fault
finding in Section 4.1, VSM
Adjust valve timing
Drain fuel tank and refill with
correct grade fuel
Remove cylinder head and
renew valves
Remove cylinder head and
renew valves
/ guides or
springs
Rectify as required
Adjust as necessary
Refer to Fuel System fault
finding in Section 5.1, VSM
Rebore
1 re-ring as necessary
Rectify as required
Adjust valve timing
Overhaul engine as required
Renew
camshaft(s)
Drain fuel tank and refill with
correct grade fuel
Renew valve, springs or
guides
Renew valve springs and
valves as required
Renew pistons
Refer to Detonation Knock
fault finding
Renew valve
Re
-cut or renew valve seat
Rectify as required
Refer to Fuel System fault
Tindim in Section 5.1, VSM
issue 1 August 1994 5

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
4.4 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
Issue 1 August 1994 13

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