1994 JAGUAR XJ length

AJ16 Engine Service Manual
kern
For piston grade F
Application
alinder block bore diameter after
boning
Specification
90,990 to 90,998
mm
zylinder head For
piston grade
G
For piston grade H
t0.020 in.
:rankshaft
90,999 to 91,007 mm
91,008 to 91,016 mm
91,513 to 91,526 mm
:onnecting rod To
within 15
gm cm (imbalance to
be corrected by drilling up to four
holes in each balance weight
9,5
mm diameter x 29 mm deep
' maximum)
'iston
'iston diameter Length
between centers
Bore for connecting rod bearing
Connecting rod bearing diametrical
clearance
Connecting rod bearing side
clearance
Bore for small end bushing
Type
Skirt clearance
Grade
F
Grade G
Grade
H
+0.020 in.
Number
of compression rings
'iston ring
____ Blue: 52,990 to 53,000 mm
3,2 liter: 175785 to 175,285 mm
4,O liter: 166,320 to 166,420 mm
56,731 mm
0,023 to 0,059 mm
0,132 to 0,233 mm
26,975 to 27,000 mm
AE413P/PD (BS 1490-198SLM 13TF)
phosphorus treated
0,Ol to 0,026 mm
90,972 to 90,980 mm
90,980 to 90,989 mm
90,990 to 90,998 mm
91,480 to 91,506 mm
2
Material
I Aluminum
alloy
Material
I3,2 liter: cast iron
Number of main bearings
Main bearing type
Journal diameter
Thrust washer thickness
Permissible end float
Balancing
Diametrical clearance
Crankpin diameter
4,O liter: forged steel
7
Vandervell
VP2C
Pink 76,210 to 76,220 mm
White: 76.220 to 76,230 mm
Green: 76,230 to 76,240 mm
2.57 to 2,62 mm
0,lO to 0,28 mm
Number of oil control rings
Gap when fitted in bore 1
Top compression ring:
0,40 to 0,65
mm
Second compression ring: 0,40 to
0,65 mm
Oil control ring: 0.30 to 0,55 mm
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AJ16 Engine Service Manual
Item
Type
Length
Outside diameter
Inside diameter
Material ~
Application
Specification
Chamfer locking
3,2
liter: 68,37 to 68,50 mm
4,O liter: 77,12 to 77,25 mm
23,807 to 23,812 mm
14,30 to 14.81 mm
Cast iron
'iston pin
2amshaft
dalve
Number of journals
Nominal
lift
Permissible end float
4djustment of valve clearance 7
9,95 mm
0.13 mm
rlalve Guide
Valve
stem diameter
Valve clearance
Jalve seat Intake
and exhaust: 6,947 to 6,960
mm
Intake and exhaust: 0,30 to 0,36 mm
Jalve seat insert outside diameter Outside
diameter
rappet
lalve spring Standard
- no
groove: 10,993 to
11,005 mm
1st oversize - 1 groove: 11,043 to
11,055
mm (production only)
2nd oversize
- 2 grooves: 1 1,143 to
11,155 mm
:amshaft sprocket
:rankshaft sprocket Diametrical
clearance
Free length
Number
of teeth
ntermediate sprocket
0,02 to 0,05 mm
43,5 mm
30
xv Issue 1 August 1994

AJ16 Engine Service Manual
0 Application Item
'rimary timing chain Type
Pitch
Roller diameter
secondan/ timing chain Type
Number of pitches
Pitch
Number of
pitches Specification
Endless duplex
80
9,525
mm
6,35 mm
Endless duplex
86
9,525
mm
lil pump chain
lil filter
lil pressure (engine at normal
,perati ng temperature)
Si1 pump
I Roller diameter 16,35 mm
I Type I Endless simplex
Roller diameter
6,35 mm
Deflection (at mid-point of free side) 2 to 4 mm (with a load of 50 N)
Type Full flow disposable canister
At
idle speed 0,5 bar (minimum)
At
4000 RPM 4,83 bar (minimum)
Type Rotor
Rotor end float
0,l mm
Number of pitches I52
Pitch 19,525 mm
___ Overall length
Working length Mandrel length
Mandrel diameter 35 mm
30 mm
57 mm
11,ll mm
Si1 pressure relief valve
Application
Generator
/ water pump drive belt (normally aspirated
engines)
Generator
/ water pump drive belt (4.0 liter
supercharged engine)
I Rotor lobe clearance 10,2 mm I
Specification
Burroughs method: new belt
556 to 578 N. Run for one
minute, allow belt to cool and reset to the in
-service
setting. In service if tension falls below
356 N, reset at
511 to 534 N
.Clavismethod: new belt 174 to 180 Hz. Run for one
minute, allow belt to cool and reset to the in
-service
setting. In service
if tension falls below 140 Hz, reset at 167 to 173 Hz. (Measuring point: mid-way between
crankshaft and generator pulleys)
Burroughs method: new belt
560 to 600 N. Run for one
minute, allow belt to cool and reset to the in
-service
setting. In service if tension falls below
335 N, reset at
405 to 445 N
Clavis method: new belt
180 to 186 Hz. Run for one
minute, allow belt to cool and reset to
the in-service
setting. In service if tension falls below
131 Hz, reset at
155 to 161 Hz. (Measuring point: mid-way between
crankshaft and generator pulleys)
__ ___
.- ...
pket she sizes ___ Outside diameter
1
1
Drive Belt Tensions
0
Issue 1 August 1994 xvi

AJ16 Engine Service Manual
. The dimension must be taken between the valve stem and
the back of the cam. Should
this dimension not be ob-
tained, metal must be ground from thevalveseat of the in-
sert.
&&: Use only suitable grinding equipment.
* Remove only very small amounts of metal from the valve
seat at one time before re-checking the clearance.
. Examinethecamfollowersforwear on the topface. Check
for any sign of barreling on the side faces (Fig. 1). Renew
all followers that are worn or suspect. Wash the valves,
springs, collets, followers and air dry.
. After the valve springs have been thoroughly washed,
they must be examined for fatigue and distortion. Renew
as necessary.
. Test the valve springs either by comparison with the fig- ures given in Service Data in the Preliminary Pages, or by
comparison with a new valve spring (using a recom- mended valve spring testing machine).
. To test against a new valve spring, insert both valve
springs end to end between the test equipment. Apply a
load to partly compress the springs and measure their
comparative lengths (Fig.
2).
&@:
. If the distance 'A' is smaller than the distance 'B', then 'A'
b: Spring distortion is determined by positioning the
spring upright on a surface plate and checking the
squareness of each end with a set square (Fig.
3). All
valve springs which have diminished in length and/ or are not square must be renewed.
. Fit the valves into the guides and place the cylinder head
on wooden blocks.
. Fit the valve spring seats, intake valve guide oil seals,
springs and collars.
. Compress the springs using Service Tool MS 1519A and
insert the split collets.
. Refit the original shims (1 Fig. 4) in the valve collar re- cesses. (Ensure that the shims are seated correctly and fit
the cam followers, see Section 4.3).
If the cylinder head has been overhauled to the ex-
tent of having the valve seats recut, each shim
should be 0,010 in. smaller than the original.
. Lubricatethecamshaftsand fittothecylinder head,ensur- ingthattheyarefittedwiththeslotsto thetop. Fitthecam- shaft caps and torque tighten the securing bolts. Measure
the valve clearance between the heel of the cam and the
cam follower, turning the camshaft as necessary to
measure
all the clearances see Section 4.3.
It is advisable to set the valve clearances to the
upper
limit to allow for the clamping effect exper- ienced through torque tightening upon engine re- assembly.
Afinal checkof the valve clearances should be done
when the cylinder head is fitted and torque tigh
- tened to the cylinder block.
Clean the cylinder head thoroughly and checkthe cylinder
head and cylinder block for warping, bowing or cracks.
. Fit the cylinder head, see Section 4.4.
'A' is the old spring.
must be renewed.
&&:
m:
&@:
Fig. 1
K
Fig. 2
I Fig. 4
Issue 1 August 1994 18