1994 JAGUAR XJ6 water pump

Engine (AJ16) 1-
Fixing lightening Torque
(Nm)
Cooling System
(continued)
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 to cylinder head
Water pipe bracket to inlet manifold 21,5 - 28.5
1,5
- 2,5
1,5
- 2,5
2,5
- 3,5
2,5
- 3,5
2 1,5
- 28,5
21.5 - 28,5
21,5 - 28,5
Water pump assembly
Water pump to timing cover 21,5 - 28,5
21,5 - 28,5
Water pump to water rail 2,5 - 3,5
Water rail to cylinder block
X300 VSM iii Issue 1 August 1994
21,5 - 28,5
@
Water temperature sensor to thermostat housing
Water temperature transmitter to thermostat housing 14,5 - 19,5
14,5 - 19,5
44,5 - 59,5
Engine Mounting
*Engine mounting bracket screw
' Exhaust Manifold
Exhaust manifold to cylinder head
Heatshield to exhaust manifold
Lifting eye setscrew (slave item only) 44,5 - 59,5
21,5 - 28,5
21,5 - 28,5
Miscellaneous Hoses
Hose clamp, heater return hose to throttle body
Hose clamp, hose to cam cover
Hose clamp, water pump
Oil Cooler (4,O liter supercharged)
Hose clamp, oil cooler hose to radiator cradle
Oil cooler clamp screw
5-7
Oil cooler pipe bracket screw
Oil cooler pipes to engine
Oil cooler to body
Tube nut,
all except those shown below
Tube nut, transmission pipes to transmission
1,5 - 2,5
2,5
- 3.5
2,5
- 3,5
7
- 10
1,5
- 2.5
14
- 18
17
-23
17
- 23
16
- 20
Oil Pump, Filter & Oil Pan
Drain plug 64,8 - 79,2
Filter head to cylinder block 21,5 - 28,5
Oil filter cartridge 12 - 15
Oil pan to cylinder block 21,5 - 28.5
Oil pan to timing cover 21,5 - 28,5
Oil pump and oil pump carrier to cylinder block 21,5 - 28.5
Rear cover to body 9,5 - 12,5
Relief valve plug 35,7 - 48,3
Supercharger
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

Idler bracket / timing cover to cylinder black
Idler bracket to water pump
Idler mounting bracket to thermostat housing
lntercooler water pipes
Outlet elbow to supercharger
Pulley to carrier 22 - 28
22
- 28
22
- 28
22
- 28
22
- 28
22
- 28
43
- 57
22
- 28
43
- 57
22
- 28
22
- 28
8,5
- 11,5
Supercharger mounting bracket to engine
Supercharger to mounting bracket
Supercharger
mounting stud
Tensioner bracket
/ timing cover to cylinder block
Tensioner bracket to adapter
Throttle bodv adapter to
bypass actuator
Engine (AJ16)
Fixing lightening Torque
Supercharger (continued)
Air duct upper casting to lower
Bypass valve disc to spindle
Bypass
mlve to throttle body
Elbow to intercooler
2,5 - 3,5
2.5
- 3,5
8,5
- 11,5
22 - 28 ~~ ~
111.
SERVICE MATERIALS
Description USOS Notea 1 I I Hylosil 102 sealant 1 Half moon seals to cylinder head I I Oil pick-up strainer to transfer housing I 1 Oil pump transfer housing to cylinder block 1
[ Rear seal housing to cylinder block , [Thermostat housing to extension , I Thermostat outer housing to inner housing 1 , [Timing cover blanking plate to timing cover 1 I I Timing cover to cylinder block
I Locktite 501 locking compound I Oil pump drive plate bolt
,
,
I Oil pump front cover to body 1
I Oil pump rear cover to body
I Exhaust system joints
Tivoli Kay Adhesives No. 5696
sealant
X300 VSM Issue 1 August 1994 iv

€3 Cooling System (AJ16)
Fixing
Fan cowl assembly to radiator
Header tank bracket to body
Header tank to body
Hose clip,
all except those shown below
Hose clip, bleed hose to radiator
Radiator drain plug
Radiator temperature switch
Lower
radiator cradle to body
Supercharger pump mounting
Supercharger pump to instrumounts
Supercharger radiator to body
Top radiator panel to body
1. SERVICE TOOLS & EQUIPMENT
No Jaguar service tools are required for working on the cooling system. Some normal workshop items will be required,
including
a pressure tester, hydrometer and thermometer.
Tightening Torque
(Nm)
8-9
7-1 0
2,5-3,5
2,5-3,5
1,5-2,5
1,5-2,5
13-17
7
-1 0
7-10
5-7
7-10
7
-10
Description UseS
To be issued
111. SERVICE MATERIALS
Notes
Iv: SZRVICE DATA
Application
Engine thermostat temperature rating
Coolant header cap pressure rating
Generator
/ water pump drive belt tension, new belt
Generator
/ water pump drive belt tension, service
tension
_____ ~~ Generator / water
pump drive belt tension measuring
point
Smcification
88OC
1,2 bar
Set to:
Run for one minute and allow belt to cool.
Reset to: (Burroughs method) 511 to
534 N;
Burroughs method: 51 1 to 534 N.
Clavis method: 167 to 173 Hz
Mid
-way between crankshaft and generator pulleys
(Burroughs method)
556 to 578
N;
(Clavis method) 174 to 180 Hz.
(Clavis method) 167 to 173
Hz
0
0
0
0
X300 VSM Issue 1 August 1994 ii

Cooling System (AJl6) m
4.1.1 COOLING SYSTEM DESCRIPTION
4.1.1.1 Major Components
o Main engine crossflow radiator, incorporating a concentric tube cooler for the power steering fluid mounted in
the right
-hand radiator side tank. Vehicles with automatic transmission have a transmission fluid cooler
mounted in the left
-hand radiator side tank; for 4,O liter supercharged engines a six-plate cooler is fitted; other
vehicles have
a tube-type cooler. Adouble-action temperature switch, for controlling the radiator cooling fans,
is mounted in the left
-hand radiator side tank.
0 Two electrically operated radiator cooling fans, mounted behind the main radiator.
0 Coolant circulating pump, belt driven from the engine crankshaft.
0 Coolant header tank with pressure relief cap and coolant level probe.
o Engine thermostat.
4.1.1.2
0 Heater matrix.
o Electrically operated coolant circulating pump, mounted on the left-hand side of the engine bulkhead.
o Solenoid operated valve, located adjacent to the coolant circulating pump.
Components for Climate Control System
4.1.1.3 Components for Supercharged Engine
0 0 Supercharger crossflow radiator, mounted in front of the main radiator. The supercharger radiator is reverse- circuited, i.e. the coolant inlet is at the bottom of the radiator.
0 Electrically operated coolant circulating pump, located at the left-hand side of the main radiator.
4.1.1.4 Operation
The configuration of the cooling system for normally aspirated and supercharged (4,O liter) engines is shown in Sub- section 4.1.2.
The cooling system is pressurized, which allows the system to operate at a higher temperature without overheating.
The header tank is fitted with a pressure relief cap to protect the system against overpressure.
Under cold start conditions, coolant is forced by the engine driven water pump through the cylinder block and cylinder
head to the thermostat housing. The thermostat is closed to give rapid engine warm up, hence the coolant is returned
directly to the water pump inlet. When normal engine operating temperature is reached, the thermostat opens and
coolant is diverted through the radiator before returning to the water pump inlet. In vehicles fitted with
a supercharger,
coolant is circulated through the supercharger radiator and intercooler by the supercharger water pump. The super- charger cooling circuit uses the same coolant header tank as the main engine cooling system.
The radiator cooling fans operate in series and parallel under the control of the double
-action radiator mounted tem- perature switch. The fans are also controlled by the climate control system on vehicles fitted with air conditioning.
Under hot operating conditions, the fans may continue to operate after the engine has been switched off. The fans
stop automatically when the coolant temperature has been reduced sufficiently.
The system also provides the coolant supply for the climate control system, which is described in Section
14.
X300 VSM 1 Issue 1 August 1994

€3 Cooling System (AJ16)
4.1.2 COOLING SYSTEM CONFIGURATION
The configuration of the cooling system for normally aspirated and supercharged engines is shown in Fig. 1 and Fig. 2. The main coolant flows, with the system at normal operating temperature (i.e. with the engine thermostat open),
are indicated by arrows.
1
2 7
J26-265
1. Header Tank 4. Thermostat 7. Heater
2. Radiator 5. Throttle Body 8. Heater Pump
3. Water Pump 6. Engine 9. Heater Valve
Fig. 1 Cooling System, Normally Aspirated Engine
1
i-266
1. Header Tank 5. Water Pump 9. Engine
2. Supercharger Pump 6. Thermostat IO. Heater
3. Supercharger Radiator 7. Throttle Body 11. Heater Pump
4. Main Radiator 8. Intercooler 12. Heater Valve
Fig.
2 Cooling System, Supercharged Engine
Issue 1 August 1994 X300 VSM 2

area washed to remove all traces of coolant.
CAUTION: To prevent the possibility of damage to the heater circuit pump and supercharger pump (where fitted),
the pumps should be electrically isolated if the ignition has to be turned ON while the cooling system is
drained.
WARNING: DO NOT REMOVE THE HEADER TANK PRESSURE CAP WHILE THE ENGINE IS HOT. IF THE CAP MUST
BE REMOVED, PROTECT THE HANDS AGAINST ESCAPING STEAM AND SLOWLY TURN THE CAP ANTI
- CLOCKWISE UNTIL THE EXCESS PRESSURE CAN ESCAPE. LEAVE THE CAP IN THIS POSITION UNTIL
ALL THE STEAM AND PRESSURE HAS ESCAPED AND THEN REMOVE THE CAP COMPLETELY.
WARNING: WHEN DRAINING THE COOLANT WITH THE ENGINE HOT, PROTECT THE HANDS AGAINST CONTACT
WITH HOT COOLANT.
WARNING: WHEN WORKING WITHIN THE ENGINE COMPARTMENT, KEEP CLEAR OF THE RADIATOR COOLING
FANS. THE FANS COULD START WITHOUT WARNING EVEN IF THE ENGINE IS NOT RUNNING.
4.1.3.2 Working Practices
Whenfilling thesystem with coolant,ensurethatthevehicle isstanding on a level surfaceandthatthecoolant is poured
in slowly so that airlocks are not introduced into the system. Airlocks can seriously affect the operation of the climate
control system and can cause damage to the heater circuit pump (and supercharger circuit pump if fitted).
Cooling System (AJ16)
4.1.3 SERVICE PROCEDURES
4.1.3.1 Safety Precautions
The anti-freeze specified in Appendix AI must be used wherever possible. It is designed to afford the maximum cor- rosion protection to all metals found in the engine cooling system, as well as having the frost protection properties
necessary during the winter months.
Should
it not be available, then anti-freeze conforming to Ford Motor Company specification ESLbM97B49-A may be
used. To provide optimum temperature and corrosion protection, the specified anti-freeze concentration must always
be used.
Once coolant has been drained from the system,
it must be discarded and not reused. Anti-freeze is harmful to the
environment. Used coolant must be disposed of safely and never poured down a drain connected to the public sewer.
CAUTION: Never fill or topup the system with water only.
CAUTION : Anti-freeze is harmful to paintwork. Coolant spillages must be wiped up immediately and the affected
Hose clips should always be positioned so that there is proper access for tightening and that the clip does not foul or
interfere with the operation of any components.
Drive belts must always be tensioned to the specified value and the tension checked
at the correct point on the belt.
This information is given in Subsection IV in the preliminary pages.
0
When tightening components, the torque figures given in Sukection II in the preliminary pages should always be
used for the fastenings listed.
4.1.3.3 Coolant Change
The coolant must be changed at intervals of four years. The system should be drained from the radiator drain plug,
flushed and filled with fresh coolant. Flushing should be carried out thoroughly to remove all the old coolant from the
engineand heater matrix. (The heatervalve isopen withthe ignition OFF). AfterfiIling,checkthecoolant concentration
with a hydrometer. For the specified anti-freeze and coolant concentration, see Appendix AI.
X300 VSM 3 Issue 1 August 1994

4.1.5 FAULT DIAGNOSIS
4.1.5.1 Introduction
The following diagnostic procedures are provided to assist properly qualified persons to identify and rectify the faults
in the system which are most likely to be encountered. Reference is made to the Electrical Diagnostic Manual (EDM),
which should be consulted for all electrical faults. When investigating faults relating to temperature, the prevailing
ambient temperature conditions should be taken into account. The climate control system is dealt with in Section 14.
Possible Cause
Thermostat stuck closed
Incorrect thermostat rating
Faulty temperature gauge
Faulty temperature transmitter
4.1.5.2 Diagnostic Procedures
Check
Test thermostat
Check thermostat operating
temperature
Refer to EDM
Refer to EDM
Symptom
herheating
Cooling fan(s) not operating 3verheating at
dle
roo cold
Refer to EDM
Incorrect thermostat rating
Thermostat not fitted
Cooling
fan(s) operating con-
tinuously Faulty temperature gauge
Faulty temperature transmitter
Radiator
core blocked
Radiator grille obstructed
Check thermostat operating
temperature
Remove thermostat housing
and inspect
Refer to EDM
Refer to EDM
Refer to EDM
Concentration of
anti
-freeze too high
Drive belt slack
Drive belt broken
Water pump seized
Insufficient coolant
Internally collapsed hoses
Incorrect ignition timing
Fuel
/ air mixture too weak
Incorrect valve
timing
Cylinder head gasket leaking
Brakes binding Check
for
hotspots in radiator
Check grille for obstruction
Check strength of coolant
Check belt tension
Visual check
Slacken drive belt and turn
water
pump pulley by hand.
Check belt for damage
Check coolant level
Pressure test system and
check for deformation of hoses
Refer to EDM
Refer to EDM
Check valve
timing
Pressure-test system. (Check
for contamination of coolant
in header tank)
Check brake calipers for stick
-
ing pistons and seized brake
pad pins
Thermostat stuck open
I Test thermostat
Remedy
Renew thermostat
Renew thermostat
Renew gauge
Renew transmitter
Flush
or renew radiator
Remove obstruction from
grille
Drain and fill
with coolant of
correct concentration
Adjust belt to correct tension
or renew belt
if worn
Renew belt
Renew water pump. Renew
drive belt
if required
Top-up coolant
Renew hoses as required
Rectify
as required
Rectify
as required
Correct valve
timing
Renew head gasket
Rectify
as required
Rectify
as required
Renew thermostat
Renew thermostat
Fit thermostat
Rectify
as required
Renew gauge
Renew transmitter
0
e
0
0
Issue 1 August 1994 X300 VSM

Diagnostic Procedures (continued)
Symptom
Loss of cool-
Possible Cause Check
Loose clips on hoses
Hoses perished Visual check
Radiator core leaking Pressure
-test system
Water
pump seal leaking Pressure-test system
Thermostat gasket leaking Pressure
-test system. (Check
for distortion of thermostat
housing)
Inspect cap or test cap spring
pressure
Pressure
-test system. Check
strength of coolant
Pressure
-test system. Check
for contamination of coolant
and engine lubrication system
Identify
component(s)
contamination of engine
lubrication system)
Check
clips for correct
tight-
ness
Header tank cap defective
Porosity
in castings Pressure-test system
Corrosion caused by con
-
centration of anti-freeze being
too low
Cylinder head gasket leaking
Cracked or damaged internal
engine component affected. (Check for
Remedy
Tighten clips as required
Renew hoses as required
Repair or renew radiator
Renew water
pump
Renew gasket. Renew hous-
ing if required
Renew cap
Rectify as required
Rectify as required. Drain and
fill with coolant of correct con-
centration
Renew head gasket
Rectify as required