engine JAGUAR XJ 1994 2.G AJ16 Engine Manual

AJ16 Engine Range
Service Manual
Published by Produtt Dwelopmcnt & Putillcations Jaguar Cars Limited
Part ot crt - JJW 10 04 1 2 / 50

AJ16 Engine Service Manual
CON TENTS
Section SRO Page
Foreword ........................................................................\
.. iii
I ................ Service Tools & Equipment ........................................................... iv
I1 ................ Torque Tightening Specifications ....................................................... vii
111 ............... Service Materials .................................................................... xii
1V ............... Service Data ...................................................................... xiii
1 ................ General Description .................................................................. 1
1.1 .............. Construction ........................................................................\
1
1.2 .............. Cylinder Head Design ................................................................ 7
1.3 .............. Crankcase Breather ................................................................... 7
1.4 .............. Lubrication System ................................................................... 1
1.5 .............. Cooling System ...................................................................... 2
1.6
.............. Supercharger ........................................................................\
2
2 ................ Service Procedures ................................................................... 2
2.1 .............. SPSloint ControlSystem .............................................................. 2
2.2 .............. Sealants ........................................................................\
.... 2
3 ................ Fault Diagnosis ...................................................................... 3
3.1
.............. Introduction ........................................................................\
. 3
3.2
.............. Diagnostic Procedures ................................................................ 3
4
................ Service Operations ................................................................... 7
4.1 .............. Camshaft, Renew .............................................. 12.13.01 ............. 7
4.2 .............. Camshaft Cover Gasket. Renew .................................. 12.29.39 ............. 9
4.3
.............. Valve Clearance, Checkand Adjust ............................... 12.29.48 ............ 10
4.4 .............. Cylinder Head Gasket, Renew ................................... 12.29.01 ............ 13
4.5
.............. Cylinder Head, Overhaul ........................................ 12.29.19 ............ 16
4.6
.............. Cylinder Head Casting, Renew ................................... 12.29.15 ............ 19
4.7
.............. Piston and Connecting Rod, Engine Set, Renew ..................... 12.17.10 ............ 20
4.8
.............. Connecting Rod Bearing, Engine Set, Renew ....................... 12.17.16 ............ 22
4.9
.............. Main Bearing, Engineset, Renew ................................. 12.21.39 ............ 23
4.10 ............. Crankshaft, Renew ............................................. 12.21.33 ............ 24
4.11
............. Crankshaft Damper/Pulley Assembly, Renew ...................... 12.21.09 ............ 26
4.12
............. Crankshaft End-float, Check andAdjust ........................... 12.21.26 ............ 27
4.13
............. Crankshaft Front Oil Seal, Renew ................................. 12.21.14 ............ 28
4.14
............. Crankshaft Rear Oil Seal, Renew ................................. 72.21.20 ............ 29
4.15
............. Engine Flywheel, Renew ........................................ 12.53.07 ............ 30
4.16
............. Engine Drive-plate, Renew ..................................... 12.53.13 ............ 31
4.17 ............. Engine Rear/ Transmission Adapter Plate, Renew ................... 12.53.03 ............ 32
4.18
............. Engine Assembly, Overhaul ...................................... 12.4 7 . 05 ............ 33
4.19
............. liming Chain, Gear and Tensioner, Engine Set, Renew ............... 12.65.13 ............ 37
4.20
............. Timing Chain Damper, Vehicle Set, Renew ......................... 12.65.48 ............ 40
4.21
............. liming Chain Tensioner, Upper, Renew ............................ 12.65.29 ............ 41
4.22
............. Timing Chain Tensioner, Lower, Renew ............................ 12.65.30 ............ 42
4.23
............. Timing Sprocket, Intermediate, Renew ............................ 12.65.26 ............ 43
4.24
............. Auxiliary Shaft, Renew ......................................... 12.10.30 ............ 44
4.25
............. Auxiliary Shaft Rear Seal. Renew ................................. 12.10.32 ............ 45
0
i Issue 1 August 1994

AJ16 Engine Service Manual
Section Title SRO Page
4.26 ............. Oil Filter Head Gasket. Renew ................................... 12.60.03 ............ 46
4.27
............. Oil Pan Gasket. Renew ......................................... 12.60.38 ............ 47
4.28
............. Oil Pump '0' Rings. Renew ...................................... 12.60.27 ............ 48
4.29
............. Oil Pick-up Strainer, Renew ..................................... 12.60.20 ............ 49
4.30
............. Oil Pressure Relief Valve Assembly, Renew ......................... 12.60.56 ............ 50
4.3
1 ............. Oil Pump. Renew .............................................. 12.60.26 ............ 51
4.32
............. Oil Pump, Overhaul ............................................ 12.60.32 ............ 52 ~
Issue 1 August 1994 ii

AJ16 Engine Service Manual
FOREWORD
This Service Manual has been designed to enable the skilled Jaguartechnician to correctly service and repair the range of Jaguar AJ16 in-line six-cylinder engines.
It assumes that the engine has been removed from the vehicle, in accordance with the Vehicle Service Manual, and
is
in a clean condition and all service tools and materials are available.
An index can be found at the rear of this manual.
Issue 1 August 1994 iii

AJ16 Engine Service Manual
1. SERVICE TOOLS & EQUIPMENT
Illustration
not illustrated Jaguar
Number
18G 55A
18G 1433
18G 1434
18G 1435
18G
1436lA
18G 1431
18G 1437
-1
18G 1465
18G 1469
Description
Piston ring compressor
Camshaft timing tool
Jackshaft bushing remover
/ replacer
Camshaft dummy caps
Crank pulley remover and timing
damper
oil pressure simulator
Front pulley lock
Adapter Engine lifting bracket
Auxiliary drive shaft seal replacer ~~
Issue 1 August 1994 iv

AJ16 Engine Service Manual
Jaguar Number ~~
JD
118
JD 128
JD
129
JD 130
JD 550
-3
JD 61 18C
MS 53C
MS 1519A
__ ~ Description
Auxiliary drive
shaft seal remover
Crank front seal remover
Crank front seal replacer
Chain link remover
/ replacer
Crank rear seal replacer adapter
Valve spring compressor
Engine support beam
Valve spring compressor
Notes
Issue 1 August 1994 V

AJ16 Engine Service Manual
Illustration
not illustrated
Jaguar Number
MS 1520
MS 1520-2
Description
Engine stand
Adapter assembly
for MS 1520
'Snap-On' Oil filter canister removal
tool
Notes
YA 992
issue 1 August 1994 vi

AJ16 Engine Service Manual
Fixing
II.
Tightening Torque
(Nm)
TORQUE TlGH TENlNG SPECIFICATIONS
Air Cleaner
Air box bracket screw 8,5 - 11.5
9.5
- 12,5
9,5 - 12,5
6,3 - 8,7
8.5
- 11,5
7 -9
Air box to bracket
Air box to instrumount
Air cleaner bracket setscrew
Air cleaner support bracket
(4,O liter supercharged)
Air temperature sensor to air box
1 Hose clamp, air box to air meter ~
Hose
clamp, air box to body
1,2 - 1,6
1.2
- 1,6 , , lnstrumount bracket Taptite screw I 9,5 - 12,5
trumpet to body ~ 9,5 - 12,5
Compressor
to bracket
_________ Connecting rod bearing nut 52 - 55 (SPS System) _______ ~
Bypass
elbow to thermostat housing
Fan drive unit setscrew
Fan drive unit to pulley
Hose clamp, breather to thermostat
Hose clamp, breather to throttle body
Hose clamp, bypass hose
Hose clamp, water pump to pipe
Thermostat cover to housing
Thermostat housing to cylinder head
Water pipe bracket to intake manifold
Water pump assembly
Water pump to timing cover
Water pump to water
rail
Water rail to cylinder block
Water temperature sensor to thermostat housing
Water temperature transmitter to thermostat housing
9,5 - 12,5
12- 16
21,5 - 28,5
1,5-2,5
1,5 - 2,5
2,5
- 3.5
2,5
- 3,5
21,5 - 28,5
21,5 - 28,5
21.5- 28,5
21,5 - 28,5
21.5 - 28,5
2,5 - 3,5
21,5 - 28,5 1
14,5- 19,5
14,5- 19,5
1 Crankshaft
Clutch to flywheel (4,O liter)
Crankshaft bolt
Drive
-plate to crankshaft (3,2 liter) ~___~.~ Drive-plate to crankshaft (4,O liter supercharged automatic)
Flywheel to
crankshaft setscrew (4,O liter) _______
Timing ring to damper
22,5 - 27,5
183 - 223
88 - 108
123
- 149
123
- 149
15.5
- 20.5
-~
___________
vi i Issue 1 August 1994

AJ16 Engine Service Manual
Cylinder Block
Adapter to cylinder block
Bearing cap to cylinder block
Blanking plate to cylinder block
Manual transmission to engine
(4,O liter supercharged automatic)
Oil drilling blanking plug
Oil gallery blanking setscrew
Oil pressure sensor
Oil pressure sensor plug
Oil seal adapter to cylinder block
Transmission adapter to cylinder block
Water drain plug
Windage tray to cylinder block
Cylinder Head and Camshaft Cover
Bearing cap to cylinder head
Camshaft coupling bolt
(Nm)
43 - 57
136
- 142 (SPS
System)
21,5 - 28,5
43 - 57
29
- 39
21,5 - 28,5
23 - 27
8,5- 11,5
21,5 - 28,5
44.5 - 59,5
64.5 - 79.5
21.5
- 28,5
17 - 23
22
- 28
Camshaft cover to cylinder head
- - . ~. Cylinder head to cylinder block
Cylinder head to timing cover -
______ ____ Exhaust manifold to cylinder head
On
-plug coil cover to camshaft cover
Rear cover to cylinder head
4-5
59 - 61 (SPS System) ~~ -. . - 21,5 - 28,5
22 - 28
_. . -.. ___ Dipstick
Tube
Dipstick tube assembly nut
Dipstick tube attachment to tube support bracket
(4,O liter supercharged)
__ Dipstick tube bracket (4,O liter supercharged)
Dipstick tube to bracket
Drive Chain System
Dipstick tube bracket screw
Auxiliary shaft assembly setscrew
Coupling to intermediate shaft
Damper to cylinder block (bolt)
Damper to cylinder block (screw)
Damper to distance piece
Damper to saddle
Distance piece to cylinder block
Endplate to damper
Housing to cylinder block (bolt)
Housing to cylinder block
(capscrew)
Pivot bracket to cylinder block
Pivot plate to cylinder block
Sprocket to hub setscrew
Engine Mounting
Engine mounting bracket to engine
Issue 1 August 1994 viii
81 -99
15.5 - 20,5
5-7
9,5
- 12,5
5%: 7.8
30,5 - 37,5
12-16
21,5 - 28,5
21.5 - 28,5
21,5 - 28,5
21,5 - 28,5
21,5 - 28,5
21.5 - 28,5
21,5 - 28,5
21,5 - 28,5
21,5 - 28,5
2 1,5 - 28,5
9,5 - 12,5
445 - 59,5

AJ16 Engine Service Manual
Exhaust Manifold
Exhaust manifold to cylinder head
Heatshield to exhaust manifold
Lifting eye setscrew (slave item only)
.~ Fuel System
Fuel pressure regulator to bracket
Fuel rail connecting nut
. i------
44,5 - 59.5
21.5
- 28,5
21.5 - 28,5
~- 30.5 - 41,5
12,5 - 15,5
Fixing
- Adjuster bracket to oil pan
Adjuster sleeve
to generator
Generator mounting bracket pivot bolt
Sleeve to adjuster bolt
21,5 - 28,5
17 - 23
34
- 46
11 - 15
__~___.___ 21.5 - 28,5 __ ~~ ~ Generator
Mounting
bdjuskr bolt to timing cover
Intake Manifold
Blanking plate to intake manifold (in place of adapter) 9,5 - 12,5
8,5- 11,5
9,5 - 12,5
36 - 44
14.5
- 19.5
LBreather adapter to intake manifold (4,O liter normally aspirated)
l EGR adapter to intake manifold
EGR pipe to adapter
EGR sensor to intake manifold 1
1 Intake manifold steady screw (4,O liter supercharged)
Intake manifold
to cylinder head
Pedestal to throttle body
22 - 28
21,5 - 28,5
9,5 - 12,5
Pressure regulator to intake manifold
Pressure regulator to intake manifold
(4.0 liter supercharged)
9,5 - 12,5
5-7
Throttle linkage baseplate to pedestal
assembly nut
Purge adapter
to intake manifold
Throttle body to intake manifold
9,5 - 12,5
21,5 - 28,5
9,5 - 12.5
1.8 - 2,2
'Throttle cable abutment to intake manifold
Throttle linkage actuator nut
9,5 - 12,5
Throttle stop screw locknut
Miscellaneous Hoses
Hose clamp, breather hose to restrictor
Hose clamp, heater return hose to throttle body
4,3 - 5,7
1.5
- 2,5
1,5
- 2.5
Hose clamp, hose to cam cover 2,5 - 3.5
' Hose clamp, restrictor to throttle body
I Oil cooler clamp screw 5-7
1.5
- 2,5
Oil
cooler pipe bracket screw 1.5 - 2.5
l Hose clamp, thermostat housing to restrictor ~
Hose
clamp, water pump
Oil Cooler (4.0 Liter Supercharged)
Hose clamp, oil cooler hose to radiator cradle
..
Oil cooler pipes to engine 14-18
1,5
- 2,5
2,5
- 3.5
7
-10
Oil cooler to body
Tube nut, all except those shown below 17 - 23
17
- 23
16 - 20 ,Tube nut, transmission pipes to transmission
Issue 1 August 1994 ix