key JAGUAR XJ 1994 2.G AJ16 Engine Manual

AJ16 Engine Service Manual
b:
1 Secure with new snap-rings, never re-use old ones.
1 Fit the rings to the pistons ensuring that gaps are posi-
tioned as shown in Fig. 1.
1 Lubricate and compress the rings using Service Tool 18G 55A (Fig. 2).
1 Insert the piston skirt into the bore and using a suitable im- plement such as a wooden hammer shaft, gently tap the
piston into
the cylinder bore.
1 Ensure that the connecting rod does not foul either the cyl-
inder block or camshaft.
Lubricate (using clean engine oil) and fit the bearing shells
to the connecting rod and the connecting rod bearing cap.
Fit the rod to the crankshaft, and fit the connecting rod
bearing cap to the connecting rod.
CAUTION: The connecting rod bearing nuts and bolts
MUST be renewed during assembly and torque
tightened asdescribed in Section2.1, SPS Joint
Control System.
Pistons are marked
'FRONT'. Ensure
that the mark- ing faces the front of the engine.
1 Fit and tighten the connecting rod bearing nuts.
1 Repeat the operation for the remaining pistons.
1 Ensure crankshaft rotation during assembly.
1 Clean and fit the windage trays. Fit and tighten the secur- ing bolts.
1 Removethe oil pumpandoverhau1,seeSection 4.32. Refit
when serviceable.
1 Lubricate the lower timing chain. Fit the chain to the inter- mediate sprocket, fit the chain to the lower sprocket and
then assemble the intermediate sprocket and chain to the
cylinder block.
= Should the intermediate sprocket be worn or damaged,
the assembly must be renewed.
= Fit the spacers to the lower pivoting damper and fit the as-
sembly to the cylinder block.
1 Fit the tab washer and securing bolts.
1 Tighten the bolts and lock over the tabs.
1 Renew the lower tensioner assembly, see Section 4.22.
Fit a dial gauge to the top of the cylinder block and turn the
1 Lubricate the upper chain with clean engine oil and fit to
1 Fit an elastic band around the upper dampers tosecurethe
1 Renew the crankshaft front oil seal, see Section 4.13.
1 Refit the timing cover.
= Lubricate and fit the oil seal distance spacer. Fit and seat
1 Renew the rear housing oil seal, see Section 4.14.
1 Refit the oil pan, see Section 4.27.
1 Refit the cylinder head, see Section 4.4.
1 Remove the engine from the stand.
1 Refit the transmission unit to the engine.
1 Refit the engine/ transmission unit to the vehicle, see Sec-
engine over until No.1 piston is at TDC (Fig. 3).
the intermediate sprocket.
chain.
the crankshaft pulley woodruff key.
tion 3.1 in the appropriate Vehicle Service Manual.
V'
ill'.,
Fia. 1
Fig.
2
Fig. 3
Issue 1 August 1994 36

AJ16 Engine Service Manual
4.24 Auxiliary Shaft, Renew
SRO 12.10.30
Remove the timing cover.
. Remove the pulley woodruff key and remove the oil seal
spacer from the crankshaft.
. Remove the flanged bolts (3 Fig. 1) securing the tensioner
pedestal.
Remove the pedestal / tensioner assembly and chain
damper (1 Fig. 1).
. Remove the tensioner pivot pin (2 Fig. 1) and remove the
tensioner from the pedestal. Clean the pivot pin.
. Remove the flanged bolts (5 Fig. 1) securing the upper
static damper. Remove the damper (4 Fig. 1) and upper
timing chain (6 Fig. 1).
Remove the bolts (11 Fig. 1) securing the chain tensioner
and remove the assembly (17 Fig. 1).
Remove the power assisted steering pump assembly, see
Section 10 in the appropriate Vehicle Service manual
. Remove the pump drive coupling.
. Remove the flanged bolt (1 Fig.2) and the drive-plate (2 Fig. 2).
Using Service Tool JD 118, remove the auxiliary shaft rear
oil seal (3 Fig. 2) from its housing.
. Using right-angled snap-ring pliers remove the snap-ring (5 Fig. 2) securing the drive shaft (4 Fig.2).
. Lift the timing chain (8 Fig. 1) from the sprocket (7 Fig. 11, remove the shaft / sprocket assembly and retrieve the
thrust washer.
. Clean all component parts and checkfor wear or damage.
Renew worn or damaged parts as necessary. Clean the auxiliary bearing housing.
. Check for wear and if necessarychangethe auxiliaryshaft bushes.
. Refit the housing with new gasket. Fit and tighten the se-
curing bolts.
. Lubricate the shaft and refit the to the housing, engaging
the chain with the gear as it is fitted. Lubricate and fit the
thrust washer and secure with the snap-ring.
. Renew the auxiliary shaft rear oil seal, see Section 4.25.
. Refitthe power assisted steering pump assembly, see Sec-
. Refit the lower chain tensioner, see Section 4.22.
Refit the upper chain tensioner, see Section 4.21.
. Renew the oil seal (1 Fig. 3) and refit the timing cover.
tion
10 in
the appropriate Vehicle Service manual.
Fig. 1
Fig. 2
Fig. 3
Issue 1 August 1994 44