JAGUAR XJ6 1994 2.G Service Manual

Idler bracket / timing cover to cylinder black
Idler bracket to water pump
Idler mounting bracket to thermostat housing
lntercooler water pipes
Outlet elbow to supercharger
Pulley to carrier 22 - 28
22
- 28
22
- 28
22
- 28
22
- 28
22
- 28
43
- 57
22
- 28
43
- 57
22
- 28
22
- 28
8,5
- 11,5
Supercharger mounting bracket to engine
Supercharger to mounting bracket
Supercharger
mounting stud
Tensioner bracket
/ timing cover to cylinder block
Tensioner bracket to adapter
Throttle bodv adapter to
bypass actuator
Engine (AJ16)
Fixing lightening Torque
Supercharger (continued)
Air duct upper casting to lower
Bypass valve disc to spindle
Bypass
mlve to throttle body
Elbow to intercooler
2,5 - 3,5
2.5
- 3,5
8,5
- 11,5
22 - 28 ~~ ~
111.
SERVICE MATERIALS
Description USOS Notea 1 I I Hylosil 102 sealant 1 Half moon seals to cylinder head I I Oil pick-up strainer to transfer housing I 1 Oil pump transfer housing to cylinder block 1
[ Rear seal housing to cylinder block , [Thermostat housing to extension , I Thermostat outer housing to inner housing 1 , [Timing cover blanking plate to timing cover 1 I I Timing cover to cylinder block
I Locktite 501 locking compound I Oil pump drive plate bolt
,
,
I Oil pump front cover to body 1
I Oil pump rear cover to body
I Exhaust system joints
Tivoli Kay Adhesives No. 5696
sealant
X300 VSM Issue 1 August 1994 iv

3.1.1 ENGINE, GENERAL
The 3.2 /4,0 liter normallv aspirated
and the 4.0
Engine (AJ16)
liter supercharged engined vehicles are equipped with the AJ 16family of six cylinder in-line engines. The engines have a fully mapped engine management system with digital ignition and
individual on-plug ignition coils.
This section describes the service procedures to be carried out with the engine in situ.
It also covers the renewal of the engine / transmission unit.
For information relating to strip
-down, inspection, fault diagnosis, renovation and rebuild work, refer to the AJ16
Engine Service Manual.
X300 VSM 1 Issue 1 August 1994

Engine (AJ16)
3.1.2 ENGlNE/ TRANSMlSSlON UN/& RENEW
SRO 12.41.02/20
The engine/transmission unit on the AJ 16 normally aspirated and supercharged engined vehicles are fitted ontothree
engine mounting/bracket assemblies. The two front engine mountings for the 3.2/4.0 liter normally aspirated and the
4.0 liter supercharged engined vehicles are identical. They are fitted to the front crossmember on either side of the
engine bay. Rubber to metal
engine/transmission rear mounts used for both engine types, are secured to a support
bracket which traverses the two body underframe longitudinal members. For access to remove the engine carry out the following procedures:
WARNING: WHEN WORKING WlTHlN THE ENGINE COMPARTMENT, KEEP CLEAR OF THE RADIATOR COOLING
FANS AS THEY COULD START WITHOUT WARNING EVEN IF THE ENGINE IS NOT RUNNING.
. Remove the hood, see SRO 76.16.01, section 13
. Remove the air cleaner assembly.
. Depressurize the fuel system, see SRO 19.50.02, section 5.1.
Disconnect the battery.
. In line with the relevant SRO's and sections, remove all appropriate obstructing parts, including their fixing and
. Disconnect all mechanical and isolate all electrical linkages leading to and from the engine.
. De-gas the airconditioning system, see section 14, Charge Recovery (System depressurization).
mounting
arrangements.
CAUTION : Do not vent refrigerant directly to the atmosphere and always use Jaguar approved recovery/recycle/re- charge equipment.
. Drain the engine oil, see 3.1.3 this section.
. Drain the coolant, see SRO 26.10.01, section 4.1.
WARNING: DO NOT REMOVE THE HEADER TANK PRESSURE CAP WHILE THE ENGINE IS HOT. IF THE CAP MUST
BE REMOVED, PROTECT THE HANDS AGAINST ESCAPING STEAM AND SLOWLY TURN THE CAP ANTI- CLOCKWISE UNTILTHE EXCESS PRESSURE CAN ESCAPE. LEAVETHE CAP IN THIS POSITION UNTIL ALL
STEAM AND PRESSURE HAS ESCAPED AND THEN REMOVE THE CAP COMPLETELY.
Before lifting the complete engine/transmission unit with an engine hoist from the engine bay, ensure that two engine
lifting brackets (tool 18G. 1465) are secured equally spaced to the inlet manifold studs. The engine lifting brackets
should be positioned towards the front and the rear of the assembly. Ensure the front of the vehicle is jacked
up secure- ly on stands when removing the assembly.
e
0
0
X300 VSM Issue 1 August 1994 2

Engine
3.1.3 ENGINE OIL, RENEW
SRO 12.60.00
. Undo and remove the sump plug positioned at the rear of
the sump, drain the engine oil into a suitable receptacle
and dispose of
it in a safe and environmentally friendly
manner.
Replenish the engine oil, to the correct level on the dip-
stick (see Fig. 1).
When the oil is renewed, start the engine, wait for the oil
light to extinguish and switch off the engine for 30 sec- onds.
. Finally remove and wipe clean the dip stick,
check the oil level - replenish if necessary.
. For recommended engine oil refer to Appendix AI.
3.1.4 OIL FILTER CARTRIDGE, RENEW
SRO 12.60.04
The white oil filter cartridge displaying the Jaguar logo, is lo- cated on the left-hand side of the engine below the throttle
assembly (Fig. 2).
When refitting, tighten the oil filter cartridge using hand
pressure only.
On no account use an oil filter strap designed
forthe removal
of cartridges.
m: The normal tightening torque of the oil filter is a 3/8 to 1/2 turn after initial contact.
1 JLX-076
Fig. 1
-~ ~ ~~~~~ Issue 1 August 1994 X300 VSM 3

Engine (AJ16)
3.1.5 FRONT ENGINEMOUNTING BRACKETASSEMBLY, RENEW
SRO 12.45.01 LH
SRO 12.45.03 RH
Each of the two engine mounting bracket assemblies com- prises a mounting rubber (1 Fig. 1) with an insulator (2 Fig.
1) clamped between two brackets ( 3&4 Fig. I).
The front of the engine complete with attached mounting
bracket assemblies is seated on support brackets welded to
the front crossmember and is secured to the brackets by
a single fixing arrangement comprising nuts, bolts and
washers.
. Jack up the vehicle and secure the engine hoist (Service
Tool MS53 C) to lifting eyes of the front engine lifting
brackets.
. Remove the front engine mounting bracket assembly to
front crossmember fixing screws. These can be accessed
via
two round openings positioned underneath the cross- member.
= Remove any obstructing parts preventing the front end of
the engine from being lifted from its seating.
Lift the front end of the engine / transmission unit slightly
and detach the front mounting bracket assemblies from
the lower engine housing.
3.1.6
SRO 12.45.04 REAR
ENGINE MOUNTING ASSEMBLY RENEW
The rear engine mounting assembly comprises a rubber to
metal engine/transmission rear mount (1 Fig. 2) secured to a support bracket (2 Fig. 2) by a single fixing arrangement.
. With the aid of the engine hoist (Service Tool MS53 C) se- cured to the lifting eyes of the rear engine lifting brackets,
and a jack positioned under the rear mounting bracket,
take the weight of the engine.
. Undo and remove the fixing arrangement securing the
rear engine mounting bracket assembly.
. Lower the jack and remove assembly.
. Dismantle the assembly, clean all components and exam- ine for any signs of wear or damage.
Renew components as necessary.
J12-8LL
Fig. 1
J 12- 8 LS
Fig. 2
8
Issue 1 August 1994 4 X300 VSM

SECTION CONTENTS
-
Engine (V12)
m
X300 VSM i Issue 1 August 1994
Sub-section Title SRO Page
Ito111 ............ PreliminaryPages .................................................................... i
3.2.7 . . . . . . . . . . . . . Engine,General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3.2.2.. . . . . . . . . . . . Engine/ Transmission Unit, Renew. . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . 12.37. 01/90 . . . . . . . . . . 2
3.2.3
. . . . . . . . . . . . . Engine Oil, Renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.60.00 . . . . . . . . . . . . . 3
3.2.4
. . . . . . . . . . . . . Oil Filter Canister, Renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.60.04 . . . . . . . . . . . . . 3
3.2.5..
. . . . . . . . . . . Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.60.68 . . . . . . . . . . . . . 4
3.2.6
. . . . . . . . . . . . Front Engine Mounting Bracket Assembly, Renew . . . . . . . . . . . . . . . . . . . 12.45.01 LH
12.45.03 RH ... . . . . , . . 4
3.1.7
. . . . . . . . . . . . Rear Engine Mounting Assembly, Renew . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.45.08 . . . . . . . . . . . . . 5

Illustration
not illustrated
Jaguar Number
JD 183
18G 1465
MS 53C
YA 992
11. TORQUE TIGHTENING SPECIFICATIONS
ing tool
Engine
lifting bracket
Engine support beam
'Snap-On' Oil filter
canister removal tool
Fixing lightening Torque (Nm)
Oil cooler to body 17-23
Oil cooler hose clamp to radiator cradle
Oil cooler pipes to engine
Heat shield to hydraulic mount
Hose clamp
- hose to air cleaner and induction elbow
7-10
17
-23
4
-5
3
-4
111. SERVICE MATERIALS
I Description I US88 I Notem I
I Hylosil 102 sealant I Filler cap 'Oring I I
Vaseline or Silicon lTop of oil filler tube 15000
Tivoli Kay Adhesives
No. 5696 sealant Exhaust
system joints
Issue 1 August 1994 ii X300 VSM

Engine (V12)
3.2.1 ENGINE, GENERAL
The twelve cylinder, vee formation engine has a capacity of 6.0 liters. Each cylinder bank has a single overhead
camshaft and two valves percylinder. The engine has a fully mapped engine management system with digital ignition
and two ignition coils.
This section describes the service procedures to be carried out with the engine in situ.
It also covers the renewal of
the engine / transmission unit.
For information relating
tostrip-down, inspedion,fault diagnosis, renovation and rebuild work, referto the VI2 Engine
Service Manual.
X300 VSM 1 Issue 1 August 1994

3.2.2 ENGINE - GEARBOX/ TRANSMISSION
ASSEMBLY, RENEW
SRO 12.37.01/90
The engine /transmission unit on the V12 6.0 liter model is mounted on three engine mounting / bracket assemblies
fitted to the front crossmember on either side of the engine bay. The engine/ transmission rear mount is a mounting
bracket and spring assembly fitted and secured to body underframe longitudinal members. For access to remove the
engine carry
out the following procedures:
WARNING: WHEN WORKING WITHIN THE ENGINE COMPARTMENT, KEEP CLEAR OF THE RADIATOR COOLING
FANS AS THEY COULD START WITHOUT WARNING, EVEN IF THE ENGINE IS NOT RUNNING.
. Remove the hood, see SRO 76.16.01, section 13.
. Remove the two air cleaner assemblies, see SRO’s 19.10.01 & 19.10.02.
. Remove the engine cover, see SRO 12.29.93 (V12 Engine Service Manual).
Depressurize the fuel system, see SRO 19.50.02, section 5.1.
In line with the relevant SRO’s and sections, remove all appropriate obstructing parts, including their fixing and
. Disconnect all mechanical and isolate all electrical linkages leading to and from the engine.
. De-gas the air conditioning system, see section 14, Charge Recovery (System depressurization).
Disconnect
the battery.
mounting arrangements.
CAUTION: Do
not vent refrigerant directly to the atmosphere and always use Jaguar approved recovery/recycle/ra charge equipment.
Drain the engine oil, see 3.2.3 this section.
Drain the coolant, see SRO 26.10.01, section 4.1.
WARNING: DO NOT REMOVE THE HEADER TANK PRESSURE CAP WHILE THE ENGINE IS HOT. IF THE CAP MUST
BE REMOVED, PROTECT THE HANDS AGAINST ESCAPING STEAM AND SLOWLY TURN THE CAP ANTI- CLOCKWISE UNTIL THE EXCESS PRESSURE CAN ESCAPE. LEAVE THE CAP IN THIS POSITION UNTIL ALL
STEAM AND PRESSURE HAS ESCAPED AND THEN REMOVE THE CAP COMPLETELY.
Before
lifting the complete engine/transmission unit with an engine hoist from the engine bay, ensure that two engine
lifting brackets (tool 18G. 1465) are secured equallyspaced to the inlet manifold studs. The four engine lifting brackets
should be positioned towards the front and the rear of the assembly. Ensure the front of thevehicle is jacked
up secure- ly on stands when removing the assembly.
X300 VSM Issue 1 August 1994 2

Engine (V12)
3.2.3 ENGINE OIL, RENEW
SRO 12.60.00
. Undo and remove the sump plug positioned at the rear of
the sump, drain the engine oil into a suitable receptacle
and dispose of
it in a safe and environmentally friendly
manner.
. Replenishtheengineoiltothecorrect level (1 Fig. 1) onthe
dipstick.
1ynfa: If the '0' ring on the on the filler cap is damaged, re- move the '0' ring and clean the groove. Secure a
new '0' ring in position using silicon sealant. Treat
the screw threads with copper grease, and grease
the top face of the oil filler with Hylosil lubricant.
When the oil is renewed, start the engine, wait for the oil
light to extinguish and switch off the engine for 30 sec- onds.
. Finally remove and wipe clean the dip stick
(Fig. l), check the oil level - replenish as necessary.
For recommended engine oil refer to Appendix AI. Fig.
1
3.2.4
OIL FILTER CARTRIDGE, RENEW
SRO 12.60.04
The white oil filter cartridge displaying the Jaguar logo, is lo- cated on the lower left-hand side of the engine, near side of
the sump. Access for removing the cartridge is from under- neath the vehicle (Fig. 2).
Remove the catalyst heat shield (where fitted) and use a coil
spring type filter wrench to remove the cartridge.
Start and run the engine for a few seconds to charge the
filter, then stop the engine and
checkthe oil level. Replenish
as necessary.
I Fig. 2
Issue 1 August 1994 X300 VSM 3
r