1997 JAGUAR XJ6 seat removal

incorporated throughout. The refitting of
manifolds and external parts is all that’s
necessary. Engines in this rebuilt form are
available from Jaguar dealers, and some
independent rebuilders.
Give careful thought to which alternative is
best for you and discuss the situation with
local automotive machine shops, auto parts
dealers and experienced rebuilders before
ordering or purchasing replacement parts.
8 Engine overhaul-
dismantling sequence
1It’s much easier to dismantle and work on
the engine if it’s mounted on a portable
engine stand. A stand can often be rented
quite cheaply from an equipment rental yard.
Before the engine is mounted on a stand, the
driveplate and rear oil seal retainer should be
removed from the engine.
2If a stand isn’t available, it’s possible to
dismantle the engine with it blocked up on the
floor. Be extra careful not to tip or drop the
engine when working without a stand.
3If you’re going to obtain a rebuilt engine, all
external components must come off first, to
be transferred to the replacement engine, just
as they will if you’re doing a complete engine
overhaul yourself. These include:
Alternator and brackets
Emissions control components
Distributor, spark plug leads and spark
plugs
Thermostat and housing cover
Water pump
EFI components
Intake/exhaust manifolds
Oil filter
Engine mounts
Driveplate
Transmission adapter plate
Note:When removing the external
components from the engine, pay close
attention to details that may be helpful or
important during refitting. Note the installed
position of gaskets, seals, spacers, pins,
brackets, washers, bolts and other small items.
4If you’re obtaining a short block, which
consists of the engine block, crankshaft,
pistons and connecting rods all assembled,
then the cylinder head, sump and oil pump will
have to be removed as well from your engine
so that your short-block can be turned in to
the rebuilder as a core. See Engine rebuilding
alternativesfor additional information
regarding the different possibilities to be
considered.
5If you’re planning a complete overhaul, the
engine must be dismantled and the internal
components removed in the following order:
Intake and exhaust manifolds
Valve cover
Upper timing chain and camshaft
sprocketsCamshafts
Timing chain cover
Cylinder head
Sump
Oil pump
Piston/connecting rod assemblies
Crankshaft rear oil seal retainer
Crankshaft and main bearings
6Before beginning the dismantling and
overhaul procedures, make sure the following
items are available. Also, refer to Section 21
for a list of tools and materials needed for
engine reassembly.
Common hand tools
Small cardboard boxes or plastic bags for
storing parts
Gasket scraper
Ridge reamer
Micrometers
Telescoping gauges
Dial indicator set
Valve spring compressor
Cylinder surfacing hone
Piston ring groove-cleaning tool
Electric drill motor
Tap and die set
Wire brushes
Oil gallery brushes
Cleaning solvent
Special Jaguar tools
Engine lifting brackets (18G 1465)
Timing damper simulator (18E 1436)
Camshaft TDC tool (18G 1433)
9 Cylinder head- dismantling
2
Note: New and rebuilt cylinder heads are
available from Jaguar and some independent
rebuilders. Due to the fact that some
specialised tools are necessary for the
dismantling and inspection procedures, and
replacement parts may not be readily
available, it may be more practical and
economical for the home mechanic to
purchase a replacement cylinder head rather
than taking the time to dismantle, inspect and
recondition the original.1Cylinder head dismantling involves removal
of the intake and exhaust valves and related
components. It’s assumed that the lifters and
camshafts have already been removed (see
Part A as needed).
2Before the valves are removed, arrange to
label and store them, along with their related
components, so they can be kept separate
and reinstalled in the same valve guides they
are removed from (see illustration).
3Compress the springs on the first valve with
a spring compressor and remove the keepers
(see illustration). Carefully release the valve
spring compressor and remove the retainer,
the spring and the spring seat (if used). Note:
If your spring compressor does not have an
end (such as the one shown) with cut-outs on
the side, an adapter is available to use with a
standard spring compressor.
Caution: Be very careful not to nick or
otherwise damage the lifter bores when
compressing the valve springs.
4Pull the valve out of the cylinder head, then
remove the oil seal from the guide. If the valve
binds in the guide (won’t pull through), push it
back into the cylinder head and deburr the
area around the keeper groove with a fine file
or whetstone.
5Repeat the procedure for the remaining
valves. Remember to keep all the parts for
each valve together so they can be reinstalled
in the same locations.
6Once the valves and related components
have been removed and stored in an
organised manner, the cylinder head should
be thoroughly cleaned and inspected. If a
complete engine overhaul is being done,
finish the engine dismantling procedures
before beginning the cylinder head cleaning
and inspection process.
10 Cylinder head-
cleaning and inspection
2
1Thorough cleaning of the cylinder head(s)
and related valve train components, followed
by a detailed inspection, will enable you to
decide how much valve service work must be
2B•6 Engine removal and overhaul procedures
9.2 A small plastic bag, with an appropriate
label, can be used to store the valve train
components so they can be kept together
and reinstalled in the correct guide
3261 Jaguar XJ6
9.3 Compress the spring until the keepers
can be removed with a small magnetic
screwdriver or needle-nose pliers - use a
valve spring compressor with an adapter
(arrowed) to remove the keepers

done during the engine overhaul. Note:If the
engine was severely overheated, the cylinder
head is probably warped (see paragraph 12).
Cleaning
2Scrape all traces of old gasket material and
sealing compound off the cylinder head
gasket, intake manifold and exhaust manifold
sealing surfaces. Be very careful not to gouge
the cylinder head. Special gasket-removal
solvents that soften gaskets and make
removal much easier are available at car
accessory outlets.
3Remove all built up scale from the coolant
passages.
4Run a stiff wire brush through the various
holes to remove deposits that may have
formed in them. If there are heavy deposits in
the water passages, the bare head should be
professionally cleaned at a machine
workshop.
5Run an appropriate-size tap into each of the
threaded holes to remove corrosion and
any thread sealant that may be present. If
compressed air is available, use it to clear the
holes of debris produced by this operation.
Warning: Wear eye protection
when using compressed air!
6Clean the exhaust and intake manifold stud
threads with a wire brush.
7Clean the cylinder head with solvent and dry
it thoroughly. Compressed air will speed the
drying process and ensure that all holes and
recessed areas are clean. Note:Decarbonising
chemicals are available and may prove very
useful when cleaning cylinder heads and valve
train components. They are very caustic and
should be used with caution. Be sure to follow
the instructions on the container.
8Clean the lifters with solvent and dry themthoroughly. Compressed air will speed the
drying process and can be used to clean out
the oil passages. Don’t mix them up during
cleaning - keep them in a box with numbered
compartments.
9Clean all the valve springs, spring seats,
keepers and retainers with solvent and dry
them thoroughly. Work on the components
from one valve at a time to avoid mixing up
the parts.
10Scrape off any heavy deposits that may
have formed on the valves, then use a
motorised wire brush to remove deposits from
the valve heads and stems. Again, make sure
that the valves don’t get mixed up.
Inspection
Note:Be sure to perform all of the following
inspection procedures before concluding that
machine workshop work is required. Make a
list of the items that need attention. The
inspection procedures for the lifters and
camshafts, can be found in Part A.
Cylinder head
11Inspect the cylinder head very carefully for
cracks, evidence of coolant leakage and other
damage. If cracks are found, check with an
automotive machine workshop concerning
repair. If repair isn’t possible, a new cylinder
head should be obtained.
12A common problem on aluminium engines
is erosion of the cylinder head or engine block
coolant passages due to improper sealing.
Using a new cylinder head gasket held
against the cylinder head, trace the bolt holes
and coolant passage outlines in pencil on the
cylinder head. Use the gasket to trace the
same on the top of the engine block (see
illustration). If the top of the engine block has
eroded outsideof the pattern around thewater passages or cylinder head bolt holes,
the engine block must be renewed; the
manufacturer doesn’t recommend resurfacing
it. If the cylinder head has eroded outside of
the water passage holes but the erosion is
away fromthe combustion chamber, the
eroded area can be built up with metal-
impregnated epoxy and machined flat again.
13Using a straightedge and feeler gauge,
check the cylinder head gasket mating
surface (on the engine block and cylinder
head) for warpage (see illustration). If the
warpage exceeds the limit found in this
Chapter’s Specifications, it can be resurfaced
at an automotive machine workshop, but no
more then 0.010-inch of material should be
removed. If the cylinder head had been
overheated, take it to the machinist for
inspection before proceeding further. It’s
possible that the overheating could have
annealed (softened) the aluminium of the
cylinder head, making it unsuitable for
machine work. In this case, a new cylinder
head is required.
Note 1:To check if a cylinder head has been
machined previously, measure the height
between the cylinder head gasket surface and
the valve cover mounting surface with a large
micrometer or vernier caliper and compare
with Specifications.
Note 2:Jaguar aluminium cylinder heads
require precision machine work. It is best to
find a machine workshop that has
considerable experience in servicing Jaguar
cylinder heads.
14Examine the valve seats in each of the
combustion chambers. If they’re pitted,
cracked or burned, the cylinder head will
require valve service that’s beyond the scope
of the home mechanic.
Engine removal and overhaul procedures 2B•7
2B
3261 Jaguar XJ6 10.12 Place the new head gasket on the engine block, and trace
around the water passages and bolt holes - make sure there is no
erosion of the aluminium beyond these lines
10.13 Check the cylinder head and engine block gasket surfaces
for warpage by trying to slip a feeler gauge under a precision
straightedge (see the Specifications for the maximum warpage
allowed and use a feeler gauge of that thickness) - check both the
cylinder head and engine block (shown)

15Check the valve stem-to-guide clearance
with a small hole gauge and micrometer, or a
small dial bore gauge (see illustration). Also,
check the valve stem deflection with a dial
indicator attached securely to the cylinder
head. The valve must be in the guide and
approximately 1/16-inch off the seat. The total
valve stem movement indicated by the gauge
needle must be noted, then divided by two to
obtain the actual clearance value. If it exceeds
the stem-to-guide clearance limit found in this
Chapter’s Specifications, the valve guides
should be renewed. After this is done, if
there’s still some doubt regarding the
condition of the valve guides they should be
checked by an automotive machine workshop
(the cost should be minimal).
Valves
16Carefully inspect each valve face for
uneven wear, deformation, cracks, pits and
burned areas. Check the valve stem for
scuffing and galling and the neck for cracks.
Rotate the valve and check for any obvious
indication that it’s bent. Look for pits and
excessive wear on the end of the stem. The
presence of any of these conditions indicates
the need for valve service by an automotive
machine workshop.
17Measure the margin width on each valve
(see illustration). Any valve with a margin
narrower than 1/32-inch will have to be
replaced with a new valve.
Valve components
18Check each valve spring for wear (on the
ends) and pits. Measure the free length and
compare it to this Chapter’s Specifications
(see illustration). Any springs that are shorter
than specified have sagged and should not be
re-used. The tension of all springs should be
pressure checked with a special fixture before
deciding that they’re suitable for use in a
rebuilt engine (take the springs to an
automotive machine workshop for this check).
Note:If any valve springs are found broken on
1988 or 1989 engines, all springs should be
replaced with the improved springs used in
1990 (after VIN 9EPCLA120245) and later
engines. They are identified with a white
stripe. If your engine has springs with white-
stripes, they have already been replaced, and
only broken ones need be replaced.
19Stand each spring on a flat surface and
check it for squareness (see illustration). If
any of the springs are distorted or sagged,
renew all of the springs.
20Check the spring retainers and keepers
for obvious wear and cracks. Any
questionable parts should be renewed, as
extensive damage will occur if they fail during
engine operation.
21If the inspection process indicates that the
valve components are in generally poor
condition and worn beyond the limits specified,
which is usually the case in an engine that’s
being overhauled, reassemble the valves in the
cylinder head and refer to Section 11 for valve
servicing recommendations.
11 Valves- servicing
5
1Because of the complex nature of the job
and the special tools and equipment needed,
servicing of the valves, the valve seats and the
valve guides, commonly known as a valve job,
should be done by a professional.
2The home mechanic can remove and
dismantle the cylinder head(s), do the initial
cleaning and inspection, then reassemble and
deliver them to a dealer service department or
an automotive machine workshop for the
actual service work. Doing the inspection will
enable you to see what condition the cylinder
head(s) and valvetrain components are in and
will ensure that you know what work and new
parts are required when dealing with an
automotive machine workshop.
3The dealer service department, or
automotive machine workshop, will remove
the valves and springs, will recondition or
renew the valves and valve seats, recondition
the valve guides, check and renew the valve
springs, spring retainers and keepers (as
necessary), replace the valve seals with new
ones, reassemble the valve components and
make sure the installed spring height is
correct. The cylinder head gasket surface will
also be resurfaced if it’s warped.
4After the valve job has been performed by a
professional, the cylinder head(s) will be in like
new condition. When the cylinder heads are
returned, be sure to clean them again before
refitting on the engine to remove any metal
particles and abrasive grit that may still be
present from the valve service or cylinder
head resurfacing operations. Use compressed
air, if available, to blow out all the oil holes and
passages.
12 Cylinder head- reassembly
2
1Regardless of whether or not the cylinder
head was sent to an automotive machine
workshop for valve servicing, make sure it’s
clean before beginning reassembly. Renew
the cylinder head rear plate gasket any time
that the engine is overhauled or the cylinder
head is reconditioned (see Part A of this
Chapter for renewal procedure).
2If the cylinder head was sent out for valve
servicing, the valves and related components
will already be in place. Begin the reassembly
procedure with paragraph 8.
3Refit new seals on each of the valve guides.
Gently push each valve seal into place until
it’s seated on the guide.
Caution: Don’t hammer on the valve seals
once they’re seated or you may damage
them. Don’t twist or cock the seals during
refitting or they won’t seat properly on the
valve stems.
2B•8 Engine removal and overhaul procedures
10.15 Use a small dial bore gauge to
determine the inside diameter of the valve
guides - subtract the valve stem diameter
to determine the stem-to-guide clearance10.17 The margin width on each valve
must be as specified (if no margin exists,
the valve cannot be re-used)
10.18 Measure the free length of each
valve spring with a dial or vernier caliper10.19 Check each valve spring for
squareness
3261 Jaguar XJ6

4Beginning at one end of the cylinder head,
lubricate and refit the first valve. Apply moly-
base grease or clean engine oil to the valve
stem.
5Place the spring seat or shim(s) over the
valve guide and set the valve spring and
retainer in place.
6Compress the springs with a valve spring
compressor and carefully refit the keepers in
the upper groove, then slowly release the
compressor and make sure the keepers seat
properly. Apply a small dab of grease to each
keeper to hold it in place if necessary (see
Haynes Hint).
7Repeat the procedure for the remaining
valves. Be sure to return the components to
their original locations - don’t mix them up!
13 Pistons/connecting rods-
removal
4
Note :Prior to removing the piston/connecting
rod assemblies, remove the cylinder head(s),
the sump and the oil pump transfer tubes by
referring to Chapter 2A.
1Use your fingernail to feel if a ridge has
formed at the upper limit of ring travel (about
1/4-inch down from the top of each cylinder).
If carbon deposits or cylinder wear have
produced ridges, they must be completely
removed with a special tool (see illustration).
Follow the manufacturer’s instructions
provided with the tool. Failure to remove the
ridges before attempting to remove the
piston/connecting rod assemblies may result
in piston damage.
2After the cylinder ridges have been
removed, turn the engine upside-down so the
crankshaft is facing up. Remove the screws
and the front and rear baffle plates from the
bottom of the engine block (see illustration).
3Before the connecting rods are removed,
check the endplay with a feeler gauge. Slide
the blade between the first connecting rod
and the crankshaft throw until the play is
removed (see illustration). The endplay is
equal to the thickness of the feeler gauge(s). If
the endplay exceeds the specified service
limit, new connecting rods will be required. Ifnew rods (or a new crankshaft) are installed,
the endplay may fall under the service limit (if
it does, the rods will have to be machined to
restore it - consult an automotive machine
workshop for advice if necessary). Repeat the
procedure for the remaining connecting rods.
4Check the connecting rods and caps for
identification marks. If they aren’t plainly
marked, use a small centre punch to make the
appropriate number of indentations on each rod
and cap (1, 2, 3, etc, depending on the cylinder
they’re associated with) (see illustration).
5Loosen each of the connecting rod cap nuts
1/2-turn at a time until they can be removed by
hand. Remove the number one connecting rod
cap and bearing insert. Don’t drop the bearing
insert out of the cap. Note:These engines use
special connecting rod and main bearing cap
bolts that are designed to be used one time
only. They can be used during Plastigage
checks, but must be replaced with new bolts
when the engine is finally reassembled.
6Slip a short length of plastic or rubber hose
over each connecting rod cap bolt to protect
the crankshaft journal and cylinder wall as the
piston is removed (see illustration).
7Remove the bearing insert and push the
connecting rod/piston assembly out through
the top of the engine. Use a wooden hammer
handle to push on the upper bearing surface
in the connecting rod. If resistance is felt,
double-check to make sure that all of the
ridge was removed from the cylinder.
Engine removal and overhaul procedures 2B•9
2B
13.2 Remove the screws (arrowed) and
remove the front and rear baffle plates13.3 Check the connecting rod side
clearance with a feeler gauge as shown
13.4 The connecting rods and caps should
be marked by cylinder number - if they
aren’t, mark them with a centre punch to
avoid confusion during reassembly13.6 To prevent damage to the crankshaft
journals and cylinder walls, slip sections of
hose over the connecting rod bolts before
removing the pistons
3261 Jaguar XJ6 13.1 A ridge reamer is required to remove
the ridge from the top of each cylinder -
do this before removing the pistons!
The keepers are easier to fit if a small
amount of grease is applied to keep
them in place

2Using a gasket scraper, remove all traces of
gasket material from the engine block. Be very
careful not to nick or gouge the gasket sealing
surfaces.
3Remove the main bearing caps and
separate the bearing inserts from the caps
and the engine block. Tag the bearings,
indicating which cylinder they were removed
from and whether they were in the cap or the
engine block, then set them aside.
4Remove all of the threaded oil gallery plugs
from the engine block. The plugs are usually
very tight - they may have to be drilled out and
the holes retapped. Use new plugs when the
engine is reassembled.
5If the engine is extremely dirty, it should be
taken to an automotive machine workshop to
be steam cleaned or hot tanked.
6After the engine block is returned, clean all
oil holes and oil galleries one more time.
Brushes specifically designed for this purpose
are available at most car accessory outlets.
Flush the passages with warm water until the
water runs clear, dry the engine block
thoroughly and wipe all machined surfaces
with a light, rust preventive oil. If you have
access to compressed air, use it to speed the
drying process and to blow out all the oil
holes and galleries. Warning: Wear eye protection
when using compressed air!
7If the engine block isn’t extremely dirty or
sludged up, you can do an adequate cleaning
job with hot soapy water and a stiff brush.
Take plenty of time and do a thorough job.
Regardless of the cleaning method used, be
sure to clean all oil holes and galleries very
thoroughly, dry the engine block completely
and coat all machined surfaces with light oil.
8The threaded holes in the engine block
must be clean to ensure accurate torque
readings during reassembly. Run the proper
size tap into each of the holes to remove rust,
corrosion, thread sealant or sludge and
restore damaged threads (see illustration). If
possible, use compressed air to clear the
holes of debris produced by this operation.
9Refit the main bearing caps and tighten the
bolts finger tight.
10After coating the sealing surfaces of the
new core plugs with suitable sealant, refit
them in the engine block (see illustration).
Make sure they’re driven in straight and
seated properly or leakage could result.
Special tools are available for this purpose,
but a large socket, with an outside diameter
that will just slip into the core plug, a 1/2-inchdrive extension and a hammer will work just
as well.
11Apply non-hardening sealant (such as
Permatex no. 2 or Teflon pipe sealant) to the
new oil gallery plugs and thread them into the
holes in the engine block. Make sure they’re
tightened securely.
12If the engine isn’t going to be
reassembled right away, cover it with a large
plastic trash bag to keep it clean.
16 Engine block- inspection
2
1Before the engine block is inspected, it
should be cleaned as described in Section 15.
2Visually check the engine block for cracks,
rust and corrosion (see illustration 10.12).
Look for stripped threads in the threaded
holes. It’s also a good idea to have the engine
block checked for hidden cracks by an
automotive machine workshop that has the
special equipment to do this type of work,
especially if the vehicle had a history of
overheating or using coolant. If defects are
found, have the engine block repaired, if
possible, or renewed. If the top of the engine
block has been eroded by coolant leakage
and the erosion is near the cylinder bores, the
engine block must be renewed.
3Check the cylinder bores for scuffing and
scoring.
4Check the cylinders for taper and out-of-
round conditions as follows (see illustrations):
5Measure the diameter of each cylinder at
the top (just under the ridge area), centre and
bottom of the cylinder bore, parallel to the
crankshaft axis.
6Next, measure each cylinder’s diameter at
the same three locations perpendicular to the
crankshaft axis.
7The taper of each cylinder is the difference
between the bore diameter at the top of the
cylinder and the diameter at the bottom. The
out-of-round specification of the cylinder bore
Engine removal and overhaul procedures 2B•11
2B
16.4a Measure the diameter of each
cylinder at 90° to engine centreline (A), and
parallel to engine centreline (B) - out-of-
round is the difference between A and B;
taper is the difference between A and B at
the top of the cylinder and A and B at the
bottom of the cylinder16.4b The ability to “feel” when the
telescoping gauge is at the correct point
will be developed over time, so work
slowly and repeat the check until you’re
satisfied that the bore measurement is
accurate
3261 Jaguar XJ6
15.8 All bolt holes in the engine block -
particularly the main bearing cap and
cylinder head bolt holes - should be
cleaned and restored with a tap (remove
debris from holes after this is done)15.10 A large socket on an extension can
be used to drive the new core plugs into
the bores
16.4c The gauge is then measured with a
micrometer to determine the bore size

is the difference between the parallel and
perpendicular readings. Compare your results
to this Chapter’s Specifications.
8If the cylinder walls are badly scuffed or
scored, or if they’re out-of-round or tapered
beyond the limits given in this Chapter’s
Specifications, have the engine block rebored
and honed at an automotive machine
workshop. If a rebore is done, oversize
pistons and rings will be required.
9Using a precision straightedge and feeler
gauge, check the engine block deck (the
surface that mates with the cylinder head) for
distortion (see illustration 10.13). If it’s
distorted beyond the specified limit, it can be
resurfaced by an automotive machine
workshop.
10If the cylinders are in reasonably good
condition and not worn to the outside of the
limits, and if the piston-to-cylinder clearances
can be maintained properly, then they don’t
have to be rebored. Honing is all that’s
necessary (refer to Section 17).
17 Cylinder honing
3
1Prior to engine reassembly, the cylinder
bores must be honed so the new piston rings
will seat correctly and provide the best
possible combustion chamber seal. Note:If
you don’t have the tools or don’t want to
tackle the honing operation, most automotive
machine shops will do it for a reasonable fee.
2Before honing the cylinders, refit the main
bearing caps (without bearing inserts) and
tighten the bolts to the specified torque.
3Two types of cylinder hones are commonly
available - the flex hone or “bottle brush” type
and the more traditional surfacing hone with
spring-loaded stones. Both will do the job, but
for the less-experienced mechanic the “bottle
brush” hone will probably be easier to use.
You’ll also need some paraffin or honing oil,
rags and a variable-speed electric drill motor.
The drill motor should be operated at a
steady, slow speed. Proceed as follows:
a) Mount the hone in the drill motor,
compress the stones and slip it into the
first cylinder (see illustration).
Warning: Be sure to wear safety
goggles or a face shield!
b) Lubricate the cylinder with plenty of
honing oil, turn on the drill and move the
hone up-and-down in the cylinder at a
pace that will produce a fine crosshatch
pattern on the cylinder walls. Ideally, the
crosshatch lines should intersect at
approximately a 60° angle (see
illustration). Be sure to use plenty of
lubricant and don’t take off any more
material than is absolutely necessary to
produce the desired finish. Note:Piston
ring manufacturers may specify a smallercrosshatch angle than the traditional 60° -
read and follow any instructions included
with the new rings.
c) Don’t withdraw the hone from the cylinder
while it’s running. Instead, shut off the drill
and continue moving the hone up-and-
down in the cylinder until it comes to a
complete stop, then compress the stones
and withdraw the hone. If you’re using a
“bottle brush” type hone, stop the drill
motor, then turn the chuck in the normal
direction of rotation while withdrawing the
hone from the cylinder.
d) Wipe the oil out of the cylinder and repeat
the procedure for the remaining cylinders.
4After the honing job is complete, chamfer
the top edges of the cylinder bores with a
small file so the rings won’t catch when the
pistons are installed. Be very careful not to
nick the cylinder walls with the end of the file.
5The entire engine block must be washed
again very thoroughly with warm, soapy water
to remove all traces of the abrasive grit
produced during the honing operation. Note:
The bores can be considered clean when a
lint-free white cloth - dampened with clean
engine oil - used to wipe them out doesn’t
pick up any more honing residue, which will
show up as grey areas on the cloth. Be sure to
run a brush through all oil holes and galleries
and flush them with running water.
6After rinsing, dry the engine block and
apply a coat of light rust preventive oil to all
machined surfaces. Wrap the engine block in
a plastic bag to keep it clean and set it aside
until reassembly.
18 Pistons/connecting rods-
inspection
2
1Before the inspection process can be
carried out, the piston/connecting rod
assemblies must be cleaned and the original
piston rings removed from the pistons. Note:
Always use new piston rings when the engine
is reassembled.
2Using a piston ring refitting tool, carefully
remove the rings from the pistons. Be careful
not to nick or gouge the pistons in the
process.
3Scrape all traces of carbon from the top of
the piston. A hand-held wire brush or a piece
of fine emery cloth can be used once the
majority of the deposits have been scraped
away. Do not, under any circumstances, use a
wire brush mounted in a drill motor to remove
deposits from the pistons. The piston material
is soft and may be eroded away by the wire
brush.
4Use a piston ring groove-cleaning tool to
remove carbon deposits from the ring
grooves. If a tool isn’t available, a piece
broken off the old ring will do the job. Be very
careful to remove only the carbon deposits -
don’t remove any metal and do not nick or
scratch the sides of the ring grooves (see
illustrations).
5Once the deposits have been removed,
clean the piston/connecting rod assemblies
with solvent and dry them with compressed
air (if available). Make sure the oil return holes
2B•12 Engine removal and overhaul procedures
17.3a A “bottle brush” hone will produce
better results if you have never done
cylinder honing before17.3b The cylinder hone should leave a
smooth, crosshatch pattern with the lines
intersecting at approximately a 60° angle
18.4a The piston ring grooves can be
cleaned with a special tool, as shown . . .18.4b . . . or a section of a broken ring
3261 Jaguar XJ6

working up to it in three steps. Note:Use the
old bolts for this step (save the new bolts for
final refitting).Use a thin-wall socket to avoid
erroneous torque readings that can result if
the socket is wedged between the rod cap
and nut. If the socket tends to wedge itself
between the nut and the cap, lift up on it
slightly until it no longer contacts the cap. Do
not rotate the crankshaft at any time during
this operation.
16Remove the nuts and detach the rod cap,
being careful not to disturb the Plastigauge.
17Compare the width of the crushed
Plastigauge to the scale printed on the
envelope to obtain the oil clearance (see
illustration). Compare it to this Chapter’s
Specifications to make sure the clearance is
correct.
18If the clearance is not as specified, the
bearing inserts may be the wrong size (which
means different ones will be required). Before
deciding that different inserts are needed,
make sure that no dirt or oil was between the
bearing inserts and the connecting rod or cap
when the clearance was measured. Also,
recheck the journal diameter. If the Plastigauge
was wider at one end than the other, the journal
may be tapered (refer to Section 19).
Final connecting rod refitting
19Carefully scrape all traces of the
Plastigauge material off the rod journal and/or
bearing face. Be very careful not to scratchthe bearing, use your fingernail or the edge of
a credit card to remove the Plastigauge.
20Make sure the bearing faces are perfectly
clean, then apply a uniform layer of clean
moly-base grease or engine assembly lube to
both of them. You’ll have to push the piston
higher into the cylinder to expose the face of
the bearing insert in the connecting rod, be
sure to slip the protective hoses over the
connecting rod bolts first.
21At this time, remove the original
connecting rod bolts/nuts and replace them
with new bolts/nuts. They are of a design
which requires they be used only once. The
old ones are OK for Plastigauge checking, but
for final assembly use only new connecting
rod bolts/nuts. Refit the rod cap and tighten
the nuts to the torque listed in this Chapter’s
Specifications. Again, work up to the torque in
three steps.
22Repeat the entire procedure for the
remaining pistons/connecting rod assemblies.
23The important points to remember are:
a) Keep the back sides of the bearing inserts
and the insides of the connecting rods and
caps perfectly clean during assembly..
b) Make sure you have the correct piston/
connecting rod assembly for each
cylinder.
c) The dimple on the piston must face the
front of the engine.
d) Lubricate the cylinder walls with clean oil.
e) Lubricate the bearing faces when refitting
the rod caps after the oil clearance has
been checked.
24After all the piston/connecting rod
assemblies have been properly installed,
rotate the crankshaft a number of times by
hand to check for any obvious binding.
25As a final step, the connecting rod
endplay must be checked. Refer to Section 13
for this procedure.
26Compare the measured endplay to this
Chapter’s Specifications to make sure it’s
correct. If it was correct before dismantling
and the original crankshaft and connecting
rods were reinstalled, it should still be right.
However, if new connecting rods or a new
crankshaft were installed, the endplay may beinadequate. If so, the connecting rods will
have to be removed and taken to an
automotive machine workshop for resizing.
26 Initial start-up
and running-in after overhaul
1
Warning: Have a suitable fire
extinguisher handy when starting
the engine for the first time.
1Once the engine has been installed in the
vehicle, double-check the engine oil and
coolant levels.
2With the spark plugs out of the engine and
the ignition system and fuel pump disabled,
crank the engine until oil pressure registers on
the gauge or the light goes out.
3Refit the spark plugs, hook up the plug
leads and restore the ignition system and fuel
pump functions.
4Start the engine. It may take a few
moments for the fuel system to build up
pressure, but the engine should start without
a great deal of effort.
5After the engine starts, it should be allowed
to warm up to normal operating temperature.
While the engine is warming up, make a
thorough check for fuel, oil and coolant leaks.
6Shut the engine off and recheck the engine
oil and coolant levels.
7Drive the vehicle to an area with no traffic,
accelerate from 30 to 50 mph, then allow the
vehicle to slow to 30 mph with the throttle
closed. Repeat the procedure 10 or 12 times.
This will load the piston rings and cause them
to seat properly against the cylinder walls.
Check again for oil and coolant leaks.
8Drive the vehicle gently for the first
500 miles (no sustained high speeds) and
keep a constant check on the oil level. It is not
unusual for an engine to use oil during the
running-in period.
9At approximately 500 to 600 miles, change
the oil and filter.
10For the next few hundred miles, drive the
vehicle normally. Do not pamper it or abuse it.
11After 2000 miles, change the oil and filter
again and consider the engine run-in.
2B•18 Engine removal and overhaul procedures
25.17 Measure the width of the crushed
Plastigauge to determine the big-end
bearing oil clearance
3261 Jaguar XJ6

3261 Jaguar XJ6
3
Chapter 3
Cooling, heating and air conditioning systems
General
Radiator cap pressure rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5 to 117.5 psi
Thermostat rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 to 207° F
Torque wrench settingsNm lbf ft
Coolant pipe to block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 to 28 16 to 21
Fan assembly-to-drive hub nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 to 28 16 to 21
Fan clutch-to-fan blade bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 to 28 16 to 21
Thermostat cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 to 28 16 to 21
Thermostat housing-to-block bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 to 28 16 to 21
Water pump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 to 28 16 to 21 Air conditioning and heating system - check and maintenance . . . . 13
Air conditioning compressor - removal and refitting . . . . . . . . . . . . . 15
Air conditioning condenser - removal and refitting . . . . . . . . . . . . . . 16
Air conditioning evaporator and expansion valve - removal
and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Air conditioning receiver/drier - removal and refitting . . . . . . . . . . . . 14
Antifreeze/coolant - general information . . . . . . . . . . . . . . . . . . . . . . 2
Coolant level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1
Coolant temperature sender unit - check and renewal . . . . . . . . . . . .9
Cooling system check . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1
Cooling system draining, flushing and refilling . . . . . . . . See Chapter 1
Drivebelt check, adjustment and renewal . . . . . . . . . . . See Chapter 1
Engine cooling fans - check and renewal . . . . . . . . . . . . . . . . . . . . . 4Engine oil cooler - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Heater and air conditioning blower motors -circuit check
and component renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Heater and air conditioning control assembly -
check, removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Heater core - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Radiator, expansion tank and coolant reservoir -
removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Thermostat - check and renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Underbonnet hose check and renewal . . . . . . . . . . . . . . See Chapter 1
Water pump - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Water pump and pipes - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3•1
Specifications Contents
Easy,suitable for
novice with little
experienceFairly easy,suitable
for beginner with
some experienceFairly difficult,
suitable for competent
DIY mechanic
Difficult,suitable for
experienced DIY
mechanicVery difficult,
suitable for expert DIY
or professional
Degrees of difficulty
54321
1 General information
Engine cooling system
All vehicles covered by this manual employ a
pressurised engine cooling system with
thermostatically-controlled coolant circulation.
An impeller type water pump mounted on the
front of the block pumps coolant through the
engine. The coolant flows around each cylinder
and toward the rear of the engine. Cast-in
coolant passages direct coolant around the
intake and exhaust ports, near the spark plug
areas and in proximity to the exhaust valve
guides.A wax-pellet type thermostat is located in
the thermostat housing at the front of the
engine. During warm up, the closed
thermostat prevents coolant from circulating
through the radiator. When the engine
reaches normal operating temperature, the
thermostat opens and allows hot coolant to
travel through the radiator, where it is cooled
before returning to the engine.
The cooling system is sealed by a pressure-
type radiator cap. This raises the boiling point
of the coolant, and the higher boiling point of
the coolant increases the cooling efficiency
of the radiator. If the system pressure exceeds
the cap pressure-relief value, the excess
pressure in the system forces the spring-
loaded valve inside the cap off its seat and
allows the coolant to escape through the
overflow tube into a coolant reservoir. Whenthe system cools, the excess coolant is
automatically drawn from the reservoir back
into the radiator. This type of cooling system is
known as a closed design because coolant
that escapes past the pressure cap is saved
and reused.
The Jaguar cooling system on 1988 and
1989 models has both a manifold tank and a
coolant recovery tank. The manifold tank is the
highest point in the cooling system and is the
location of the “radiator” cap (the cap is not on
the radiator). The recovery tank down in the
passenger’s footwell collects heated coolant
as described above. Models from 1990 to
1994 do not have a coolant recovery tank, but
have an enlarged manifold tank. In all models,
the recovery tank has a sensor in it to detect a
low coolant level, and the instrument panel has
a warning light to that effect.