engine JAGUAR XJ 1994 2.G AJ16 Engine Manual

AJ16 Engine Service Manual
1 Clean and polish the crankshaft journals, lubricate and
carefully assemble the crankshaft into the cylinder block,
fit the thrust washers ensuring that the steel side of the
washer is mated to the cylinder block (1 Fig. 1).
1 Rotate the crankshaft to ensure that it turns freely.
1 Fit the main bearing shells into the main bearing caps, lu- bricate and fit to the cylinder block.
1 Start the securing bolts and carefullytap the main bearing
caps to ensure they are seated to the cylinder block.
1 Rotate thecrankshaft to ensurethat it still turnsfreely, pull
down each bearing cap individuallyand torque tighten the
securing bolts.
1 Rotate the crankshaft between pulling down each bearing
cap.
1 Check and if necessary adjust the crankshaft end-float in
accordance with Section 4.12.
1 Renew the crankshaft rear oil seal, see Section 4.14.
1 Fit a new bearing shell to the connecting rod, lubricate
1 Fit a bearing shell to theconnecting rod bearing cap, lubri-
with clean engine oil and fit to the crankshaft.
cate and fit to the connecting rod.
Fit and torque tighten
1 Turn the crankshaft over ensuring that there are no 'tiaht'
the nuts.
spots, and that the crankshaft rotates freely.
-
1 Repeat this procedure for the remaining five cylinders.
WUTION: 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.
1 Clean and inspect for wear or damage all the timing gears,
chains, guides and tensioners.
1 Renew any suspect component.
1 Fit and seat the crankshaft sprocket woodruff key and fit the sprocket to the crankshaft.
1 Refit the timing chains - upper and lower; and the upper
and lower tensioners, see Section 4.19.
1 Fit a dial gauge to the top ofthe cylinder blockand turn the
engine over until No.1 and 6 pistons are at TDC (Fig. 2).
1 Lubricate the upper chain and fit it to the intermediate
sprocket.
0 1 Fit an elastic band to retain the upper dampers and chain.
. Lubricate the oil pump drive chain, fit the chain to the
crankshaft sprocket and lodge in the correct position.
1 Renew the timing cover oil seal and refit the timing cover.
. Lubricate and fit the oil seal distance piece. Fit and seatthe
1 Refit the oil pump, see Section 4.31.
1 Refit the flywheel (Manual), see Section 4.15, or refit the
1 Refit the oil pan, see Section 4.27.
1 Refit the crankshaft damper /pulley assembly, see Section
1 Refit the cylinder head, see Section 4.4.
1 Remove the engine from the stand and refit the trans-
1 Refit the engine/transmission unitto thevehicle, see Sec-
damper woodruff key.
drive
-plate (Automatic), see Section 4.16.
4.11.
mission unit.
tion
3.1 in the appropriate Vehicle Service Manual.. Fig.
1
Fig. 2
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AJ16 Engine Service Manual
4.11
SRO 12.21.09
. Remove the air conditioning compressor drive belt.
. Remove the generator drive belt.
. Fit ServiceTool 18G 1437 (1 Fig. 1)tothecrankshaft pulley
. Wedge the tool against the crossmember.
. Remove the pulley retaining bolt.
. Remove Service Tool 18G 1437 from the pulley.
. Fit Service Tool 18G 1436/A to the pulley and tighten the
securing bolts.
. Eghten the center bolt to withdraw the pulley from the
crankshaft and remove the tool.
. Remove the timing plate securing bolts and remove the
timing plate.
. Fitthetiming platetothe new pulleyandtightenthesecur-
ing bolts.
. Fit the pulley to the engine, hand tighten the securing bolt
and fit Service Tool 18G 1437.
. Wedge the tool against the front crossmember, torque
tighten the securing bolt and remove Service Tool 18G
1437.
Crankshaft Damper / Pulley Assembly, Renew
(3 Fig. 1) and tighten the securing bolts (2 Fig. 1).
. Refit the generator drive belt.
. Refit the air conditioning compressor drive belt.
.. J
J12-830
Fia. 1
Issue 1 August 1994 26
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0
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AJ16 Engine Service Manual
4.12
SRO 12.21.26
Crankshaft End-float, Check and A4ust
Remove components as required for access and proceed as
follows.
Remove the oil pan, see Section 4.27.
Remove the oil pump pick-up pipes (3 Fig. I), see Section
Remove the crankshaft windage trays (6 Fig. 1).
. Mount a suitable dial gauge and position the stylus on the
crankshaft front pulley.
. Zero the gauge, and with the use of a suitable lever,
measure the crankshaft end-float (Fig. 2). For the correct
end-float, see Service Data in the Preliminary Pages.
If the end-float exceeds the tolerances, remove the center
main bearing cap, and renew the thrust washers.
&&: When refitting the thrust washers, ensure that the
bearing face (grooved) (1 Fig. 3) and not the steel
side contacts the crankshaft.
. Recheck the end-float and if satisfactory, clean the main
bearing cap and bearing, lubricate with clean engine oil
and
fit the cap assembly to the cylinder block.
4.28. 0
Fit and
torque tighten the securing bolts.
CAUTION: The main bearing securing bolts MUST be re
-
newed during assembly and torque tightened as described in Section 2.1, SPS Joint Control
System.
Ensure that the bearing cap is the correct way round
with the cap numbers corresponding to the
numbers stamped on the oil pan mounting face.
Rotate the crankshaft to ensure that it is not being
'pinched' and will rotate freely.
m Remove the dial gauge and torque tighten the main bear- ing cap. Refit the windage trays to the cylinder block and
secure with the bolts.
w:
Refit the oil pump pick-up pipes, see Section 4.28.
Refit the oil pan, see Section 4.27.
Refit the oil filler / drain back tube.
Replace the components removed for access.
0
3
Fia. 1
Fig. 2
Fig.
3
27 Issue 1 August 1994

AJ16 Engine Service Manual
4.13
SRO 12.21.14
. Removethecrankshaftdamper/pulleyassembly,seeSec- tion 4.11.
- Remove the old oil seal from the timing cover using Ser-
vice Tool JD 128 (A Fig. 1).
. Fit the new oil seal (prior to fitting the crankspacer) using
Service Tool JD 129 and the crankshaft pulley bolt (B Fig.
1 ).
= Inspect the edges of the spacer for nicks, burrs and wear
marks. Renew if necessary.
. Refit the crankshaft damper/ pulley assembly, see Section 4.11.
Crankshaft Front Oil Seal, Renew
Fig. 1
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AJ16 Engine Service Manual
4.14 Crankshaft Rear Oil Seal, Renew
SRO 12.21.20
Remove the flywheel (Manual), see Section 4.15, or the
Remove the transmission adapter securing bolts and re-
Carefully remove the old oil seal from the adapter, clean
CAUTION: Do not remove the plastic ‘0 ring protector
from the new seal prior to fitting to the adapter.
Fit the new seal (3 Fig. 1) to the adapter and apply sealant to the appropriate faces. See Service Materials in the Pre- liminary Pages.
Locate the plastic’o’ ring protector (1 Fig. 1) on to the end of the crankshaft (2 Fig. 1).
. Push the rear seal housing (4 Fig. 1) over the crankshaft
and
up to the rear cylinder block face.
Remove the plastic ‘0’ ring protector (1 Fig. 1).
. Fit and torque tighten the transmission adapter securing
drive
-plate
(Automatic), see Section 4.16.
move the adapter.
the adapter and lubricate
the seal mounting face.
bolts.
. Refit the flywheel (Manual), see Section 4.15, or the drive- plate (Automatic), see Section 4.16.
Fin. 1
Issue 1 August 1994 29

AJ16 Engine Service Manual
4.15 Engine Flywheel, Renew
SRO 12.53.07
1 Remove the transmission unit.
. Hold the flywheel in one position and remove the bolts se-
CAUTION: Make a note of the position of any balance
weights relative to the clutch cover.
Remove the balance weights. Remove the clutch assem-
curing the clutch cover to the flywheel.
bly.
WARNING: THE TWIN-MASS FLYWHEEL IS EXTREMELY HEAVY. ASSISTANCE WILL BE REQUIRED
DURING REMOVAL / REFIlTING.
Remove the eight securing bolts (1 Fig. 1) and remove the
flywheel (2 Fig. 1). Remove the needle roller race and fit
to the new flywheel.
. Fit the new flywheel to the crankshaft and tighten the se- curing bolts to the recommended torque value.
. Fit the clutch assembly to the flywheel ensuring that the
‘flywheel side’
of the drive-plate faces the flywheel. Align
the clutch with a dummy input shaft. Fit the balance
weights to the clutch cover and torque tighten the secur- ing bolts.
1 Remove the dummy shaft.
Fit the housing to the adapter plate, fit and torque tighten
the securing bolts I nuts.
1 Refit the transmission unit. Fio.
1
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AJ16 Engine Service Manual
4.16 Engine Driveplate, Renew
SRO 12.53.13
1 Remove the transmission unit.
Remove the drive-plate securing bolts (1 Fig. 1).
Remove the drive-plate (2 Fig. 1).
. Check the crankshaft rear oil seal for leaking, renew as
Fit the new drive-plate to the crankshaft. Fit and tighten
1 Refit the transmission unit.
necessary,
see Section
4.14.
the securing bolts.
I Fin. 1
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AJ16 Engine Service Manual
4.17 Engine Rear/ Transmission Adapter Plate, Renew
SRO 12.53.03
1 Remove the engine flywheel (Manual), see Section 4.1 5, or
the engine drive
-plate (Automatic), see Section 4.16.
Remove the lower bolt securing the starter motor and re-
position the starter motor away from the adapter plate.
1 Remove the adapter plate securing bolts and remove the
adapter plate.
* Remove the dowel pegs and blanking plugs from the
adapter plate.
m Discard the adapter plate.
1 Fit the blanking plugs and dowel pegs to the new adapter
. Fit the assembly to the rear of the engine and torque
. Re-position the starter motor to the adapter plate and se-
m Refittheengineflywheel (Manual),see Section 4.15, orthe
plate.
tighten the securing bolts.
cure with the lower bolt.
engine drive
-plate (Automatic), see Section 4.16.
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AJ16 Engine Service Manual
4.18 &;ne Assembly, Overhaul
SRO 12.41.05
. Remove the engine and transmission unit, see Section 3.1
. Remove the transmission unit from the engine.
. Fit the engine to a stand.
. Place a drain tray belowthe cylinder block drain plug and
Overhaul the cylinder head, see Section 4.5.
1 Remove the oil pan, see Section 4.27.
. Remove the oil pump, see Section 4.31.
. Remove the windage trays.
. Clean all components, check for damage and wear and
. Remove the rear oil seal housing, see Section 4.1 4.
. Remove the timing cover assembly.
1 Remove the pedestal bolts and tab washer.
. Remove the pedestal / tensioner assembly and damper.
Slacken off the oil pump drive chain damper securing
bolts and move the damper clear of the chain. Push back
the lock tabs
(1 Fig. 1) and remove the securing bolts (2
Fig. 1) from the oil pump drive sprocket (3 Fig. 1).
in the appropriate Vehicle Service Manual.
drain any remaining coolant from the engine.
renew as required.
. Remove the drive sprocket and shim pack.
. Remove the oil pump drive chain (5 Fig. l), remove the
elastic band from the upper dampers and remove the
upper timing chain.
1 Remove the lower tensioner securing bolts and remove
the tensioner.
. Push back the lower chain fixed damper securing bolt lock
tabs and remove the bolts.
. Remove the damper and tab washer.
. Repeat for the remaining fixed and pivot dampers and re- move the lower chain and intermediate sprocket.
Remove the crankshaft pulley spacer and the crankshaft
pulley woodruff key.
= Remove the drive sprockets and woodruff keys from the
crankshaft.
1 Checkall drive sprocketsforwear, distortion and damaged
teeth. Renew as required.
. Remove the power assisted steering pump assembly, see
Section 10 in the appropriate Vehicle Service Manual and
reposition away from the timing cover area.
. Renew the auxiliary shaft, see Section 4.24.
1 Renew the auxiliary shaft bushes, see Section 4.19.
1 Remove the oil pump drive chain damper.
. Remove the spacers from behind the damper.
. Remove the pistons and connecting rods and renew, see
Section 4.7.
. Refit the connecting rod bearing shells to one connecting
rod and cap and fit the rod to the crankshaft. Torque
tighten
the nuts and checkthe side clearance between the end face of the rod and the journal shoulder (Fig. 2) -see
Service Data in the Preliminary Pages.
Remove the connecting rod from the crankshaft.
. Repeat for the remaining five connecting rods. Fig.
1
Fig. 2
Issue 1 August 1994 33

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