1994 JAGUAR XJ steering

AJ16 Engine Service Manual
0 Fixing
Oil Pump, Filter and Oil Pan
Baffle tray to oil pan
Drain plug to oil pan
Pick
-up to carrier
Filter head to cylinder block
Front cover to body
Oil filter canister
Oil pan to cylinder block
Oil pan to timing cover
Oil pump and oil pump carrier to cylinder block
Rear cover to body
Relief valve plug Tightening
Torque
(Nm)
21,5 - 28,5
64.8 - 79,2
9,5 - 12,5
21.5 - 28.5
9,5
- 12,5
12-15
21,5 - 28,5
21,5 - 28,5
21,5 - 28.5
9.5
- 12,5
35,7 - 48,3
Power Steering
Adapter to housing 21,5 - 28,5
Power steering pump to adapter
Power steering pump to engine
spark Plug
Starter Motor
Starter motor to adapter
Transmission to starter motor
Supercharger-
Spark plug
--
44.5 - 59,5
22 - 28
22
- 28
43
- 57
43
- 57 -___
Adapter to timing cover
Air duct clamp to intercooler
Air duct hoses
Air duct lower to intercooler 22 - 28
2,5
- 3,5
2,5
- 3,5
2,5 - 3,5
Air duct upper casting to lower
Bypass valve to throttle body
Elbow to intercooler
Idler bracket
/ timing cover to cylinder block
Idler bracket to water pump
X Issue 1 August 1994
2,5 - 3,5
8,5
- 11,5
22 - 28
22
- 28
22
- 28
Idler mounting bracket
Intercooler water pipes
Outlet elbow to supercharger
Pulley to carrier
Supercharger mounting bracket to engine
Supercharger mounting stud 22 - 28
22
- 28
22
- 28
22
- 28
43
- 57
22
- 28
Supercharger to mounting bracket 43 - 57
Tensioner bracket / timing cover to cylinder block 22 - 28
Tensioner bracket to adapter
Throttle body adapter to bypass actuator 22 - 28
8,5
- 11.5

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
4.19 Timing Chain, Gear and Tensioner, Engine Set,
Renew
SRO 12.65.13
Remove the timing cover.
Remove the upper tensioner pedestal flanged securing
bolts (3 Fig. 1).
Remove the pedestal / tensioner assembly and chain
damper (1 Fig. 1).
= Remove the tensioner pivot pin (2 Fig. 1) and remove the
tensioner from the pedestal.
Remove the flanged bolts (5 Fig. 1) securing the upper
static damper and remove the damper
(4 Fig. 1) and re- move the damper pedestal and the upper timing chain (6 Fig. 1).
= Remove the lower timing chain tensioner securing bolts (11 Fig. 1) and remove the tensioner assembly (10, 12 Fig. 1).
Remove the lower timing chain (8 Fig. 1) from the inter- mediate sprocket (9 Fig. 1).
Remove the intermediate sprocket and bearing.
Remove the bolts (16 Fig. 1) securing the oil pump drive
chain damper and remove the damper (17 Fig. 1).
= Remove the flanged bolts securing the lower static
damper
(14 Fig. 1) and remove the damper (15 Fig. 1).
. Fit and tighten the bolt securing the crankshaft pulley. Fit Service Tool JD 130 chain link remover! replacer (1 Fig. 2) to the master link (rotate the engine as necessary to align
the link). Ensure the tool aligns to the master link, position
the 'E' gate (2 Fig. 2) to the tool and seat behind the chain (3 Fig. 2).
Fit and tighten the tool handle ensuring that the extractor cones (4 Fig. 2) line up with the link pins. Extract the link.
Slacken the tool carefully ensuring that no components
fall into the oil pan. Remove the oil pump chain.
Remove the lower timing chain from the sprockets.
Using a suitable drift, remove the crankshaft sprocket.
Remove the power assisted steering pump assembly, see
Section 10 in the appropriate Vehicle Service Manual.
Remove the bolt securing the drive-plate. Remove the
drive-plate.
Remove the auxiliaryshaftoil seal,see Section 4.25. Using
right-angled snap-ring pliers, displace and remove the
drive shaft snap-ring.
Remove the drive shaft.
Remove the drive shaft rear thrust washer.
. Fit Service Tool 18G 1434 to the bearing situated in the
front of the cylinder block (2 Fig. 3). Locate the center peg.
Tighten the tool nut to withdraw the bearing shell (1 Fig.
3).
. Remove the tool and shell assembly. Slacken off the tool
nut and withdraw the center peg. Remove and discard the
shell. Remove the blanking plate from the timing cover.
Repeat the procedure to remove the timing cover and
drive shaft housing bearing shells.
Fig. 1
Fia. 2
J I, 6..
Fia. 3
37 Issue 1 August 1994

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

AJ16 Engine Service Manual
4.24 Auxiliary Shaft, Renew
SRO 12.10.30
Remove the timing cover.
. Remove the pulley woodruff key and remove the oil seal
spacer from the crankshaft.
. Remove the flanged bolts (3 Fig. 1) securing the tensioner
pedestal.
Remove the pedestal / tensioner assembly and chain
damper (1 Fig. 1).
. Remove the tensioner pivot pin (2 Fig. 1) and remove the
tensioner from the pedestal. Clean the pivot pin.
. Remove the flanged bolts (5 Fig. 1) securing the upper
static damper. Remove the damper (4 Fig. 1) and upper
timing chain (6 Fig. 1).
Remove the bolts (11 Fig. 1) securing the chain tensioner
and remove the assembly (17 Fig. 1).
Remove the power assisted steering pump assembly, see
Section 10 in the appropriate Vehicle Service manual
. Remove the pump drive coupling.
. Remove the flanged bolt (1 Fig.2) and the drive-plate (2 Fig. 2).
Using Service Tool JD 118, remove the auxiliary shaft rear
oil seal (3 Fig. 2) from its housing.
. Using right-angled snap-ring pliers remove the snap-ring (5 Fig. 2) securing the drive shaft (4 Fig.2).
. Lift the timing chain (8 Fig. 1) from the sprocket (7 Fig. 11, remove the shaft / sprocket assembly and retrieve the
thrust washer.
. Clean all component parts and checkfor wear or damage.
Renew worn or damaged parts as necessary. Clean the auxiliary bearing housing.
. Check for wear and if necessarychangethe auxiliaryshaft bushes.
. Refit the housing with new gasket. Fit and tighten the se-
curing bolts.
. Lubricate the shaft and refit the to the housing, engaging
the chain with the gear as it is fitted. Lubricate and fit the
thrust washer and secure with the snap-ring.
. Renew the auxiliary shaft rear oil seal, see Section 4.25.
. Refitthe power assisted steering pump assembly, see Sec-
. Refit the lower chain tensioner, see Section 4.22.
Refit the upper chain tensioner, see Section 4.21.
. Renew the oil seal (1 Fig. 3) and refit the timing cover.
tion
10 in
the appropriate Vehicle Service manual.
Fig. 1
Fig. 2
Fig. 3
Issue 1 August 1994 44

AJ16 Engine Service Manual
4.25
SRO 12.10.32
Auxiliary Shaft Rear Seal, Renew
* Remove the power assisted steering pump assembly, see
Section
10 in the appropriate Vehicle Service Manual.
. Remove the pump drive coupling.
Remove the flanged bolt (1 Fig.1) and the drive-plate (2
Using ServiceTool JD 118, remove the auxiliary shaft rear
Note: Under no circumstances must the plastic insert be
removed prior to fitting the seal.
* Using ServiceTool 18G 1469fit and fully seat the auxiliary
Refit the power steering pump drive-plate and secure with
Refitthe power assisted steering pump assembly, see Sec-
Fig. 1).
oil seal (3 Fig. 1) from its housing.
shaft oil seal.
its bolt.
tion
10 in the appropriate Vehicle Service Manual.
Fig.
1
Issue 1 August 1994 45