Page 1

. I .

a.

BY APPOINTMENT TO HER MAJESTY QUEEN ELIZABETW

THE QUEEN MOTHER MANUFACTURERS OF DAIMLER AND JAGUAR C A R S JAGUAR CARS LIMITED COVENTRY ENGLAND

JAGUAR VOLUME 2 Contains Sections

12.

ENGINE 2.9

12.

ENGINE 3.6

17.

EMISSION CONTROL

18.

ENGINE MANAGEMENT 2.9

18.

ENGINE MANAGEMENT 3.6

19.

FUEL SYSTEM

26.

COOLING SYSTEM 2.9

26.

COOLING SYSTEM 3.6

30.

EXHAUST SYSTEM 2.9

30.

EXHAUST SYSTEM 3,6

-

2.9 3.6 SERVICE MANUAL Published by

Jaguar Cars .im ted

Publication Part

N O JJM IO 04 05


ENGINE 2.9 CONTENTS OPERATION

DESCRlPTlON

AUXILLIARY SHAFT .................................................... RENEW .................... AUXILLIARY SHAFT REAR SEAL ................................... RENEW .................... CAMSHAFT ................................................................ RENEW .................... CAMSHAFT CARRIER .................................................. RENEW .................... CAMSHAFT COVER GASKET ........................................ RENEW .................... CONNECTING ROD BEARING-ENGINE SET ....................... RENEW .................... CRANKSHAFT ............................................................ RENEW .................... CRANKSHAFT DAMPER ............................................... RENEW .................... CRANKSHAFT END FLOAT ........................................... CHECK& ADJUST ..... CRANKSHAFT FRONT OILSEAL .................................... RENEW .................... CRANKSHAFT PULLEY AIR CONDITIONING DRIVE ........... RENEW .................... CRANKSHAFT PULLEY AIR CONDITIONING DRIVE (AIR CONDITIONING FITTED) ...................................... RENEW .................... CRANKSHAFT REAR OIL SEAL ...................................... RENEW .................... CRANKSHAFT TIMING GEAR ........................................ RENEW .................... CYLINDER HEAD CASTING ........................................... RENEW .................... CYLINDER HEAD - COMPLETE ...................................... RENEW .................... CYLINDER HEAD GASKET ............................................. RENEW .................... CYLINDER HEAD .......................................................... OVERHAUL .............. CYLINDER PRESSURES ................................................. CHECK ..................... ENGINE ....................................................................... DESCRIPTION ........... ENGINE ASSEMBLY ...................................................... RENEW .................... ENGINE OIL ................................................................. DRAIN &REFILL ........ ENGINE MOUNTING BRACKET - LEFT HAND ................... RENEW .................... ENGINE MOUNTING BRACKET- RIGHT HAND ................. RENEW .................... ENGINE MOUNTING - ENGINE SET ................................. RENEW .................... ENGINE REAR/GEARBOX ADAPTOR PLATE .................... RENEW .................... FLYWHEEL ................................................................. RENEW .................... FRONT ENGINE MOUNTING - LEFT HAND ....................... RENEW .................... FRONT ENGINE MOUNTING - RIGHT HAND ..................... RENEW .................... INTERMEDIATESPROCKET ........................................... RENEW .................... LOWER TIMING CHAIN ................................................. RENEW .................... LOWER TIMING CHAIN TENSIONER ............................... RENEW .................... MAIN BEARING-ENGINE SET ......................................... RENEW .................... OIL COOLER ................................................................ RENEW .................... OILCOOLER HOSE-VEHICLE SET .................................... RENEW .................... OILCOOLER RETURN HOSE ........................................... RENEW .................... OIL COOLER SUPPLY HOSE ........................................... RENEW .................... OIL FILTER CANISTER ................................................... RENEW .................... OIL FILTER HEAD GASKET ............................................ RENEW .................... OIL PICK UP STRAINER ................................................. RENEW .................... OIL PRESSURE RELIEF VALVE ASSEMBLY ....................... CHECK&OVERHAUL . OIL PRESSURE TRANSMITTER ...................................... RENEW .................... OIL PUMP ................................................................... OVERHAUL .............. OIL PUMP ................................................................... RENEW .................... OILPUMP DRIVE CHAIN AND DAMPER ........................... RENEW .................... OIL PUMP DRIVE CHAIN DAMPER .................................. RENEW .................... OIL PUMP DRIVE SPROCKET ......................................... RENEW .................... OIL PUMP PIPE '0' RINGS .............................................. RENEW .................... OIL SUMP ................................................................... RENEW .................... OIL SUMP GASKET ....................................................... RENEW .................... PISTON ANDCONNECTING ROD ENGINE SET .................. RENEW .................... REAR ENGINE MOUNTING ............................................. RENEW .................... SPARKING PLUG INSERTS ............................................ FITTING ................... TIMING CHAIN DAMPER-VEHICLE SET ........................... RENEW .................... TIMING CHAIN-ENGINE SET .......................................... RENEW .................... TIMING CHAIN, GEAR AND TENSIONER-ENGINESET ........ RENEW .................... TIMING COVER GASKET ............................................... RENEW ....................

12-1

OPERATION PAGE No No 12.10.30 .... 12.10.32 .... 12.13.02 .... 12.13.24 .... 12.29.39 .... 12.17.16 .... 12.21.33 .... 12.21.09 .... 12.21.26 .... 12.21.14 .... 12.21.08 ....

12-04 12-07 12-08 12-144 12-12 12-13 12-15 12-22 12-28 12-38 12-1 12

12.2 1.08 .... 12.21.20 .... 12.65.25 .... 12.29.15 .... 12.29.10 .... 12.29.02 .... 12.29.19 .... 12.25.01 .... 12.00.00 .... 12.41.02 .... 12.60.00 .... 12.45.15 .... 12.45.15 .... 12.45.13 .... 12.53.03 .... 12.53.07 .... 12.45.01 .... 12.45.03 .... 12.65.26 .... 12.65.16 .... 12.65.30 .... 12.21.39 .... 12.60.68 .... 12.60.73 .... 12.60.76 .... 12.60.74 .... 12.60.04 .... 12.60.03 .... 12.60.20 .... 12.50.56 .... 12.60.50 .... 12.60.32 .... 12.60.22 .... 12.60.31 .... 12.60.29 .... 12.60.30 .... 12.60.27 .... 12.60.44 .... 12.60.38 .... 12.17.01 .... 12.45.04 .... 12.29.78 .... 12.65.48 .... 12.65.14 .... 12.65.13 .... 12.65.04 ....

12- 124 12-34 12-85 12-1 16 12-124 12-127 12-129 12-33 12-03 12-148 12-31 12-49 12-48 12-1 14 12-31

12-32 12-50 12-49 12-76 12-80 12-66 12-56 12-52 12-55 12-52 12-54 12-42 12-41 12-47 12-42 12-39 12-24 12-26 12-137 12-62 12-45 12- 14 1 12-40 12-44 12-36 12-1 13 12-142 12-90 12-95 12-106 12-59


ENGINE 2.9 DESCRIPTION

OPERATION

OPERATION PAGE No No

TIMING GEAR-ENGINE SET ........................................... UPPER TIMING CHAIN .................................................. UPPER TIMING CHAIN TENSIONER ................................. VALVE CLEARANCES ................................................... VALVE CLEARANCES ...................................................

RENEW .................... RENEW .................... RENEW .................... CHECK ..................... CHECK & ADJUST .....

12.65.22 .... 12-100 12.65.15 .... 12-73 12.65.29 .... 12-69 12.29.47 .... 12-51 12.29.48 .... 12-146

16958

12-2


ENGINE 2.9

2.9 ENGINE CUT AWAY

12-3


ENGINE 2.9 AUXILLIARY DRIVE SHAFT RENEW

12.10.22

Open and remove the bonnet. Remove cylinder head, operation 12.29.02. Remove and discard the head gasket. Remove the damper woodruff key and remove the oil seal spacer from the crankshaft. Remove the elastic band from the upper dampers, knock down the lock tabs on the bolts securing the tensioner pedestal. Remove the pedestal bolts and tab washer (3 Fig 1). Remove the pedestal/tensioner assembly and chain damper (1 Fig 1). Remove the tensioner pivot pin (2 Fig 1) and remove the tensioner from the pedestal, clean the pivot pin. Knock down the lock tab ears of the bolts securing the upper static damper. Remove the bolts (5 Fig I), tab washer, upper damper, damper (4Fig 1) pedestal and upper timing chain (6 Fig 1). Removethe bolts (1 0 Fig 1) securing the chain tensioner and remove the assembly. Remove the chain (8Fig 1) from intermediate sprocket (9 Fig 1) and remove. Remove the power assisted steering pump housing to auxilliary shaft housing securing bolts (1 Fig 2),remove the power-assisted steering pump drive coupling and remove the auxilliary shaft rear oil seal using Service Tool JD 118(18G 1468). Using right-angled circlip pliers remove the drive shaft securing circlip (1 Fig 3), lift the timing chain (8Fig 1) off the shaft gear (7 Fig I), remove the shaft (2Fig ?) and collect the thrust washer (3 Fig 2). Clean all component parts removed and check for wear or damage, should any of these conditions prevailthen the component must be replaced. Clean the auxilliary bearing housing . Check for wear and if necessary change the auxilliary shaft bushes (5 Fig 2) using Service Tool 18G 1434. Refit the housing (4 Fig 2) with new gasket (6 Fig 2) and secure with the bolts (1 Fig 2). Lubriucate the shaft and refit the shaft into the housing, engaging the chain with the gear as it is fitted. Lubricate and fit the thrust washer (3 Fig 2) and secure with the Girlcip (1 Fig 3). Lubricate new oil seal and using Service Tool 18G 1469, fit and seat the shaft rear oil seal (2 Fig 3). NOTE: Under no circumstances must the plastic seal insert be removed prior to fitting the seal. Fit the drive coupling to the power assisted steering pump, align the pump shaft with the auxilliary shaft, connect the pump shaft to the drive shaft and tighten the pump housing securing bolts (1 Fig 2). Lubricate the intermediate sprocket bearing, lift the chain (8 Fig 1) and engage the sprocket fully in the chain and seat into the bearing.

19

18

Fig 1

Fig 2

Fig 3

7 i

J12-540


ENGINE 2.9 Assemble the plunger, spring and base to the guide, lubricate the assembly. Fit the guide assembly to the tensioner housing, reposition the chain damper for access ensuring that no loose links are left below the crankshaft, fit the tensioner assembly (10 Fig 1 page 12-4) to the cylinder block with the guide facing downwards. Fit but do not tighten the upper tensioner securing bolt (1 1 Fig 1 page 12-4), push the guide into the housing to release the base and align with the damper. Align the damper with the lower bolt hole, fit and tighten the lower bolt (11 Fig 1 page 12-4). Finally tighten the upper bolt, fill the tensioner oil reservoir with oil and work the tensioner to prime with oil. Refill the reservoir with oil and ensure that the tensioner is fully primed. Lubricate the upper timing chain (6 Fig 1 page 12-4) and fit to the intermediate sprocket, fit the upper static damper, fit the tab washer, secure with the bolts and knock up the lock tab ears. Fit a new tensioner (1 Fig 1 page 12-4) to the pedastal and fit the tensioner pivot pin (2 Fig 1 page 12-4). Align a new tab washer to the tensioner and fit the securing bolts (3 Fig 1 page 12-4). Align the damper to the tensioner and fit the damper/tensioner assembly to the engine ensuring that the damper does not foul the the distributor drive shaft sprocket. Finally tighten the securing bolts and knock up the lock tab ears. Repositionthe upper tensioner and secure to the upper dampers with an elastic band. Remove the oil seal (1 Fig 1) from the timing cover, clean all of the gasket surfaces, oil seal spacer, pointer and crankshaft damper. Fit a new oil seal to the timing cover ensuring that the front of the seal is flush with the front face of the timing cover (1 Fig 2). Apply 'Hylosil 102' to the timing cover gasket faces and the outer edge of the sump face. Reverse the timing cover and cylinder head removal procedures to reassemble. Ensure that the cooling system is fitted with the correct solution of anti-freeze and water and that the engine oil is free of water. Should this condition prevail, the oil filter must be replaced and the engine oil drained; refill with new engine oil. Refit the bonnet.

12-5

Fig 1

Fig 2


ENGINE 2.9 DATA SERVICE TOOLS JD 1 1 8 (1 8G 1468)Auxilliary drives oil seal remover C3993 Camshaft timing tool 18G 1436 Crankshaftpulley remover 18G 1437 Front pulley lock JD 101 Timing chain tension release hook 186 1434 Timing cover bush remover replacer 186 7469 Auxilliary drive oil seal replacer TORQUE FIGURES Adjustment trunnion to alternator securing bolt 23-27Nm Alternator adjustment bolt to timing cover nut

23-27Nm Alternator adjustment bolt-trunnion lock nuts 1214Nm Alternator pivot bolt 23-27Nm Alternatorpivot bolt nut 23-27Nm Banjo bolt to cylinder head 13-16Nm Dipstick to bracket 5-8Nm Camshaft cover to cam carrier (nut)23-27Nm Camshaft cover to cam carrier (screw) 9.5-12Nm Camshaft sprocket to camshaft23-27Nm Clip-hose to breather pipe 2.4Nm Crankshaft pulley to crankshaft 203.5Nm Crankshaftpulley to crankshaft damper 23-27Nm Crankshaft speed sensor housing to timing cover 23-27Nm Cylinder block drain plug to cylinder block 68-75Nm Cylinder head to cylinder block (bolts) 23-27Nm Cylinder head to cylinder block (nuts) 82-86Nm Distributor clamp plate to timing cover 9.5-12Nm Drive plate centre coupling 9.5-12Nm Exhaust manifold to cylinder head 23-2 7Nm Fan/torquatrol unit to water pump 23-27Nm Heat shield to exhaust manifold 23-27Nm Heater pipe to cylinder head 23-27Nm Heaterpipe to inlet manifold 9.5-12Nm Hose-bottom hose to waterpump 3.8-4.3Nm Hose-expansion tank to water pump 2.5-3.5Nm Hose-heater return pipe to water pump 2.5-3.5Nm Hose-water pump to thermostat housing 2.5-3.5Nm Hydraulic pump to timing cover 23-27Nm Inlet manifold to cylinder head 23-27Nm Intake elbow to throttle housing 2.4Nm Lower chain tensioner to cylinder block 23-27Nm Oil sump to timing cover23-27Nm Power steering pump to mounting 23-27Nm Reaction shoe to cylinder head 23-27Nm Timing cover to cylinder block 23-27Nm Top hose to thermostat housing 3.8-4.3Nm Upper static damper to cylinder block 23-27Nm Upper timing chain tensioner to cylinder block 23-27Nm Waterpump to timing cover23-27Nm

0

a

8 12-6


. ..

ENGINE 2.9

w'

SPANNER SIZES 6mm 8mm 1Omm 13mm 19mm (SERVICE TOOL- 18G 1436) 30mm

1/2in AF(SERVICE TOOL-BOLTS 18G 1437/1) 9/16in AF 5/8in A F 13/16in AF 1Ornm (ALEN KEY)

3 / 4 WHITWORTH

OILS/GREASES/SEAIANTS Half moon seals to cam carrier 'HYLOSIL 102' Hydraulicpump drive plate securing bolt 'LOCTITE' '0' Rings 'PETROLEUMJELLY' Sump to timing cover ' HYLOSlL 1 0 2'. Timing cover to cylinder head 'HYLOSIL 102'. Thermostat housing to extension piece ' HYLOSIL 102'. 0474b/10

AUXILLIARY SHAFT REAR SEAL RENEW

12.10.32

Remove the power steering pump drive coupling and remove the distributor drive shaft oil seal using Service Tool JD 1 18 (18G 1468). Clean and lubricate the new seal and mating faces. Using Service Tool 18G 1469 fit and fully seat the drive shaft seal (2 Fig 1). NOTE: Under no circumstances must the plastic seal insert be removed prior to fitting of the seal. Refit the power steering pump drive coupling.

TORQUE FIGURES Steering pump to adaptor 49-54Nm Fig 1

SERVICE TOOLS

JD 1 1 8 (186 1 4 6 8 ) Auxilliary shaft oil seal remover 18G 1 4 6 9 Auxilliary shaft oil seal replacer

12-7

... .

-


.. .

.

ENGINE 2.9 SPANNER SIZES 13mm 19mm (SERVICE TOOL) 1

0439b

I

CAMSHAFT RENEW

12.13.02

Open the bonnet. Release the plug lead retaining clips from the camcover brackets. Unclip the distributer cap. Disconnect the HT lead from the coil and position the plug leads over the inlet manifold. Remove the nuts (1 Fig 1) and bolts (2 Fig 1) securing the camcover to the cam carrier. Remove the camcover (3 Fig 1). Remove and discard the cam cover gasket and the half moon seal from the rear of the cylinder head. Clean the cam cover and cylinder head. Jack up the vehicle and place on two stands. Rotate the engine and set at T.D.C. number 1 cylinder. Remove the bolts (5 Fig 2) securing the reaction shoe (6 Fig 2) to the cylinder head, remove the shoe and discard the gasket. Using service tool JD 101 (1 Fig 2) de-tension the upper timing chain tensioner. Knock down the lock tab ears securing the camshaft sprocket bolts, remove the bolts (2 Fig 2) and tab washers. Gradually remove the nuts (1 Fig 3) securing the camshaft caps. NOTE: Slacken each nut two turns at a time to release the load on the camshaft until the valve springs are fully relaxed. Note the position of the caps (2 Fig 3) relative to the cylinder head and remove. Remove the camshaft (3 Fig 3). Clean all component parts and inspect for wear and/or damage. Oil the camshaft journals. Place the replacement camshaft (3Fig 3)in the cylinder head with the slot for the timing gauge facing upwards, re-oil the camshaft journals and fit the bearing caps (2 Fig 3)back in their respective positions. Fit the nuts (1 Fig 3)and gradually tighten each nut of each camshaft cap two turns at a time until all the caps are fully secured and torqued tightened. Using Service Tool C3993 camshaft timing tool, set the camshaft to T.D.C. Position the chain (3Fig 2) over the sprocket and align the sprocket to the camshaft. Fit the reaction shoe (6 Fig 2) and release the upper tensioner. Remove the clip securing the inner wheel and align the securing bolt holes, fit the bolts.

5

2

J12

PPI

Fig 1

Fig 2

3

I

512 45.

Fig 3

12-8

4


ENGINE 2.9 Rotate the engine as necessary to measure the valve clearances (Fig 1) between the heel of the camshaft and the cam followers, the correct clearance is 0.0 12 to 0.014 in.

DATA Valve clearances Inlet 0.012-0.014in Exhaust 0.012-0.014in

EXCESSIVE CLEARANCE

Inches

Size of existing shim Plus the actual clearance noted

0.100 0.019 0.1 19

Less the specified valve clearance

0.013 Fig 1

= required shim size

0.106

INSUFFICIENT CLEARANCE

Inches

Size of existing shim Plus the actual clearance noted

0.107 0.0 10 0.1 17

Less the specified valve clearance

0.0 13

0.104

= required shim size

Available shim sizes Letter

Thickness

A

0.085 in 0.086 in 0.087 in 0.088 in 0.089 in 0.089 in 0.090 in 0.091 in 0.094 in 0.095 in 0.096in 0.097 in 0.098 in 0.099 in 0.100 in 0.101 in 0.102 in 0.103 in 0.104 in 0.105 in 0.106 in 0.107 in 0.108 in

B

C D F G H I J

K

L M N

0 P

0 R S T U V

w X

12-9


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ENGINE 2.9 Should the clearances by incorrect, Remove the bolts (5 Fig 2 page 12-8) securing the reaction shoe to the cylinder head, remove the shoe. Using Service Tool JD 101 (1 Fig 2 page 12-8) de-tensionthe upper timing chain tensioner. Remove the bolts (2 Fig 2 page 12-8) securing the camshaft sprocket. Gradually remove the nuts (1 Fig 3 page 12-8) securing the camshaft caps. NOTE: Slacken each nut two turns at a time to release the load on the camshaft until the valve springs are fully relaxed. Note the position of the caps relative to the cylinder head and remove. Remove the camshaft (3 Fig 3 page 12-8). Using a suitable magnet remove the cam followers (1 Fig 1). Remove all the shims or only those requiring adjustment, check the size of the existing shims with a micrometer and note the reading. Calculate the size of the shim required following the examples in DATA. Refit the cam followers. Oil the camshaft journals. Place the replacement camshaft (3 Fig 3 page 12-8) in the cylinder head with the slot for the timing gauge facing upwards re-oil the camshaft journals and fit the bearing caps back in thier respective positions. Fit the nuts (1 Fig 3 page 12-8) and gradually tighten each nut of each camshaft cap two turns at a time until all the caps are fully secured and torqued up. Using Service Tool C3993 camshaft timing tool, set the camshaft to T.D.C. Position the chain (3 Fig 2 page 12-8) over the sprocket and align the sprocket to the camshaft. Using a new gasket fit the reaction shoe (6 Fig 2 page 12-8) and release the upper tensioner. Remove the clip securing the inner wheel and align the securing bolt holes, fit new tab washers and bolts (2 Fig 2 page 12-8). Tighten the bolts and knock up the lock tabs. Rotate the engine as necessary to measure the valve clearances between the heel of the camshaft and the cam followers, the correct clearance is 0.0 12 to 0.014 in. Clean the cam cover and cylinder head. Apply 'Hylosil 102' to the half moon seal and fit to the aperture in the rear of the cam carrier. Fit a new gasket to the cam carrier, fit and align the carncover (3 Fig 1 page 12-8). fit the plug lead brackets and secure the assembly to the cam carrier with the nuts (1 Fig 1 page 12-8) and bolts (2 Fig 1 page 12-8). Refit the distributor cap and plug lead clips to the brackets. Reconnectthe HT lead to the coil. Close the bonnet.

-

12-10

~

- -

r.

. - _G2_- ,l

Fig 1

-

4

J12 155


ENGINE 2.9 DATA SERVICE TOOLS C3993 Camshaft timing tool JD 101 Timing chain tension release hook

DATA Valve clearances Inlet 0.0 12-0.014in Exhaust 0.012-0.014in

EXCESSIVECLEARANCE

Inches

Size of existing shim Plus the actual clearance noted

0.100 0.0 19

0.1 19 Less the specified valve clearance

0.0 13

= required shim size

0.106

INSUFFICIENT CLEARANCE

Inches

Size of existing shim Plus the actual clearance noted

0.107 0.010 0.1 17

Less the specified valve clearance

0.013

= required shim size

0.104

Available shim sizes Letter

Thickness

A

0.085 in 0.086 in 0.087 in 0.088 in 0.089 in 0.089 in 0.090 in 0.091 in 0.094 in 0.095 in 0.096 in 0.097 in 0.098 in 0.099 in 0.100 in 0.101 in 0.102 in 0.103 in 0.104 in 0.105 in 0.106 in 0.107 in 0.108 in

B C

D F G H . I

J K L M N 0 P Q R S T U V

w X

12-1 1


ENGINE 2.9 TORQUE FIGURES Searing caps to camshaft carrier 11- 13.5Nm Camshaft cover to cam carrier (nut)23-27Nm Camshaft cover to cam carrier (screw) 9.5- 12Nm Camshaft sprocket to camshaft23-27Nm Reaction shoe to cylinder head 23-27Nm

SPANNER SIZES 1Omm 13mm 9/16in AF

OILS/GREASES/SEAU N TS Half moon seals to cam carrier 'HYLOSIL 102'.

CAMSHAFT COVER GASKET RENEW

12.29.39

Open the bonnet. Release the plug lead retaining clips from the camcover brackets. Unclip the distributer cap. Disconnect the HT lead from the coil and position the plug leads over the inlet manifold. Remove the nuts (1 Fig 1) and bolts (2 Fig 1) securing the camcover to the cam carrier. Remove the camcover (3Fig 1). Remove and discard the cam cover gasket and the half moon seal from the rear of the cylinder head. Clean the cam cover and cylinder head. Apply 'Hylosil 102' to the half moon seal and fit to the aperture in the rear of the cam carrier. Fit a new gasket to the cam carrier, fit and align the camcover, fit the plug lead brackets and secure the assembly to the cam carrier with the nuts and bolts. Refit the distributor cap and plug lead clips to the brackets. Reconnectthe HT lead to the coil. Close the bonnet.

12-12

1

I

,

5

2

4 J17411

Fig 1


ENGINE 2.9 DATA TORQUE FIGURES Camshaft cover to cam carrier (nut)23-27Nm Camshaft cover to cam carrier (screw) 9.5-12Nm

SPANNER SIZES 8mm 13mm

01LS/GR EASES/SEAlANTS Half moon seals to cam carrier 'HYLOSIL102'. 0452b

CONNECTING ROD BEARING ENGINE SET RENEW

12.17.16

Open the bonnet. Drain the engine oil and remove the front crossmember. Remove the bolt securing the dipstick to the inlet manifold and remove the dipstick. Remove the air cleaner element. Slacken the alternator adjusting nut and pivot nut, pivot the alternator towards the engine and disconnect the drive belt. Remove the alternator link arm trunnion bolt. From below disconnect the alternator feed wires and remove the alternator pivot bolt and nut, remove the alternator. Remove the rear spacers and move the power assisted steering pipes for access. Slacken the union securing the oil drain back tube to the sump and pull tube clear of the sump. Position the steering rack to allow access to the sump securing bolts slacken the bolts with the exception of two bolts, remove sump securing bolts (1 Fig 1). Remove the bell housing to sump securing bolts. Finally remove the remaining sump bolts and lower the sump (2 Fig 1). Place a suitable drain tin below the oil transfer housing area and remove the housing securing bolts (1 Fig 2), remove the housing assembly (2 Fig 2) and pull the pipes (3 Fig 2) from the housing.

Fig 1

Fig 2

12-13


ENGINE 2.9 Remove and discard the '0'rings, clean the housing and oil pipes. Remove the bolts (1 Fig 1) securing the crankshaft windage trays (2 Fig 1) to the cylinder block and remove the trays. Turn the engine over for access to the first connecting rod. Remove the nuts (1 Fig 2) securing the cap (2 Fig 2) to the connecting rod and remove the cap and bearing assembly. Note the position of the cap relative to the connecting rod and also that they are numbered to each other (1 Fig 3). Discard the bearing shell (2 Fig 3), move the connecting rod and piston up the bore and remove the bearing shell from the connecting rod (3Fig 3). Remove the 'paired' bearing cap ie 1-6,2-5,3-4. as in the previous description. Clean and polish the crankshaft journals, oil the new bearings and fit two halves to the connecting rods. NOTE: Ensure that the 'tag' (4 Fig 3) on the shell is fully seated in the connecting rod. Oil the crankshaft journals. Pull one piston and rod down the bore and guide onto its relative crankshaftjournal. Fit a bearing shell to the 'matched' connecting rod cap. NOTE: Ensure that the 'tag' (4 Fig 3) on the shell is fully seated in the connecting rod, oil the shell and fit to the crankshaft/connecting rod assembly. Ensure that the 'numbers' (1 Fig 3)are fitted together. Fit the securing nuts (1 Fig 2) and tighten. Repeat the procedure for the second piston and connecting rod assembly. Rotate the crankshaft for the second matched pair and repeat the procedure. Repeat the procedurefor the third pair. Clean the windage trays (2 Fig 1) fit and secure to the cylinder block with the bolts (1 Fig 1). Carefully fit new '0' rings to the oil pipes (1 Fig 4), lubricate the '0' rings with petroleum jelly. Remove the drain tin and fit the pipes to the oil pump. Apply 'Hylosil 102' to the tranfer housing gasket face, fit the housing (2 Fig 2 page 12-13) to the engine and secure with the bolts ( 1 Fig 2 page 12- 13).

Fig 1

-

12-14

Fig 4

Profile for 1638322

1988 JAGUAR XJ6 Service Repair Manual  

1988 JAGUAR XJ6 Service Repair Manual  

Profile for 1638322
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