manifold JAGUAR X308 1998 2.G User Guide

E
ngine Management System Components
Electronic Throt
tle
The
electronic throttle assembly, in resp
onse to signals from both the driver and the ECM, adjusts idle speed, sets the
throttle valve to the position requested by the driver's accelerator / throttle pedal, cruise and traction control, power
limitation and catalyst warm-up.
Mass
Air Flow Meter
The sensor i
s located in the air flow mete
r assembly and outputs an analogue voltag e to the ECM. This sensor measures air
flow into the engine inlet system and is calibrated to measure kg / hour.
In
take Air Temperature
Th
e intake air temperature sensor is loca
ted in the air flow meter assembly and outputs an analogue voltage to the ECM.
The ECM will substitute a default value eq ual to 50°C should this sensor fail.
Fuel Injectors
The eigh
t bottom fed fuel injectors are located in the fuel rails. Th
e fuel injectors are electromagnetic solenoid valves
controlled by the ECM. The pulse time for the injector combined with the fuel pr essure determines the volume of fuel
injected to the manifold.
Fue
l Delivery
The fu
el pump provides fuel to the fuel rail where the circulat
ing pressure is controlled by a pressure regulator valve; excess
fuel is returned to the fuel tank.
The pressure regulator valve is controlled by manifold depression so that fuel delivery pressure is maintained at
approximately 3 bar above manifold pressure.
Fuel Pump
Relay
The ECM controls thi

s component for normal
engine running. The security system may disable this relay via communication
with the ECM.
Fuel Lev
el Sensing
The tank fuel

is measured by the fuel le
vel sensor . This signal is used by the ECM as an in put to certain diagnostics.
Eva
porative Valve
Excess vapour

formed in the fuel tank is
absorbed into the evaporative emission pu rge control canister. While the engine is
running, the fuel absorbed in the canister is gradually purged back into the engine. The rate of purging is governed by
engine operating conditions and vapour concentration level. Operating conditions which affect the purge rate are:
2—Purge
valve
3—Engine

torque reduction
4—E

lectronic throttle assembly
5—Coo

ling fans
6—Ignition amplifier driver
7—Engine overspeed
8—Cli

mate control compressor clutch
9—O

BDII information (J1962, CAN, ISO)

10—F
uel pump relay
11—Heat

ed oxygen sensor
12—Vari

able valve timing
13—MIL sw

itching



ECM Out
puts
It

em
Par
t Number
De
scription
1—Exhaus

t gas recirculation

Thi
s sensor uses a piezo-electric sensing element to detect kn
ock which may occur under acceleration at critical conditions.
Should detonation be present the ECM will retard ignition timing of individual cylinders.
Exhaust G
as Recirculation
The EGR
valve (where fitted) reduces NOx
emissions by recirculating a portion of the exhaust gases back into the inlet
manifold.
Heated Oxyg
en Sensors
The h
eated oxygen sensors, one per bank, are situated upstream of the catalysts. Integral
to the sensors are heaters
(under ECM control) which allow the sensor s to reach their operating temperature as soon as possible after engine start. A
comparison between the level of oxygen in the exhaust gas to that in the atmosphere produces an output signal. This signal
is used by the engine closed loop fuel strategy to make fuelling corrections and so control overall emission levels.
Oxygen Sensors

Thes
e sensors, one per bank, are situated downstream of the
catalyst. The comparison of upstream and downstream signals
allows determination of cata lyst conversion efficiency.




Knock Sensor

Engi
ne -
Torqu
e Specifications


De
s
cription
Nmlb
-
ft
lb
-
in
A
ccessory
drive belt tensioner
43--
A
ccessory
drive belt idler pulley
61--
Air in
ta
ke tube to throttle body
5--
A/C
pipes t
o receiver / drier
9--
A/C pipe m

anifold joints
9--
Camsh

aft bearin
g caps10--
Ca
msh
aft cove
r10--
Ch
arge Air Co
oler Adaptor to cylinder head (SC)
21--
Co
olan
t outlet pipe (AJ26 NA)
10--
Cran
kshaft damper bolt - no lockin
g ring
St
ag
e 1
80--
Stag

e 2
80°--
C
r
ankshaft damper bolt - with locking ring
37
5--
Cra
nkshaft position sensor
10--
Cy
li
nder head bolts M10
35--
Cy
lin
der head bolts M8 (two at front of head)
25--
Driv
es
haft (propshaft) drive flan
ge bo
l
ts
82--
ERG p
i
pe to exhaust manifold
21--
Engi

ne compartment cover (bonnet) hinges
25--
En
gine
coolant radiator top securing panel
25--
E
ng
ine front mounting
70--
En
gine
oil cooler pipes (clamp)
21--
En
gi
ne / Transmission assembly rear mounting centre bolt
35--
En
gi
ne / Transmission assembly rear mounting outer bolts
25--
Ex
ha
ust downpipe support bracket to flywheel housing
50--
Ex
ha
ust downpipe to lower mounting bracket
48--
E
x
haust camshaft sprocket
St
age 120--
Stage 290 °--
Ex
haust manifold to cylinder head
18--
Ex
ha
ust manifold flange to downpipe
18--
E
x
haust Torca clamps
55--
Fuel cross-over elbo

w
10--
Fu
el f
eed pipe to intake manifold
10--
Fuel
Injector (AJ
26)
5--
Fuel
injector ha
rness clips to camshaft cover (SC)
5--
Fu
el p
ressure re
gu
l
ator to intake manifold
10--
F
u
el rail to Char
ge
A
ir Cooler Adaptor (SC)
21--
In
ta
ke manifold to cylinder heads
21--
Inta

ke elbow support brackets
18--
Oil f
i
lter
17--
Oil C
o
oler
7--
P
AS pu
mp hose unions
25--
P
r
imary timing chain fixed guide
12--
P
r
imary timing chain tensioner
12--
Pr

imary timing chain tensioner blade
14--
S
e
condary timing chain tensioner to cylinder
12--
S
t
eerin
g ra
ck45--
Thro
ttle body to intake elbow
21--
Th
ro
ttle cable abutment to throttle body
5--
Th
ro
ttle intake elbow to intake manifold
21--
Ti
mi
ng cover
12--
Variable camshaft t
i
ming oil control unit to intake camshaft
St
ag
e 1
20--
St
ag
e 2
90
°--
Var
iable camshaft timing oil control unit housing (bolt and nut)
21--
Va
ria
ble camshaft timi
ng oil control solenoid
12--
Wa
ter pump pulley
12--

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.

7.
Remove the coolant outlet pipe.
1. Remove the four bolts which secure the outlet pipe.
2. Remove the outlet pipe from the bypass hose and from the cylinder heads.
8. Remove and discard the sealing ring s from the outlet pipe grooves.

9.
Remove the nuts which secure the catalytic converter to the B-Bank
exhaust manifold flange.

10 . Re
move the VVT bush carrier.
1. Remove the two bolts and one nut which secure the carrier to the cylinder block.
2. Release the carrier from the two ring dowels and remove it.

11. R
emove the seals from the bush carrier.
1. Remove the sealing ring (scarf jointed) from the carrier bush groove.
2. Remove the O-ring from the carrier oil-way recess.
12. Raise the vehicle on a ramp.
13. Remove the crankshaft position sensor.

Inst
allation
Cl
ean the gasket faces of the catalyst and the exhaust manifold.
38. Clean cylinder head and cylinder block gasket faces.
E
nsure that all threaded holes in the cylinder block face are clean and
free from oil.
Cl
ean and inspect the cylinder head bolts. They may be re-used on two
occasions. When re- used, each bolt head should be marked with one
dot from an automatic centre punch.
39. Clean and inspect all relevant components and mating faces.

1.
CAUTIONS:
If a replacement cylinder head is to be installed to a vehicle with VCT
the cylinder head must have the oil gallery blind rivet removed before
installation.
Make sure that all debris is removed from the cylinder head and cylinder
head oil gallery.
Vehicles fitted with VCT: Remove the blind rivet from the VCT oil gallary.
• NOTE: The centre bore of the blind rivet is 6 mm diameter.
I
dentify the VCT oil supply gallery and the 8 mm blind rivet.
U

sing a suitable 3 mm punch release the centre of the blind rivet until
it is released from the outer part of the blind rivet.
U
sing a suitable extraction tool, remo
ve the remaining part of the blind
rivet.
2.
Clean the component mating faces.

3.
Check cylinder head face for distortio
n, across the center and from corner
to corner.

shown
.
If the

m
easurement
is less than
51.88 mm
the cylinder
head requires
replacement.

6.
Install a new gasket to the downpipe catalyst flange.

7.
Install and align a new cylinder head gasket to the cylinder block face.

8.
With assistance, install the cylinder head.
E
ngage t
he cylinder head with the dowels on the block face, and the
exhaust manifold flange with the studs on the downpipe catalyst.
9. Install the cylinder head bolts, hand tight only.
10. Tighten the cylinder head bolts in stages, in the sequence shown, using
the following procedure:
Stage 1 - ti
ghten all M10 bolt
s in sequence, to 20 Nm.

4.
For cylinder head face distortion
data, refer to specifications.
For additional information, refer to: Specifications
(303-01 Engi
ne,
Specifications).
5. NOTE: For
cylinder head with
distortion above the
maximum allowance,
the cylinder head
material must be
measured.
Measure the
cylinder head
material.
Che c
k
measurement
from the
centre of the
exhaust
dowel to the
cylinder head
face as

30. U
se a wedge 303 - 533 (or two if required) between the primary chain
tensioner and tensioner blade, to ta ke up the slack in the chain, for
tightening the VVT unit and exhaust camshaft sprocket.

31 . C
AUTION: Make sure that a new bolt is installed.
Tighten the exhaust camshaft sprocket securing bolt. 1. Install the chain tensioner tool 303 - 532 to the sprocket holes.
Apply
force to the tool in an anti
-clockwise direction to tension the
chain on its drive side.
2. Whilst applying the opposing force to the sprocket and chain, tighten the sprocket securing bolt to 20 Nm +90°.

32 . C
AUTION: Make sure that a new bolt is installed.
Tighten the VVT unit securing bolt. 1. Whilst still applying the opposing force to the sprocket and chain (using 303 - 532), check that the wedges are still in place, tighten
the VVT unit securing bolt to 20Nm +90°.
Re
move the chain tensioning tool and the wedge(s).
33
. R
emove the camshaft locking tool 303 - 530.
34. Raise the vehicle on the ramp.
35. Remove the crankshaft setting tool 303 - 531.

36 . In
stall the crankshaft position sensor.
1. Install the sensor to the flywheel housing and install the securing bolt. Tighten to 10 Nm.
2. Install the access grommet to the housing.
37. Lower the ramp.
38. Install and tighten the nuts which secure the exhaust manifold to the

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).

E
ngine - Cylinder Head RH
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 front 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.