ECU JAGUAR XJ 1994 2.G AJ16 Engine Manual

AJ16 Engine Service Manual
SERVICE OPERATIONS
4.1 Camshaft, Renew
SRO 12.13.01
Remove camshaft cover, see Section 4.2.
Drain the cooling system, see Section 4.1 in the appropri
- ate Vehicle Service Manual.
1 Rotate the engine and set No. 1 cylinder at TDC using Ser- viceTool 18G 1433 (1 Fig. 1).
Push back the lock tabs (1 Fig.2) from the camshaft
sprocket securing bolts (2 Fig. 2). and slacken off the bolts.
Remove the upper chain tensioner valve clamp bolt
(3 Fig.
2), remove the clamp (4 Fig. 2) and remove the
valve (5 Fig. 2).
1 Using a 3 mm Allen key, wind backthe tensioner (6 Fig. 2) (turn clockwise) until the snail engages in the park posi- tion. Remove the tensioner housing securing bolt (7 Fig. 2) and withdraw the tensioner assembly (8, 9 Fig. 2).
1 Remove and discard the '0' ring (9 Fig. 2) and gasket (10 Fig. 2).
. Remove the camshaft sprocket securing bolts and tab
washers (1,2 Fig. 2) and remove the sprockets (11 Fig. 2) (ensure that neither the bolts nor the tab washer drop into
the timing case).
CAUTION: Do not rotate the engine while the camshaft is
disconnected.
. Remove the cylinder head bolt from No. 2 cap, left-hand
1 Remove No. 2 cap from the left-hand camshaft.
1 Fit spacer tool 18G 1435 (2 Fig. 3) to the head.
Fit and torque tighten the cylinder head bolt.
Repeat the procedure for Nos 3,4,5 and 6 caps, left-hand
camshaft (3 Fig. 3).
Remove the cylinder head bolt from
No. 7 cap, left-hand
camshaft.
Loosen in sequence the securing bolts from Nos 1 and 7 caps, until theleft-handcamshaft isfree. Liftthecamshaft
from the cylinder head and fit spacer tool 18G 1435 to No. 7 cylinder head bolt position (5 Fig. 3). Fit and torque
tighten the bolt.
Clean
all components and examine for wear and damage.
Renew all worn or damaged components.
Lubricate the new left
-hand camshaft.
Fit the camshaft at approximately TDC.
Lubricate Nos 1 and 7 caps.
Fit No. 1 cap but do not tighten the securing bolts. Remove No. 7 cap cylinder head bolt.
1 Remove the spacer tool. Fit No. 7 cap but do not tighten
the securing bolts.
1 Finally tighten Nos 1 and 7 cap securing bolts in sequence.
Remove No. 4 cap cylinder head bolt and remove the
spacer tool. Lubricate and fit No. 4 cap.
CAUTION: The cylinder head bolts MUST be renewed dur- ing assembly and torque tightened as de- scribed in Section 2.1, SPS Joint Control System.
camshaft
(1 Fig. 3).
1 Repeat
the procedure for the right-hand camshaft.
1
Fia. 1
Fia. 2
Fig. 3
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AJ16 Engine Service Manual
. Fit and tighten No. 4 cap securing bolts.
. Fit and tighten No. 4 cap cylinder head bolt.
CAUTION: The cylinder head bolts MUST be renewed dur- ing assembly and torque tightened as de- scribed in Section 2.1, SPS Joint Control
System.
. Repeat the procedure for Nos 2,3,5 and 6 caps, left-hand
Set the left-hand camshaft to TDC.
. Repeat the procedure for the right-hand camshaft.
. Check and adjust valve clearances see Section 4.3.
Refit the camshaft cover, see Section 4.2.
camshaft. ~~
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AJ16 Engine Service Manual
4.2 Camshaft Cover Gasket, Renew
SRO 12.29.39
1 Remove the top cover and disconnect the on-plug coils
from the spark plugs.
. Disconnect the camshaft cover breather hose.
1 Remove the camshaft cover to cylinder head securing
Screws (1 Fig. 11, and remove the camshaft cover (2 Fig. 1).
. Remove and discard the camshaft cover gasket (3 Fig. 1).
. Clean the camshaft cover and cylinder head mating faces.
1 Fit a new gasket to the camshaft cover.
. Refit the camshaft cover.
1 Fit and tighten the camshaft cover securing screws.
. Reconnect the breather hose.
1 Reconnect the on-plug coils to the spark plugs and fit the
top cover.
I Fia. I
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AJ16 Engine Service Manual
4.3
SRO 12.29.48
1 Remove camshaft cover, see Section 4.2.
1 Rotate the engine as necessary to measurethevalve clear- ances between the heel of the cam and the cam follower
(Fig.
1). See Service Data in the Preliminary Pages for the
correct valve clearances.
1 Make a note of each clearance measurement.
1 Should the clearances be incorrect, proceed as follows:
1 Rotate the engine and set No. 1 cylinder at TDC using Ser- viceTool 18G 1433 (1 Fig. 2).
Push back the lock tabs (1 Fig. 3) from the camshaft
sprocket securing bolts (2 Fig. 3).
1 Slacken off the bolts and tab washers.
1 Remove the upper chain tensioner valve clamp bolt
(3 Fig. 3), remove the clamp (4 Fig. 3) and remove the
valve (5 Fig. 3).
1 Using a 3 mm Allen key, wind back the tensioner (turn
clockwise) until the snail engages in the park position.
1 Remove the tensioner housing securing bolt (7 Fig. 3) and
remove the tensioner assembly (8,9 Fig. 3).
1 Remove and discard the '0' ring (9 Fig. 3) and gasket (10 Fig. 3).
1 Remove the camshaft sprocket securing bolts/tab washers (1,2 Fig. 3) and remove the sprockets (1 1 Fig. 3).
1 Remove the cylinder head bolt from No. 2 cap, left-hand
camshaft (1 Fig. 4).
1 Remove the cap securing bolts from No. 2 cap, left-hand
cams haft.
. Remove No. 2 cap from the left-hand camshaft.
1 Fit spacer tool 18G 1435 (2 Fig. 4) to the head.
1 Fit and torque tighten the cylinder head bolt.
1 Repeat the procedure for Nos 3,4,5 and 6 caps, left-hand
camshaft
(3 Fig. 4).
1 Remove the cylinder head bolt from No. 7 cap, left-hand
camshaft.
1 Loosen in sequence the securing bolts from Nos 1 and 7 caps, until the left-hand camshaft is free. Lift the camshaft
from the cylinder head and fit spacer tool 18G 1435 to No. 7 cylinder head bolt position (5 Fig. 4). Fit and torque
tighten the bolt.
Valve Clearance, Check and Aa'just
1 Repeat the procedure for the right-hand camshaft.
CAUTION: The cylinder head bolts
MUST be renewed dur- ing assembly and torque tightened as de- scribed in Section 2.1, SPS Joint Control
System.
111 ...
Fig. 1
1
Fig. 2
Fig. 3
Fig. 4
Issue 1 August 1994 10 ~~

1.
Remove all the valve shims or only those requiring adjust- ment, check the size of the existing shims with a micrometer
and note the reading. Calculate the size of the
shim required
following the examples shown below:
VALVE CLEARANCES
For valve clearances see Service Data in the Preliminarv
I Pages
Excessive Clearance inches
Size of existing shim
Plus the actual clearance noted
Less the specified valve clearance
I
00.100
0.019
0.119
0.013
Required shim size = 0.106
Insufficient Clearance inches
Size of existing shim
0.107
Plus the actual clearance noted o.010
0.117
Less the specified valve clearance 0.013
Required shim size = 0.104
I
Fit the relevant shims to the cylinder head.
Note:
. Fit the left-hand camshaft at approximately TDC.
. Lubricate Nos 1 and 7 caps.
1 Fit No 1 cap. Fit but do not tighten the cap securing bolts.
. Remove No 7 cap cylinder head bolt.
. Remove the spacer tool.
1 Fit No. 7 cap. Fit but do not tighten the cap securing bolts.
. Finally tighten Nos 1 and 7 cap securing bolts in sequence.
. Remove No. 4 cap cylinder head bolt and remove the
. Lubricate and fit No. 4 cap.
. Fit and tighten No. 4 cap securing bolts.
. Fit and tighten No. 4 cap cylinder head bolt.
9 Repeat the procedure for Nos 2,3,5 and 6 caps, left-hand
CAUTION: The cylinder head bolts MUST be renewed dur- ing assembly and torque tightened as de- scribed in Section 2.1, SPS Joint Control
System.
See
Service Data in the Preliminary Pages for
avail- able valve shim sizes.
I
3
spacer tool.
camshaft.
1 Set the left-hand camshaft to TDC.
. Repeat the procedure for the right-hand camshaft.
Fit and align the camshaft sprockets to the chain and the
camshafts
AJ16 Engine Service Manual
11 issue 1 August 1994

AJ16 Engine Service Manual
1 Move all the slack in the chain to the tensioner side.
1 Fit upper chain tensioner tool 18G 14361A (2 Fig. 1). Fit and
tighten the tool securing bolts (1 Fig. 1).
1 Tension the cam chain.
1 Remove the camshaft coupling (12 Fig.2) from the
sprocket (11 Fig. 2) and align the securing bolt holes. Fit
the bolts (2 Fig. 2) and tab washers (1 Fig. 2), tighten the
securing bolts and lock over the tabs.
1 Repeat the procedure for the other sprocket.
1 Slacken off the chain tensioner tool securing bolts
1 Remove the tensioner tool.
1 Clean the tensioner assembly and gasket faces.
= Fit a new housing gasket (10 Fig. 2). Fit and lubricate a
new ‘0’ ring (9 Fig. 2).
1 Fitthetensionerassembly (8,9 Fig. 2)tothecylinderhead.
Fit andtighten thetensioner assembly securing bolt (3 Fig.
2).
(1 Fig. 1).
1 Fit but do not tighten the valve clamp bolt.
1 Clean the valve assembly and fit new ‘0‘ rings (13 Fig. 2).
Lubricate the tensionervalve (5 Fig. 2). Using an Allen key,
release the tensioner, by turning the
Allen key anti-clock- wise.
1 Fit the tensioner valve (5 Fig. 2). Position the clamp (4 Fig. 2) over the valve.
1 Tighten the clamp bolt (3 Fig. 2).
1 Refit the camshaft cover, see Section 4.2. Fig.
1
I Fia. 2
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AJ16 Engine Service Manual
4.4 Cylinder Head Gasket, Renew
SRO 12.29.01
Drain the cooling system, see Section 4.1 and depressurize
the fuel system,see Section 5.1 (thesesections are in the ap- propriate Vehicle Service Manual). Disconnect the exhaust
system with the vehicle supported on axle stands. Remove
components as required for access to the cylinder head and
proceed as follows.
1 Rotate the engine to TDC No. 1 cylinder.
1 Remove the camshaft cover, see Section 4.2.
1 Push backthe lock tabs and remove the camshaft sprocket
securing bolts (2 Fig. 1). Remove the tab washers (1 Fig. 1).
1 Remove the upper chain tensioner valve clamp bolt (1 Fig. 2), remove the clamp (2 Fig. 2) and remove the
valve (3 Fig. 2).
1 Using a 3 mm Allen key, wind back the tensioner (turn
clockwise) until the snail engages in the park position.
1 Remove the tensioner housing securing bolt (4 Fig. 2) and
withdraw the tensioner assembly.
1 Re-position thetiming chain between the upper dampers.
1 Remove the cylinder head front securing bolts.
1 Remove the remaining cylinder head securing bolts/ nuts.
Remove the upper static damper pedestal assembly and
remove the cylinder head.
0 1 Fit an elastic band to retain the dampers and chain.
. Remove and discard the head gasket.
1 Remove and discard the exhaust manifold sealing rings.
1 Place the cylinder head on suitable blocks on a bench.
Clean the cylinder head thoroughly and check the cylinder
head and cylinder block for warping, bowing or cracks.
Renew if defective.
1 Fit a new cylinder head gasket.
1 Fit the cylinder head assembly to the engine, ensure no
hoses or cables are trapped.
A2616
Fig. 1
Fin. 2
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AJ16 Engine Service Manual
= Refit the upper static damper assembly.
lighten the cylinder head bolts with reference to the se- quence shown in Fig. 1.
CAUTION: The cylinder head bolts MUST be renewed dur- ing assembly and torque tightened as de-
scribed in Section 2.1, SPS Joint Control
System.
Ensure that the camshaft is still on TDC using Ser
-
vice Tool 18G 1433 (1 Fig. 2).
Fit the harness clip and hose bracket to the cylinder head
front securing bolts.
Fit and tighten the front securing bolts.
1433 (1 Fig. 2).
b:
= Check the camshafts are set atTDC using Service Tool 18G
= Raise the timing chain from between the upper dampers.
Remove the elastic band.
= Fit and engage the sprockets to the chain and camshafts.
. Move all the chain free play to the tensioner side.
Fit upper chain tensioner tool 18G 1436/A (2 Fig. 3).
Fit and tighten the tool securing bolts (1 Fig. 3).
Tension the timing chain.
sprocket
(1 1 Fig. 4) and align the securing bolt holes.
bolts
(2 Fig. 4). Lock over the tabs.
Release the tension on the timing chain.
Re
-position the
chain over the camshafts.
. Remove the camshaft coupling (12 Fig. 4) from the
. Fit the tab washers (1 Fig. 4). Fit and tighten the securing
. Slacken off the upper chain tensioner tool securing bolts.
Remove the upper chain tensioner tool 18G 14361A (2 Fig.
Clean the tensioner assembly and gasket faces.
3).
Fit a new housing gasket (10 Fig. 4). Lubricate andfita new '0' ring (9 Fig. 4).
. Fit the tensioner to the cylinder head.
. Fit and tighten the tensioner assembly securing bolt
Clean the valve assembly and fit new '0' rings.
Using an Allen key, release the tensioner, ie turn the Allen
(4 Fig. 3).
Lubricate the tensioner valve.
key
anti-clockwise.
I
104 2 5 7 I l2
I Fig. 1
1
Fig. 2
Fig. 3
Fig. 4
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AJ16 Engine Service Manual
4.5 Cylinder Head, Overhaul
SRO 12.29.19
1 Remove the cylinder head, see Section 4.4.
1 Place the cylinder head on suitable blocks on a bench.
1 Remove the spark plugs and the intake and exhaust mani-
folds.
1 Mark the position of the camshaft caps relative to the
head, remove the cap securing bolts and remove the caps
(1 Fig. 1).
1 Remove the camshafts.
. Using a magnet, lift out the cam followers (1 Fig. 2).
1 Remove the valve springs, using Service Tool MS 1519A,
1 Retrieve the collars, collets and spring retaining plates.
1 Remove the valves, noting the relationship between valve
and guide to ensure correct pairing during re-assembly.
* Remove the seals from the intake valve guides and re- move the cylinder head rear blanking plate.
1 Clean all component parts.
1 Check for wear and burning of valves or seats.
1 Check the cylinder head face for distortion.
1 If distortion is evident, a maximum of 0,25 mm may be re- moved by skimming the cylinder head.
1 Taking care not to damage the inside surface of the com-
bustion chambers, clean the intake and exhaust ports.
CAUTION: When using scrapers or wire brushes for re- moving carbon deposits, avoid scratching the
valve faces and seats. A soft wire brush is the most suitable implement for this purpose.
1 Clean all carbon and other deposits from the valve guide
using a suitable valve guide brush. Thoroughly wash the
cylinder head to ensure that all loose carbon is removed
and dry the cylinder head with a high pressure air line.
. After cleaning and polishing each valve, examine the
stems for straightness and wear, using a suitable dial
gauge and vee
-block see example at Fig. 3.
1 Examine the valve faces for burns, pitting and distortion.
Renew any valves that are excessively worn, bent, or too
badly pitted to be salvaged by refacing.
Support the
valves using a wooden block.
valve spring compressor.
/ 112 310
Fig. 1
Fia. 2
I
JlZ 268
Fia. 3 I " 1
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AJ16 Engine Service Manual
Note: No attempt should be made to clean up a burnt or
badly pitted valve face by extensive 'grinding in' of
the valve to the seat.
m Lightly lap the valves into the seats with a fine grinding
compound. The reseating operation should leave the fin- ished surfaces smooth. Excessive lapping will groove the
valve face resulting in a poor seat when the engine is hot.
A
- Correctly seated B - Undesirable condition C - Rectified condition
. Totestthe valvesforconcentricity withtheirseats,coatthe face of the valve with Prussian blue or similar, and rotate
the valve against the seat. If the valve face is concentric
with the valve stem, a mark will be made all around the
face. Should
a mark be made on only one side of the face,
the face is not concentric with the valve stem. Clean the
valve and again coat with Prussian blue and rotate the
valve against the seat.
. Check that the valve guide is concentric with the valve
seat,
if not, the seat must be re-cut. Whenever valves are
renewed the seats must be re-cut prior to lapping of the
valves. Check valve guide wear by inserting a new valve
into the guide to be checked,
lift it 6 mm from its seat and
rock it sideways.
. Movement of the valve across its seat (A Fig. 2) must not
exceed 0,04 to 0,07 mm. Should the movement exceed
this tolerance, the valve guide must be renewed. Ensure
that the relevant valve guide is selected prior to fitting.
. When new guides are to be fitted they should always be
one size larger than the old guide.
. Cylinder head bores will require reaming as follows: Re- move the old valve guide and ream the cylinder head to
the relevant dimension. Immerse the cylinder head in
boiling waterfor30 minutes. Coat the guide with graphite
grease, and drive in the guide from thecamshaft side until
the snap
-ring is seated in the groove.
b: The interference should not be sufficient to require
the use of excessive force when fitting the guide.
1 After fitting a valve guide, the valve seat must be recut using Service Tool MS 204 (Fig. 3). Examine the valveseat
inserts for pitting or excess wear. If renewal is necessary,
proceed as follows.
1 Remove the inserts by machining, leaving approximately 0,25 mm of metal which can easily be removed by hand
without damaging the cylinder head. Measure the diam- eter of the insert recess in the cylinder head. Grind down
the outside diameter of the new insert to a dimension 0,08
mm larger than the insert recess.
Heat the cylinder head for 30 minutes from cold to a tem- perature of 15OOC 1, Fit the insert ensuring that it beds
evenly in the recess. When the cylinder head has cooled,
re
-cut the valve seat using Service Tool MS 204. For cor- rect valve seat angles see Service Data in the Preliminary
Pages.
If new valve inserts have been fitted, the clearance
between valve stem and cam must be checked, see
Service Data in the Preliminary Pages.
. Fig. 1 shows:
U:
I
A
JIZ 2M
Fia. 2
Fig. 3
Issue 1 August 1994 17