1994 JAGUAR XJ engine

AJ16 Engine Range
Service Manual
Published by Produtt Dwelopmcnt & Putillcations Jaguar Cars Limited
Part ot crt - JJW 10 04 1 2 / 50

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
Section Title SRO Page
4.26 ............. Oil Filter Head Gasket. Renew ................................... 12.60.03 ............ 46
4.27
............. Oil Pan Gasket. Renew ......................................... 12.60.38 ............ 47
4.28
............. Oil Pump '0' Rings. Renew ...................................... 12.60.27 ............ 48
4.29
............. Oil Pick-up Strainer, Renew ..................................... 12.60.20 ............ 49
4.30
............. Oil Pressure Relief Valve Assembly, Renew ......................... 12.60.56 ............ 50
4.3
1 ............. Oil Pump. Renew .............................................. 12.60.26 ............ 51
4.32
............. Oil Pump, Overhaul ............................................ 12.60.32 ............ 52 ~
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AJ16 Engine Service Manual
FOREWORD
This Service Manual has been designed to enable the skilled Jaguartechnician to correctly service and repair the range of Jaguar AJ16 in-line six-cylinder engines.
It assumes that the engine has been removed from the vehicle, in accordance with the Vehicle Service Manual, and
is
in a clean condition and all service tools and materials are available.
An index can be found at the rear of this manual.
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AJ16 Engine Service Manual
1. SERVICE TOOLS & EQUIPMENT
Illustration
not illustrated Jaguar
Number
18G 55A
18G 1433
18G 1434
18G 1435
18G
1436lA
18G 1431
18G 1437
-1
18G 1465
18G 1469
Description
Piston ring compressor
Camshaft timing tool
Jackshaft bushing remover
/ replacer
Camshaft dummy caps
Crank pulley remover and timing
damper
oil pressure simulator
Front pulley lock
Adapter Engine lifting bracket
Auxiliary drive shaft seal replacer ~~
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AJ16 Engine Service Manual
Jaguar Number ~~
JD
118
JD 128
JD
129
JD 130
JD 550
-3
JD 61 18C
MS 53C
MS 1519A
__ ~ Description
Auxiliary drive
shaft seal remover
Crank front seal remover
Crank front seal replacer
Chain link remover
/ replacer
Crank rear seal replacer adapter
Valve spring compressor
Engine support beam
Valve spring compressor
Notes
Issue 1 August 1994 V

AJ16 Engine Service Manual
Illustration
not illustrated
Jaguar Number
MS 1520
MS 1520-2
Description
Engine stand
Adapter assembly
for MS 1520
'Snap-On' Oil filter canister removal
tool
Notes
YA 992
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AJ16 Engine Service Manual
Fixing
II.
Tightening Torque
(Nm)
TORQUE TlGH TENlNG SPECIFICATIONS
Air Cleaner
Air box bracket screw 8,5 - 11.5
9.5
- 12,5
9,5 - 12,5
6,3 - 8,7
8.5
- 11,5
7 -9
Air box to bracket
Air box to instrumount
Air cleaner bracket setscrew
Air cleaner support bracket
(4,O liter supercharged)
Air temperature sensor to air box
1 Hose clamp, air box to air meter ~
Hose
clamp, air box to body
1,2 - 1,6
1.2
- 1,6 , , lnstrumount bracket Taptite screw I 9,5 - 12,5
trumpet to body ~ 9,5 - 12,5
Compressor
to bracket
_________ Connecting rod bearing nut 52 - 55 (SPS System) _______ ~
Bypass
elbow to thermostat housing
Fan drive unit setscrew
Fan drive unit to pulley
Hose clamp, breather to thermostat
Hose clamp, breather to throttle body
Hose clamp, bypass hose
Hose clamp, water pump to pipe
Thermostat cover to housing
Thermostat housing to cylinder head
Water pipe bracket to intake manifold
Water pump assembly
Water pump to timing cover
Water pump to water
rail
Water rail to cylinder block
Water temperature sensor to thermostat housing
Water temperature transmitter to thermostat housing
9,5 - 12,5
12- 16
21,5 - 28,5
1,5-2,5
1,5 - 2,5
2,5
- 3.5
2,5
- 3,5
21,5 - 28,5
21,5 - 28,5
21.5- 28,5
21,5 - 28,5
21.5 - 28,5
2,5 - 3,5
21,5 - 28,5 1
14,5- 19,5
14,5- 19,5
1 Crankshaft
Clutch to flywheel (4,O liter)
Crankshaft bolt
Drive
-plate to crankshaft (3,2 liter) ~___~.~ Drive-plate to crankshaft (4,O liter supercharged automatic)
Flywheel to
crankshaft setscrew (4,O liter) _______
Timing ring to damper
22,5 - 27,5
183 - 223
88 - 108
123
- 149
123
- 149
15.5
- 20.5
-~
___________
vi i Issue 1 August 1994