JAGUAR XJ 1994 2.G AJ16 Engine Manual

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

AJ16 Engine Service Manual
4.25
SRO 12.10.32
Auxiliary Shaft Rear Seal, Renew
* 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.1) and the drive-plate (2
Using ServiceTool JD 118, remove the auxiliary shaft rear
Note: Under no circumstances must the plastic insert be
removed prior to fitting the seal.
* Using ServiceTool 18G 1469fit and fully seat the auxiliary
Refit the power steering pump drive-plate and secure with
Refitthe power assisted steering pump assembly, see Sec-
Fig. 1).
oil seal (3 Fig. 1) from its housing.
shaft oil seal.
its bolt.
tion
10 in the appropriate Vehicle Service Manual.
Fig.
1
Issue 1 August 1994 45

AJ16 Engine Service Manual
4.26
SRO 12.60.03
. Place a drain tray under the oil filter.
. Remove the oil filter cartridge (1 Fig. 1).
Oil Filter Head Gasket, Renew
If the vehicle is fitted with an oil cooler, remove the oil
cooler pipe clamp nut and clamp. Notethe position of and
disconnect the pipes from the oil supply housing.
. Remove and discard the '0' rings. Remove the filter head
securing bolts
(2 Fig. 1).
Remove the inner (3 Fig. 1) and outer (4 Fig. 1) housings.
. Thoroughly clean the housings, the oil cooler pipes (if fitted) and the cylinder block face.
9 Apply sealanttothe outer housing, align the inner housing
with the outer housing and fit the securing bolts to the
housing assembly. See Service Materials in the Prelimi- nary Pages. Align the assembly to the aperture in the cyl- inder block, fit and tighten the securing bolts.
If the vehicle is fitted with an oil cooler, fit new '0' rings to
the oil cooler pipes. Lubricate and connect the pipes
to the
housing.
. Fit the clamp plate and fit a new oil filter.
. Fill the engine with oil to the correct level, see Section 3.1
in the appropriate Vehicle Service Manual. Fia.
1 ~~~
Issue 1 August 1994 46

AJ16 Engine Service Manual
@ 4.27 Oil Pan Gasket, Renew
SRO 12.60.38
Remove components as required for access and proceed as
follows.
. Drain the engine oil, see Section 3.1 in the appropriate Ve-
= Remove all but two oil pan bolts (1 Fig. 1).
= Remove the bell housing to oil pan bolts.
. Remove the two remaining oil pan bolts and lower the oil
pan (2 Fig. 1).
. Clean all components and examine for damage and wear.
Renew any damaged components. Discard the oil pan
gasket.
&&: If renewing the oil pan, transfer all components to
the new oil pan.
Clean the gasket face on the cylinder block.
. Fit new oil pan gasket.
. Lift the oil pan into position, fit and torque tighten these-
hicle Service Manual.
curing bolts.
in the appropriate Vehicle Service Manual.
. Fill the engine with oil to the correct level, see Section 3.1
Replace the components removed for access.
112-83L
Fig. 1
Issue 1 August 1994 47

AJ16 Engine Service Manual
4.28
SRO 12.60.27
Remove the oil pan, see Section 4.27.
m Place a suitable drain tray under the oil transfer housing
area and remove the transfer housing / pick-up pipe (1,2,
4,5 Fig. 1).
Oil Pump Pipe '0' Rings, Renew
. Remove the oil pump pick-up pipes (3 Fig. 1).
. Remove and discard the 'O'rings. Clean the transfer hous- ing and oil pipes.
. Carefully fit new '0' rings (lubricated with petroleum jelly)
to the oil pipes (1 Fig. 2) and refit the pipes to the oil pump.
. Fit the transfer housing to the engine. Fit and tighten the
securing bolts.
. Refit the oil pan, see Section 4.27.
Fig. 1
Fig. 2
Issue 1 August 1994 48

AJ16 Engine Service Manual
4.29 Oil Pick-up Strainer, Renew
SRO 12.60.20
1 Remove the oil pan, see Section 4.27.
1 Remove the bolts securing the rear windage tray (1 Fig. 1) to the cylinder block and remove the tray.
1 Remove the three bolts (2 Fig. 1) securing the strainer and
remove the strainer (3 Fig. 1).
1 Clean all components and examine for damage and wear.
Apply sealant to the replacement strainer, and
fit and se- cure to the housing with the bolts. See Service Materials
in the Preliminary Pages.
1 Refittherear windagetraytothecylinder blockand secure
with the bolts.
1 Refit the oil pan, see Section 4.27.
Fig. 1
Issue 1 August 1994 49

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
Issue 1 August 1994 50

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