Engine (2.5L/3.0L): Overhaul Jaguar S-type I рестайлинг

Cylinder Head - Assembly and Disassembly

Special Tools Tool Illustration Tool Name Tool Number Valve Spring Compressor 303-252

Scheme 126

Scheme 127

Scheme 128

1. Remove the bucket tappet and shim assemblies.
2. Using the special tool, compress the valve springs. Remove the valve collets.
3. Remove the valve spring retainers and valve springs. Remove the valve spring retainers. Remove the valve springs. Remove the valve stem oil seals.
4. Remove the valves from the cylinder heads. Remove the intake valves. Remove the exhaust valves.
5. Inspect the cylinder heads and the related components. Refer to «Engine System - General Information»(ref-311296) .
6. Remove the pipe plugs and alignment dowels as necessary to clean the cylinder heads.

Assembly

1. Clean gasket material, dirt and foreign material from cylinder heads. Wash with a suitable soap and water solution and dry completely using compressed air if pipe plugs have been removed.
2. Install the pipe plugs and alignment dowels to cylinder heads. Apply pipe sealant to plugs prior to installation.
3. Install the valves into the cylinder heads. Install the intake valves. Install the exhaust valves.
4. Install the valve spring retainers and valve springs. Install the valve stem oil seals. Install the valve springs. Install the valve spring retainers.
5. Using the special tool, compress the valve springs. Install the valve collets.
6. Install the bucket tappet and shim assemblies.

Scheme 129

1. Remove the top compression ring.
2. Remove the second compression ring.
3. Remove the first oil control ring.
4. Remove the oil control spacer ring.
5. Remove the second oil control ring.
6. Remove the retaining clips.
7. Remove the piston pin and the connecting rod from the piston.
8. Clean and inspect the connecting rod and the piston. For additional information, refer to «Engine System - General Information»(ref-311296) .

Scheme 130

Scheme 131

Scheme 132

Scheme 133

Scheme 134

1. Install the piston pin. Lubricate the piston pin and piston bore.
2. Install the retaining clips.
3. Check the piston ring end gap. For additional information, refer to «Engine System - General Information»(ref-311296) .
4. Lubricate the piston and piston rings.
5. Install the second oil control ring.
6. Install the oil control spacer ring.
7. Install the first oil control ring.
8. Install the second compression ring. The top of the second compression ring has a "0" marked on it. Position this side of the ring towards the top of the piston.
9. Install the top compression ring. The top compression ring can be installed with either side up.

Special Tools Tool Illustration Tool Name Tool Number Wrench Strap-Universal 303-D055 Crankshaft Rear Seal Installer 303-178 Crankshaft Rear Seal Installer Adapter Bolts 303-384 Piston Ring Compressor 303-372 Cylinder Bore Protector 303-535

Scheme 135

Scheme 136

Scheme 137

Scheme 138

Scheme 139

Scheme 140

Scheme 141

Scheme 142

Scheme 143

1. Clean all the mating faces and reusable parts thoroughly and check for damage. If gasket material remains on the cylinder head after cleaning, use a plastic tipped scraper to remove remaining material.
2. Reseal oil passage blanking plugs, as necessary.
3. Install the upper crankshaft thrust washer. Align assembly tab on thrust bearing to machining spot face on cylinder block.
4. Install the upper crankshaft main bearings. Lubricate the bearings and thrust washer.
5. Install the crankshaft.
6. Install the lower crankshaft bearings into the cylinder block. Install the lower crankshaft thrust main bearing into lower cylinder block. Install the lower crankshaft main bearings into lower cylinder block. Lubricate the bearings and thrust washer.
7. Apply a bead of sealant to the cylinder block housing. Use Silicone gasket and sealant.
8. Install the lower cylinder block on the cylinder block. Push crankshaft rearward to seat the crankshaft thrust washer.
9. Complete the tightening sequence. Stage 1: Bolts 1-8, 25 Nm Stage 2: Bolts 9-16, 40 Nm Stage 3: Bolts 1-16, 90° Stage 4: Bolts 17-22, 25 Nm Verify the crankshaft rotates freely.
10. Remove excess sealant which may squeeze out at the front cover sealing surface.
11. Using the special tools, install the crankshaft rear oil seal.
12. Install special tools to the connecting rods. Position the crankshaft journal at the bottom of the stroke.
13. Using the special tool compress the rings and install the piston and connecting rod. Lubricate all piston components.
14. Position the connecting rod cap on the appropriate connecting rod. Stage 1: 23 Nm Stage 2: 43 Nm Stage 3: 105°
15. Rotate the crankshaft to check correct operation.
16. Install the oil pump. Tighten to 10 Nm.
17. Install the oil pan baffle. Stage 1: 5 Nm Stage 2: 45°
18. Install the oil pump tube. Install a new O-ring seal. Tighten to 10 Nm.
19. Tighten to 5 Nm + 45°.
20. Install the engine coolant housing. Install new 'O' ring seals. Tighten to 25 Nm.
21. Position the crankshaft. Turn the crankshaft until the key is in the 11 o'clock position. Remove the crankshaft pulley bolt and washer.
22. Install a new cylinder head gasket (LH shown - RH similar). Make sure the cylinder head dowels are correctly located. Install a new cylinder head gasket.
23. Install the LH cylinder head. Tighten to 30 Nm. Tighten 90°. Loosen 360°. Tighten to 30 Nm. Tighten 90°. Tighten 90°.
24. Install the RH cylinder head. Tighten to 30 Nm. Tighten 90°. Loosen 360°. Tighten to 30 Nm. Tighten 90°. Tighten 90°.
25. Install the LH inlet camshaft.
26. Install the LH inlet camshaft bearing cap bolts evenly. Install the inlet camshaft bearing caps. Tighten to 10 Nm.
27. Install the LH exhaust camshaft.
28. Install the LH exhaust camshaft bearing cap bolts evenly. Install the exhaust camshaft bearing caps.
29. Install the RH inlet camshaft.
30. Install the RH inlet camshaft bearing cap bolts evenly. Install the inlet camshaft bearing caps.
31. Install the RH exhaust camshaft.
32. Install the RH exhaust camshaft bearing cap bolts evenly. Install the exhaust camshaft bearing caps.
33. Rotate the right-hand intake camshaft clockwise until the camshaft sprocket alignment mark is at the 5 O'clock position and rotate the right-hand exhaust camshaft sprocket clockwise until the camshaft sprocket alignment mark is at the 12 O'clock position.
34. Install the crankshaft inner sprocket.
35. Install the left-hand timing chain outer guide. Tighten the retaining bolts in the sequence shown in two stages. Stage 1: Tighten bolt 1 to 25 Nm. Stage 2: Tighten bolts 2 to 25 Nm.
36. Install the left-hand timing chain.
37. Install the left-hand timing chain inner guide.
38. Secure the left-hand timing chain tensioner in the vice jaws.
39. Using a suitable tool, hold the left-hand timing chain tensioner ratchet lock mechanism away from the ratchet stem.
40. Slowly compress the left-hand timing chain tensioner.
41. Using a suitable tool, retain the left-hand timing chain tensioner piston.
42. Install the left-hand timing chain tensioner. Tighten to 25 Nm.
43. Release the tension in the left-hand timing chain tensioner. Remove the retaining tool.
44. Make sure the left-hand timing chain alignment marks have remained correctly positioned to the camshaft sprocket and crankshaft sprocket alignment marks.
45. Install the crankshaft pulley retaining bolt and washer.
46. Rotate the crankshaft clockwise until the crankshaft keyway is at the 3 O'clock position.
47. Remove the crankshaft pulley retaining bolt and washer.
48. Install the crankshaft outer sprocket.
49. Install the right-hand timing chain inner guide. Tighten the retaining bolts in the sequence shown in two stages. Stage 1: Tighten bolt 1 to 25 Nm. Stage 2: Tighten bolts 2 to 25 Nm.
50. Install the right-hand timing chain.
51. Install the right-hand timing chain outer guide.
52. Secure the right-hand timing chain tensioner in the vice jaws.
53. Using a suitable tool, hold the right-hand timing chain tensioner ratchet lock mechanism away from the ratchet stem.
54. Slowly compress the right-hand timing chain tensioner.
55. Using a suitable tool, retain the right-hand timing chain tensioner piston.
56. Install the right-hand timing chain tensioner. Tighten to 25 Nm.
57. Release the tension in the right-hand timing chain tensioner. Remove the retaining tool.
58. Make sure all the timing chain alignment marks are in the positions shown.
59. Install the crankshaft pulley retaining bolt and washer.
60. Check the engine valve timing is correctly set. Rotate the crankshaft two complete turns clockwise. Make sure the alignment marks on the camshaft sprockets are in the positions shown when the crankshaft keyway is at the 11 O'clock position.
61. Remove the crankshaft pulley retaining bolt and washer.
62. Install the CKP sensor pulse wheel.
63. Carry out a valve clearance check. «Valve Clearance Check - General Procedures»(ref-311287-S13135242802009032500000) .
64. Install new front timing cover gaskets.
65. Apply a 6 mm diameter dot of silicone sealant meeting Jaguar specification to the indicated locations.
66. Install the engine front cover, completing the tightening sequence . Tighten to 25 Nm.
67. Install the oil pan rear retaining bolts. Complete the tightening sequence. Tighten to 25 Nm.
68. Install the valve covers. Complete the tightening sequence. Tighten to 10 Nm.
69. Install the left-hand idler pulley. Tighten to 25 Nm.
70. Using the special tools, install the crankshaft pulley. Coat the crankshaft pulley keyway with silicone gasket sealant meeting Jaguar specification. Coat the sealing surfaces of the crankshaft pulley with silicone gasket sealant meeting Jaguar specification.
71. Install the crankshaft pulley retaining bolt. Torque to 120 Nm. Loosen the bolt (minimum 1 turn). Torque to 50 Nm. Angle Torque to 90°.
72. Install the accessory drive belt tensioner. Tighten 45 Nm.
73. Install the water pump and coolant hose assembly. Attach the hose. Install the water pump and coolant hose assembly. Tighten to 25 Nm.
74. Install the coolant crossover tube. Tighten to 10 Nm
75. Install the engine oil pressure and oil temperature sensors. Tighten to 14Nm.
76. Install the oil filter housing assembly. Tighten all oil filter housing retaining bolts to 25 Nm.
77. Tighten the oil filter housing assembly retaining bolts in sequence. Tighten to 150 Nm. Tighten to 40 Nm + 90 degrees.
78. Install the engine rear backing plate.
79. Install the flywheel. Prevent the engine from rotating. Tighten to 80 Nm.
80. Install the exhaust manifolds. Tighten to 25 Nm.
81. Install the exhaust manifold heat shields. Tighten to 10 Nm.
82. Install the oil level indicator tube.
83. Install the A/C compressor mounting bracket. Tighten to 25 Nm.
84. Install the air conditioning (A/C) compressor. Tighten to 25 Nm.
85. Install the power steering pump. Tighten to 25 Nm.
86. Install the generator. Tighten to 48 Nm.
87. Install the right-hand idler pulley. Tighten to 25 Nm.
88. Install the accessory drive belt. Use a 3/8 inch drive bar to release the accessory drive belt tensioner. Install the accessory drive belt.
89. Install the left-hand knock sensor. Tighten to 25 Nm.
90. Install new lower intake manifold gaskets.
91. Install the lower intake manifold and injector supply manifold. Tighten to 10 Nm.
92. Install the ignition coils. Tighten to 10 Nm.
93. Install the engine wiring harness. Tighten to 10 Nm.
94. Connect the engine wiring harness electrical connectors.
95. Connect the left-hand ignition coils.
96. Connect the left-hand camshaft position sensor.
97. Attach the engine harness.
98. Connect the right-hand ignition coils.
99. Attach the engine harness.
100. Attach the engine harness retaining bracket.
101. Disconnect the right-hand camshaft position sensor.
102. Install the rear knock sensor. Attach the knock sensor wiring harness. Install the rear knock sensor. Tighten to 25 Nm.
103. Attach engine harness.
104. Attach the engine harness.
105. Connect the electrical connectors.
106. Install the coolant hose.
107. Install the coolant hose.
108. Connect the oil cooler coolant hoses.
109. Install the evaporative emission purge valve hose.
110. Install the engine breather hose.
111. Install new intake manifold gaskets.
112. To install, reverse the removal procedure. Install new intake manifold gaskets. Tighten to 10 Nm.
113. Connect the evaporative emission canister purge valve transfer pipe.
114. Attach the intake manifold rear retaining bracket. Tighten to 10 Nm.
115. Attach the engine wiring harness from the intake manifold rear retaining bracket.
116. Attach the intake manifold front retaining bracket. Tighten to 10 Nm.
117. Install the fuel pressure regulator bracket. Tighten to 10 Nm.
118. Tighten to 7 Nm.
119. Connect the fuel pressure regulator vacuum hose.
120. Connect the electrical connectors.
121. Connect the positive crankcase ventilation (PCV) hose.
122. Connect the throttle position sensor.
123. Connect the throttle motor electrical connector.

Engine - Installation

Special Tools Tool Illustration Tool Name Tool Number Engine lifting Bracket 303-661 Engine Support Bracket 303-021 5 point security torx bit 418-535