1995 Jaguar XJS Service & Repair Manual

4.0L 6-CYL VIN [7] Article Text 1995 Jaguar XJS For 1 Copyright © 1998 Mitchell Repair Information Company, LLC Thursday, November 25, 2010 02:13PM ARTICLE BEGINNING 1995-96 ENGINES Jaguar - 4.0L 6-Cylinder XJS * PLEASE READ THIS FIRST * NOTE: For repair procedures not covered in this article, see ENGINE OVERHAUL - GENERAL INFORMATION article in GENERAL INFORMATION section. ENGINE IDENTIFICATION Engine may be identified by Vehicle Identification Number (VIN) stamped on metal plate. VIN plate is located on top left of dash and is visible through windshield. The seventh character identifies engine model. ENGINE IDENTIFICATION CODE TABLE Engine Code 4.0L ................................................... 7 ADJUSTMENTS VALVE CLEARANCE ADJUSTMENT 1) Remove coil cover and coils from spark plugs. Disconnect cam cover breather hose. Remove cam cover and gasket. Rotate crankshaft, and record clearance between heel of each cam lobe and its respective cam follower. If valve clearance is not within specification, adjustment is necessary. See VALVE CLEARANCE SPECIFICATIONS table. VALVE CLEARANCE SPECIFICATIONS TABLE Application In. (mm) All Valves ........................... .012-.014 (.30-.36) NOTE: In the following step, if after setting No. 1 piston at TDC camshafts do not indicate TDC, valve timing may have been changed as per Technical Service Bulletin (TSB). If valve timing has been modified, there should be 2 punch marks on timing cover (next to camshaft position sensor). See Technical Service Bulletin Number SECTION 03.1, No. 04 dated

4.0L 6-CYL VIN [7] Article Text (p. 2) 1995 August, 1995. 2) If adjustment is necessary, rotate crankshaft until No. 1 piston is at TDC. Ensure pointer on front timing cover aligns with arrow on timing ring. Using Timing Gauge (18G 1433), ensure camshafts are at TDC. Remove tensioner valve clamp bolt, and swing clamp away from center of chain tensioner. See Fig. 1. Fig. 1: View Of Camshaft Upper Timing Chain Tensioner Courtesy of Jaguar Cars Inc. 3) Remove valve from center of tensioner. Insert a 3-mm Allen wrench into center of tensioner. Turn Allen wrench clockwise until tensioner is in fully relieved position. Remove remaining chain tensioner bolt. Remove chain tensioner, "O" ring and gasket. CAUTION: DO NOT rotate crankshaft while camshaft sprocket is disconnected from camshaft. Serious damage to valve train components may occur. 4) Rotate crankshaft until timing notches in camshaft flanges are pointing down. Remove 2 accessible camshaft sprocket mounting bolts (per camshaft) and lock tabs. Rotate crankshaft until Timing Gauge (18G 1433) can be inserted into slot of camshaft front flange. Remove remaining camshaft sprocket mounting bolts and lock tabs from camshafts. Remove camshaft sprockets from camshafts. 5) Counting from front, remove cylinder head bolt from No. 2 intake camshaft bearing cap. Remove remaining bolts from No. 2 bearing cap. Remove bearing cap, and install Spacer (18G 1435) to cylinder head. Spacer is used to keep cylinder head from moving. Reinstall cylinder head bolt, and tighten it to 39 ft. lbs. (53 N.m). Repeat step 5) for No. 3-6 bearing caps. 6) Remove cylinder head bolt from No. 7 bearing cap. Alternating between No. 1 and 7 bearing caps, remove remaining bolts and bearing caps. Remove intake camshaft. Install spacer and No. 7 cylinder head bolt. Tighten bolt to 39 ft. lbs. (53 N.m). Repeat steps 5) and 6) for exhaust camshaft. 7) Note cam follower location for installation reference.

4.0L 6-CYL VIN [7] Article Text (p. 3) 1995 Jaguar XJ Remove cam follower from valve requiring adjustment. Remove adjusting pad, and measure its thickness. Use adjusting pad's measured thickness and difference between valve's measured clearance and specified clearance to calculate required thickness of NEW adjusting pad. NOTE: Always return cam followers to their original position. 8) Adjusting pads are available in .001" (.03 mm) increments, ranging from .085" (2.16) to .108" (2.74 mm), and are marked with letters from "A" to "Z" respectively. Insert correct adjusting pads, and install cam followers. Ensure No. 1 piston is at TDC. Install intake camshaft, and align it with timing gauge. CAUTION: Always use NEW cylinder head bolts. 9) Lubricate cam bearing caps with clean engine oil. Install No. 1 bearing cap. Remove No. 7 cap cylinder head bolt and spacer. Install No. 7 bearing cap. Alternately tighten No. 1 and 7 bearing caps. Remove spacers from cylinder head in following order: No. 4, 2, 3, 5 and 6. After one spacer is removed, immediately install camshaft bearing cap before removing next spacer. 10) Ensure intake camshaft is still at TDC. Install exhaust camshaft, and align it with timing gauge. Repeat step 9) for exhaust camshaft bearings. Tighten NEW cylinder head bolts in sequence to 43- 45 ft. lbs. (59-61 N.m), then turn bolt an additional 90 degrees. See Fig. 2. 11) Fit camshaft sprockets onto camshafts. Move all slack in timing chain to tensioner side. Install Upper Chain Tensioner Tool (18G 1436). See Fig. 3. Tighten center bolt on tensioner tool to tension upper chain. Fig. 2: Cylinder Head Tightening Sequence Courtesy of Jaguar Cars Inc.

4.0L 6-CYL VIN [7] Article Text (p. 4) 1995 Jaguar XJSFor 1 Copyright © 1998 Mitchell Repair Information Company, LLCT Fig. 3: Installing Upper Chain Tensioner Tool Courtesy of Jaguar Cars Inc. 12) Remove inner sprocket retaining clip. See Fig. 4. Remove inner sprocket, and align sprocket holes with holes in camshaft. Reinstall inner sprocket. Install lock tabs and retaining bolts. Install inner sprocket retaining clip. 13) Remove tensioner tool. Clean tensioner gasket mating surfaces. Install NEW tensioner gasket. Lubricate and install NEW "O" ring on tensioner. Install tensioner assembly into cylinder head. Tighten lower tensioner retaining bolt. DO NOT tighten tensioner valve clamp bolt at this time. 14) Clean tensioner valve assembly, and install NEW "O" rings. Insert 3-mm Allen wrench into center of tensioner. Turn Allen wrench counterclockwise to release tensioner. Lubricate and install tensioner valve. 15) Position tensioner clamp over tensioner valve. Tighten tensioner clamp bolt. Using NEW gasket, install cam cover. Tighten cam cover bolts in sequence and to specification. See Fig. 5. See TORQUE SPECIFICATIONS. Install coils and coil cover. Install cam cover breather hose. Fig. 4: Exploded View Of Camshaft Sprocket Courtesy of Jaguar Cars Inc.

4.0L 6-CYL VIN [7] Article Text (p. 5) 1995 Jaguar XJSFor 1 Copyright © 1998 Mitchell Repair Information Company, LLCT Fig. 5: Cam Cover Tightening Sequence Courtesy of Jaguar Cars Inc. REMOVAL & INSTALLATION NOTE: For installation reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Also place mating marks on engine hood and other major assemblies before removal. FUEL PRESSURE RELEASE Open trunk. Remove trunk front trim panel to access fuel tank. Disconnect fuel pump connector. Start engine and let it idle until engine stalls. Turn ignition off. Reconnect fuel pump connector. ENGINE NOTE: Manufacturer recommends removing engine and transmission as an assembly. Removal 1) Relieve fuel pressure. See FUEL PRESSURE RELEASE. Disconnect negative battery cable. Remove hood. Remove air cleaner assembly. Drain cooling system. Remove accessory drive belts. 2) Remove fan clutch and shroud. Disconnect coolant hoses and transmission cooler hoses from radiator. Remove radiator. Disconnect wiring harness connectors as necessary. Remove power steering pump. Disconnect fuel inlet line from fuel injector rail. 3) Disconnect fuel return line from pressure regulator. Mark and disconnect vacuum lines as necessary. Disconnect and remove throttle cable from throttle linkage. Remove mass airflow sensor and hoses. Remove oil cooler pipes from oil filter housing. 4) Attach lifting device to engine. Lift and support front of vehicle. Drain engine oil. Disconnect heat shield from exhaust

4.0L 6-CYL VIN [7] Article Text (p. 6) 1995 Jaguar X manifold. Disconnect exhaust pipes from exhaust manifold. Disconnect shift cable from transmission. Position floor jack underneath transmission. Mark drive shaft flanges for installation reference. Disconnect drive shaft from transmission. 5) Remove transmission rear mount. Lower front of vehicle. Remove crankshaft pulley and damper. Discharge A/C system. Remove A/C condenser. Disconnect hoses from A/C compressor. Remove engine bracket-to-front engine mount nuts. 6) Check for wires, hoses or any other components that are still attached. Being careful not to damage steering rack, lift and remove engine/transmission assembly from engine bay. Remove transmission from engine. Installation Carefully lower engine/transmission assembly into position, and tighten front engine mounts. Reverse removal procedure to complete installation. Check all fluid levels. Evacuate and recharge A/C system. INTAKE MANIFOLD Removal 1) Disconnect negative battery cable. Drain cooling system. Remove air cleaner assembly. Remove engine oil dipstick tube retaining bolt. Disconnect hoses from intake throttle elbow. Disconnect cam cover breather hose. Remove oil filler tube from lower housing. Disconnect throttle cable. 2) Disconnect heater hose from cylinder head. Remove intake manifold bolts and nuts. Disconnect ground wire from front stud. Remove engine wiring harness from intake studs. Remove oil filler tube upper mounting bracket. 3) Check for wires, hoses or any other components that are still attached. Carefully remove intake manifold and gaskets from cylinder head. Installation Clean gasket mating surfaces. Install NEW intake manifold gaskets. Install intake manifold, and tighten nuts to specification. See TORQUE SPECIFICATIONS. EXHAUST MANIFOLDS Removal Raise and support vehicle. Disconnect oxygen sensor connector. Disconnect exhaust downpipes from manifolds. Remove heat shield. Remove front and rear exhaust manifolds and gaskets. Installation Clean gasket mating surfaces. Install NEW exhaust manifold gaskets. Install exhaust manifolds. Tighten nuts to specification. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure.

4.0L 6-CYL VIN [7] Article Text (p. 7) 1995 Jaguar XJSFor 1 Copyright © 1998 Mitchell Repair Information Co CYLINDER HEAD Removal 1) Relieve fuel pressure. See FUEL PRESSURE RELEASE. Disconnect negative battery cable. Remove intake manifold. See INTAKE MANIFOLD. Remove thermostat housing. Raise and support vehicle. 2) Remove exhaust bracket from transmission. Disconnect exhaust downpipes from manifolds. Lower vehicle. Remove coil cover and coils from spark plugs. Disconnect cam cover breather hose. Remove cam cover and gasket. NOTE: In the following step, if after setting No. 1 piston at TDC camshafts do not indicate TDC, valve timing may have been changed as per Technical Service Bulletin (TSB). If valve timing has been modified, there should be 2 punch marks on timing cover (next to camshaft position sensor). See Technical Service Bulletin Number SECTION 03.1, No. 04 dated August, 1995. 3) Rotate crankshaft until timing notches in camshaft flanges are pointing down. Remove 2 accessible camshaft sprocket mounting bolts (per camshaft) and lock tabs. Rotate crankshaft until Timing Gauge (18G 1433) can be inserted into slot of camshaft front flange. Ensure timing marks align. CAUTION: DO NOT rotate crankshaft while camshaft sprocket is disconnected from camshaft. Serious damage to valve train components may occur. 4) Remove remaining camshaft sprocket mounting bolts and lock tabs from camshafts. Remove tensioner valve clamp bolt, and swing clamp away from center of chain tensioner. See Fig. 1. Remove valve from center of tensioner. Insert 3-mm Allen wrench into center of tensioner. 5) Turn Allen wrench clockwise until tensioner is in fully relieved position. Remove remaining chain tensioner bolt. Remove chain tensioner, "O" ring and gasket. Remove camshaft sprockets from camshafts. Remove cylinder head-to-engine block front nuts/bolts. 6) Remove upper chain guide. Remove remaining cylinder head bolts. Check for wires, hoses or other components that are still attached. Remove cylinder head and gasket. Inspection Ensure all mating surfaces are clean. Measure cylinder head for warpage. If warpage exists, disassemble and resurface cylinder head. Maximum resurface limit is .010" (.25 mm). CAUTION: Always use NEW cylinder head bolts. Installation 1) Install NEW head gasket. Using Timing Gauge (18G 1433),

4.0L 6-CYL VIN [7] Article Text (p. 8) 1995 Ja ensure camshafts are still at TDC. Ensure No. 1 piston is still at TDC. Install cylinder head. Tighten NEW cylinder head bolts in sequence to 45 ft. lbs. (61 N.m), then turn bolt an additional 90 degrees. See Fig. 2. 2) Position wiring harness clip and hose bracket, and install front cylinder head bolts. Fit camshaft sprockets onto camshafts with slack in timing chain on tensioner side of chain. DO NOT rotate crankshaft or camshaft to position slack in timing chain on tensioner side. Install Upper Chain Tensioner Tool (18G 1436). See Fig. 3. Tighten center bolt on tensioner tool to tension upper chain. 3) Remove inner sprocket retaining clip. See Fig. 4. Remove inner sprocket, and align sprocket holes with holes in camshaft. Reinstall inner sprocket. Install lock tabs and retaining bolts. Install inner sprocket retaining clip. 4) Remove tensioner tool. Clean tensioner gasket mating surfaces. Install NEW tensioner gasket. Lubricate and install NEW "O" ring on tensioner. Install tensioner assembly into cylinder head. Tighten lower tensioner retaining bolt. DO NOT tighten valve clamp bolt at this time. 5) Clean tensioner valve assembly, and install NEW "O" rings. Insert 3-mm Allen wrench into center of tensioner. Turn Allen wrench counterclockwise to release tensioner. Lubricate and install tensioner valve. 6) Position tensioner clamp over tensioner valve. Tighten tensioner clamp bolt. Using NEW gasket, install cam cover. Install coil cover and coils to spark plugs. Install cam cover breather hose. To complete installation, reverse removal procedure. FRONT COVER Removal 1) Disconnect negative battery cable. Remove hood. Remove intake manifold. See INTAKE MANIFOLD. Remove cylinder head. See CYLINDER HEAD. Remove fan clutch and radiator fan shroud. 2) Remove oil pan-to-front cover bolts. Remove power steering pump. Remove plastic power steering pump drive coupling. Remove bolt securing power steering drive plate. Using pry bar, remove power steering drive plate from auxiliary shaft. Remove alternator belt. Remove crankshaft damper. 3) Remove crankshaft speed sensor, and set aside. Disconnect coolant hoses from water pump. Remove water pump. Remove alternator adjusting bolt from front cover. Remove front cover retaining bolts and cover. Remove crankshaft Woodruff key and spacer. Remove front cover oil seal. Installation Clean gasket mating surfaces. Install NEW front cover oil seal. Ensure seal is flush with cover. Apply Hylosil 102 sealant to front cover gasket area and outer edge of oil pan. Install front cover. Using NEW "O" ring, install crankshaft spacer and Woodruff key. To complete installation, reverse removal procedure.

4.0L 6-CYL VIN [7] Article Text (p. 9) 1995 Jaguar XJSFor 1 Copyright © 1998 Mitchell Repair Information Company, LLCT FRONT COVER OIL SEAL Removal Remove front spoiler from underneath vehicle. Remove fan clutch and radiator shroud. Remove accessory drive belts. Remove crankshaft pulley and damper. Remove Woodruff key and spacer. Using Seal Remover/Installer (JD 129), remove oil seal from front cover. Installation Using Remover/Installer (JD 129) and crankshaft damper bolt, install NEW oil seal. Using NEW "O" ring, install crankshaft spacer. Install Woodruff key. To complete installation, reverse removal procedure. UPPER TIMING CHAIN & TENSIONER Removal Remove cylinder head. See CYLINDER HEAD. Remove front cover. See FRONT COVER. Remove upper chain. Remove pedestal/tensioner assembly and chain guide. See Fig. 6. Remove tensioner pivot pin and separate tensioner from pedestal. Installation Fit NEW tensioner to pedestal and install pivot pin. Align chain guide to tensioner and install pedestal/tensioner assembly. Ensure chain guide does not interfere with auxiliary shaft sprocket. Install NEW timing chain. Install front cover. To complete installation, reverse removal procedure. Fig. 6: Identifying Timing Chains & Components Courtesy of Jaguar Cars Inc. LOWER TIMING CHAIN & TENSIONER

4.0L 6-CYL VIN [7] Article Text (p. 10) 1995 Jaguar XJSFor 1 Copyright © 1998 Mitchell Repair Information Company, LLC Removal 1) Remove cylinder head. See CYLINDER HEAD. Remove front cover. See FRONT COVER. Remove upper chain. 2) Remove upper pedestal/tensioner assembly and chain guide. See Fig. 6. Remove tensioner pivot pin, and separate tensioner from pedestal. Remove lower timing chain tensioner. Remove lower timing chain. 3) Disassemble lower timing chain tensioner, and check for wear and damage. Replace tensioner if necessary. Installation 1) If reusing lower tensioner, clean, lubricate and reassemble tensioner. Install NEW lower timing chain. Install lower timing chain tensioner. Fill lower tensioner oil reservoir with oil, and work tensioner to prime with oil. Fit NEW upper tensioner to pedestal, and install pivot pin. 2) Align upper chain guide to tensioner, and install pedestal/tensioner assembly. Ensure chain guide does not interfere with auxiliary shaft sprocket. Install NEW upper timing chain. Install front cover. To complete installation, reverse removal procedure. CAMSHAFTS NOTE: In the following step, if after setting No. 1 piston at TDC camshafts do not indicate TDC, valve timing may have been changed as per Technical Service Bulletin (TSB). If valve timing has been modified, there should be 2 punch marks on timing cover (next to camshaft position sensor). See Technical Service Bulletin Number SECTION 03.1, No. 04 dated August, 1995. Removal 1) Remove coil cover and coils from spark plugs. Disconnect cam cover breather hose. Remove cam cover and gasket. Rotate crankshaft until No. 1 piston is at TDC. Using Timing Gauge (18G 1433), ensure camshafts are at TDC. 2) Remove tensioner valve clamp bolt, and swing clamp away from center of chain tensioner. See Fig. 1. Remove valve from center of tensioner. Insert 3-mm Allen wrench into center of tensioner. 3) Turn Allen wrench clockwise until tensioner is in fully relieved position. Remove remaining chain tensioner bolt. Remove chain tensioner, "O" ring and gasket. Rotate crankshaft until timing notches in camshaft flanges are pointing down. CAUTION: DO NOT rotate crankshaft while camshaft sprocket is disconnected from camshaft. Serious damage to valve train components may occur. 4) Remove 2 accessible camshaft sprocket mounting bolts (per camshaft) and lock tabs. Rotate crankshaft until Timing Gauge (18G 1433) can be inserted into slot of camshaft front flange. Remove remaining camshaft sprocket mounting bolts and lock tabs from

1995 Jaguar XJS Service & Repair Manual

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