engine JAGUAR XJ 1994 2.G AJ16 Engine Manual

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
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
4.19 Timing Chain, Gear and Tensioner, Engine Set,
Renew
SRO 12.65.13
Remove the timing cover.
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 and the upper timing chain (6 Fig. 1).
= Remove the lower timing chain tensioner securing bolts (11 Fig. 1) and remove the tensioner assembly (10, 12 Fig. 1).
Remove the lower timing chain (8 Fig. 1) from the inter- mediate sprocket (9 Fig. 1).
Remove the intermediate sprocket and bearing.
Remove the bolts (16 Fig. 1) securing the oil pump drive
chain damper and remove the damper (17 Fig. 1).
= Remove the flanged bolts securing the lower static
damper
(14 Fig. 1) and remove the damper (15 Fig. 1).
. Fit and tighten the bolt securing the crankshaft pulley. Fit Service Tool JD 130 chain link remover! replacer (1 Fig. 2) to the master link (rotate the engine as necessary to align
the link). Ensure the tool aligns to the master link, position
the 'E' gate (2 Fig. 2) to the tool and seat behind the chain (3 Fig. 2).
Fit and tighten the tool handle ensuring that the extractor cones (4 Fig. 2) line up with the link pins. Extract the link.
Slacken the tool carefully ensuring that no components
fall into the oil pan. Remove the oil pump chain.
Remove the lower timing chain from the sprockets.
Using a suitable drift, remove the crankshaft sprocket.
Remove the power assisted steering pump assembly, see
Section 10 in the appropriate Vehicle Service Manual.
Remove the bolt securing the drive-plate. Remove the
drive-plate.
Remove the auxiliaryshaftoil seal,see Section 4.25. Using
right-angled snap-ring pliers, displace and remove the
drive shaft snap-ring.
Remove the drive shaft.
Remove the drive shaft rear thrust washer.
. Fit Service Tool 18G 1434 to the bearing situated in the
front of the cylinder block (2 Fig. 3). Locate the center peg.
Tighten the tool nut to withdraw the bearing shell (1 Fig.
3).
. Remove the tool and shell assembly. Slacken off the tool
nut and withdraw the center peg. Remove and discard the
shell. Remove the blanking plate from the timing cover.
Repeat the procedure to remove the timing cover and
drive shaft housing bearing shells.
Fig. 1
Fia. 2
J I, 6..
Fia. 3
37 Issue 1 August 1994

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
Fit a new linkto the drive chain (2 Fig. 1).
Fit and align a link plate to Service Tool JD 130 (1 Fig. 1).
Ensure that the link and tool clamp holes are aligned. Fit the tool /link plate assembly to the drive chain.
. Fit the ‘E’ gate (3 Fig. 1) to the tool and chain link. Ensure
that the chain is central to the tool. Tighten the tool center
bolt, fully seating the plate
on to the link.
Slacken off the tool center bolt.
. Re-position the tool clamp (4 Fig. 1) away from the chain.
Locate the link riveting head on to the
clamp. Tighten the
tool center bolt (finger tight, then further /2 to 3/4 turn).
Slacken off the tool center bolt. Remove the tightening
bar.
Re-position the clamp away from the chain.
Re-position the ‘E’ gate away from the tool / chain. Re- move the tool retaining handle and remove the tool.
Attach a dial test indicatorto the topof the engine with the
stylus resting on a piston. Rotate the engine and set No. 1 cylinder (Fig. 2) at TDC. Refit the lower static damper. Fit and tighten the securing bolts and lock over the tab
washer. 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 to
- wards the center of the engine.
Tighten the bolts securing the damper.
. Lubricate the intermediate sprocket bearing.
Lift up the chain, engage the sprocket in the chain, and lo-
cate the sprocket into the bearing.
. Refit the lower tensioner assembly.
. Lubricate the upper timing chain.
. Refit the upper chain to the intermediate sprocket.
. Refit the upper static damper.
Fit and tighten the securing bolts.
Refit the upper tensioner.
. Renew the oil seal (1 Fig. 3) and refit the timing cover.
Fig. 1
-v II
Fig. 2
.12-Kl
Fig. 3
39 Issue 1 August 1994

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

4.21 Timing Chain Tensioner, Upper, Renew
SRO 12.65.29
Remove the timing cover.
Remove the upper timing chain (6 Fig. 1).
Remove the flanged bolts (3 Fig. 1) securing the tensioner
Remove the pedestal / tensioner assembly and chain
Remove the tensioner pivot pin (2 Fig. 1) and remove the
Clean the pivot pin.
Fit a new tensioner to the pedestal and fit the tensioner
pivot pin. Secure the tensioner with the flanged bolts.
Align the damper to the tensioner and fit the damper/ten- sioner assembly to the engine.
Ensure that the damper does not foul the auxiliary shaft
sprocket.
Finally tighten the securing bolts.
Fit the new timing chain.
Re-position the upper tensioner and temporarily secure to
Renew the timing cover oil seal and refit the timing cover.
pedestal.
damper
(1 Fig. 1).
tensioner from the pedestal.
the upper dampers with an elastic band. 1 13 19 18 17
Fig. 1
41 Issue 1 August 1994

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
e 4.23 Timing Sprocket, Intermediate, Renew
SRO 12.65.26
. 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).
. Remove the lower timing chain (8 Fig. 1).
. Remove the intermediate sprocket (9 Fig. 1).
. Examine all components (1-6 Fig. 2) for wear or damage.
. Renew worn or damaged parts as necessary.
. Fit the new intermediate sprocket.
. Fit the lower timing chain. Fit the guide assembly, valve
and '0' ring to the tensioner housing. Re-position the
chain damper for access.
. 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.
. Align the damper to the tensioner and fit the damper! ten- sioner assembly to the engine.
. Tighten the securing bolts.
. Refit the upper timing chain.
. Re-position the upper tensioner and temporarily secure to
. Renew the timing cover oil seal and refit the timing cover.
the upper dampers with an elastic band.
/ 13 1s 18 ir
Fig. 1
1 L
6
J12 7II
Fig. 2
Issue 1 August 1994 43

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