check engine JAGUAR XJ 1994 2.G AJ16 Engine Manual

AJ16 Engine Service Manual
CAUTION: The connecting rod bearing nuts, bolts and
main bearing securing bolts MUST be renewed during assembly and torque tightened as de- scribed in Section 2.1, SPS Joint Control Sys- tem.
. Ensuring that the main bearing caps are marked relative
to the cylinder block, remove the main bearing cap bolts
and remove the caps. Carefully
lift out the crankshaft.
Place the crankshaft
on suitable blocks on a bench. Re- move and discard the bearing shells and the thrust
washers. Clean the cylinder block, crankshaft and bearing
caps.
. Check the crankshaft journals for wear and ovality, for tol- erances - see Service Data in the Preliminary Pages.
. If any ofthe dimensions are outside the stated tolerances,
then the Crankshaft must be renewed.
Fit suitable bolts to the oil gallery plugs and pull to remove
(Fig.
1 ). Check all cylinder block oil galleries for cracks and
blockages. Fit new '0' rings to the oil gallew plugs, lubri- cate the '0' rings and fit the plugs to the cylinder block oil
galleries.
Check all bearing housings for cracks, distortion and any
signs of bearing movement, i.e. scoring or overheating,
renew as necessary.
Checkthecylinder block/cylinder head mating surface for
warping, bowing and cracks.
Check the bore wear in the cylinder block with a suitable
comparator (Fig.
2). This must be done in at least six posi- tions in the bore (Fig. 3).
Maximum bore wear normally occurs towards the
top of the bore, across its thrust axis.
If standard size replacement pistons are being fitted,
they must bethesamegradeasthe markingsonthe
cylinder block.
If new piston
ringsare being fitted without reboring,
de-glaze the cylinder bores using a hone or glaze buster. This operation will not increase the size of
the bores and will givethe bores across-hatchedfin- ish.
&&:
m:
b:
Fia. 1
Fig. 2
1
m2 3
,!I 25s
Fig. 3
34 Issue 1 August 1994

AJ16 Engine Service Manual
0 1 Insert each new piston ring into the cylinder bore, (1 Fig. 1) ensuring they are square in the cylinders and checkthe gap using a strip gauge (2 Fig. 1).
. If the gap is insufficient, then a small flat file or carborun- dum stone can be used on the butting ends of the ring. En- sure that after filing no burrs remain.
Ensure that the rings are not inter
-mixed after they
have been gapped and that each piston/ring assem- bly is matched to its respective bore.
Measure the piston skirt clearance using a long strip
gauge. Insert the strip gauge down the right-hand side of
the cylinder bore, insert the correct piston INVERTED into
the bore (with the piston pin parallel to the axis of the
crankshaft).
. Push the piston down the cylinder until it reaches its
tightest point in the bore. At this point, withdraw the strip
gauge; a steady resistance should be felt.
1 If the tolerances are outside those given in Service Data in
the Preliminary Pages, the pistons must be renewed as a
complete set.
Note:
0
Fit the new main bearing shell halves to the cylinder block
and lubricate with clean engine oil.
1 Clean and polish the crankshaft journals (remove any
scratches with lapping tape, polishing in an anti-clockwise
direction ONLY. against the crankshaft rotation), lubricate
with clean engine oil and carefully assemble the crank
- shaft into the cylinder block.
1 Fit the thrust washers ensuring that the grooved bearing
Check the crankshaft rotates freely.
1 Fit the remaining new bearing shell halves into the main
1 Lubricate with clean engine oil.
. Fit the caps to the cylinder block.
1 Start off the securing bolts (approximately 2 or 3 turns)
and very gently tap the main bearing caps to ensure they
are seated on the cylinder block.
face contacts
the crankshaft
(1 Fig. 2).
bearing caps.
= Check the crankshaft still rotates freely.
. Pull down each bearing cap individually and torque
1 Check the crankshaft still rotatesfreely after pulling down
tighten
the bolts.
each bearing cap.
Check the crankshaft end-float, see Section 4.12.
. Fit new woodruff keys to the crankshaft, never re-use old
. Fit the timing and oil pump sprockets to the crankshaft.
1 Check the connecting rods for parallelism, twist and bend,
If any connecting rod is unusable, then the complete set
1 Lubricate the small end bush, slide the piston pin through
ones.
using
a suitable measuring jig (Figs.
3 and 4).
must be renewed.
the piston and connecting rod. Fia.
1
Fig. 2
Fig. 3
Fig. 4
Issue 1 August 1994 35

AJ16 Engine Service Manual
Clean all component parts and check for wear or damage,
renew worn or damaged components as necessary.
Check
forwear and renewtheauxiliaryshaft bushes (1 Fig.
1) using Service
Tool 18G 1434 (2 Fig. 1).
. Lubricate all bearing shells. Refit all shells using 18G 1434.
CAUTION: Ensure that the oil feed holes are lined up with the holes in the bearing shell (1 Fig. 2).
. Fit the timing cover blanking plate to the timing cover. Fit and tighten the securing bolts.
Lubricate and fit the auxiliary shaft to the housing.
Lubricate and fit the thrust washer.
. Refit the auxiliary shaft snap-ring.
Fit a new oil seal to the rear of the shaft.
Fit and align the oil pump drive-plate to the auxiliary shaft.
. Apply sealant to the bolt securing the driveplate, fit and
tighten the bolt. See Service Materials in the Preliminary
Pages.
Refit the power assisted steering pump, see Section 10 in
the appropriate Vehicle Service manual.
Fit the new sprocket to the crankshaft.
Using a straight edge (2 Fig. 3). check the alignment of the
oil pump drive sprocket (1 Fig. 3). and the crankshaft
sprocket (4 Fig. 3).
Push back the lock tabs from one bolt securing the oil
pump drive sprocket, and remove the bolt.
. Rotate the sprocket. Push back the locktabs from the sec- ond bolt, and remove the bolt.
m Rotate the sprocket, push back the lock tabs and remove the remaining bolt.
. Remove the tab washer and drive sprocket.
Remove the shims (3 Fig. 3). Calculate the thickness of
shim(s) required for correct sprocket alignment.
Fit and tighten a dummy stud to the oil pump drive flange. Fit and align the shims to the flange. Fit and align the
sprocket.
Fit and align the new tab washer.
Fit and tighten the first sprocket securing bolt. Do not lock
over the tab washer at this stage.
m Rotate the sprocket for access.
. Fit and tighten the second sprocket securing bolt. Lock
m Rotate the sprocket for access.
= Remove the dummy stud.
. Rotate the sprocket for access.
Re-tighten the first securing bolt.
. Re-check the sprocket alignment.
= Re-adjust as necessary.
m Lubricate the newtiming chain and position thechain over
. Lubricate the oil pump drive chain.
. Fit the drive chain to the oil pump sprocket.
* Engage the drive chain to the crank sprocket.
Ensure that the drive chain ends are on the damper side of
If the alignment is incorrect, proceed as follows:
over the
tab washer.
Fit and tighten the third
sprocket securing bolt. Lock over the tab washer.
Lock over the tab
washer.
the auxiliary drive shaft and crankshaft sprocket.
the sprockets.
Fia. 1
I I // , I,
Fia. 2
i Fig. 3
Issue 1 August 1994 38

AJ16 Engine Service Manual
4.20
SRO 12.65.48
Remove the timing cover.
1 Remove the upper tensioner pedestal flanged securing
bolts (3 Fig. 1).
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.
. Remove the flanged bolts (5 Fig. 1) securing the upper
static damper and remove the damper (4 Fig. 1) and re-
move the damper pedestal.
1 Remove the lower timing chain tensioner securing bolts (11 Fig. 1) and remove the tensioner assembly (10, 12
Fig. 1).
1 Remove the bolts (16 Fig. 1) securing the oil pump drive
chain damper, remove the damper (17 Fig. 1).
1 Remove the flanged bolts (14 Fig. 1) securing the lower
static damper, and remove the damper
(15 Fig. 1).
Clean all component parts and checkfor wear or damage,
renew worn or damaged components as necessary.
1 Fit the oil pump chain damper in position, do not tighten
the securing bolts
at this stage. Take any slack out of the
chain using hand pressure to push the damper towards
the
center of the engine and tighten the damper securing
bolts.
Timing Chain Damper, Vehicle Set, Renew
1 Refit the lower tensioner assembly.
Refitthe upper static damper. Fit and tighten thesecuring
bolts. Refit the upper tensioner.
Renew the timing cover oil seal and refit the timing cover.
1 13 19 18 17
Fig. 1
Issue 1 August 1994 40

AJ16 Engine Service Manual
4.22
SRO 12.65.30
. Remove the timing cover.
. Remove the upper timing chain (6 Fig. 1) and 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.
. Remove the bolts (11 Fig. 1) securing the lower timing
chain tensioner, and remove the tensioner assembly (10 Fig. 1).
Timing Chain Tensioner, Lower, Renew
. Remove the lower timing chain (8 Fig. 1).
. Clean the lower tensioner assembly, remove the ball valve (1 Fig. 2) and ensure that the base of the housing (2 Fig. 2) is clean.
. Check that the ball valve is free by shaking the assembly
to ensure it rattles. If it does not, renew the valve assem- bly. If it does, renew and lubricatethe 'O'ring (3Fig. 2) and
press the valve back into the housing. The ball free move-
ment is 0,45-0,74 mm.
. Inspect the housing and the hydraulictensioner piston (4
Fig. 2) for excessive wear or scoring. Also check that the
oil hole (5 Fig. 2) is clear in the end of the piston.
. Lubricate the component parts with clean engine oil. As-
semble the tensioner by pressing and twisting the snail
clockwise until the pawl locks in the 'parK position. Fit the
tensioner assembly to the cylinder block with the guide
facing downwards.
. Fit but do not tighten the tensioner upper securing bolt,
push the guide into the housing to release the base and
align with the damper.
Align the damper with the lower bolt hole, fit and tighten
the lower bolt.
. Tighten the upper bolt, fill the tensioner oil reservoir with
oil and work the tensioner to prime with oil.
. Fit the upper tensioner to the pedestal and fit the tensioner
pivot pin, and secure with the flanged bolts
(6 Fig. 2).
m Fit the lower static damper, and secure with the flanged
bolts.
17 i3 is ii
Fig. 1
6
112 7; I
Fig. 2
42 Issue 1 August 1994

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

AJ16 Engine Service Manual
4.30
SRO 12.60.56
Remove the oil pan, see Section 4.27.
Remove oil pressure relief valve screw cap (1 Fig. 1) and
collect spring (2 Fig.
I), valve (4 Fig. I), and mandrel (3 Fig. 1).
Check the valve spring and mandrel for wear, scoring or pitting, renew if damaged.
Measure the components against the specifications listed in Service Data in the Preliminary Pages.
If any of the components are suspect, they must be re- newed.
. Lubricate and assemble the mandrel, spring and valve.
Fit and tighten the relief valve screw cap.
. Refit the oil pan, see Section 4.27.
Oil Pressure ReYief Valve AssemblB Renew
1116.1
Fig. 1
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AJ16 Engine Service Manual
4.31 Oil Pump, Renew
SRO 12.60.26
Remove the oil pan, see Section 4.27.
1 Place a drain tray under the transfer housing. Remove the
housing bolts and housing
(1,2 Fig. 1).
. Remove the pick-up pipes (3 Fig. l), push back the lock
tabs (1 Fig. 2) and remove the pump sprocket bolts (2 Fig. 2).
. Remove the oil pump drive sprocket (3 Fig. 2), tab washer (4 Fig. 2) and shims.
. Remove the oil pump securing bolts and remove the
pump.
. Removethe pressure relief valve cap, spring, mandrel and
valve
(1-4 Fig. 3).
1 Clean the mating face in the cylinder block, the relief valve
assembly, sprocket and shims.
. Lubricate the relief valve assembly, assemble into new
pump, tighten the cap.
. Fitthe new oil pump tothe engine and tighten thesecuring
bolts.
1 Movethedrivechain asfar rearward aspossible,fit a shim
pack of 0.015 in. thickness to the oil pump flange (3 Fig. 4), align the bolt holes, fit the drive sprocket and two securing
bolts. Using
a straight edge (2 Fig. 41, check the alignment
of the oil pump drive sprocket (1 Fig. 4) and crankshaft
sprocket (4 Fig. 4).
1 Remove and refit the pump drive sprocket and adjust the
value of shim thickness as required in order to align the
sprockets.
. When the alignment is satisfactory, remove the pump
sprocket. Fit the chain and shims to the sprocket,fit to the
oil pump. Fit the tab washer and securing bolts. Tighten
the bolts and lock over the tabs.
. Ensure that the tension of the oil pump drive chain is cor- rect, see Service Data in the Preliminary Pages. Adjust by
slackening the tensioner securing screws, tapping the
tensioner inwards to increase the tension, and securing in
position when the tension is correct.
1 Fit new ‘0 rings to the oil pump pick-up pipes.
. Lubricate and refit the pipes to the pump.
1 Fit and seat the transfer housing. Fit and tighten the secur-
. Refit the oil pan, see Section 4.27.
ing bolts.
Fig. 3
Fig. 4
Issue 1 August 1994 51

AJ16 Engine Service Manual
4.32 Oil Pump, Overhaul
SRO 12.60.32
8 Remove the oil pump, see Section 4.31.
1 Remove the bolts securing the pump body.
1 Remove the pump body, pump outer rotor, backplate se-
1 Clean all component parts of the pump.
1 Check all the clearance and components for undue wear
(Fig.
1) and (Fig. 2). Check tolerances, see Service Data in
the Preliminary Pages.
curing
bolts, the backplate and the bearing shell.
. Fit the bearing shell to the housing.
1 Apply sealantto the backplate gasketface,fitthe backplate
and securing bolts. See Service Materials in the Prelimi- nary Pages.
1 Fit the outer rotor.
a Lubricate the relief valve assembly and assemble into the
1 Tighten the relief valve cap.
1 Refit the oil pump, see Section 4.31.
pump.
Fia. 1
Fin. 2
Issue 1 August 1994 52

D
Drive belt tensions, xvi
F
Fau It diagnosis
Diagnostic procedures, 3
Introduction, 3
Foreword, iii
General description
Construction, 1
Cooling system, 2
Crankcase breather, 1
Cylinder head, 1
Lubrication system, 1
Supercharger, 2
S
Service data, xiii
Service materials, xii
Service operations
Check & adjust
Crankshaft end
-float, 27
Valve clearances, 10
Cylinder head, 16
Engine assy., 33
Oil pump, 52
Auxiliary shaft, 44
Auxiliary shaf? rear seal, 45
Camshaft, 7
Camshaft cover gasket, 9
Connecting rod bearings, 22
Crankshaft, 24
Crankshaft damper /pulley assy., 26
Crankshaft front oil seal, 28
Crankshaft rear oil seal, 29
Cylinder head casting, 19
Cylinder head gasket, 13
Drive-plate, 31
Flywheel, 30
Main bearings, 23
Oil filter head gasket, 46
Oil pan gasket, 47
Oil pick-up strainer, 49
Oil pressure relief valve, 50
Oil pump, 51
Oil pump pipe ‘0’ ring, 48
Pistons &connecting rods, 20
Timing chain damper, 40
Timing chain tensioner
Overhaul
Renew
Lower,
42
Upper, 41
Timing chain, gear & tensioner, 37
Timing sprocket, Intermediate, 43
Transmission adapter plate, 32
Service procedures
Sealants, 2
SPS joint control system, 2
Service tools & equipment iv
T
Torque tightening specifications,
53