4.0L V8: Other Jaguar S-type I

FUEL PRESSURE RELEASE

Note. Special tool required: Fuel Pressure Gauge (310-058) or equivalent. see scheme 205

1. Disconnect battery and remove the fuel system service valve cap. (Scheme 207)
2. Install the fuel pressure gauge to the fuel system service valve. (Scheme 209)
3. Relieve the fuel system pressure by rotating the valve on the fuel pressure gauge counterclockwise. (Scheme 208) When relieving the fuel system pressure, catch any displaced fuel in a suitable container. (Scheme 210)
4. Store the drained fuel safely and ensure that the lid is closed securely. Remove the fuel pressure gauge from the fuel system service valve and install the service valve cap.
5. Connect the battery. See «BATTERY RECONNECT PROCEDURE»(ref-161157-S14898758862004032200000) under MISCELLANEOUS.

Scheme 207

Scheme 208

Scheme 209

Scheme 210

ENGINE

Note. Special tools required: Windshield Wiper Remover Tool (501-065), Engine Lifting Brackets (303-536), and an overhead lifting crane with a minimum safe working load capacity of 1100 lbs. (500 kg). see scheme 207and see scheme 208.

Note. "A" bank refers to the right/passenger side of the vehicle and "B" bank refers to left/driver side of the vehicle.

INTAKE MANIFOLD

Note. Special tools required: Windshield Wiper Remover Tool (501-065). see scheme 207

Note. "A" bank refers to the right/passenger side of the vehicle and "B" bank refers to left/driver side of the vehicle.

EXHAUST MANIFOLD

Note. "A" bank refers to the right/passenger side of the vehicle and "B" bank refers to left/driver side of the vehicle.

VALVE COVERS

Note. "A" bank refers to the right/passenger side of the vehicle and "B" bank refers to left/driver side of the vehicle.

CYLINDER HEAD

Note. The 4.0L V8 has no engine timing alignment marks on the crankshaft or camshafts. Engine timing is achieved by installing the Crankshaft Setting Peg (303-531) and Camshaft Locking Tool (303-530). With the crankshaft setting peg in position, ensure the timing flat on each camshaft is in the uppermost position before installing camshaft locking tool.

Note. "A" bank refers to the right/passenger side of the vehicle and "B" bank refers to left/driver side of the vehicle.

CRANKSHAFT DAMPER/FRONT OIL SEAL

Note. Special tools required: Crankshaft Main Locking Tool (303-191), Adaptor (303-191-02), Crankshaft Front Seal Remover (303-541), Crankshaft Front Seal Installer (303-542) and Crankshaft Pulley/Damper Remover (303-588). see scheme 209- see scheme 213.

TIMING CHAIN COVER

Note. "A" bank refers to the right/passenger side of the vehicle and "B" bank refers to left/driver side of the vehicle.

PRIMARY TIMING CHAINS

Note. The 4.0L V8 has no engine timing alignment marks on the crankshaft or camshafts. Engine timing is achieved by installing the Crankshaft Setting Peg (303-531) and Camshaft Locking Tool (303-530). With the crankshaft setting peg in position, ensure the timing flat on each camshaft is in the uppermost position before installing camshaft locking tool.

Note. Variable Valve Timing (VVT) unit may also be referred to as variable camshaft timing oil control unit.

Note. Special Tools Required: Crankshaft Setting Peg (303-531), Camshaft Locking Tool (303-530), Chain Tensioning Tool (303-532), and Primary Chain Wedge (303-533). see scheme 214- see scheme 217.

Note. "A" bank refers to the right/passenger side of the vehicle and "B" bank refers to left/driver side of the vehicle.

SECONDARY TIMING CHAIN

Note. The 4.0L V8 has no engine timing alignment marks on the crankshaft or camshafts. Engine timing is achieved by installing the Crankshaft Setting Peg (303-531) and Camshaft Locking Tool (303-530). With the crankshaft setting peg in position, ensure the timing flat on each camshaft is in the uppermost position before installing camshaft locking tool.

Note. Variable Valve Timing (VVT) unit may also be referred to as variable camshaft timing oil control unit.

Note. "A" bank refers to the right/passenger side of the vehicle and "B" bank refers to left/driver side of the vehicle.

CAMSHAFT

Note. This procedure includes tappet and shim procedure.

CRANKSHAFT REAR OIL SEAL

Note. Special tool required: Crankshaft Rear Oil Seal Remover/Installer (303-538). see scheme 218

OIL PAN (UPPER)

Manufacturer does not give an in vehicle procedure for the upper oil pan.

OIL COOLER

Note. Special tool required: Oil Filter Remover/Installer (303-752). see scheme 219

Battery Disconnect Procedure

Note. Before disconnecting the battery make sure that no data is required from the Powertrain Control Module (PCM), as battery cable disconnection will erase any fault codes and idle/drive values held in the Keep Alive Memory (KAM). It is not necessary to disconnect or remove electronic control modules. When the battery is disconnected all previous climate control settings and fault codes will be lost. It is necessary to record any settings or fault codes before battery disconnection to prevent customer complaint. This procedure should be used to disconnect the battery while carrying out repairs that refer to the battery being disconnected.

1. Obtain and record the audio unit key code and preset radio frequencies.
2. Reposition the luggage compartment floor covering and disconnect the battery ground cable. see scheme 160

Battery Reconnect Procedure

Note. Following reconnection of the battery, the engine should be allowed to idle as the stored idle and drive values contained within the Powertrain Control Module (PCM) have been lost. This may cause driveability concern if the following procedure is not carried out.

1. Connect the battery negative cable. see scheme 160 Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-161157-S07430046262004032200000).
2. Start the engine and allow to idle until the engine reaches normal operating temperature. Turn the engine off.
3. Restart the engine and allow to idle for approximately 2 minutes. This will allow the PCM to learn the idle values.
4. Apply and hold the brake pedal, select drive and allow the engine to idle for a further 2 minutes.
5. Drive the vehicle for approximately 5 miles, under various driving conditions, to enable the PCM to complete the learning strategy.
6. Reset audio and climate controls to original settings to avoid customer complaint.

Scheme 211

Fitting Pistons

Note. The bed plate must be in place and tightened to the specification; however, the bearing shells should not be installed.

1. Using a dial bore indicator, measure each of the cylinder bores. Measure cylinder bore in different directions and at different heights to determine if there is any out-of-roundness or tapering. (Scheme 213) Verify measurements are within specification. See «CYLINDER BLOCK»(ref-161157-S40888364462004040500000) table under ENGINE SPECIFICATIONS. If the measurement is out of the specification, hone out the cylinder block or install a new block.
2. Using a micrometer, measure the piston diameter at the height of the piston pin bore, but offset by 90 degrees. see scheme 177 Verify that measurements are within specification. See «PISTONS, PINS & RINGS»(ref-161157-S18731105492004040500000) table under ENGINE SPECIFICATIONS. If measurements are not within specification, install both a new piston and a new piston pin.

Scheme 212

Piston Rings

1. Remove the all piston rings. (Scheme 214)
2. Using a feeler gauge, measure the piston ring gap. (Scheme 215) Verify that measurements are within specification. See «PISTONS, PINS & RINGS»(ref-161157-S18731105492004040500000) table under ENGINE SPECIFICATIONS.
3. Using a feeler gauge, measure the piston ring clearance. (Scheme 216) Verify that measurements are within specification. See «PISTONS, PINS & RINGS»(ref-161157-S18731105492004040500000) table under ENGINE SPECIFICATIONS.
4. Lubricate the piston and piston rings and install the piston rings in the following order: Install the second oil control ring. Install the oil control spacer ring. Install the first oil control ring. Install the second compression ring. The top of the second compression ring has a "Of" marked on it. Position this side of the ring towards the top of the piston. Install the top compression ring. The top compression ring can be installed either side up. (Scheme 214) Make sure the piston ring gaps are positioned at different positions opposite the thrust side of the piston before installation.

Scheme 213

Scheme 214

Scheme 215

Connecting Rod Bearings

Note. Journals are numbered from timing chain side of engine to flywheel side of engine. Main and rod bearing selection is made by using crankshaft and block codes. (Scheme 217) First 5-digits of the crankshaft code are use to determine crankshaft main bearing journal diameters. Last-4 digits of the crankshaft code are use to determine crankshaft rod bearing journal diameters. First 8-digits of the block code are used to determine cylinder bore diameter. Last 5-digits of block code are use to determine block main bearing journal diameter.

1. Remove connecting rod bearings and inspect bearings for wear. (Scheme 218)
2. Crankshaft rod bearing journal codes are the last 4-digits of crankshaft code. Sixth digit of crankshaft code is for journal No. 1, seventh digit is for journal No. 3, etc. If rod bearing journal code is "A", use rod bearings with bearing grade color of Blue. If rod bearing journal code is "B", use rod bearings with bearing grade color of Green. If rod bearing journal code is "C", use a rod bearing with bearing grade color of Yellow.
3. Connecting rods MUST BE fitted to cylinder position marked on rod and rod cap. Each connecting rod has a thin and thick flange. The thin flange side is also marked with a dimple adjacent to the bearing. Connecting rods are installed on their respective journals with thin flanges (dimples) facing each other.
4. Connecting rod bolts MUST BE replace after each use. Tighten connecting rod bolts in proper sequence to specification. See «TORQUE SPECIFICATIONS»(ref-161157-S07430046262004032200000). Center-punch bolts after torque sequence is complete.

Scheme 216

Scheme 217

Crankshaft & Main Bearings

Note. Journals are numbered from timing chain side of engine to flywheel side of engine. Main and rod bearing selection is made by using crankshaft and block codes. (Scheme 217) First 5-digits of the crankshaft code are use to determine crankshaft main bearing journal diameters. Last 4-digits of the crankshaft code are use to determine crankshaft rod bearing journal diameters. First 8-digits of the block code are used to determine cylinder bore diameter. Last 5-digits of block code are use to determine block main bearing journal diameter.

1. Remove the bed plate bolts in the proper sequence. (Scheme 219) Remove the bed plate from the cylinder block.
2. Remove and discard the rear crankshaft oil seal. (Scheme 220)
3. Remove the crankshaft. (Scheme 221)
4. Remove the crankshaft thrust and main bearings. (Scheme 222)
5. Check the crankshaft bearing journal clearance by: Installing the crankshaft main bearings and crankshaft without lubrication, into the cylinder block. Position a strip of plastigage, equal to the width of the bearing, on the bearing journal. (Scheme 223) Install the bed plate, with bearing shells, tighten to specification in proper sequence. See «TORQUE SPECIFICATIONS»(ref-161157-S07430046262004032200000). (Scheme 224) Carefully remove the bed plate, being careful not to disrupt the plastigage. Compare the width of plastigage with the plastigage scale. (Scheme 225) The plastigage reading is the bearing clearance. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-161157-S40220769102004040200000) table under ENGINE SPECIFICATIONS. If the measurements are not within specification, install a new crankshaft.
6. Crankshaft main bearing journal codes are the first 5-digits of the crankshaft code. First digit of crankshaft code is for journal No. 1, second digit is for journal No. 2, etc. Block main bearing journal codes are the last 5-digits of the block code. Ninth digit of block code is for journal No. 1, tenth digit is for journal No. 2, etc. To select the proper bearing for each journal, refer to illustration. (Scheme 226)
7. Install and lubricate the upper crankshaft main bearings and thrust washers. (Scheme 222)
8. Install the crankshaft. (Scheme 221)
9. Apply RTV Sealant (WSS-M4G320-A3) to the cylinder block. (Scheme 227)
10. Install and lubricate the lower bearings to the bed plate. Install the bed plate with bearing shells to the cylinder block. Tighten bed plate bolts to specification in proper sequence. See «TORQUE SPECIFICATIONS»(ref-161157-S07430046262004032200000). Remove excess sealant which may squeeze out at the front cover sealing surfaces.
11. Ensure that the transit sleeve is correctly in place and install the NEW seal over the crankshaft. Do not use any lubricant on the seal, the transit sleeve or the crankshaft.
12. Carefully remove the transit sleeve, leaving the seal in place.
13. Install and align Crankshaft Rear Oil Seal Remover/Installer (303-538) to the crankshaft. Unscrew the 2 nuts towards the head of each outer bolt. Unscrew the center bolt until it is below the mounting surface of the tool. Install the crankshaft rear oil seal remover/installer on the rear of the crankshaft and lightly tighten. see scheme 123
14. Tighten the nuts, finger tight, to hold the tool assembly against the seal. Check that the seal and the tool are approximately parallel to the rear of the engine. see scheme 124
15. Hold the outer bolts stationary, and in turn, tighten the nuts a small amount (approximately 2 to 3 flats) until the crankshaft rear seal is pressed fully into the housing and the crankshaft rear oil seal remover/installer contacts the cylinder block. see scheme 128
16. Remove the crankshaft rear oil seal remover/installer from the crankshaft. Check that the seal is located correctly.

Scheme 218

Scheme 219

Scheme 220

Scheme 221

Scheme 222

Scheme 223

Scheme 224

Scheme 225

Scheme 226

Thrust Bearing

Using a dial indicator, measure the crankshaft end play by sliding the crankshaft in both directions. (Scheme 228) Note the maximum and minimum values on the dial indicator. End play equals the difference in the 2 readings. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS. If the value is out of the specification, install NEW thrust bearings to take up the end float and repeat the measurement.

Scheme 227

Cylinder Block

1. Remove the lower oil pan bolts and remove the lower oil pan. see scheme 153 Remove and discard the gasket.
2. Remove the 3 oil strainer bolts and remove the oil strainer. (Scheme 229) Discard the "O" ring.
3. Remove the upper oil pan bolts and remove the upper oil pan. (Scheme 230) Discard the upper oil pan gasket.
4. Remove the 4 oil pump bolts and remove oil pump. (Scheme 211) Discard the oil pump gasket.
5. Remove the connecting rod bolts, the connecting rod caps and the lower connecting rod bearings. (Scheme 231) Discard the connecting rod bolts after removal.
6. Inspect the tops of the cylinder bores. If necessary remove any ridge and carbon build-up from each cylinder.
7. Install the Crankshaft Protectors (303-535) to connecting rod to prevent damage to the crankshaft bearing journals and cylinder bore surfaces. (Scheme 232)
8. Rotate the crankshaft to locate pistons at the bottom of travel. Push the piston, connecting rod and upper bearing through the top of the cylinder. (Scheme 233) Reattach the connecting rods and caps after removal to avoid mismatch.
9. Remove crankshaft. See «CRANKSHAFT & MAIN BEARINGS»(ref-161157-S04468483832004040500000).
10. Clean gasket material, dirt and foreign material from cylinder block. Wash with a suitable soap and water solution and dry the cylinder block completely using compressed air. Reseal oil passage plugs, as necessary.
11. Install crankshaft. See «CRANKSHAFT & MAIN BEARINGS»(ref-161157-S04468483832004040500000).
12. Prepare the piston assembly for installation by: Installing the connecting rod bearings. Installing the crankshaft protectors to connecting rod to prevent damage to the crankshaft bearing journals and cylinder bore surfaces. Positioning the crankshaft journal at the bottom of the stroke. Lubricating all piston components. Using the Piston Ring Compressor (303-372) to compress the piston rings. see scheme 201
13. Install the piston assembly. Remove the crankshaft protectors from the connecting rods and install the connecting rod cap. (Scheme 231) Tighten the connecting rod bolts to specification. See «TORQUE SPECIFICATIONS»(ref-161157-S07430046262004032200000). Rotate the crankshaft to check for correct operation. Repeat procedure until all piston assemblies are installed.
14. Using a NEW oil pump gasket, install the oil pump onto the front of the crankshaft. (Scheme 211) Ensure that the drive flats on the inside of the pump gear engage correctly with the mating flats on the crankshaft. Install the 4 oil pump bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-161157-S07430046262004032200000).
15. Using a NEW gasket, install the upper oil pan and upper oil pan bolts. (Scheme 230) Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-161157-S07430046262004032200000).
16. Using a NEW "O" ring, install the oil strainer and oil strainer bolts. (Scheme 229)
17. Install a NEW oil pan gasket to the upper oil pan by inserting the seal into the locating positions in the groove, working around from a corner. Press in the remainder of the seal, following the same procedure. see scheme 154
18. Align and install the lower oil pan, installing but not tightening all 17 bolts. see scheme 153
19. Tighten the lower oil pan bolts to specification and in the proper sequence. See «TORQUE SPECIFICATIONS»(ref-161157-S07430046262004032200000). see scheme 155
20. Using a NEW sealing washer, install the engine oil drain plug and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-161157-S07430046262004032200000).

Scheme 228

Scheme 229

Scheme 230

Scheme 231

Scheme 232

Scheme 233

Oil Pressure

Oil pressure is supplied by the oil pump which is fitted to the front of the engine and is driven directly by the crankshaft. The inlet and outlet ports align with oil passages in the bed plate with a rubber coated metal gasket to seal the pump to bed plate. An integral pressure relief valve regulates pump outlet pressure at 65.3 psi (4.5 BAR).