9g AJ16 Engine Service Manual CONTENTS Section 410 an 412. 41a 4n4 ANS 416 417 418. 419 4.20 420 422. ADB. 424 "Service Data « ++ Construction... « Cylinder Head Design = Crankcase Breather . «Lubrication System «Supercharger SPS Joint Control System « Sealants. + Iniroduction .. « Service Operations «Camshaft, Renew .... 12.29.39 Valve Clearance, Check and Adjust 12.29.48 ++ Cylinder Head Gasket, Renew ....+.+ 12.29.01 « Cylinder Head, Overhaul....-.+-+ 12.29.19 Cylinder Head Casting, Renew 12.29.15 Piston and Connecting Rod, Engine Set, Renew . 12.17.10 « Connecting Rod Bearing, Engine Sot, Renow . 12.17.16 ‘Main Bearing, Engine Set, Renew 12.21.39... + Crankshaft, Renew . 12.21.33 rankshat Damper /Puley Assembly, Renew . 12.21.09 Crankshaft End-float, Check and Adjust - 12.21.26 Crankshaft Front Oil Seal. Renew 12.21.14. Crankshaft Rear Oil Seal, Renew 12.21.20 .. = Engine Flywheel, Renew Title Foreword Service Tools & Equipment Torque Tightening Speciation ee General Description Service Procedures . Fault Diagnosis Diagnostic Procedures : 12.13.01 Camshaft Cover Gasket, Renew . 12.53.07 12.53.13 12.53.03 = 12.41.05 12.65.13 12.65.48 12.65.29 12.65.30 Engine Drive-plate, Renew . E Engine Rear / Tansmission Adapter Plate, Renew Engine Assembly, Overhaul Timing Chain, Gear and Tensioner, Engine Set, Renew Timing Chain Damper, Vehicle Set, Renew Timing Chain Tensioner, Upper, Renew . Timing Chain Tensioner, Lower, Renew . «Timing Sprocket, Intermediate, Renew anannee 12.65.26 vee AB = Auxillary Shaft, Renew . 12.10.30 Tesue 2 June 1995AJ16 Engine Service Manual Section 425 4.26 427 4.28 4.29 4.30 431 4.32 433 434 Issue 2 June 1995, + Oil Pump, Overhaul . + Cylinder Head Rear Blanking Pate, Renew. Ol Filter Head Gasket, Renew Oil Pan Gasket, Renew (Oil Pump ‘0’ Rings, Renew ll Pick-up Strainer, Renew .... ry Shaft Rear Seal, Renew . (Oil Pressure Relief Valve Assembly, Renew O11 Pump, Renew . Top Cover, Renew . SRO + 12.10.32 12.60.03 = 12.60.38 « + 12.60.27 « = 12.60.20 . 12.60.56 = 12.60.26 « = 12.60.32... 2 12.29.36. 12.29.93 . Page 45 46 a7 48 49 50 5 52 53B AJ16 Engine Service Manual FOREWORD ‘This Service Manual has been designedto enable the skilled Jaguar technician to correctly service and repair the range ‘of Jaguar AJ16 in-line six-cylinder engines. It assumes that the engine is in a clean condition and that all service tools Removal of the engine and transmission unit, if required, is covered in Section 3.1 of the appropriate Vehicle Service Manual. ‘An index can be found at the rear of this manual. iit Tseue 2 dune 1995AJ16 Engine Service Manual SERVICE TOOLS & EQUIPMENT Jeguer Number | Description Notes 186 55A Piston ring compressor 786 TA Camshaft timing tool 18G 1434 ~~ [Jackshaft bushing remover / replacer t or 186 1435 Camshaft dummy caps is a 186 1436/A | Crank pulley remover and timing | a damper oll pressure simulator | 186 1437 Front pulley lock See eeEnnnn ‘not ilustrated 186 1437-1 ‘Adapter 186 1465 Engine lifting bracket 186 1469 ‘Auxiliary drive chat seal roplacer Issue 2 June 1995AJ16 Engine Service Manual Taquar Naber | Besorption Notes Joti Taslany drive shaft seal remover Joie Trani Ton aeal rarnover De Crank Wont weal replace? JD 130 Chain link remover / replacer ~~ OTe ‘DuieK pipe disconnecting tool 7 @4in diameter) ‘JD 203 Quick-fit pipe disconnecting tool ain diometor J 550-3 Crank rear eval replcer adapter JO 6T1aC Valve spring compressor | | ws Engine suppor beam a “\s ue 2 June 1995AJ16 Engine Service Manual tool Wustration Jeguar Number Description Notes MS 15194 Valve spring compressor MS 1520 Engine stand MS 1520-2 ‘Adapter assembly for MS 1520 WAeaE Snap-On’ Oil filter canister removal Issue 2 June 1995B AJ16 Engine Service Manual n TORQUE TIGHTENING SPECIFICATIONS f Fixing Tightening Torque | (Nea) Se SOOO eS EGS Ende cease nasenaeenaennaennaennaeenaennaennaannas C_ Ait Box bracket screw 55-115 Air box to bracket 95-125 1 Air box to instrumount 95-125 Air cleaner bracket setscrew aaanaaia 63-87 Air cleaner support bracket (6,0 Inter supercharged) i ‘ B5-15 | ‘Air temperature sensor to air box 7-9 Hose clamp, air box to air meter i 72-16 | Hose clamp, air box to body Ti nana 12-16 1 ‘meter to intake gaiter (4,0 Iter supercharged) 7 12-168 |inatrumount bracket Taptite sorew +—~=~=~*~*“‘=CS~*~*<*<=*‘“*‘“‘*‘*;*‘*«‘“YS!”*S*«‘ HT ‘Trumpet to body 95-125 ‘Air Conditioning Compressor Mounting Belt tensioner assembly to compressor bracket s—=—<“—*s*s‘s*~*s*~*s*s*~*~*s*s~sYCSC*«‘“‘ét [Compressor bracket to cylinder block [ 22-28 [Compressor to bracket { 2-28 {Tider pulley to tensioner assombly 22-28 Connecting Rod | ‘Connecting rod bearing nut 52 — 55 (SPS System) | Bypass elbow to thermostat housing Coolant pipe bracket to intake manifold Coolant pump assembly ‘Coolant pump to timing cover ‘Coolant pump to coolant rail (Coolant ral to cylinder Block a Fan drive unit setscraw Fan drive unit to pulley : Hose clamp, breather to thermostat naa ate Hose clamp, breather to throttle body Fiose clamp, bypass hose Hose clamp, coolant pump to pipe 25-35 "Thermostat cover to housing 215-285 Thermostat housing to cylinder head 25-285 183-223, 38-108 23-149 [Flywheel to crankshaft seiscrew (4,0 ier) 123-148 Timing ring to damper 155-205 Issue 2 June 1996AJ16 Engine Service Manual ightening (Nm) Cylinder Brock Adapter to cylinder block 43-57 ‘Adapter sorew to ovlinder block e-a7 [Bearing cap to evlinder biock 136 142 (SPS System) Blanking plate to oylinder Blook 25-285 Coolant drain plug 64,5-79,5 Git arting branking plug EEE Oil gallery Blanking setecrew 2S= 285 Oil pressure sensor 23-27 [il pressure sensor plug 35-115 Oil seal adapter to cylinder block 215-785 (Windage tray to ovlinder block 215-265 Cylinder Head and Camshaft Cover Bearing cap to oylinder head t 7-8 | Camshaft coupling bolt | 22-28 ‘Camshaft cover to cylinder head t 5 {Gylinder head to cylinder block {39-61 (SPS System) Dipstick tube to bracket Drive Chain System ‘Auxiliary shaft assembly sets ‘Coupling to intermediate shaft Damper to cylinder block (bolt) [Cylinder head to timing cover 215-285 Exhaust manifold to cylinder head 22-28 ‘On-plug coil cover to camshaft cover 5 Rear cover to cylinder head 25-285 Dipstick Tube ick tube assembly nut 31-99 Dipstick tube attachment to tube support bracket (4,0 liter supercharged) 155-205 jak tube bracket screw (3,2 liter & 4,0 liter normally aspirated) 95-125 | Dipstick tube bracket screw (4,0 liter supercharged) a 8-7 ee 305-375 2-16 EE Damper to eylinder Block (ecrew 215-285 Damper to distance piece B= 285 Damperto saddle 215-285 Distance piece to cylinder block a 21,5 ~ 28,5 Endplate to damper 215-785 Housing to ylinder Block bolt Zis= 265 Housing to eyinder block (eapssrew! 215-285 Intermediate shaft bianking plug ori Pivot bracket to eylinder block 25-285 Pivot plate to cylinder Block 215-785 Sprocket to hub setecrew 7=10 Engine Mounting Engine mounting bracket to engine 57 ‘Issue 2 June 1995 vi@ AJ16 Engine Service Manual Fixing Tightening Torque (Nm) | Exhaust Manifold 1 Exhaust manifold to cylinder head 145-595 Heatshield to exhaust manifold 215-285 Lifting eye setscrew (slave tem only) a 215-28! Fuel System Adjust jo generator Fuel pressure regulator to bracket 305-415 | Fuel rail connecting nut 125-155 Fuel rail to intake manifold 95-125, ‘Generator Mounting ] ‘Adjuster bolt to timing cover 26-265 ‘| ‘Adjuster bracket to oil pan 215-285 Generator mounting bracket pivet balt Sleeve to adjuster bolt Intake Manifold EGR adapter to intake manifold Blanking plate to intake manifold (in place of adapter) EGR pipe to adapter [EGR sensor to intake manifold 165-195 Intake manifold steady sorew (OT 22-78 id fo evinder Read 715-265 Pedestal to trots body 35-185 Pressure regulator to intake manifold 357125 Pressure regulator to intake manifold (40 liter supercharged) 5-7 Purge adapter to intake manifold ~s5-15 ‘Throttle body o intake manifold 715=285 hentia raha ata tv intata Tani Saas ‘Throttle linkage actuator nut 7 1,8=2,2 Throttle linkage baseplate to pedestal 95-125 Throttle spindle assembly nut 35-45 Throttle stop sorew locknut Miscellaneous Hoses Hose clamp, bre Hose clamp, heater return hose to throttle body jther hose to restrictor Hose clamp, hose to cam cover Hose clamp, restrictor to throttle body Hose clamp, thermostat housing to restrictor 43-57 Hose clamp, coolant pump (il Cooler (4,0 Liter Supercharged) Oil eooler clamp eerew Oil cooler pipe bracket screw Oil cooler pipes to engine Oil cooler to body Hose clamp, oil cooler hose to radiator cradle Issue 2 June 1995