1994 JAGUAR XJ drain bolt

AJ16 Engine Service Manual
Cylinder Block
Adapter to cylinder block
Bearing cap to cylinder block
Blanking plate to cylinder block
Manual transmission to engine
(4,O liter supercharged automatic)
Oil drilling blanking plug
Oil gallery blanking setscrew
Oil pressure sensor
Oil pressure sensor plug
Oil seal adapter to cylinder block
Transmission adapter to cylinder block
Water drain plug
Windage tray to cylinder block
Cylinder Head and Camshaft Cover
Bearing cap to cylinder head
Camshaft coupling bolt
(Nm)
43 - 57
136
- 142 (SPS
System)
21,5 - 28,5
43 - 57
29
- 39
21,5 - 28,5
23 - 27
8,5- 11,5
21,5 - 28,5
44.5 - 59,5
64.5 - 79.5
21.5
- 28,5
17 - 23
22
- 28
Camshaft cover to cylinder head
- - . ~. Cylinder head to cylinder block
Cylinder head to timing cover -
______ ____ Exhaust manifold to cylinder head
On
-plug coil cover to camshaft cover
Rear cover to cylinder head
4-5
59 - 61 (SPS System) ~~ -. . - 21,5 - 28,5
22 - 28
_. . -.. ___ Dipstick
Tube
Dipstick tube assembly nut
Dipstick tube attachment to tube support bracket
(4,O liter supercharged)
__ Dipstick tube bracket (4,O liter supercharged)
Dipstick tube to bracket
Drive Chain System
Dipstick tube bracket screw
Auxiliary shaft assembly setscrew
Coupling to intermediate shaft
Damper to cylinder block (bolt)
Damper to cylinder block (screw)
Damper to distance piece
Damper to saddle
Distance piece to cylinder block
Endplate to damper
Housing to cylinder block (bolt)
Housing to cylinder block
(capscrew)
Pivot bracket to cylinder block
Pivot plate to cylinder block
Sprocket to hub setscrew
Engine Mounting
Engine mounting bracket to engine
Issue 1 August 1994 viii
81 -99
15.5 - 20,5
5-7
9,5
- 12,5
5%: 7.8
30,5 - 37,5
12-16
21,5 - 28,5
21.5 - 28,5
21,5 - 28,5
21,5 - 28,5
21,5 - 28,5
21.5 - 28,5
21,5 - 28,5
21,5 - 28,5
21,5 - 28,5
2 1,5 - 28,5
9,5 - 12,5
445 - 59,5

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
Issue 1 August 1994 7

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

AJ16 Engine Service Manual
4.12
SRO 12.21.26
Crankshaft End-float, Check and A4ust
Remove components as required for access and proceed as
follows.
Remove the oil pan, see Section 4.27.
Remove the oil pump pick-up pipes (3 Fig. I), see Section
Remove the crankshaft windage trays (6 Fig. 1).
. Mount a suitable dial gauge and position the stylus on the
crankshaft front pulley.
. Zero the gauge, and with the use of a suitable lever,
measure the crankshaft end-float (Fig. 2). For the correct
end-float, see Service Data in the Preliminary Pages.
If the end-float exceeds the tolerances, remove the center
main bearing cap, and renew the thrust washers.
&&: When refitting the thrust washers, ensure that the
bearing face (grooved) (1 Fig. 3) and not the steel
side contacts the crankshaft.
. Recheck the end-float and if satisfactory, clean the main
bearing cap and bearing, lubricate with clean engine oil
and
fit the cap assembly to the cylinder block.
4.28. 0
Fit and
torque tighten the securing bolts.
CAUTION: The main bearing securing bolts MUST be re
-
newed during assembly and torque tightened as described in Section 2.1, SPS Joint Control
System.
Ensure that the bearing cap is the correct way round
with the cap numbers corresponding to the
numbers stamped on the oil pan mounting face.
Rotate the crankshaft to ensure that it is not being
'pinched' and will rotate freely.
m Remove the dial gauge and torque tighten the main bear- ing cap. Refit the windage trays to the cylinder block and
secure with the bolts.
w:
Refit the oil pump pick-up pipes, see Section 4.28.
Refit the oil pan, see Section 4.27.
Refit the oil filler / drain back tube.
Replace the components removed for access.
0
3
Fia. 1
Fig. 2
Fig.
3
27 Issue 1 August 1994

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
Issue 1 August 1994 33

AJ16 Engine Service Manual
4.26
SRO 12.60.03
. Place a drain tray under the oil filter.
. Remove the oil filter cartridge (1 Fig. 1).
Oil Filter Head Gasket, Renew
If the vehicle is fitted with an oil cooler, remove the oil
cooler pipe clamp nut and clamp. Notethe position of and
disconnect the pipes from the oil supply housing.
. Remove and discard the '0' rings. Remove the filter head
securing bolts
(2 Fig. 1).
Remove the inner (3 Fig. 1) and outer (4 Fig. 1) housings.
. Thoroughly clean the housings, the oil cooler pipes (if fitted) and the cylinder block face.
9 Apply sealanttothe outer housing, align the inner housing
with the outer housing and fit the securing bolts to the
housing assembly. See Service Materials in the Prelimi- nary Pages. Align the assembly to the aperture in the cyl- inder block, fit and tighten the securing bolts.
If the vehicle is fitted with an oil cooler, fit new '0' rings to
the oil cooler pipes. Lubricate and connect the pipes
to the
housing.
. Fit the clamp plate and fit a new oil filter.
. Fill the engine with oil to the correct level, see Section 3.1
in the appropriate Vehicle Service Manual. Fia.
1 ~~~
Issue 1 August 1994 46

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

AJ16 Engine Service Manual
4.28
SRO 12.60.27
Remove the oil pan, see Section 4.27.
m Place a suitable drain tray under the oil transfer housing
area and remove the transfer housing / pick-up pipe (1,2,
4,5 Fig. 1).
Oil Pump Pipe '0' Rings, Renew
. Remove the oil pump pick-up pipes (3 Fig. 1).
. Remove and discard the 'O'rings. Clean the transfer hous- ing and oil pipes.
. Carefully fit new '0' rings (lubricated with petroleum jelly)
to the oil pipes (1 Fig. 2) and refit the pipes to the oil pump.
. Fit the transfer housing to the engine. Fit and tighten the
securing bolts.
. Refit the oil pan, see Section 4.27.
Fig. 1
Fig. 2
Issue 1 August 1994 48