Engine: Removal & Installation Jaguar XJS Series 3

Removal

1. Relieve fuel pressure. See «FUEL PRESSURE RELEASE»(ref-49029-S13974539342001011500000) under REMOVAL & INSTALLATION. 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 if 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 if necessary. Disconnect and remove throttle cable from throttle linkage. Remove airflow meter 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 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.

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/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.

Clean gasket mating surfaces. Install NEW intake manifold gaskets. Install intake manifold, and tighten nuts to specification. See TORQUE SPECIFICATIONS .

Raise and support vehicle. Disconnect oxygen sensor connector. Disconnect exhaust downpipes from manifolds. Remove heat shield. Remove front and rear exhaust manifolds and gaskets.

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.

1. Relieve fuel pressure. See «FUEL PRESSURE RELEASE»(ref-49029-S13974539342001011500000) under REMOVAL & INSTALLATION. Disconnect negative battery cable. Remove intake manifold. See «INTAKE MANIFOLD»(ref-49029-S42426843242001011500000) under REMOVAL & INSTALLATION. Remove thermostat housing. Remove distributor cap and spark plug wires.
2. Rotate crankshaft until No. 1 piston is at TDC. Note rotor and distributor location for installation reference. Remove distributor. Raise and support vehicle. Remove exhaust bracket from transmission. Disconnect exhaust downpipes from manifolds. Lower vehicle. Remove cam cover.
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. 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 scheme 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.

1. Install NEW head gasket. Using Timing Gauge (18G 1433), 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 scheme 2
2. Position wiring harness clip and hose bracket, and install front cylinder head bolts. Fit camshaft sprockets onto camshafts. Move all slack in timing chain to tensioner side. Install Upper Chain Tensioner Tool (18G 1436). see scheme 3 Tighten center bolt on tensioner tool to tension upper chain.
3. Remove inner sprocket retaining clip. see scheme 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 and cam cover seals, install cam cover. Install distributor and cam cover breather. To complete installation, reverse removal procedure.

1. Disconnect negative battery cable. Remove hood. Remove intake manifold. See «INTAKE MANIFOLD»(ref-49029-S42426843242001011500000) under REMOVAL & INSTALLATION. Remove cylinder head. See CYLINDER HEAD under «REMOVAL & INSTALLATION»(ref-49029-S04271634292001011500000) . 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.

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.

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.

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.

Remove cylinder head. See CYLINDER HEAD under REMOVAL & INSTALLATION. Remove front cover. See FRONT COVER under REMOVAL & INSTALLATION. Remove upper chain. Remove pedestal/tensioner assembly and chain guide. (Scheme 5) Remove tensioner pivot pin and separate tensioner from pedestal.

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.

Scheme 5

1. Remove cylinder head. See CYLINDER HEAD under «REMOVAL & INSTALLATION»(ref-49029-S04271634292001011500000). Remove front cover. See FRONT COVER under REMOVAL & INSTALLATION. Remove upper chain.
2. Remove upper pedestal/tensioner assembly and chain guide. (Scheme 5) 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.

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.

1. Remove distributor cap and spark plug wires. Disconnect breather hose from cam cover. Remove cam cover, gasket and seals. Rotate crankshaft until No. 1 piston is at TDC. Using Timing Gauge (18G 1433), ensure camshafts are at TDC. Mark distributor rotor and housing location for installation reference.
2. Remove distributor. Remove tensioner valve clamp bolt, and swing clamp away from center of chain tensioner. see scheme 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 camshafts. Remove camshaft sprockets.
5. Counting from the 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. 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. Install spacer and No. 7 cylinder head bolt. Tighten bolt to 39 ft. lbs (53 N.m). Remove intake camshaft. Repeat steps 5) and 6) for exhaust camshaft.

1. Ensure No. 1 piston is still at TDC. Install intake camshaft and align with Timing Gauge (18G 1433). CAUTION: Always use NEW cylinder head bolts.
2. 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 and NEW cylinder head bolt. Alternately tighten No. 1 and 7 bearing caps. Remove spacers from cylinder head in the following order: No. 4, 2, 3, 5 and 6. After one spacer is removed, immediately install camshaft bearing cap before removing next spacer.
3. Ensure intake camshaft is still at TDC. Install exhaust camshaft and align with timing gauge. Repeat step 2) for exhaust camshaft bearings. Tighten NEW cylinder head bolts in sequence to 45 ft. lbs. (61 N.m), then turn bolt an additional 90 degrees. see scheme 2
4. Fit camshaft sprockets onto camshafts. Move all slack in timing chain to tensioner side. Install Upper Chain Tensioner Tool (18G 1436). see scheme 3 Tighten center bolt on tensioner tool to tension upper chain.
5. Remove inner sprocket retaining clip. see scheme 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.
6. 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.
7. 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.
8. Position tensioner clamp over tensioner valve. Tighten tensioner clamp bolt. Using NEW gasket and cam cover seals, install cam cover. Install distributor and cam cover breather hose.

1. Remove cylinder head. See CYLINDER HEAD under «REMOVAL & INSTALLATION»(ref-49029-S04271634292001011500000). Remove front cover. See FRONT COVER under REMOVAL & INSTALLATION. Remove pedestal/tensioner assembly and chain guide. (Scheme 5)
2. Remove tensioner pivot pin, and separate tensioner from pedestal. Remove upper left chain guide. Remove upper chain. Remove lower chain tensioner. Remove power steering pump. Remove power steering pump drive coupling.
3. Remove oil seal from power steering pump adapter. Remove snap ring from auxiliary shaft. Remove lower chain from auxiliary sprocket. Remove auxiliary shaft/sprocket assembly and thrust washer.

1. Using NEW gasket, install power steering pump adapter (if removed). Lubricate and install auxiliary shaft. Install thrust washer and snap ring. Lubricate and install NEW oil seal into pump adapter. Install drive coupling to power steering pump.
2. Align pump shaft with auxiliary shaft, and connect pump shaft to drive coupling. Install and tighten pump retaining bolts. Attach chains to appropriate sprockets. Install lower chain tensioner. Fill lower tensioner oil reservoir with oil, and work tensioner to prime with oil.
3. Fit NEW upper tensioner to pedestal, and install pivot pin. Align upper chain guide to tensioner, and install pedestal/tensioner assembly. Ensure chain guide does not interfere with auxiliary shaft sprocket.
4. Using Seal Remover/Installer (JD 129), install NEW front cover oil seal. Install front cover. To complete installation, reverse removal procedure.

Remove engine and transmission as an assembly. See ENGINE under REMOVAL & INSTALLATION . Remove transmission from engine. Mark drive plate-to-crankshaft position for installation reference. Remove drive plate from crankshaft. Remove oil seal housing bolts and housing. Remove oil seal from housing. Clean and inspect seal housing.

Using Seal Installer (JD 550-3 and 18G 134), install NEW oil seal. DO NOT remove plastic "O" ring protector from NEW seal. Apply Hylosil 102 sealant to seal housing gasket area. Install seal housing. Remove plastic "O" ring protector. Install and tighten seal housing bolts. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.