engine JAGUAR X308 1998 2.G Workshop Manual

Engine - Crankshaft Rear Seal4.0L SC V8 - AJ26
In-vehic
le Repair
Remov
a
l
S
p
ecial Tool(s)
Crankshaft Rear Oi
l Seal R
emover /
Replacer.
303 - 538
1. Open the engine compartment and fit paint protection sheets.

2. Disc
onnect the batt
ery ground cable.
Re
move the battery cover.
3. Remove the transmission. Refer to Operation 44.20. 01 in
Section 307-01B.
4. Remove the drive plat e. Refer to Operation (SC) 12.53.13.

5. Fi
t and align the seal removal tool 303 - 538 to the crankshaft.
1. Unscrew the two nuts towards the head of each bolt to allow the bolts to fit fully into the crankshaft.
2. Unscrew the center bolt until it is below the face of the main tool and position the tool to the rear of the
crankshaft.
3. Lightly tighten the two scre ws so that they fully locate
in the crankshaft.

6. Hold the tool against th e cr
an
kshaft and lightly and evenly
tighten the two nuts to the face of the tool; to secure the tool
and to hold it parallel to the face of the crankshaft.
7. Secure the oil seal to the tool using the three self-tapping

3.
Fit
the tool to the crankshaft.
En

sure that the cent
re bolt is unscrewe d to below the face
which is to fit to the crankshaft and position the tool to the
crankshaft.
Chec k that
the nuts are fully unscrewed and enter the two
bolts to the crankshaft thre ads and lightly tighten.

4. Tight
en the nuts, finger tight, to hold the tool assembly against

the seal. Check that the seal and the tool are approximately
parallel to the rear of the engine.

5. Pres s th
e seal into the housing.
Ho
ld e
ach bolt stationary, in
turn, and tighten its nut a
small amount (approximately two to three flats) in turn, to
press the seal fully into the housing. until the tool is in
contact with the cylinder block.
6. Remove the tool from the crankshaft.
Chec k that
the seal is located correctly.
7. Fit the drive plate. Refer to Operation (SC) 12.53.13.
8. Install the transmission. Refer to Operation 44.20. 01 in
Section 307-01B.
9. Remove the paint protection sheets and close the engine
compartment cover.
10. Connect the battery and fit the battery cover.
Re
fe
r to the Battery Reconnection Procedure 86.15.15.

E
ngine - Cylinder Head LH
In-ve
hicle Repair
Remova

l
CAU
TION: If a replacement cylinder head is to be installed to a
vehicle with variable camshaft timing (VCT) the cylinder head m ust have the
oil gallery blind rivet removed before installation.
Spe
cial Tool(s)

Cams

haft setting
303-530

Ti
ming chain tensioning
303-532

Wedges, prim
ary chain
303-533

Cr
ankshaft setting
303-531
1.
Open the engine compartment and install paintwork protection sheets.
2. Set the engine compartment cover to the service access position.

3.
Disconnect the battery ground cable.
Re

move the battery cover.
4. Remove the engine fron cover.For additional information, refer to: Engine
Front Cover (303-01 Engi
ne, In-vehicle Repair).
5. Remove the Inlet Manifold. Refer to Operation 30.15.01 in this Section. This operation includes depressurising the fuel system and removing the throttle
housing.
6. Disconnect the hoses and multi-plug from the coolant outlet pipe.
1. Release and reposition the hose clip, and disconnect the heater hose.
2. Disconnect the multi-plug from the temperature sensor.
3. Release and reposition the hose clip along the bypass hose.

1
. Remove the bolt which secures the crankshaft position sensor to
the flywheel housing.
R
emove the sensor and allow it to hang free under the engine.
2. Remove the access grommet (for torque converter bolts) from the housing.
14. Install the damper securing bolt (old one) to the crankshaft, hand-tight
only.

15
.
Rotate the crankshaft until the triangular arrow indent on the drive plate is
visible through the access hole; confirm that the timing flat on each
camshaft is uppermost.

16
.
Install the crankshaft setting peg 3 03 - 531 to the crankshaft position
sensor location.
1. Install the crankshaft setting peg 303 - 531.
Position
the crankshaft so that the setting peg engages fully into the
timing slot.
2. Install and tighten the bolt to secure the setting peg.
17. Remove the damper securing bolt from the crankshaft.
18. Lower the vehicle on the ramp.

19
.
Install the camshaft locking tool 303 - 530 to the B-Bank camshafts,
aligning the shafts slightly as necessary.

20
.
Loosen the bolt which secures the sprocket to the camshaft.

28
.
Remove the secondary chain tensioner.
1. Remove the two bolts which secure the chain tensioner to the cylinder head.
2. Remove the tensioner.

29
.
Remove the primary chain guide.
1. Remove the bolt which secures the chain guide.
2. Note the orientation of the chain guide and remove it from the upper retaining pin.

30
.
Remove the camshafts.
1. Remove the bolts which secure the camshaft caps; loosen them evenly, in stages.
2. Remove the camshaft caps. Note their orientation and markings -
each is marked with its position (a number) and orientation (an
arrow).
3. Remove the camshafts from the engine.

31
.
Remove the tappets and shims.
1. Note the position of each tappet, for reassembly, and remove each
tappet and shim assembly - retain each shim with its original
tappet.
Mark
the inside face of each tappet in pencil or felt tipped pen, with its
original position within the cylinder head.
32. Disconnect the plug from the engine position sensor, at the rear of the
cylinder head.

33. R
emove residual coolant from the cylinder head.
1. Place a drain tray under the engine.
2. Use a syringe with a length of thin rubber pipe connected, to drain the residual coolant from the outlet pipe water-way.
A s u
itable syringe is Snap On YA 745.

34 . R
emove the cylinder head.
1. Place cloth around the area of th e cylinder head to absorb coolant
spillage, when removing the head.
2. Remove the bolts (10xM10 and 2xM8) which secure the cylinder head.
3. With assistance, remove the cylinder head.

35 . R
emove the cylinder head gasket.
1. Note how the gasket is installed and remove it.
2. Remove and discard the cloth, placed previously to absorb coolant spillage.
Wipe up any l e
aked coolant.
36. Remove the coolant drain tray from under the engine.
37. Remove and discard the gasket from the downpipe catalyst.

15
.
Connect the plug to the engine position sensor, at the rear of the cylinder
head.

16
.
Install the tappet and shim assemblies.
Lu
bricate each tappet assembly.
1. Install each tappet and shim asse mbly to its previously identified
position in the cylinder head.

17
.
Apply oil (EP-90) to the camshaft and bearing surfaces, as follows:
To th
e upper face of each bearing surface (two places) in the cylinder
head.
To th
e upper face of each bearing surface (two places) in each bearing
cap.
On
the cam lobes ONLY, not on the base circle area.
18. Install the camshafts.
1. Install the camshafts to position in the cylinder head, with the timing flats uppermost.

2. In
stall the camshaft caps to their respective locations (inlet 0 to 4
and exhaust 5 to 9 from the front) and in the correct orientation
(arrow to front of engine).
3. Install and tighten the cap securing bolts. Tighten evenly, in stages, to 10 Nm.
19. Install the camshaft locking tool 303 - 530, align the camshafts as
necessary.

20 . Install the chain guide
.
The
c
hain guide must be installed so that the slotted hole is towards
the top, and the rais ed shoulder to the cylinder block.
1. Install the chain guide to the block and locate it onto the upper retaining pin.
2. Install the retaining bolt and tighten it to 12 Nm.

21. P
ush the secondary chain tensioner piston into the body to provide
clearance for installing the chain.
1. Insert a thin rigid wire through the hole in the end of the tensioner
piston to displace the ball from the non-return valve seat.
2. With the wire in position, press the piston fully into the tensioner body.
Rem
ove the wire.

22 . Ins
tall the secondary chain tensioner to the engine.
1. Fully seat the tensioner to the cylinder head.
2. Install the two bolts which secure the tensioner and tighten to 12 Nm.

23 . N
OTE: Assemble the VVT unit, the exhaust camshaft sprocket and the
secondary chain, in preparation for installing to the engine.
Install the VVT unit to the engine.
1. Install the above assembly to the camshafts with the chain correctly positioned over the tensioner; VVT unit to the inlet and
the sprocket to the exhaust.
2. Install, but do not tighten, each bolt which secures the VVT unit and the exhaust sprocket to the camshafts.
24. Install the chain tensioning tool 303 - 532 to the exhaust camshaft
sprocket.

d
ownpipe catalyst.

39
.
Install new seals to the B-Bank VVT bush carrier.
1. Install the new sealing ring (scarf jointed) to the carrier bush groove.
2. Install a new O-ring to the carrier oil-way.

40
.
Install the bush carrier to the cylinder block.
Lu
bricate the seal (scarf
jointed) and the bush.
1. Install the bush carrier assembly.
Chec
k that the seals are
in place and that the ri ng dowels are engaged
squarely. Fully locate the assembly as much as possible by hand
pressure.
2. Install the two securing bolts and one nut. Tighten to 21 Nm.
41. Install new sealing rings to the coolant outlet pipe grooves.

42
.
Install the coolant outlet pipe.
1. Install the outlet pipe to the bypass hose and to the cylinder heads.
2. Install the four bolts which secure the outlet pipe.

43
.
Connect the hoses and multi-plug to the coolant outlet pipe.
1. Connect the heater hose and reposition the hose clip.
2. Connect the multi-plug to the temperature sensor.
3. Expand and reposition the hose clip along the bypass hose.
44. Install the Inlet Manifold. Refer to Operation 30.15.01 in this Section. This
operation includes installing the throttle housing.
45. Install the engine front cover.For additional information, refer to: Engine
Front Cover (303-01 Engi
ne, In-vehicle Repair).

46
. Mov
e the engine compartment cover from the service position and connect

the gas struts.
47. Remove the paint protection sheets and close the cover.
48. Connect the battery and install the battery cover.
Refe
r to the Battery Reconne
ction Procedure 86.15.15.