timing belt JAGUAR XJ 1994 2.G AJ16 Engine Manual

AJ16 Engine Service Manual
0 Application Item
'rimary timing chain Type
Pitch
Roller diameter
secondan/ timing chain Type
Number of pitches
Pitch
Number of
pitches Specification
Endless duplex
80
9,525
mm
6,35 mm
Endless duplex
86
9,525
mm
lil pump chain
lil filter
lil pressure (engine at normal
,perati ng temperature)
Si1 pump
I Roller diameter 16,35 mm
I Type I Endless simplex
Roller diameter
6,35 mm
Deflection (at mid-point of free side) 2 to 4 mm (with a load of 50 N)
Type Full flow disposable canister
At
idle speed 0,5 bar (minimum)
At
4000 RPM 4,83 bar (minimum)
Type Rotor
Rotor end float
0,l mm
Number of pitches I52
Pitch 19,525 mm
___ Overall length
Working length Mandrel length
Mandrel diameter 35 mm
30 mm
57 mm
11,ll mm
Si1 pressure relief valve
Application
Generator
/ water pump drive belt (normally aspirated
engines)
Generator
/ water pump drive belt (4.0 liter
supercharged engine)
I Rotor lobe clearance 10,2 mm I
Specification
Burroughs method: new belt
556 to 578 N. Run for one
minute, allow belt to cool and reset to the in
-service
setting. In service if tension falls below
356 N, reset at
511 to 534 N
.Clavismethod: new belt 174 to 180 Hz. Run for one
minute, allow belt to cool and reset to the in
-service
setting. In service
if tension falls below 140 Hz, reset at 167 to 173 Hz. (Measuring point: mid-way between
crankshaft and generator pulleys)
Burroughs method: new belt
560 to 600 N. Run for one
minute, allow belt to cool and reset to the in
-service
setting. In service if tension falls below
335 N, reset at
405 to 445 N
Clavis method: new belt
180 to 186 Hz. Run for one
minute, allow belt to cool and reset to
the in-service
setting. In service if tension falls below
131 Hz, reset at
155 to 161 Hz. (Measuring point: mid-way between
crankshaft and generator pulleys)
__ ___
.- ...
pket she sizes ___ Outside diameter
1
1
Drive Belt Tensions
0
Issue 1 August 1994 xvi

AJ16 Engine Service Manual
1.5 Coohg System
The engine is liquid cooled by a mixture of water and anti-freeze circulating around the coolant passages. The coolant
pump is mounted on the left hand side of the cylinder block and is driven from the crankshaft nose by a three point
belt drive (which includes the generator). The pump is a fully assembled bolt
-on unit. The coolant is fed into the cylin- der block at two places via an external delivery pipe. The coolant is drawn from the cylinder head via a self-contained
thermostat housing back to the radiator or recirculated according to the thermostat position.
7.6 Supercharger
The supercharger optionally available on the 4,O liter engine is a Roots blower type which gives better engine efficiency
at part throttle conditions and responsive off
-boost performance. The principal changes to the engine for the super- charged version are to the piston, valve timing, intake manifold and the additional drive to the supercharger. A lower
compression ratio
of 8.5:l is used which provides the optimum balance between high speed performance and fuel
economy.
The engine heat exchanger of the intercooler system is incorporated into the intake manifold. The blower incorporates
an air by
-pass system which improves efficiency under part throttle conditions. The by-pass valve is controlled by a vacuum actuator referenced to the intake manifold pressure.
2. SERVICE PROCEDURES
2.1 SPS )oint Control System
Afeature of the engine is the use of the SPS joint control system on the cylinder head bolts, crankshaft main bearing
bolts and connecting rod bearing nuts and bolts. This system ensures that the joints receive maximum clamp loading
for a given fixing size and type of material by tightening the fixing to its particular yield point. This greatly helps to
prevent premature cylinder head gasket failures.
0
CAUTION: All SPS fixings must be used only once. Discard
fixings on removal and replace with new bolts/
nuts every time a 'strip down' has been carried
out.
The SPS system in service requires the fixing to be
set to a specific torque initially; it must then be ro
- tated through 90 degrees exactly. The accuracy of
thiscannot betoo highlystressed. Toobtainthecor- rect setting, use Special Tool LST 122, or a self-man-
ufactured tool using the dimensions illustrated (Fig.
I).
SeeTorqueTightening Specifications in the Prelimi-
nary Pages for the correct torque figures.
b:
w:
2.2 Sealants
One of the specified sealants for use on this engine is the Marston compound known as Hylosil 102, a white amine cure
system rubber. Should this not be available an equivalent amine cure sealant must be used. Under no circumstances
should any acidtoxy cure system be used. Loctite sealants are specified for certain applications. See Service Materials
in the Preliminary Pages for the correct sealant for each application.
Issue 1 August 1994 2

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
0
0
0

D
Drive belt tensions, xvi
F
Fau It diagnosis
Diagnostic procedures, 3
Introduction, 3
Foreword, iii
General description
Construction, 1
Cooling system, 2
Crankcase breather, 1
Cylinder head, 1
Lubrication system, 1
Supercharger, 2
S
Service data, xiii
Service materials, xii
Service operations
Check & adjust
Crankshaft end
-float, 27
Valve clearances, 10
Cylinder head, 16
Engine assy., 33
Oil pump, 52
Auxiliary shaft, 44
Auxiliary shaf? rear seal, 45
Camshaft, 7
Camshaft cover gasket, 9
Connecting rod bearings, 22
Crankshaft, 24
Crankshaft damper /pulley assy., 26
Crankshaft front oil seal, 28
Crankshaft rear oil seal, 29
Cylinder head casting, 19
Cylinder head gasket, 13
Drive-plate, 31
Flywheel, 30
Main bearings, 23
Oil filter head gasket, 46
Oil pan gasket, 47
Oil pick-up strainer, 49
Oil pressure relief valve, 50
Oil pump, 51
Oil pump pipe ‘0’ ring, 48
Pistons &connecting rods, 20
Timing chain damper, 40
Timing chain tensioner
Overhaul
Renew
Lower,
42
Upper, 41
Timing chain, gear & tensioner, 37
Timing sprocket, Intermediate, 43
Transmission adapter plate, 32
Service procedures
Sealants, 2
SPS joint control system, 2
Service tools & equipment iv
T
Torque tightening specifications,
53