I
nstallation
6.
R
elease stabilizer bar from link arms.
R
emove nut securing stabilizer bar to link.
R
elease link arm from stabilizer bar.
Repeat operation
at opposite
end of stabilizer bar.
7. N
OTE: On vehicles fitted with an engine oil cooler, it may be
necessary to release the stabilizer bar from each ball joint in turn
to achieve the required cl earance from cooler pipes.
Remove stabilizer bar from crossbeam.
R
emove stabilizer bar securing bolts.
R
emove stabilizer bar mountin
g brackets and remove bar
from crossbeam.
8. Re
move mounting brackets and
rubbers from stabilizer bar.
1. CAUTION: Make sure the Ca strol NTR grease is only
applied to the inner surface of the mounting bushes. Failure to
follow this instruction may affect the retention of the bushes in
the retaining brackets.
Engine System - General Inform
ation -
Eng
ine
Engine Torque
Engine Power
Lubricants, Fluids, Sealants and Adhesives
Capacities
Descr
iption
Mode
l
Capaci
ty
90
°'Ve
e' 8 Cylinder 32 Valves
AJ263.
2 L
iters
90
°'Ve
e' 8 Cylinder 32 Valves
AJ264 Li
te
rs
EngineNm (D
I
N)/Rpm
M
a
ximum Delivered - 3.2L
3
08 at
4500
M
a
ximum Delivered - 4.0L
3
93 at
4250
M
a
ximum Delivered - 4.0L SC
5
26 at
3500
EngineBH
P (D
IN)/Rpm
M
a
ximum Delivered - 3.2L
2
40 at
6250
M
a
ximum Delivered - 4.0L
2
90 at
6100
M
a
ximum Delivered - 4.0L SC
3
65 at
6000
UnitS
p
ecification
Engine Oil
-
USA/Canada
API SH or SJ
/ ILSAC G
F-2
Engine
Oil
- Mexico
API SJ
Engine
Oil
- UK and ROW
API SH or SJ
/ ACEA A2
Engine Oil -
Supercharged
API SH or SJ
/ ACEA A3
Anti-Freez
e
ESD-M97B
49
-A
Sealant-Engine B
l
ock-to-Bedplate an
d Sump-to-Bedplate (RTV Silicone)
Loct
ite 5699 Ultra Grey
Sealant-Engine
C
ore Plugs and Bloc
k Stub Pipe (Anaerobic Sealant)
Loctite 648
UnitLit
ers
Engine
Oil-W
ith Oil Cooler
7,
3
Engine Oil-W i
thout Oil Cooler
6,
5
Cool ant
-Complete System
10
Coo
lan
t-Engine Only
3,
7
Val v
e Clearances (Cold)
S
p
ecification
Inlet0.
20
mm
Exhaus
t0.25
-0.30 mm
Engine System - General Infor
mation - Engine
Description an
d Operation
The AJ26 power unit is available in 3.2 L and 4.0 L versions, and comprises:
An eight cylinder 9
0 degree 'V' config
uration liquid cooled aluminium cylinder block incorporating 'Nikasil' plated
cylinder bores.
Pi
stons of open-ended skirt design, with
two compression and one oil control ring.
Two al
uminium cylinder heads, each
incorporating two camshafts.
F
our valves per cylinder.
Al
uminium valve lifters and top mounted shims.
Vari
able valve timing (VVT) of the inlet camshafts (4.0 L normally aspirated only).
Camshaft
covers manufactured from Vinylester.
Al
uminium timing cover which accommodat
es the crankshaft front oil seal.
Sin
gle row primary and secondary chains dr
ive the camshafts of each cylinder bank.
An alu
minium bed pl
ate, incorporating iron main bearing supports, which accomm odate the oil pump pick-up,
diverter val
ve (if fitted) and oil filter.
Main
bearings
which are grooved in the upper positions and plain in
the lower positions. They are manufactured from
aluminium / tin material.
A c
rankshaft with under
cuts and rolled fillets for extra strength.
Fracture
-split connecting rods in sintered-forged steel.
Brackets
bolted to the front of
the cylinder
block are used to mo unt all accessories.
A sin
gle, seven ribbed vee belt
drives the accessories.
An au
tomatic belt tensioner for the front accessory drive,
incorporating a wear indicator.
An advanced en
gine management system inco
rporating electronic throttle control.
The un
it meets the requirements of the CARB OBDII USA legislation.
Ancillary Systems
The an
ci
llary systems, driven by the engine, each have a
detailed Description and Operation along with Diagnostic
Procedures, and Removal and Installation instructions ; refer to the following sections of this manual:
Power Steeri
ng Pump - Section 211-02
Ai
r Conditioning Compressor - Sectio
n 412-03
Engine
C
ooling Pump - Section 303-03
Generator
- Sectio
n 414-02
The drive belt, idler pulley and automatic tensioner are described in Section 303-05.
The engine starting system is described in Section 303-06.
En
gine Management and Emission Control System
Engine Control Modu
le (ECM)
Engine
management and exhaust emissions are controlled by the ECM, which has the
following main functions:
Fu
el injection
Idle
s
peed
Ignition Ev
aporative loss system
Engine
cooling fans Clim
ate control compressor clutch demand
The microprocessor within the ECM receiv es signals from various sensors and other modules and uses a pre-determined
program to compute engine management functions.
Adaptive functions are incorporated in the ECM to cater for co ntinuous adjustments to its computations to suit prevailing
conditions. Because the system also controls emissions to suit all modes, neither CO levels nor idle speed require service
attention or adjustment, except if an error should occur.
On Board Diagnostics are controlled by the ECM with the continuous monitoring of incoming signals and the subsequent
verification against what the module expects to 'see'. Should a si gnal be incorrect or missing, the ECM will substitute a fixed
value to provide the 'limp home mode' and alert the driver of the problem. Fixed values may be adopted for:
Transmission oil
temperature
Mechanica
l
guar
d position
Throttle blade angle Camshaft position
Inta
k
e air temperature
Diagnostic trouble codes (DTC), including OBD II codes, are stored in the ECM memo ry and can be read by an appropriate
retrieval tool.
Should either the ECM or TCM fa il, ensure that the control housing cooling fan is operating correctly. Failure of the cooling
fan MUST be rectified before renewing a control module and details of a fa n failure should accompany a returned control
module.
Speed an
d load
Coo
l
ant temperature
Ti
me el
apsed from start up
Cl
osed l
oop fuelling
Determination of the vapour concentration is made by stepped opening of the EVAP valve and subsequent monitoring of the
fuelling correction. This function is performed prior to purging, so that at the onse t of purging the EVAP valve can be set to
the optimum position. Should the ECM be unable to determine the concentration before purging, a default value is
employed, which is then modified whilst purging is in progress.
When the purging process is operational th e ECM modifies the basic fuelling calculation to maintain the correct air / fuel
ratio.
Purging is inhibited during fuel cut-off and stability / traction control intervention.
Coolant Temperature Sen
sor
Th
e
sensor outputs a voltage to the ECM which decreases as temperature increases.
Cooling Fans
In response to engi
ne coolant temperat
u
re and climate control system demand, the ECM will energize the cooling fans.
Climate Control Compressor
The E
C
M will allow the compressor clutch to be engaged if th
e engine temperature and load demand are normal. Should the
driver require maximum engine powe r or the coolant temperature be high, the request will be denied.
Cranking Signal
The ECM reacts to a signal fr
om th
e Body Processor Module (BPM) when the starter motor relay is energi
zed. This signal is
used to trigger starting, fu el and ignition strategies.
Engine Speed and Cranksh
aft Position
Engine
speed and cran
k position are moni
tored by a sensor which is mounted on the cylinder block (flywheel housing)
behind the crankshaft drive plat e. It indicates rotational speed to the ECM in the form of 12 pulses per crank revolution.
Engine speed is used for synchronization of fuel an d ignition systems, as well as other functions.
Camshaft Position
The ca
mshaft position sensor is mounted at
the rear of Bank 2 cylinder head on the inlet side and provides one signal every
720 degrees of crankshaft rotation. The signal, in conjunction with the signal from the crankshaft position sensor, indicates
to the ECM that the piston of cylinder 1A is approaching TDC on the compression stroke.
Variable Valve
Timing (Where Fitted)
By energi
si
ng a solenoid to allow the pass
age of pressurized oil on each of the inle t camshaft drives, the ECM can vary by a
single stepped amount, the relati ve timing of the inlet valves.
Ign
ition
Ignit
i
on spark is produced by
individual on-plug coil units.
There are two ignition amplifiers; module #1 drives coils 1A, 2B, 3B and 4A, whilst module #2 drives coils 1B, 2A, 3A and
4B. The ECM controls the amplifiers.
En
gine - Engine
D
iagnosis and Testing
Sym
ptom Chart
Sy
mptom Chart
Pinp
oint test A: P1392 (P1397)
VVT solenoid circuit low input
S
pecial Tool(s)
D
igital multimeter
Generi
c scan tool
Sy
mptom
Possib
le Sources
Acti
on
D
TC P1392 VVT solenoid A circuit low input
So
lenoid coil open circuit
Harness open circuit or blown fuse
Connector pins(s) bent , loose or corroded
*
*
*
GO to
P
inpoint Test A
*
D
TC P1397 VVT solenoid B circuit low input
So
lenoid coil open circuit
Harness open circuit or blown fuse
Connector pins(s) bent , loose or corroded
*
*
*
GO to
P
inpoint Test A
*
D
TC P1393 VVT solenoid A circuit high input
So
lenoid coil short circuit
Harness short circuit
Connector pins(s) bent , loose or corroded
*
*
*
GO to
P
inpoint Test B
*
D
TC P1398 VVT solenoid B circuit high input
So
lenoid coil short circuit
Harness short circuit
Connector pins(s) bent , loose or corroded
*
*
*
GO to
P
inpoint Test B
*
D
TC P1396 VVT solenoid B malfunction
O
il pressure failure
VVT solenoid sticking
Connector pins(s) bent , loose or corroded
Crankshaft position sensor failure
ECM failure
*
*
*
*
*
GO to
P
inpoint Test C
*
P
INPOINT TEST A : P1392 (P1397) VVT SOLENOID CIRCUIT LOW INPUT
•
NOTE: References in brac
kets are for Bank B (2)
T
EST CONDITIONS
D
ETAILS/RESULTS/ACTIONS
A1
: RETRIEVE DTCS
•
NOTE: Battery and or ECM disconnection prior to scanning wi
ll erase all data, ensure that the correct DTC is present.
En
gine - Valve Clea
rance Adjustment
Gene
ral Procedures
S
p
ecial Tool(s)
Tappet adjustment
3
03-
540
Ai
r gun, fan nozzl
e
303-590
1. Open the engine compartment and fit paintwork protection
sheets. Open to the service position.
2. Carefully remove both engine covers, taking care not to
damage the plasti c fixings or the rubber inserts.
3. Disc
onnect the batt
ery ground cable.
Re
move the battery cover.
4. Remove the cam cover from the 'A' bank and the 'B' bank;
including the purge valve, the on-plug ignition coils and the air
intake tube / air flow meter / air cleaner cover assembly. Refer
to Operations 12.29.43 and 12.29.44.
5. Check, and note the valve cleara nces, as described earlier in
this section.
6. Use a rag to wipe up as much oil as possible from the tappet
wells.
7. Valve adjustment involves considerable repetition. A SUMMARY
OF THE PROCEDURE follows:
1. Fit the adjusting tool base plate to one cylinder head.
2. Rotate the crankshaft to position four valves ready for
adjustment.
3. Use the attachment part of the special tool to adjust two valve clearances. Transfer the attachment and
adjust the other two valve clearances.
4. Remove the attachment pa rt from the adjusting tool
base plate.
14
. WARNING: TH
E FOLLOWING OPERATIONS REQUIRE
THE USE OF COMPRESSED AIR - ALWAYS WEAR SUITABLE EYE
PROTECTION.
Remove, clean and measure the shims.
1. Surround the immediate wo rking area with clean rag
to contain any loose objects and shims displaced by
the compressed air.
2. Use 303 - 590 Air Gun (with a fan nozzle) aimed at the edge of the shim to lift it from the tappet.
Remove the shim from each tappet, noting the
position of each.
15 . Cl
ean and measure the thickness of each shim.
16. Assess the increase or decrease required in shim thickness to
produce the correct valve clearance.
17. Select two shims of the correct size, lubricate each and fit
each to the respective tappet (as calculated in the previous
step). Shims must be fitted with the size marking facing the
tappet NOT the cam.
18 . Loos
en the knurled screws on 303 - 540 attachment to allow
the valve springs to return to their normal position.
19. Check the valve clearance of the two valves. If the clearance
is correct, remove the attachment from the base plate. transfer
the attachment to the other two valves which are in position to
be adjusted.
20. Repeat the adjustment procedure, as described in the
Summary.
21. Refit the cam covers and associated components. Refer to
Operations 12.29.43 and 12.29.44.
22. Refit the engine covers.
23. Check the engine oil level; rectify as necessary.
24. Move the engine compartment cover from the service position
and connect the gas struts.
25. Remove the paint protection sheets and close the cover.
26. Connect the battery and fit the battery cover.
Refe
r to the Battery Reconnection Procedure 86.15.15.