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Workshop Manual

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XJ-S V12 5.3L

1975-1991

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 INTRODUCTION

INTRODUCTION
The Service Manual covers the Jaguar XJ-S 3.6 and V12 models in Coupe, Cabriolet and Convertible form. It
is primarily designed to assist skilled technicians in the efficient repair and maintenance of Jaguar vehicles.

Using the appropriate service tools and carrying out the procedures will enable the operations to be
completed within the stated in the "Repair Operations Times".

The Service Manual has been produced in four volumes; this allows information to be distributed throughout
the specialist areas of the modern service facility.

The table of contents in volume 1 lists the major components and systems together with the section and
volume numbers in which they are contained. Each section starts with a list of operations in alphebetical order.

OPERATION NUMBERING

A master index of numbered operations has been compiled for universal application to all vehicles
manufactured by Jaguar Cars Limited., and therefore because of the different specifications of various
models, continuity of the numbering sequence is not maintained throughout this manual.

Each operation described in this manual is allocated a number from the master index and cross-refers with an
identical number in the "Repair Operation Times". The number consists of six digits arranged in three pairs.

Each operation is laid out in the sequence required to complete the operation in the minimum time, as
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specified in the "Repair Operation Times".

SERVICE TOOLS

Where performance of an opertion requires the use of a service tool , the tool number is quoted under the
operation heading and is repeated in, or following the instruction involving its use. A list of all necessary tools
is included in Volume 1, Section 1

REFERENCES

References to the left or right-hand side of the vehicle are made when from the rear. With the engine
and gearbox assembly removed, the timing cover end of the engine is refered t o as the front. A key to
abbreviations and symbols is given in Volume 1, Section

01-01
 INTRODUCTION

REPAIRS AND REPLACEMENTS

When service parts are required it is essential that only genuine Jaguar replacements are used.

Attention is particularly drawn to the following points concerning repairs and the fitting of replacement parts
and accessories.

1. Safety features embodied in the vehicle may be impaired if other than genuine parts are fitted. In
certain territories, legislation prohibits the fitting of parts not to the vehicle manufacturer's
specification.

2. Torque wrench setting figures given in this Service Manual must be strictly adhered.

3. Locking devices, where specified, must be fitted. If the efficiency of the locking device is impaired
during removal, it must be replaced.

4. Owners purchasing accessories while travelling abroad, should ensure that the accessory and its
fitted location on the vehicle, conform to mandatory requirements existing in their country of origin.

5. The vehicle warranty may be invalidated by the fitting of other than genuine Jaguar parts. All Jaguar
replacements have the full backing of the factory warranty.

6. Jaguar Dealers are obliged to supply only genuine service parts.

ANTI-THEFT LABELS (USA)

All Jaguar cars for export to the USA are fitted with anti-theft labels as required by the National Highway
Traffic Safety Administration.

ANTI-THEFT LABELS ON

The following must be observed when dealing with anti-theft labels on new vehicles.

NOTE: It is vital that these are strictly adhered to: manufacturer's and
dealer's obligations may be affected in regard to sections and of the Cost
Saving Act. Violation of these sections render the manufacturer and the dealer liable for selling a
vehicle not in compliance with the theft prevention standard, and also falsely certifying that the
vehicle complies with the aforementioned standard.

1. If any painting or rustproofing is carried out on the vehicle prior to first sale, the labels must be
protected; use masking tape or similar.

2. After painting or rustproofing has been completed, the masking tape must be removed from the
labels prior to to the customer.

0 1-02
 INTRODUCTION

ANTI-THEFT LABELS ON REPLACEMENT PARTS

Jaguar replacement Parts - panels, etc. are supplied to the USA in electrocoat primer fitted with anti-theft
labels. A protective mask is used to prevent the label from being damaged or obscured by paint and
rustproofing material.

The following m u s t be observed when dealing with anti-theft labels on

replacement parts.

1. The protective mask on the anti-theft label must not be removed until all preparation, painting and
rustproofing work has been carried out.

2. The protective mask m u s t be removed from the anti-theft label prior t o to the customer.

NOTE: It cannot be stressed too highly that Federal l a w requires dealers t o remove paint masks from
anti-theft labels after performing painting and rustproofing operations. Failure to comply renders
manufacturer and dealer liable for violations of t h e law. For a detailed description and label location, refer
to Volume 4, Section 77 Body Repair.

SPECIFICATION

Purchasers are advised that the specification details set out in this manual apply t o a range of vehicles and not
t o any one. For the specification of a particular vehicle, purchasers should consult a Jaguar dealer.
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The Manufacturers reserve the right to vary their specifications with or without notice, and a t such times and
in such a manner as they think fit. Major as well as minor changes may be involved in accordance with the
Manufacturer’s policy of constant product improvement.

Whilst every effort is made to ensure the accuracy of the particulars contained in this Manual, neither the
Manufacturer or the Dealer, by whom this Manual is supplied, shall in any circumstances be held liable for any
inaccuracy or the consequences thereof.

COPYRIGHT

Jaguar Cars Limited. 1988

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted
in any form, electronic, mechanical, photocopying, recording or any other means without prior written
permission of Jaguar Cars Limited., Service Department, Radford. Coventry CV6 3GB.

01-03
 INTRODUCTION

TABLE OF CONTENTS

VOLUME 1

SECTION SECTION NUMBER

INTRODUCTION................................. ............. ............. ........... ........... ........ ......... ........... 01

GENERALSPECIFICATIONDATA ................ ..... ..... ..... ..... .. ..... .... ....... ... ... ... ... ... ........ ... ...... 04
ENGINETUNINGAND DATA .......................... ................ ...... ... . ........................................ 05
TORQUE FIGURE CONVERSION CHART ............... ... ...... ....... ......... ... . ................................ 06
'GENERAL FITTING INSTRUCTIONS .... ....... ....... ....... ........ ....... ....... ......... ....... ....... ....... ...... 07
JACKING, LIFTING AND VEHICLE RECOVERy ................................................ .... ....... .......... 08
RECOMMENDED LUBRICANTS , FlUIDS,CAPACITIESAND D1MENSIONS ........................ . ...... 09
MAINTENANCE SUMMARY .................................................................. ... ..... .... ....... ... ..... 10
SERVICE TOOLS.................................. ............. .... .... . ....... .... .. .... ... ... .. .............. .. ............ 11
ENGINE 5.3 (PRE-HE) ....... ..... .. . ... ... .. .. .. ... ... ...... .. ... .... .... .... .. ... .. .... .... .. . .. ........ .............. ... 12
ENGINE 5.3 HE .................... ... ... ... ....... ... ......................................................................... 12

VOLUME 2

EMISSION CONTROL5.3: '0' TYPE FUEL INJECTION ........................................................... 17

EMISSION CONTROL5.3: 'P' TYPE FUEL INJECTION ..... .. .. ................................... .. .. .. .. .. .. .. .. 17
FUEL SYSTEM 5.3: '0' TYPE FUEL INJECTION ....... ..... .. .. ..... ..... .... .... .. ... ... ......................... 19
FUEL SYSTEM 5.3: 'P' TYPE FUEL INJECTION ................ ................................ ........ ............ 19
COOLING SYSTEM 5.3 (PRE-HE) ...................... .. .... .. .... ... .. ..... .. ... ... .. .. ..... .. ... ... .... .... .. ... ..... 26
COOLING SYSTEM 5.3 HE .................................... .. ...... ... .. .. ...... .. ... .. .. ... .......... .. .... .. .... .... 26
EXHAUST SYSTEM 5.3 ... ............. .. ... ... .. ...... .... .. ..... ... ... ... ..... .......... ..... ..... .............. ..... .. 30

VOLUME3

CLUTCH5.3 ................................................................................................................... 33
MANUALGEARBOX 5.3 (JAGUAR) ................................................ ........................... .....,. 37
AUTOMATIC TRANSMISSION V12 (BORG-WARNERMODEL 12) ......... ..... ... ........ ... ...... .. ..... . 44
AUTOMATIC TRANSMISSIONV12 (GM 400) ......................................... .... ....... .. ..... .. ........ 44
PROPELLORAND DRIVE S.HAFTS .... _.................... .. ... ....... .. ... .... .......... .. .. ... ... ....... .. .. .......... 47
FINAL DRIVE .............. .................... ... ........... .. .... ........ .... ... ... .... .. .................................... 51
STEERING ................... .. ......... ... .. .. ... ... ... ....... .. .. ... .. .... . .... ... ......... ..... ...... ..... ...... ..... ...... 57
FRONT SUSPENSION ..... .................................................................................................. 60
REAR SUSPENSION ....... ................ ......... ................. .......................... ................ ......... .... 64
8RAKE'S ............................................................................................... ..... ... ... ... ........... 70

VOLUME4

WHEELS AND TYRES . ... ........ .. ... .. .. ... ... ..... .... ... .. ............................................................ 74
BODY ........................................................................................................................... 76
BODY REPAIR ................................................................................................................ 77
AIR CONDITIONING SYSTEM ................................................. .... ........... .... ...... .. ... ......... .. . 82
HEADLAMP AND WINDSCREEN WIPERS AND WASHERS ... .. .......... ... ....... .. .......... ... ....... .. .. 84
ELECTRICAL SYSTEM ... ............................ ............................ .. .............. ... ... ... ... .............. 86
ELECTRICALCIRCUITSjHARNESSES ... .... . ... ... ... ... .. . ......................................................... 86A
INSTRUMENTS .. ........... ........ ... ... ...... ........ ................ ........ ........ .................. ......... .......... 88

01-05

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 INTRODUCTION

STANDARDIZED ABBREVIATIONS AND SYMBOLS IN THIS MANUAL

Abbreviation, Abbreviation,
Term or Symbol Term or Symbol

A Ampere HC Hydrocarbon
A.B.D.C. After bottom dead centre High compression
Alternating current Horse-power
A.F. Acrossflats size) High tension (electrical)
Ah Ampere hour
A.T.D.C. After top dead centre Internal
Atm Atmospheres Independent front suspension
Auto. Automatic transmission in Inches
Square inches
B.A. British Association (screw thread) Cubic inches
Before bottom dead centre Inches of mercury
B.D.C. Bottom dead centre
Brake horse-power Kilogrammes (mass)
Brake mean effective pressure Kilogrammes (force)
B.S. British Standards Kilogrammes per square centimetre
B.S.F. British Standard Fine (screw thread) kgf Kilogramme metres
B.S.P. British Standard Pipe (thread) Kilometres
B.S.W. British Standard Whitworth Kilometres per hour
(screw thread) Kilopascals
B.T.D.C. Before top dead centre King pin inclination
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Kilovolts
Celsius (Centigrade) Kilowatts
Centimetres
Square centimetres Pounds (mass)
Cubic centimetres Ibf Pounds (force)
Cycles per minute Ibf ft Pounds feet (torque)
Carbon monoxide Pounds per square foot
Hundredweight Ibf in Pounds inches (torque)
Pounds per square inch
Direct current Low compression
deg. Degree (angleor temperature) L.H. Left-hand
dia. Diameter H . Left-hand steering
DIN Deutsche lndustrie Norm (Standard) Left-hand thread
Low tension (electrical]
E.C.U. Electronic Control Unit
E.G.R. Exhaust Gas Recirculation M Metric (screw thread)
metres
F Fahrenheit max. Maximum
F.I. Fuel Injection MES Miniature Edison Screw
Fig. Figure (illustration) min. Minimum
ft Feet Millimetres
Feet per minute Millimetres of mercury
Miles per gallon
Grammes (mass) Miles per hour
Imperial gallons
Grammes (force)

0
 INTRODUCTION

Abbreviation, Abbreviation,
Term or Symbol Term or Symbol

N Newton 1S t First
Nm Newton metres 2nd Second
No. Numbers 3rd Third
Nox Oxides of nitrogen 4th Fourth
N.P.T.F. American Standard Taper Pipe (thread) 5th Fifth
Degree (angle or temperature)
0 Oxygen Infinity
Overdrive Minute (angle)
Outside diameter Minus (tolerance)
Ounces (mass) Negative (electrical)
ozf Ounces (force) Percentage
ozf in Ounces inch (torque) + Plus (tolerance)
+ve Positive (electrical)
para. Paragraph -ve Negative (electrical)
Part no. Part number Plus or minus (tolerance)
PAS Power assisted steering Second (angle)
Imperial pints n Ohms

r Radius
ref. Reference
Revolutions per minute
R.H. Right-hand
Right-hand steering

S.A.E. Society of Automotive Engineers

Single carburetters
sp. Specific gravity
Std. Standard
Standard wire gauge
Synchro Synchronizer
Synchro Synchromesh

T.C. Twin carburetters

T.D.C. Top dead centre
Threads per inch

U.N.C. Unified Coarse (screw thread)

U.N.F. Unified Fine (screw thread)
U.K. United Kingdom
Gallons (US)
Pints (US)

V Volts
W Watts

0 1-07
 GENERAL SPECIFICATION DATA

Key to Emissions Identification (Up to MY).

A.

C.
E. Saudi of the World LC
F. Austria
G. Germany (Catalystoption)

ENGINE

See engine tuning and data ... .......... Section05

Cooling System

3.6 Vehicles

Number of cooling fans ............. through viscous coupling

Cooling system and control .......
ing air through radiator; controlled by a
sensor in the radiator
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........... AC Delco

vehicles

Water pump; Type Centrifugal, with two outlets

Drive ................... Belt driven from crankshaft
No. of cooling fans ................ Two (one belt-driven through Holset
coupling, plus 14-bladed electrically driven, thermo-
statically controlled)
Cooling system control .......................................... 2 thermostats
Thermostat opening temperature:
B C emissions ................................ 82°C 180°F
A, C, F G emissions 190°F
Thermostat fully open temperature 200 to 205°F
Engine filler cap pressure rating ... 20
Header tank cap pressure rating .............................. 1.05 15

Engine management

3.6 vehiclesfrom MY ................................. Lucas (also refered to as Microfuelling)

Fuel Injection Equipment

Make and type 2

Up to HE ........................................ Bosch-Lucas D electronicallycontrolled
From HE ........................................ Digital, Lucas P

Make and type 3.6

Up to MY ........................... Digital, Lucas P
After MY ........................... Part of Lucas engine management, microprocessor
controlled

04-0 1
 GENERAL SPECIFICATION DATA

Fuel System Pump

Make: Up to VIN 146955 .................... Electrical, Lucas 73 175

From VIN 146955 ..................... Electrical, Lucas 7335 1
Type ................................................ Roller cell pump with integral relief valve and
return valve
Fuel pressure3.6 ............................... 3.0 bar (43.5
Fuel .............................. bar (36

TRANSMISSIONS

Final Drive Unit - 3.6Vehicles

Type ................................................ Hypoid with Powr-Lok differential

Ratio: ...............................................

Final Drive Unit- 2 Vehicles

Type ............ ... ................................. Hypoid with Power-Lok differential

Ratio ............ ... .................................

Manual Gearbox

2 (early vehicles)

Make and type ................................. Jaguar, 4-speed with baulk-ring synchromesh on

forward gears
Ratios .......... ... ................................. First gear 3.238: 1
Second gear 1.905: 1
Third gear 1.389: 1
Fourth gear 1 1
Reverse 3.428: 1

Clutch (manualtransmission V 12 vehicles)

Make and type ................................... Borg and Beck single dry plate
Clutch pedal diameter ......................... 10.50 in
Facing material .................................. Raybestos WR7
No. of damper springs ......................... 6
Damper spring colour .......................... Dark
Clutch release bearing ......................... Carbon thrust type
Clutch fluid ........................................ Castrol-Girling Universal

3.6 Vehicles

........................................ five speed with baulk-ring synchromesh

on forward gears
Ratios: ............................................. First gear 3.573: 1
Second gear 2.056: 1
Third gear
Fourthgear 1 .o:1
Fifth gear 0.76: 1
Reverse 3.463: 1

04-02
 GENERAL S FI 0N DATA

Automatic Gearbox

V 12 Vehicles 1977 From 1977

........................................ Borg-Warner Model 12 400

Ratios First gear 2.40: 1 2.48: 1
Second gear 1.46:1 1.48:
Third gear 1 1 1
Reverse 2.00: 1 2.07:
Torque converter 2.00: 1 max

3.6 Vehicles

........................................ ZF 4HP 22
Ratios .............................................. First gear 2.48: 1
Second gear 1.48: 1
Third gear 1 1
Forth gear 0.73: 1
Reverse 2.09: 1

CHASSIS

Front Suspension
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Type ................................................ Independent coil spring

Castor angle ...................................... 3.5 deg. 0.25 deg. positive
Camber angle
standard suspension .......................... 0.5 deg. 0.25 deg. negative
Camber angle
3.6 Sportspack suspension ................. 0 deg. 0.25 deg.
Front wheel alignment ......................... 0 to 3.1 8 toe in (0to 1 in. toe in)
Dampers .......................................... Telescopic, gas filled

Rear Suspension

Type ................................................ Independent coil springs, co-axial with dampers

Camber angle
standard suspension .......................... 0.75 deg. 0.25 deg. negative
Camber angle
3.6 Sportspack suspension ................. 0.25 deg. 0.25 deg. negative
Rear wheel alignment .......................... Parallel (Parallel 1/32 in)
Dampers .......................................... Telescopic, gas filled

Power Assisted Steering

Vehicles with 2 15/70 tyres

Type ................................................ Rack and Pinion

Number of turns lock to lock .................2.75
Turning circle between kerbs ............... 12.0
Turning circle between walls ................ 12.6 m (41.3 ft)

Vehicles with tyres (Standard on 3.6 models from 1988 MY, optional on V12)

Type ................................................ Rack and Pinion

Number of turns lock to lock .................2.5
Turning circle between kerbs ............... 13.1 m (43 ft)
Turning circle between walls ................ 13.7 m (44.9 ft)

04-03
 GENERAL SPECIFICATION DATA

Braking System

Up to MY

Front brakes: Make and type Girling; ventilated discs, bridge-type calipers
Rear brakes: Make and type Girling; damped discs, bridge-type calipers incorporating handbrake
friction pads.

Handbrake: Type Mechanical, operating on rear discs

Disc diameter: Front 284
Rear 10.375 in
Disc thickness: Front 0.95 in
Rear 0.50 in
Master cylinder bore diameter 28.81 0.9375 in
Brake operation Hydraulic
Hydraulic fluid Jaguar Brake and Clutch fluid or Universal. These are
conventional brake fluids to DOT 4 specification.
Main brake friction pad
material: up to VIN 144578 Ferodo 2430 slotted
from VIN 144578 Jurid 5 18
Hand brake friction pad
material: up to VIN 144578 1
from VIN 144578 Ferodo 1

Servo unit Girling

From MY:

Girling foundation brakes retained

Anti-lock system with power

boost assistance A.T.E. Ltd
Actuation unit Hydraulic: contains master cylinder with main valve, booster, solenoid valve
block and fluid reservoir.
Pump unit Hydraulic: driven by electric motor, pressure reserve from accumulator,
actuated by pressure switch
ECU Electronic solid state digital circuitry using two microprocessors
Wheel speed sensors Electrical inductive sensors providing signals to the ECU

04-04
 GENERAL SPECIFICATION DATA

ELECTRICAL EQUIPMENT

Battery
Up to VIN After VIN
145730 145730

Make and type ................................... Lucas MF3 Chloride

Voltage ............................................ 12V Nominal 12V Nominal
Number of plates per cell ..................... 11 13
Capacity at 20 hour rate ...................... 68 Ah Nominal 70 Ah Nominal
Cold Crankamps (CCA) ....................... 505 505
Reserve Capacity ............................... 120 minutes 1 10 Minutes

Alternator

3.6 Up to 1987 MY 3.6: to

2 Up MY MY
Make and type: all air
conditioned cars Lucas A 133 Bosch
Norminalvoltage .................. 12v at 20°C
Earth polarity ..................................... Negative Negative
Maximum output ................................ 75 A at 6 000
Maximum operating speed . . .__. . 15 17 500
Rotor winding resistance ....
Brush spring pressure ........
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From MY
Make and type: all air
conditioned cars .........................
Norminal voltage .........................
Earth polarity ..................................... Negative
Maximum output ..... .............. 115A at6 000
Maximum operating speed ........... 17 500

04-05
 G ENERAL SPECIFI 0N DATA

Starter Motor

Early vehicles

Make and type ................................... Lucas M45 pre-engaged

.....................
....
Light running current ........................... 1OOA at 5000 to 6000

3.6: After Engine

No. 108285
Make and Type .................................. Bosch DW Lucas
Free spin (unloaded)
12
75

10.5
8
375A
1 250
Stall torque
Input voltage .................................. 4 4
Current .......................................... 1 050A 1 OOOA
Torque ............................... 27Nm
Pull in voltage ...... 7.5
Pull in current .......
Hold in voltage ...................................
4 4
Hold in current ...................................
15A (armature 5A
disconnected)
Engagement spring check voltage ......... 7.8 8
Direction of rotation (when
viewed from pinion end) ...................... Clockwise Clockwise

Distributor

Up to HE (Digital From to HE (Digital

Lucas P injection) Lucas P injection)

Make and type ................................... Lucas Opus 36 DE Lucas 36 12

3.6
V 12 Current vehicles

Make and type ................................... Lucas Lucas 35DH T6, part of

Engine Management

Windscreen Wiper Motor

Make and type ................................... Lucas 16W

Light running speed, rack disconnected
(after 60 secondsfrom cold) ................Normal: 46 to 52 rpm; high: to 70
Light running current
(after cold) ...................... Normal: high:

04-06
 GENERAL SPECIFICATION DATA

TYRE DATA
Tyre Replacement and Wheel Interchanging

The radial-ply tyres specified below are designed to meet the high-speed performance of which this car is
capable.

UNDER NO CIRCUMSTANCES SHOULD CROSS-PLY TYRES BE FITTED.

It is recommended that tyres of the same type and make are fitted to all wheels. When replacement of worn
tyres is necessary it is preferable to fit a complete set. No attempt must be made to interchange tyres from
side to side ,front to rear or vice versa since tyre wear produces characteristic patterns depending upon their
axle position. If such positions are changed after wear has occurred, the performance of the will be
adversely affected. It should be remembered that new combinations require to be balanced.

Only tyres of identical specification to those below must be fitted as replacements and, if to different tread
pattern, should not be fitted in mixed form.

Tyre Designation Inflation pressure (cold) Remarks

Front Rear

Tyres fitted to Starfish alloy

and perforated alloy wheels
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Super Sport 2.25 2.25 Pressures may be reduced by

15/70 VR 15 32 32 0.42 (6 0.41 bar)
or 2.20 bars 2.20 bars to obtain maximum comfort
Pirelli Cinturato P5, viding a speed of
215/70 VR15 mph) is not exceeded.

Tyres fitted to Sports 2.39 2.53 Pressures may be reduced by

alloy 34 36 0.56 (8 0.55 bar)
Pirelli 2.35 bar 2.48 bar to obtain maximum comfort
VR 15 viding a speed of 160
mph) is not exceeded.

04-07
 GENERAL SPECIFICATION DATA

Recommended Snow Tyre

The following information relates to the only snow tyre recommended for the Jaguar Fit complete
sets

Tyre Designation Inflation pressure (cold) Remarks

Front Rear

Pirreli Winter 190 Tyre pressures are the same Maximum speed:
M S (Mud and Slush as for the standard tyres without snow chains -
215/65 R 15 18

with snow chains - 50

Snow chains may be fitted to the rear wheels only. Use Jaguar snow chains. Tyres may be fitted with studs
provided the maximum speed of 145 (90 is not exceeded. Studs must be of the parallel shank
type, long 8 diameter single flange; the use of studs is not permitted in certain countries.

Vehicle Stopping Distance 60 mph)

(a) fully operational maximum load ................. 182 ft

(b)fully operational light load ......................... 163 ft
(c) emergency- rears only ............................ 387 ft
(d) boost failure ........................................... 258 f t

04-08
 GENERAL SPECIFICATION DATA

BULB CHART

Watts Unipart No. Notes

Headlamps:
- not France or USA JLM 9598 Halogen H4 base bulb

- France only JLM 9599 Yellow Halogen H4 base bulb

Outer - USA only

Early vehicles JLM 9605 Halogen sealed beam light unit
Current vehicles 3 7.5

Inner - USA only

Early vehicles 50 JLM 9606 Halogen sealed beam light unit
Current vehicles 50

Headlamp pilot bulb (not USA) 4 JLM 9589 Bayonet

Front indicator lamp 21 Not USA and Canada

Front direction indicator
and side lamp JLM 9594 USA and Canada

Stop lamp 21 Bayonet

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Tail lamp 5 JLM 9587 Bayonet

Rear direction indicator 21 Bayonet

Reversing lamp 21 JLM 9592 Festoon bulb

Number plate lamp 6 JLM 293 Festoon bulb

Sidemarker (where fitted) 4 JLM 9589 USA, Canada, (Japanearly vehicles)

Flasher side repeaters 4 JLM 9589 Bayonet: not USA, Canada,

(where fitted) (not Japan early vehicles)

Rear fog guard lamps 21 Bayonet

(where fitted)

lamps 6 JLM 293 Festoon bulb

Roof lamp 10 Festoon bulb

Boot lamp 5 JLM 9590 Festoon bulb

04-09
 GENERAL SPECIFICATION DATA

BULB CHART Continued....

Watts Unipart No. Notes

Fibre optic light source 6 JLM 9601 Bayonet

instrument illumination 2.2 C 43898 Capless

Warning lights 1.2 C 38966 Capless

Automatic selector illumination 2.2 C 15788 Bayonet

Cigar lighter illumination 2.2 C 15788 Bayonet

Door hazard (puddle)lamp 5 JLM 9600 Capless

Clock (wherefitted) 2.2 C 15788 Bayonet

Fog lamps-front (wherefitted) 55 JLM 9588 Halogen

Rear quarter lamp

10 C31106 Festoon

Side marker lamp 4 JLM 9589 Bayonet

High mounted stop lamp 5 JLM 9600 only

(where fitted)

04-
 Fuse Value Protected Circuit
No.

1 20 A Cigar lighter

15A Hazard warning, seat belt logic.

35 A Clock, aerial, caravan, boot lamp.

A Panel instruments, reverse light.

15A Direction indicators, stop lamps, kickdown switch (wherefitted).

Fog rear guard (wherefitted).

10 A lighter and selector illumination.

8 3A Door locks, electric mirrors.

9 35 A Windscreen wipers.
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10 10 A Air conditioning motors

11 35 A Air conditioning controls, horn, windscreen washers,

radiator cooling fan.

12 35 A Heated rear screen, heated door mirrors.

 GENERAL SPECIFICATION DATA

FUSES: UP TO MODEL YEAR VEHICLES continued...

Main Fuse Box- L.H. Steering

Fuse Fuse Value Protected Circuit

No. Colour
Code

1 Red 20 A Front fog lamps (wherefitted).

2 Brown 15A Hazard warning, seat belt logic.

3 Light 35 A Clock, aerial, caravan, boot lamp.

blue

4 Tan A Panel instruments, reverse light.

5 Brown 15A Direction indicators, stop lamps, kickdown switch

(wherefitted).

6 Tan Fog rear guard (wherefitted).

7 Tan 10 A lighter and selector illumination.

8 Brown 3A Door locks, electric mirrors.

9 Red 35 A Windscreen wipers.

Natural 50 A Air conditioning motors

(white)

11 Light 35 A Air conditioning controls, horn, windscreen washers,

blue radiator cooling fan.

12 Light 35 A Heated rear screen, heated door mirrors

blue

04- 12
 GENERAL SPECIFICATION DATA

FUSES: UP TO MODELYEAR VEHICLES continued..

Auxiliary Fuse Box - R.H. Steering

Fuse Value Protected Circuit

No.

13 Interior and map lights.

14 3A Left-handfront side lights.

15 3A Right-hand front side lights.

16 20 A Front fog lamps (where fitted).

17 3A Speed control

Auxiliary Fuse Box- L.H. Steering

Fuse Value Protected Circuit

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No.

13 5A Interior and map lights.

14 2A Left-handfront side lights.

15 2A Right-handfront side lights.

16 Cigar lighter.

17 25 A Speed control

04- 13
 GENERAL SPECIFICATION DATA

FUSES: UP TO MODEL YEAR VEHICLES continued

Headlamp Fuse Box

Fuse Value Protected Circuit

No.

1 25 A Radiator auxiliary cooling fan motor relay

2 25 A Left-hand main beam headlamp.

3 Left-hand dip beam headlamp.

4 25 A Right-hand main beam headlamp.

1 0A Right-hand dip beam headlamp.

04- 14
 GENERAL SPECIF I 0N DATA

FUSES: FROM MODELYEAR VEHICLES

Main Fuse Box- R.H. Steering

Fuse Fuse Value Protected Circuit

No. Colour
Code

1 Red Cigar lighter, radio cassette player.

2 Brown 7.5 A Hazard warning, seat belt logic.

3 Light 15A Clock, aerial, caravan, boot lamp.

blue

4 Tan 5A Panel instruments, reverse light.

5 Brown 7.5 A Direction indicators, stop lamps, kickdown switch

(where fitted).

6 Tan 5A Fog rear guard (wherefitted).

7 Tan 5A lighter and selector illumination.

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8 Brown 7.5 A Door locks, electric mirrors.

9 Red Windscreen wipers.

10 Natural 25 A Air conditioning motor, Right-hand.

(white)

11 Light 15A Air conditioning controls, horn, windscreen washers,

blue radiator coolingfan.

12 Light 15A Heated rear screen, heated door mirrors.

blue

13 Red Seat heater - Right-hand seat (where fitted).

14 Tan 5A Seat lumbar adjustment - Right-hand seat

(where fitted).

15 Violet 3A Trip computer (wherefitted).

16 Tan 5A Air conditioning clutch relay (XJ-S 3.6 only).

17

18

19 Red A Seat heater - Left-hand seat (where fitted).

20 Tan 5A Seat lumbar adjustment - Left-hand seat

(where fitted).

04-15
 GENERAL SPECIFI 0N DATA

FUSES: FROM MODEL YEAR VEHICLES continued

Main Fuse Box - L.H. Steering

Fuse Fuse Value Protected Circuit

No. Colour
Code

1 Red Front fog lamps (where fitted).

2 Brown 7.5 A Hazard warning, seat belt logic

3 Light 15 A Clock, aerial, caravan, boot lamp

blue

4 Tan 5A Panel instruments, reverse light.

5 Brown 7.5 A Direction indicators, stop lamps, kickdown switch

(where fitted).

6 Tan 5A Fog rear guard (where fitted).

7 Tan 5A lighter and selector illumination.

8 Brown 7.5 A Door locks, electric mirrors.

9 Red A Windscreen wipers.

10 Natural 25 A Air conditioning motor, Left-hand.

(white)

11 Light 15 A Air conditioning controls, horn, windscreen washers,

blue radiator cooling fan.

12 Light 15 A Heated rear screen, heated door mirrors.

blue

13 Red A Seat heater - Right-hand seat (where fitted).

14 Tan 5A Seat lumbar adjustment - Right-hand seat

(wherefitted).

15 Violet 3A Trip computer (where fitted).

16 Tan 5A Air conditioning clutch relay (XJ-S 3.6 only).

17 15A Passive restraint - LH seat (USA only)

18 15A Passive restraint - seat (USA only)

19 Red Seat heater - Left-hand seat (wherefitted).

20 Tan 5A Seat lumbar adjustment - Left-hand seat (wherefitted).

04- 16
 GENERAL DATA

FUSES: FROM MODELYEAR VEHICLES continued....

Auxiliary Fuse Box - R.H. Steering

Fuse Fuse Value Protected Circuit

No. Colour
Code

Tan Interior and map lights.

Grey 2A Left-hand front side lights.

Grey 2A Right-handfront side lights.

Red 10 A Front fog lamps (wherefitted).

Natural 25 A Air conditioning motor, Left-hand.

(white)

Tan Speed control - XJ-S 3.6 (wherefitted)

Violet 3A Speed control - XJ-S V 12.

Light 30 A Anti-lock braking system (ABS) ECU (main relay)

green
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Light 30 A Anti-lock braking system (ABS)pump motor.

green

Auxiliary Fuse Box- L.H. Steering

Fuse Fuse Value Protected Circuit

No. Colour
Code

Tan 5A Interior and map lights.

Grey 2A Left-handfront side lights.

Grey 2A Right-hand front side lights.

Red Cigar lighter, radio.

Natural 25 A Air conditioning motor, Right-hand.

(white)

Tan 5A Speed control - XJ-S 3.6 (where fitted).

Violet 3A Speed control - XJ-S 2.

Light 30 A Anti-lock braking system (ABS) ECU (main relay).

green

Light 30 A Anti-lock braking system (ABS) pump motor

green

04- 17
 GENERAL SPECIFICATION DATA

FUSES: FROM MODELYEAR VEHICLES continued....

Headlamp 3.6

FUSE ‘A‘ -BLACK BODY

Fuse Fuse Value Protected Circuit

No. Colour
Code

Brown 7.5 A Right-hand dip beam headlamp.

Red 10 A Right-hand main beam headlamp.

Brown 7.5 A Left-hand dip beam headlamp.

Red Left-hand main beam headlamp.

Light 15 A relay.
blue

FUSE BOX ‘B’ -WHITE BODY

Fuse Fuse Value Protected Circuit

No. Colour
Code

Red Radiator fan (United Kingdom only).

Red headlamps (UnitedKingdom only).

Red Radiator fan (Rest of World except United Kingdom).

Pink 4A Heatedwasher jets.

I

04- 18
 GENERAL SPECIFICATION DATA

FUSES: FROM MODEL YEAR VEHICLES continued..

Headlamp Fuse Box- XJ-SV12

FUSE BOX ’A’ - BLACK BODY

Fuse Fuse Value Protected Circuit

No. Colour
Code

Light A Radiator auxiliary cooling fan motor relay, horn.

blue

Red A Left-hand main beam headlamp.

Brown 7.5 A Left-hand dip beam headlamp.

Red Right-hand main beam headlamp.

Brown 7.5 A Right-hand dip beam headlamp.

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FUSE BOX ’B’ -WHITE BODY

Fuse Fuse Value Protected Circuit

No. Colour
Code

Pink 4A Heated washer jets.

Red headlamps (United Kingdom only).

04- 19
 GENERAL SPECIFICATION DATA

FUSES: FROM MODELYEAR VEHICLES continued ....

In-Line Fuses

Protected
Circuit Location Value

Left-hand tail lamp. Behind the left-hand tail lamp cluster 3A

inside the luggage compartment.

Right-hand tail lamp. Behind the right-hand tail lamp cluster 3A

luggage compartment.

Aerial. Behind the right-hand tail lamp cluster A

inside the luggage compartment.

Radio cassette player. Behind unit

Cooling fan Radiator cross member. 20 A

(XJ-S 2 only).

Air conditioning clutch relay Engine compartment, Right-hand wing

(XJ-S V 12 only). valance.

Sun roof (where fitted). Adjacent to the main fuse box under the 15A
fascia panel on the driver's side.

04-20
 GENERAL SPECIFICATION DATA

FUSES: FROM
Main Fuse Box- R.H. Steering

As "From MY" but with the following differences:

Fuse Fuse Value Protected Circuit

No. Colour
Code

5 Red 10 A Direction indicators, stop lamps, kickdown switch

(where fitted)

9 Light 15 A Windscreen wipers

blue

Main Fuse Box- L.H. Steering

As "From 1987% MY" but with the following differences:

Fuse Fuse Value Protected Circuit

No. Colour
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Code

5 Red 10 A Direction indicators, stop lamps, kickdown switch

(wherefitted)

9 Light 15A Windscreen wipers

blue

Auxiliary Fuse Box- R.H. Steering

MY

Auxiliary Fuse Box- L.H. Steering

As from 1987 MY

04-2 1
 GENERAL SPECIFICATION DATA

FUSES: FROM MODELYEAR VEHICLES continued

Headlamp Fuse Box- XJ-S 3.6

FUSE BOX 'A'- BLACK BODY

Fuse Fuse Value Protected Circuit

No. Colour
Code

Brown 7.5A Right-hand dip beam headlamp.

Red Right-hand main beam headlamp

Brown 7.5A Left-handdip beam headlamp.

Red Left-handmain beam headlamp.

Light 15A Horn

blue

FUSE BOX 'B' -WHITE BODY

Fuse Value Protected Circuit

Colour
Code

Red A headlamps (United Kingdom only)

Red Radiator fan

Pink 4A Heated washer jets.

Power operated hood fuse - Convertibleonly

Fuse Fuse Value Protected Circuit

No. Colour
Code
Light 30 A Hood pump motor bracket in stowage compartment
green

In-Line Fuses

As "From MY" but with the following difference:

Cooling fan fuse, deleted (now incorporated in main fuse box).

04-22
 GENERAL SPECIFICATION DATA

CABLE COLOUR CODES

N - Brown B - Black W - White K - Pink G - Green U - Blue

- Red Yellow 0 - Slate L - Light P - Purple

ELECTRICAL SYMBOLS
Battery power Motor SoIenoid Diode

U
Ignition switched Fuse Zener diode Lamp
power

0
Logic earth Earth connection Transistor Aerial

Y
Ignition switched Resistor Signal Potentiometer
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earth

0
Cable connector Capacitor Thermister Switch

Light emitting Clock Line splice

diode (LED)

04-23
 ENGINETUNING AND DATA

ENGINE TUNING
3.6 ENGINES - UP TO 1987% M Y

Ignition Timing Federal 18 BTDC at 2000 vacuum pipe disconnected at normal

running temperature
European 21 BTDC at vacuum pipe disconnected at normal
running temperature

Valve Clearances Inlet and exhaust

Sparking Plugs Champion RC 12 YC

(0.025 in)

Ignition Coil Lucas 35 C6

Primary resistance at 20°C (68°F) 0.9 to 1.1 ohms
Secondary resistance 3.95 to
Consumption:
stationary 5.0 to 6.5 amps
running 2.5

Distributor Lucas constant energy 45 DM6

Rotation of rotor (looking down a t rotor) Clockwise
Pick-up module to timing rotor gap to (0.008 to 0.014 in)
Firing order (No. 1 cylinder at front)

Spark plug lead

resistances No.
1
2 to
3 6.1
4 to
5 9.0 K to
6 8.6 1K to

DISTRIBUTOR ADVANCE CURVE (CENTRIFUGAL)

EUROPEANVEHICLES

Advance Characteristics
(Dynamic)
Engine Advance (degrees)

6400 7.25 to 9.5

5000 7
3200 6
1800 5.25 to 7.25
1250 3
1050 0.5 to
850 - 1.2t00.8
- 1.1 to0.9
- 0.25 t00.25
1.1

05-01
 ENGINE TUNING AND DATA

ENGINE TUNING continued

3.6 ENGINES - UP TO M Y continued..

Vacuum Advance Curve

Advance (degrees)

24
12
8.5
6 0.5 to 2.5
4
2 0

Fuel Injection Equipment

Digital Lucas digital P type

Fuel pressure 2.5 bar (36

Exhaust Emission

Exhaust gas analyser reading

a t engine idle speed 1 to 2% max. CO a t 800 without
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air injection

Speed 800

Compression
Pressure Non Catalyst HC
(160 to 170)
Catalyst LC to 1 1.04 bar
150 to 160

Differential
between cylinders (max)

NOTE: Compressions to be checked with all sparking plugs removed, the throttle wide open, the engine at
operating temperature and a cranking speed of 300 (minimum).
 Continued.. .

ignition Timing Fully mapped digital ignition Lucas engine management

Valve clearances and exhaust 0.30 to 0.36 (0.0 12 to 0.0 14 in)

Sparking Plugs YC
(0.035 in)

Ignition Coil [yellow adhesive label)

Primary resistance a t 20°C (68°F) 0 5 ohms +/- 10 per cent
Secondary resistance 6 K ohms +/- 10 per cent
Secondary inductance 31H 20 per cent
Consumption stationary 5
running 2

Distributor Lucas DHTS

Rotation of rotor (looking down a t rotor) Clockwise
Resistance of rotor arm 1 K ohm (Lucas type)
Firing order (No. 1 cylinder at front)

Sparking plug
lead No. 1

to 22.3 Kohm
9.1
Kinglead Kinglead I to 4.1 K ohm

Fuel injection
equipment Microprocessor controlied Lucas engine

Fuel pressure 3 bar (43

Exhaust Emission Exhaust gas analyser reading to 2 per cent max CO at 7 0 0

without air injection at engine speed (not applicable for catalyst vehicles)

Speed 700 50

Compression
pressure European 160 to 1 70
Federal 160 to 170
Rest of the World 150 to 160

Differential between cylinders 10

NOTE: Compressions to be checked with all sparking piugs removed, the

throttle wide open, the engine at operating temperature and cranking
speed at 300 (minimum).

05-03
 AND DATA

ENGINE DATA

3.6 ENGINES

General Data

Number of cylinders ........................................... 6

Bore ...................
Stroke ..................... ........ 92
Cubic capacity ................
Compression ratio .................................. 9.6: 1 Non catalyst HC
.............................................. 8.1 : 1 Catalyst LC
Firing order ..........................................
(No. 1 cylinder a t front)

Cylinder Block

Material (cylinder block) ....... Cast Aluminium alloy

Bore diameters after honing:

..................................................... 90,990
.............................
.......
+ 0.020 in ................. 9 1,526 to 9 1,5 13
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Cylinder head

Material ............................................................ Aluminium alloy

Valve seat angle (inclusive) .................................. to

Crankshaft

Material .........................................
Number of main bearings ..................
Main bearing type ................................... Vandervell
Journal diameter ....
Journal length (ov
Front ...........................................
Centre ........................................................... 36,233 to 36,208 rnrn
Remainder ..................................................... to 30.43 rnrn
Thrust washer material .....................
Thrust washer diameter ...... 3,888 to 3,898 rnm
Thrust washer thickness 2.57
Oversize ................................................... 2.67 to rnrn (0.105 to 0.107 in)
Permissible end-float ... to 0.25 (0.004to 0.010 in)
Width of main bearing:
Front intermediate and rear ............. 1 to
Centre ........... to
Balancing (up to VIN 12881 1) Crankshaft to be balanced to 45
Balancing (from VIN 1288 1 1) Crankshaft to be balanced to 15 (0.205

Unbalance to be corrected by drilling up to 4 holes

in each balance weight 9.5 x 29 rnm max depth.
Diametrical clearance 1 to 0,084
Crankpin: Diameter ...................... 52,987 to 52,974
Length ................................................ 30,193 to 30,142

05-09
 ENGINE TUNING AND DATA

ENGINE DATA continued

3.6 ENGINES Continued ...

Connecting Rods
Length between centres 166.42 to
Big end bearing material Vandervell
Bore for big end bearing
Width of big end bearing ,38 rnrn (0.975 to 0.960 in)
Big end diametrical clearance . . ... 0,001
Big end side clearance ... ....
Small end bush material
Bore for small end bush . ............................. 26,975 rnm
Width of small end bush ... 30.00 to
Fitted bush ... 23.8 18 to 14
Bore diameter of small end bush ........... 23.48 to
Small end balance weight:
Minimum dimension
Big end balance weight:
Minimum dimension after balancing

Pistons
Type ......... ....... ................ (BS 1490-
modified
Grade
90,972 t o 90,960 rnrn
............................. 90,987 to 90,975
................ 91,241
+ in ............................ 9 1,495 to 9 1,483 rnrn

Piston Rings
No.of compression rings ....... ....
No. of oil control rings .........................
Top compression ring:
..........................................
............................. 1,495
Diameter .......... ...
Depth of chrome ...
Tangential load of
close gap to ............................................. to
Material . ...... ............................. Cast iron
Second compression ring:
Gap ........................ 0,4 to
Width ........................................ ....... 1,975
Diameter .................
Tangential load of to to
close gap ........ .............................
... Cast iron HG

05-
 ENGINETUNINGAND DATA

ENGINE

3.6 ENGINES Continued ...

Gudgeon Pins

Tvwe r locking type

Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77.25 77.12
Outside diameter ...............................
Inside diameter ... ............................... to
Permissibleoffset of centre web ........................... 1 rnm
Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . EN 3 2

Cams hafts

Number of journals ............................................. 7

Journal diameter ................................................ 26,950 to 26,937
Diametrical clearance ......................................... 0.063
Material ............................................................ Cast iron to BS 1452 Grade 17

Valves

Inlet valve material ............................................. EN 52

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Exhaust valve material ........................................ Steel 2 1-4-N

Inlet valve head diameter ..................................... to 35.17
Exhaust valve head diameter ................................
Valve stem diameter:
Inlet and exhaust .......................................... 7.897 to 7,866 rnm
Valve lift ...........................................................
Inlet valve clearance .................................. 0.031
Exhaust valve clearance ...................................... 0,031
Valve stem seal:
Material ...................................................... BLS (VITRON)
Internal diameter .......................................... to 7.85

Valve Guides and Seats

Valve guide material ........................................... Brico 2 or BS hardness

190 to 260)
Guidelength ......................................................
material ................................................... 18 SWG (0.048 in) zinc coated

Identification

No groove - Standard ......................................... to (0.5020 to0.5015 in)

1 groove - First oversize (Production) .................... 12.80 to rnm (0.5040 to 0.5035 in)
grooves - Second oversize (Service) .................. to rnm (0.5070 to 0.5065 in)
3 grooves - Third oversize (Service) ...................... 13.00 to (0.5 120 to 0.5 1 15 in)

1
 AND DATA

ENGINE

3.6 ENGINES Continued...

Valve guide (service)

Bore to be concentric with the outside diameter of the guide within

0.00 1 in. i.e. total indicator reading of 0.002 in.

Valve seat

Inlet valve seat outside diameter:

Standard .................................................... 36,404 to 36,388 rnrn
........................... 36,785 t o 36,769
Interference fit in cylinder head ............. 0,077 rnrn (0.003 in)

Standard .......................................................... 32,884 to 32,868 rnrn

Service ............................................................. 33,265 to 33,249 rnrn
Interference fit in cylinder head 0,077 rnrn (0.003 in)
Valve seat angle (inclusive) .................................. 89 deg.30' t o 89

Tappets

Tappet material ................................................. Steel

Outside diameter of tappet .................................. to rnrn (1.3125 to 1.3 130 in)
Diametrical clearance of tappet ............................. 1 to 0,020 (0.002to 0.0008 in)

Valve spring

Wire diameter ................................................... (0.148 in)

lnsidediarneter ..................................................
Total No. of coils
No. of working coi
Helix .........................................
Rate ................................................................ (202.5
Natural frequency .............................................. Hz (36,203
Free length (1.580 in)
Material ........................................................... OTEVA 60

Camshaft Sprocket

No. of teeth 30
Pitch of teeth ......................................... 9,525 rnrn (0.375 in)
Pitch circle diameter ........................................... 9 1,135 rnrn (3.588 in)
Internal serrations .............................................. 13 1
Pitch circle diameter ........................................... 66,675 rnrn (2.625 in)
Pitch of teeth 1,600 rnrn (0.063 in)
0. dia of sprocket ..................... rnrn +/- 0,050 rnrn (3.75 in +/- 0.002 in)
Total width ....................................................... 18,653 1 in)
Totatwidthacross bothteeth .............................. 15,341 to
Concentricity of teeth and sprocket not t o exceed ... 0,076 rnrn (0.003 in)

05- 12
 ENGINE TUNING AND DATA

ENGINE ...

3.6 ENGINES Continued...

Crankshaft Sprocket

........................
............................ 9.525 (0.375 in)
Pitch circle diameter ........................................... 63,906 (2.516 in)
Root diameter ................................................... 57,556 (2.266 in)
Roller diameter 6.35 (0.25 in)
Measured over (0.25in) dia. pins. 70,008 to mrn (2.759 to 2,754 in)
Tooth profile cut
Internaldiameter ................................................ 42,875 to 42,857 rnm
Overall diameter to 67.77 rnm
Width across 1 tooth to

Crankshaft damper oil seal spacer

Inside diameter .................................................. 42,875 to 42,860 mrn (1.6880 to 1.6874 in)

Outside diameter ............................................... 51.81 (2.047to 2.040 in)
Width ..............................................................

Outside diameter to be plunge ground

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chamfers to be polishedand free burrs

Intermediate shaft bush

Inside diameter (whenfitted) .. 22,010 to 21,964 (0.8665 to0.8647 in)

Outside diameter ................. 25,083 to 25,057 (0.9875 to0.9865 in)
Width ..............................................................
............................................................
Shaft size 22 rnrn (0.8645 to 0.8637 in)
Running clearance .............................................. 1 to 0,005 rnrn (0.0028to 0.0002 in)
Material ............................................................ Vandervell No.

Intermediate sprocket inner teeth

Number of teeth ................................................. 28

Pitch ................................................................ 9,525 rnrn (0.375 in)
. 85,063 rnm (3.349 in)
rnrn (3.009 in)
.. (0.25 in)
............
Tooth profile cut to ............................................. BS 228
Width across the depth to (0.6 13 to 0.604 in)
Overall diameter (3.512to 3.508 in)
 ENGINETUNINGAND DATA

ENGINE DATA Continued...

3.6 ENGINES Continued...

Intermediate sprocket outer teeth

Number of teeth .........

Pitch ................................... ............ 9,525 (0.375in)
Pitch circle diameter .................................... 60,884 (2.397in)
Root diameter ............................................ 54.53 mrn (2.147in)
Roller diameter .....................
Measured over 6,35 (0.25in) dia. pins. ............ 67.23 to I (2.647to 2.642 in)
Tooth profile cut to ....... BS 228
Overall diameter . . 65.07 t o 64,97 (2.562to 2.558 in)
W i d t h across both t 15.57to
Total width of sprocket . ............................. to

Primary timing chain

Pitches ............................................................. 80
Roller diameter .................................................. 6,35 (0.25in)
Pitch ................................................................ 9,525 rnm (0.375 in)
Type ................................................................ Endless duplex chain

Secondary timing chain

Pitches ............................................................ 86
Roller diameter .................................................. 6,35 in)
Pitch ................................................................ 9,525 (0.375in)
Type ................................................................ Endless duplex chain

Oil pump chain

Pitches ............................................................. 52
Roller diameter .................................................. 6,35 (0.25in)
Pitch ................................................................ 9,525 (0.375in)
Type ................................................................ Endless simplex chain

Dampers and tensioners

Backing material ................................................ Steel

Damper material ................................................ Rubber

Hydraulic chain tension housing

Bore diameter .................................................... 2138 to 21,36 (0.842 in)

 ENGINE TUNING AND DATA

ENGINE DATA

3.6 ENGINES Continued..

Hydraulic chain tensioner

Overall length .................................................... 45 rnrn (1.771 in)

Overall length to bottom of groove in piston ........... 41 (1.614 in)
Diameter .......................................................... 2 1,349 t o 3 1,336 (0.8405 to 0.8400 in)
Width of groove in piston .................................... 15 rnrn (0.59 in)
Non return valve primary ball diameter ................... 4,762 rnrn (0.1875 in)
Ballfreemovement ............................................

Non return valve secondary

Ball diameter ..................................................... 4,762 mrn (0.1875 in)

Ballfreemovement ............................................

Oil pressure relief valve

Relief valve:
O/D ........... rnm (0.7079to0.7067in)
I/D ................................................ to0.591 to0.571 in)
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Overall length .................................................... 35 rnm (1.378 in)

Working length ................................................. 30 (1 .18 1 in)
Bore ........................................................ 27 (1.063 in)
Material ............................................................
Cyanide Harden ................................................. 0,020 to 13 to 0.005 in) deep

Mandrel: Length ................................................. 57 (2.244 in)

Diameter ............................................. 1 1 rnrn (0.437 in)
Material ........ ........................................... Steel tube to or ERW 1)

Spring: Wall thickness ............ (0.064 in, 16 SWG) or (0.048, 18

Free length ............................. 106 rnrn (4.173 in)
Outside diameter ..................................... rnrn (0.643 in)

05-15
 ENGINE TUNING AND DATA

ENGINE DATA Continued

3.6 ENGINES Continued ...

Spring Specification

Wire diameter ................................................... (0.092 in, 13 SWG)

Mean diameter coils ............................. (0.55 1 in)
Total number of coils .............
of active coils ............

............................. (25.65

Length Load Stress

inches
, Fitted 76.00 2.992 30.29 472 68,395

Valve opening 72.00 15.58 34.35 535 77.543

Maxopenrng 2.441 44.43 692

Solid 60.80 2.392 20.7 1 45.66 71 1 103.083

Material

BS. (EN.47) Spring steel wire. Ends to be coiled and ground square to axis, feather
edges to be removed to a thickness of 020 in).

Oil filter Type .......................... Full flow disposable canister

Canister Specification

Maximum working pressure ................................

Relief valve setting . . . . . ...... 13 to 16 (0.90to
Canister to withstand ............. (250 pressure
Element filtration area ......................................... 3555 (551
Canister diameter ............................................... (3.78 in)
Canister length .............................
Canister case rna ........................... 24 SWG
Adaptor thread ..................... .... 1 in

05- 16
 ENGINE TUNING AND DATA

ENGINE DATA Continued

3.6 ENGINES Continued...

Oil Pump

(2.749 to 2.747 in)

Outer rotor width ............ 1.1009 in)
Inner rotor width

(2.7539to 2.7529 in)

2 horn clearance .._ .. .. (0.010 in)

3 horn clearance .._ . ... in)

TORQUE TIGHTENING VALUES

For wrench settings, refer to the front of the relevant section

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05-17
 TORQUE FIGURE CONVERSION CHART

NEWTON METRES TO POUND FORCE FEET

0 1 2 3 4 5 6 7 8 9

20
30
40

50 36.8781 37.6157 38.3532 39.0908 39.8284 40.5659 41.3035 42.0410 42.7786 43.5162
60 44.2537 44.9913 45.7289 46.4664 47.2040 47.9415 48.6791 49.4167 50.1542 50.8918
70 51.6294 52.3669 53.1045 53.8420 54.5796 55.3172 56.0547 56.7923 57.5299 58.2674
80 59.0050 59.7425 60.4801 61.2177 61.9552 62.6928 63.4303 64.1679 64.9055 65.6430
90 66.3806 67.1 182 67.8557 68.5933 69.3308 70.0684 70.8060 71.5435 72.281 1 73.0187

73.7562 74.4938 75.2313 75.9689 76.7065 77.4440 78.1816 78.9192 79.6567 80.3943
110 81.1318 81.8694 82.6070 83.3445 84.0821 84.8197 85.5572 86.2948 87.0323 87.7699
120 88.5075 89.2450 89.9826 90.7201 91.4577 92.1953 92.9328 93.6704 94.4080 95.1455
130 95.8831 96.6206 97.3582 98.0958 98.8333 99.5709 100.308 101.046 101.784 102.521
140 103.259 103.996 104.734 105.471 106.209 106.947 107.684 108.422 109.159 109.897

150 110.634 1 1 1.372 112.109 112.847 114.332 115.060 115.797 116.535 117.272
160 118.010 118.748 119.485 120.223 120.9' 3 121.698 123.173 123.910 124.648
170 125.386 126.123 126.861 127.598 128.336 129.073 129.81 1 130.549 131.286 132.024
180 132.761 133.499 134.236 134.974 135.71 1 136.449 137.187 137.924 138.662 139.399
140.137 140.874 141.612 142.350 143.087 143.825 144.562 145.300 146.037 146.775

200 147.512 148.250 148.988 149.725 150.463 151.200 151.938 152.675 153.413 154.150
210 154.888 155.626 156.363 157.101 157.838 158.576 159.313 160.051 160.789 161.526
220 162.264 163.001 163.739 164.476 165.214 165.951 166.689 167.427 168.164 168.902
230 169.639 170.377 171.1 14 171.852 172.590 173.327 174.065 174.802 175.540 176.277
240 177.015 177.752 178.490 179.228 179.965 180.703 181.440 182.178 182.915 183.653

250 184.391 185.128 185.866 186.603 187.341 188.078 188.816 189.553 190.291 191.029
260 191.766 192.504 193.241 193.979 194.716 195.454 196.192 196.929 197.667 198.404
270 199.142 199.879 200.617 201.354 202.092 202.830 203.567 204.305 205.042 205.780
280 206.517 207.255 207.993 208.730 209.468 210.205 210.943 21 1.680 212.418 213.155
290 213.893 214.631 215.368 216.106 216.843 217.581 218.318 219.056 219.794 220.531

300 221.269 222.006 222.744 223.481 224.219 224.956 225.694 226.432 227.169 227.907
3 10 228.644 229.382 230.1 19 230.857 23 1.595 232.332 233.070 233.807 234.545 235.282
320 236.020 236.757 237.495 238.970 239.708 240.445 241.183 241.920 242.658
330 243.396 244.133 244.871 245.608 246.346 247.083 247.821 248.558 249.296 250.034
340 250.771 251.509 252.246 252.984 253.721 254.459 255.197 255.934 256.672 257.409

350 258.147 258.884 259.622 260.359 261.097 261.835 262.572 263.310 264.047 264.785
360 265.522 266.260 266.998 267.735 268.473 269.210 269.948 270.685 271.423 272.160
370 272.898 273.636 274.373 275.1 1 1 275.848 276.586 277.323 278.061 278.799 279.536
380 280.274 281.01 1 281.749 282.486 283.224 283.961 284.699 285.437 286.174 286.912
390 287.649 288.387 289.124 289.862 290.599 291.337 292.075 292.812 293.550 294.287

295.025 295.762 296.500 297.238 297.975 298.713 299.450 300.925 301.663

410 302.400 303.138 303.876 304.613 305.351 306.088 306.826 307.563 308.301 309.039
420 309.776 310.514 31 1.251 31 1.989 312.726 313.464 314.201 314.939 315.677 316.414
430 317.152 317.889 318.627 319.364 320.102 320.840 321.577 322.315 323.052 323.790
440 324.527 325.265 326.002 326.740 327.478 328.215 328.953 329.690 330.428 331.165

450 331.903 332.641 333.378 334.1 16 334.853 335.591 336.328 337.066 337.803 338.541
460 339.279 340.016 340.754 341.491 342.229 342.966 343.704 344.442 345.179 345.917
470 346.654 347.392 348.129 348.867 349.604 350.342 35 1.080 351.817 352.555 353.292
480 354.030 354.767 355.505 356.243 356.980 357.718 358.455 359.193 359.930 360.668
490 361.405 362.143 362.881 363.618 364.356 365.093 365.831 366.568 367.306 368.044

06- 1
 TORQUE FIGURE CONVERSION CHART

NEWTON METRESTO POUND FORCE FEET

0 1 2 3 4 5 6 7 8 9
pounds force feet
5001368.781 369.519 370.256 370.994 371.731 372.469 373.206 373.944 374.682 375.419
510 376.157 376.894 377.632 378.369 379.107 379.845 380.582 381.320 382.057 382.795
520 383.532 384.270 385.007 385.745 386.483 387.220 387.958 388.695 389.433 390.170
530 390.908 391.646 392.383 393.121 393.858 394.596 395.333 396.071 396.808 397.546
540 398.284 399.021 399.759 400.496 401.234 401.971 402.709 403.447 404.184 404.922
550 405.659 406.397 407.134 407.872 408.609 409.347 410.085 410.822 41 1.560 412.297
560 413.035 413.772 414.510 415.248 415.985 416.723 417.460 418.198 418.935 419.673
570 420.410 421.148 421.886 422.623 423.361 424.098 424.836 425.573 426.31 1 427.049
580 427.786 428.524 429.261 429.999 430.736 431.474 432.21 1 432.949 433.687 434.424
590 435.162 435.899 436.637 437.374 438.1 12 438.849 439.587 440.325 441.062 441.800
442.537 443.275 444.012 444.750 445.488 446.225 446.963 448.438 449.175
610 449.913 450.650 451.388 452.126 452.863 453.601 454.338 455.076 455.813 456.551
620 457.289 458.026 458.764 459.501 460.239 460.976 461.714 462.451 463.189 463.927
630 464.664 465.402 466.139 466.877 467.614 468.352 469.090 469.827 470.565 471.302
640 472.040 472.777 473.51 5 474.252 474.990 475.728 476.465 477.203 477.940 478.678
650 479.415 480.153 480.891 481.628 482.366 483.103 483.841 484.578 485.316 486.053
660 486.791 487.529 488.266 489.004 489.741 490.479 491.216 491.954 492.692 493.429
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670 494.167 494.904 495.642 496.379 497.1 17 497.854 498.592 499.330 500.067 500.805
680 501.542 502.280 503.017 503.755 504.493 505.230 505.968 506.705 507.443 508.180
690 508.918 509.655 510.393 51 1.131 51 1.868 512.606 513.343 514.081 514.818 515.556
700 516.294 517.031 517.769 518.506 519.244 519.981 520.719 521.456 522.194 522.932
710 523.669 524.407 525.144 525.882 526.619 527.357 528.095 528.832 529.570 530.307
720 531.045 531.782 532.520 533.257 533.995 534.733 535.470 536.208 536.945 537.683
730 538.420 539.158 539.896 540.633 541.371 542.108 542.846 543.583 544.321 545.058
740 545.796 546.534 547.271 548.009 548.746 549.484 550.221 550.959 551.697 552.434
750 553.172 553.909 554.647 555.384 556.122 556.859 557.597 558.335 559.072 559.810
760 560.547 561.285 562.022 562.760 563.498 564.235 564.973 565.710 566.448 567.185
770 567.923 568.660 569.398 570.136 570.873 571.61 1 572.348 573.086 573.823 574.561
780 575.299 576.036 576.774 577.51 1 578.249 578.986 579.724 580.461 581.199 581.937
790 582.674 583.412 584.149 584.887 585.624 586.362 587.099 587.837 588.575 589.312
800 590.050 590.787 591.525 592,262 593.000 593.738 594.475 595.213 595.950 596.688
810 597.425 598.163 598.900 599.638 600.376 601.1 13 601.851 602.588 603.326 604.063
820 604.801 605.539 606.276 607.014 607.751 608.489 609.226 609.964 610.701 61 1.439
830 612.177 612.914 613.652 614.389 615.127 615.864 616.602 617.340 618.077 618.815
840 6 19.552 620.290 62 1.027 62 1.765 622.502 623.240 623.978 624.7 15 625.453 626.190
850 626.928 627.665 628.403 629.141 629.878 630.616 631.353 632.091 632.828 633.566
860 634.303 635.041 635.779 636.516 637.254 637.991 638.729 639.466 640.204 640.942
870 641.679 642.41 7 643.154 643.892 644.629 645.367 646.104 646.842 647.580 648.3 17
880 649.055 649.792 650.530 651.267 652.005 652.743 653.480 654.218 654.955 655.693
890 656.430 657.168 657.905 658.643 659.38 1 660.1 18 660.856 66 1.593 662.33 1 663.068
900 663.806 664.544 665.281 666.019 666.756 667.494 668.231 668.969 669.706 670.444
910 671.182 671.919 672.657 673.394 674.132 674.869 675.607 676.345 677.082 677.820
920 678.557 679.295 680.032 680.770 681.507 682.245 682.983 683.720 684.458 685.195
930 685.933 686.670 687.408 688.146 688.883 689.621 690.358 691.096 691.833 692.571
940 693.308 694.046 694.784 695.521 696.259 696.996 697.734 698.471 699.209 699.947
950 700.684 701.422 702.159 702.897 703.634 704.372 705.109 705.847 706.585 707.322
960 708.060 708.797 709.535 710.272 71 711.748 712.485 713.223 713.960 714.698
970 715.435 716.173 716.910 717.648 718.386 719.123 719.861 720.598 721.336 722.073
980 722.81 1 723.548 724.286 725.024 725.761 726.499 727.236 727.974 728.71 1 729.449
990 730.187 730.924 731.662 732.399 733.874 734.612 735.349 736.087 736.825
737.562 -

06-2
 TORQUE FIGURE CONVERSION CHART

POUNDS FORCE NEWTON METRES

bfft 0 1 2 3 4 5
Newton metres
6 7 8 9 I
1.3558 2.71 16 4.0675 5.4233 6.7791 8.1349 9.4907 10.8465 12.2024
13.5582 14.9140 16.2698 17.6256 18.9815 20.3373 21.6931 23.0489 24.4047 25.7605
20 27.1 164 28.4722 29.8280 31.1838 32.5396 33.8954 35.2513 36.6071 37.9629 39.3187
30 40.6745 42.0304 43.3862 44.7420 46.0978 47.4536 48.8094 50.1653 51.521 1 52.8769
40 54.2327 55.5885 56.9444 58.3002 59.6560 61.01 18 62.3676 63.7234 65.0793 66.4351

50 67.7909 69.1467 70.5025 71.8583 73.2142 74.5700 75.9258 77.2816 78.6374 79.9933
60 81.3491 82.7049 84.0607 85.4165 86.7723 88.1282 89.4840 90.8398 92.1956 93.5514
70 94.9073 96.2631 97.6189 98.9747 100.331 101.686 103.042 104.398 105.754 107.1
80 108.465 109.821 111.117 112.533 113.889 115.245 116.600 117.956 199.312 120.668
90 122.024 123.379 124.735 126.091 127.447 128.803 130.159 131.514 132.870 134.226

135.582 136.938 138.293 139.649 141.005 142.361 143.717 145.073 146.428 147.784
149.140 150.496 151.852 153.207 154.563 155.919 157.275 158.631 159.987 161.342
120 162.698 164.054 165.410 166.766 168.121 169.477 170.833 172.189 173.545 174.901
130 176.256 177.612 178.968 180.324 181.680 183.035 184.391 185.747 187.103 188.459
140 189.815 191.170 192.526 193.882 195.238 196.594 197.949 199.305 200.661 202.017

150 203.373 204.729 206.084 207.440 208.796 210.152 21 1.508 212.863 214.219 215.575
160 216.931 218.287 219.642 220.998 222.3 223.710 225.066 226.422 227.777 229.133
170 230.489 231.845 233.201 234.556 235.912 237.268 238.624 239.980 241.336 242.691
180 244.047 245.403 246.759 248.115 249.470 250.826 252.182 253.538 254.894 256.250
257.605 258.961 260.317 261.673 263.029 264.384 265.740 267.096 268.452 269.808

200 271.164 272.519 273.875 275.231 276.587 277.943 279.298 280.654 282.010 283.366
210 284.722 286.078 287.433 288.789 290.145 291.501 292.857 294.212 295.568 296.924
220 298.280 299.636 300.992 302.347 303.703 305.059 306.415 307.771 309.126 310.482
230 31 1.838 313.194 314.550 315.906 317.261 318.617 319.973 321.329 322.685 324.040
240 325.396 326.752 328.108 329.464 330.820 332.175 333.531 334.887 336.243 337.599

250 338.954 340.310 341.666 343.022 344.378 345.734 347.089 348.445 349.801 351.157
260 352.5 13 353.868 355.224 356.580 357.936 359.292 360.648 362.003 363.359 364.7 15
270 366.07 1 367.427 368.782 370.138 37 1.494 372.850 374.206 375.562 376.917 378.273
280 379.629 380.985 382.341 383.696 385.052 386.408 387.764 389.120 390.476 391.831
290 393.187 394.543 395.899 397.255 398.610 399.966 401.322 402.678 404.034 405.390

406.745 408.101 409.457 410.813 412.169 413.524 414.880 416.236 417.592 418.948
310 420.304 421.659 423.015 424.371 425.727 427.083 428.438 429.794 431.150 432.506
320 433.862 435.218 436.573 437.929 439.285 440.641 441.997 443.352 444.708 446.064
330 447.420 448.776 450.132 451.487 452.843 454.199 455.555 456.91 1 458.266 459.622
340 460.978 462.334 463.690 465.046 466.401 467.757 469.1 13 470.469 471.825 473.180

350 474.536 475.892 477.248 478.604 479.960 481.315 482.671 484.027 485.383 486.739
360 488.094 489.450 490.806 492.162 493.518 494.874 496.229 497.585 498.941 500.297
370 501.653 503.008 504.364 505.720 507.076 508.432 509.788 51 1.143 512.499 513.855
380 515.21 1 516.567 517.922 519.278 520.634 521.990 523.346 524.702 526.057 527.413
390 528.769 530.125 531.481 532.836 534.192 535.548 536.904 538.260 539.616 540.971

400 542.327 543.683 545.039 546.395 547.750 549.106 550.462 551.818 553.174 554.530
410 555.885 557.241 558.597 559.953 561.309 562.664 564.020 565.376 566.732 568.088
420 569.444 570.799 572.155 573.51 1 574.867 576.223 577.578 578.934 580.290 581.646
430 583.002 584.358 585.713 587.069 588.425 589.781 591.137 592.492 593.848 595.204
440 596.560 597.916 599.272 601.983 603.339 604.695 606.051 607.406 608.762

450 610.1 18 611.474 612.830 614.186 615.541 616.897 618.253 619.609 620.965 622.320
460 623.676 625.032 626.388 627.744 629.100 630.455 631.81 1 633.167 634.523 635.879
470 637.234 638.590 639.946 641.302 642.658 644.014 645.369 646.725 648.081 649.437
480 650.793 652.148 653.504 654.860 656.216 657.572 658.927 660.283 661.639 662.995
490 664.351 665.707 667.062 668.418 669.774 671.130 672.486 673.841 675.197 676.553
 TORQUE FIGURE CONVERSION CHART

POUNDS FORCE NEWTON METRES

bfft 0 1 2 3 4 5 6 7 8 9
I Newton metres
677.909 679.265 680.621 681.976 683.332 684.688 686.044 687.044 688.755 690.1 1 1
510 691.467 692.823 694.179 695.535 696.890 698.246 699.602 700.958 702.314 703.669
520 705.025 706.381 707.737 709.093 710.449 71 1.804 713.160 714.516 715.872 717.228
530 718.583 719.939 721.295 722.651 724.007 725.363 726.718 728.074 729.430 730.786
540 732.142 733.497 734.853 736.209 737.565 738.921 740.277 741.632 742.988 744.344
550 745.700 747.056 748.41 1 749.767 751.123 752.479 753.835 755.191 756.546 757.902
560 759.258 760.614 761.970 763.325 764.681 766.037 767.393 768.749 770.105 771.460
570 772.816 774.172 775.528 778.239 779.595 780.951 782.307 783.663 785.019
580 786.374 787.730 789.086 790.442 791.798 793.153 794.509 795.865 797.221 798.577
590 799.933 801.288 802.644 804.000 805.356 806.712 808.067 809.423 810.779 812.135
600 813.491 814.847 816.202 817.558 818.914 820.270 821.626 822.981 824.337 825.693
610 827.049 828.405 829.761 831.1 16 832.472 833.828 835.184 836.540 837.895 839.251
620 840.607 841.963 843.319 844.675 846.030 847.386 848.742 850.098 851.454 852.809
630 854.165 855.521 856.877 858.233 859.589 860.944 862.300 863.656 865.012 866.368
640 867.723 869.079 870.435 871.791 873.147 874.503 875.858 877.214 878.570 879.926
650 881.282 882.637 883.993 885.349 886.705 888.061 889.417 890.772 892.128 893.484
660 894.840 896.196 897.551 898.907 900.263 901.619 902.975 905.686 907.042
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670 908.398 909.754 91 1.1 912.465 913.821 915.177 916.553 917.889 919.245 920.600
680 921.956 923.312 924.668 926.024 927.379 928.735 930.091 931.447 932.803 934.159
690 935.514 936.870 938.226 939.582 940.938 942.293 943.649 945.005 946.361 947.717
700 949.073 950.428 951.784 953.140 954.496 955.852 957.207 958.563 959.919 961.275
710 962.631 963.987 965.342 966.698 968.054 969.410 970.766 972.121 973.477 974.833
720 976.189 977.545 978.901 980.256 981.612 982.968 984.324 985.680 987.035 988.391
730 989.747 991.103 992.459 993.815 995.170 996.526 997.882 999.238 1000.59 1001.95
740 1003.31 1004.66 1006.02 1007.37 1008.73 1010.08 1.44 1012.80 1014.15 1015.51
750 1016.86 1018.22 1019.58 1020.93 1022.29 1023.64 1025.00 1026.35 1027.71 1029.07
760 1030.42 1031.78 1033.13 1034.49 1035.84 1037.20 1038.56 1039.91 1041.27 1042.62
770 1043.98 1045.34 1046.69 1048.05 1049.40 1050.76 1052.1 1 1053.47 1054.83 1056.18
780 1057.54 1058.89 1060.25 1061.61 1062.96 1064.32 1065.67 1067.03 1068.38 1069.74
790 1071.10 1072.45 1073.81 1075.16 1076.52 1077.88 1079.23 1080.59 1081.94 1083.30
800 1084.65 1086.01 1087.37 1088.72 1090.08 1091.43 1092.79 1094.15 1095.50 1096.86
810 1098.21 1099.57 1100.92 1102.28 1103.64 1104.99 1106.35 1109.06 1 1 10.41
820 1111.77 1113.13 1114.48 1115.84 1117.19 1118.55 1119.91 1121.26 1122.62 1123.97
830 1125.33 1126.68 1128.04 1129.40 1130.75 1132.11 1133.46 1136.18 1137.53
840 1138.89 1140.24 1141.60 1142.95 1144.31 1145.67 1147.02 1149.73 1151.09
850 1152.45 1153.80 1155.16 1156.51 1157.87 1159.22 1160.58 1161.94 1163.29 1164.65
860 1166.00 1167.36 1168.72 1170.07 1172.78 1174.14 1175.49 1176.85 1178.21
870 1179.56 1180.92 1182.27 1183.63 1184.98 1186.34 1187.70 1189.05 1190.41 1191.76
880 1193.12 1194.48 1195.83 1197.19 1198.54 1199.90 1201.25 1202.61 1203.97 1205.32
890 1206.68 1208.03 1209.39 1210.75 1212.10 1213.46 1214.81 1216.17 1217.52 1218.88
900 1220.24 122 1.59 1222.95 1224.30 1225.66 1227.02 1228.37 1229.73 123 1.08 1232.44
910 1233.79 1235.15 1236.51 1237.86 1239.22 1240.57 1241.93 1243.29 1244.64
920 1247.35 1248.7 1 1250.06 125 1.42 1252.78 1254.13 1255.49 1256.84 1258.20 1259.55
930 1260.91 1262.27 1263.62 1264.98 1266.33 1267.69 1269.05 1270.40 1271.76 1273.1 1
940 1274.47 1275.82 1277.18 1278.54 1279.89 128 1.25 1282.60 1283.96 1285.32 1286.67
950 1288.03 1289.38 1290.74 1292.09 1293.45 1294.8 1 1296.16 1297.52 1298.87 1300.23
960 1301.59 1302.94 1304.30 1305.65 1307.01 1308.36 1309.72 131 1.08 1312.43 1313.79
970 1315.14 1316.50 1317.85 1319.21 1320.57 1321.92 1323.28 1324.63 1325.99 1327.35
980 1328.70 1330.06 133 1.41 1332.77 1334.12 1335.48 1336.84 1338.19 1339.55 1340.90
990 1342.26 1343.62 1344.97 1346.33 1347.68 1349.04 1350.39 135 1.75 1353.1 1 1354.46
000 1355.82 -

06-4
 GENERAL FITTING INSTRUCTIONS

F NG I NSTRUCTI0N

Precautionsagainst damage

Always fit covers to protect the wings before

commencing work in the engine compartment. Cover
the seats and carpets, wear clean overalls and wash
hands or wear gloves before working inside the car.
Avoid spilling hydraulic fluid or battery acid on
paintwork. In the event of spillage, wash off with water
immediately.
Use polythene sheets in the boot to protect carpets.
Always use a recommmended service tool, or a
satisfactory equivalent, where specified.
Protect temporarily exposed screw threads by
replacing nuts or fitting caps.

Safety precautions

Whenever possible use a ramp or pit whilst working

beneath a car, in preference t o jacking. Chock the
wheels as well as applying the handbrake.
Never rely on a jack alone t o support a car. Use axle
stands or blocks carefully placed at the jacking joints t o
provide a rigid location. Ensure that a suitable form of
fire extinguisher is conveniently located.
Check that any lifting equipment used has adequate
capacity and is fully serviceable.
Inspect power leads of any mains electrical equipment
for damage, and check that it is properly earthed.
Disconnect the earth (grounded) terminal of a car
battery.
Do not disconnect any pipes in the air conditioning
refrigeration system, if fitted, unless trained and
instructed to do so. A refridgerant is used which can
cause blindness if allowed to contact eyes.

07-01
 GENERAL FITTING INSTRUCTIONS

Safety precautionscontinued...

Ensure that adequate ventilation is provided when

volatile de-greasing agents are being used.

WARNING: FUME EXTRACTION EQUIPMENT MUST

BE IN OPERATION WHEN SOLVENTS ARE USED E.G.
TRICHLOROETHANE, WHITE SPIRIT, METHY-
LENE CHLORIDE, PERCHLORETHYLENE.

WARNING: DO NOT SMOKE IN THE VICINITY OF

VOLATILE DE-GREASINGAGENTS.

Strictly adhere to handling and safety instructions

found on containers and labels. Containers whose
capacity is over 25 litres (5 gallons) require a bund wall
in order to contain spillages.
Keep oils and solvents away from naked flames and
other sources of ignition welders.
Do not apply heat in an attempt to free stiff nuts or
fittings; as well as causing damage to protective
coatings, there is a risk of damage t o electronic
equipment and brake lines from stray heat.
Do not leave tools, equipment, split oil, etc. around or
on work areas.
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Used engine oils

Prolonged and repeated contact with mineral oil will

result in the removal of natural fats from the skin,
leading to dryness, irritation and dermatitis. In
addition, used engine oil contains potentially harmful
contaminants which may cause skin cancer. Adequate
means of skin protection and washing facilities should
be provided.

Health protection precautions

1. Avoid prolonged and repeated contact with

oils, particularly used eingine oils.

2. Wear protective clothing, including impervious

gloves where practicable.

3. Do not put oily rags in pockets.

4. Avoid contaminating clothes, particularly

derpants, with oil.

07-02
 GENERAL FITTING INSTRUCTIONS

Used engine oils Continued

5. Overalls must be cleaned regularly. Discard

unwashable clothing and oil impregnated
footwear.

6. First aid treatment should be obtained

immediatelyfor open cuts or wounds.

7. Use barrier creams, applying before each work

period, to help the removal of oil from the skin.

8. Wsah with soap and water to ensure all oil is

removed (skin cleaners and nail brushes will
help). Preparations containing lanolin replace
the natural skin oils which have been removed.

9. Do not use petrol, kerosine, diesel fuel, gas oil,

thinners or solvents for washing skin.

0. If skin disorders develop, obtain medical

advice.

1. Where practicable, degrease components

prior to handling.

12. Where there is a risk of eye contact, eye

protection should be worn, for example,
chemical goggles or face shields; in addition
an eye wash facility should be provided.

Environmental Protection Precautions

It is illegal to pour used oil on to the ground, down

sewers or drains, or into water courses.
The burning of used engine oil in small space heaters
or boilers is not recommended unless emission control
equipment is fitted; in cases of doubt, contact the
Local Authority for advice on disposal facilities.

Preparation

Before removing a component, clean it and its

surrounding area as thoroughly as possible.
Blank off any openings exposed by component
removal using greaseproof paper and masking tape.
Immediately seal fuel, oil or hydraulic lines when
separated, using plastic caps or plugs, to prevent loss
of fluid and entry of dirt.

07-03
 GENERAL FITTING INSTRUCTIONS

PreparationContinued...

Close the open ends of oilways, exposed by

component removal, with tapered hardwood plugs or
readily visible plastic plugs.
Immediately a component is removed , place it in a
suitable container: use a separate container for each
component and its associated parts.
Before dismantling a component clean it thoroughly
with a recommended cleaning agent: check that the
agent is suitable for all materials of component.
Clean the bench and provide marking materials, labels,
containers and locking wire before dismantling a
component.

Dismantling

Observe scrupulous cleanliness when dismantling

components, particulary when brake, fuel or hydraulic
system parts are being worked on.
A particle of dirt or a cloth fragment could cause a
dangerous malfunction if trapped in these sytems.
Blow out all tapped holes, crevices, oilways and fluid
passages with an air , Ensure that any '0' rings used
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for sealing are correctly replaced or renewed if

disturbed. Mark mating parts to ensure that they are
replaced as dismantled. Whenever possible use
marking ink, which avoids possibilities of distortion or
initiation of cracks, liable if centrepunch or scriber are
used.
Wire together mating parts where necessary to
prevent accidental intercharge roller bearing
components).
Wire labels onto all parts to be renewed, and to parts
requiring further inspection before being passed for
reassembly: place labelled parts and other parts for
rebuild in separate containers.
Do not discard a part due for renewal until it has been
compared with a new part, to ensure that its correct
replacement has been obtained.

07-04
 GENERAL FITTING INSTRUCTIONS

Inspection -General

Never inspect a component for wear or dimensional

check unless it is absolutely clean: a slight smear of
grease can conceal an incipient failure. When a
component is to be checked dimensionally against
figures quoted for it, use correct equipment (surface
plates, micrometers, dial gauges, etc.) in serviceable
condition.
Makeshift checking equipment can be dangerous.
Reject a component if its dimensions are outside the
limits quoted, or if damage is apparent. A part may
however, be refitted if its critical dimension is exactly
limit size, and is otherwise satisfactory.
Use Plastigauge 12 Type PG-1 for checking bearing
surface clearances in (0.0001in) steps are
providedwith it.

Ball and roller bearings

NEVER REPLACE A BALL OR ROLLER BEARING

WITHOUT FIRST ENSURING THAT IT IS AS-NEW
CONDITION

Remove all traces of lubricant from bearing under

inspection by washing it in petrol or a suitable
de-greaser: maintain absolute cleanliness throughout
the operations.
Inspect visually for markings of any form on rolling
elements, raceways, outer surface of outer rings or
inner surface of inner rings. Reject any bearings found
t o be marked, since any markings in these areas
indicates onset of wear.
Holding the inner race between the fingers and thumb
of one hand, spin the outer race and check that it
revolves absolutely smoothly. Repeat, holding the
outer race and spinning the inner race.
Rotate the outer ring with a reciprocating motion, while
holding the inner ring : feel for any check or obstruction
t o rotation, and reject the bearing if action is not
perfectly smooth.
Lubricate the bearing generously with lubricant
appropriate to installation. Inspect the shaft and
bearing housing for discolouration or other marking
suggesting that movement has taken place between
bearing and seatings.

07-05
 GENERAL FITTING INSTRUCTIONS

Ball and roller bearings Continued ...

If markings are found use Loctite in installation of

replacement bearing.
Ensure that the shaft and housing are clean and free
from burrs before fitting the bearing. If one bearing of a
pair shows an imperfection it is generally advisable to
renew both bearings: an exception could be made only
if the faulty bearing had covered a low mileage, and it
could be established tha? damage was confined to it.
When fitting the bearing to shaft, apply force only to
inner ring of bearing, and only to outer ring when fitting
into housing (Fig 1).
In the case of grease-lubricated bearings hub
bearings) fill the space between the bearing and outer
seal with a recommended grade of grease before filling
the seal.
Always mark components of separable bearings
taper-roller bearings) in dismantling to ensure correct
reassembly. Never fit new rollers in a used cup.

Fig. 1
Oil Seals

Always fit new oil seals when rebuilding an assembly.

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It is not physically possible to replace new oil seal

exactly as it has bedded down.

Carefully examine the seal before fitment to ensure

that it is clean and undamaged.

Smear sealing lips with clean grease, pack dust

excluder seals with grease, and heavily grease duplex
seals in cavity between sealing lips.

Ensure that seal spring, if provided, is correctly fitted.

Place lip of seal towards fluid to be sealed and slide

into position on shaft, using fitting sleeve (Fig. 2) when
possible to protect sealing lip from damage by sharp
corners, threads or splines. If fitting sleeve is not
available, use plastic tube or adhesive tape to prevent
damage to sealing lip.
h
J07 002
Fig. 2

07-06
 GENERAL FITTING INSTRUCTIONS

Grease the outside diameter of the seal, place it square

to the housing recess and press it into position, using
great care and if possible a 'bell piece' (Fig. 1) to ensure
that seal is not tilted. (In some cases it may be
preferable to fit the seal to the housing before fitting to
the shaft). Never let the weight of an unsupported shaft
rest in a seal.

If correct service tool is not available, use a suitable

drift approximately 0.4 (0.015 in) smaller than the ,
outside diameter of the seal. Use a hammer VERY
GENTLY on the drift if a press is not suitable.

Press or drift a seal in to the depth of housing if the

housing is shouldered, or flush with the face of the
housing where no shoulder is provided.

NOTE: Most cases of failure of leakage or oil seals are

due to careless fitting, and resulting damage to both
seals and sealing surfaces. Care in fitting is essential if 003
good results are to be obtained.

Fia. 1
Joints and joint faces

Always use the correct gaskets where they are

specified.

Use jointing compound only when recommended.

Otherwise fit joints dry.

When jointing compound is used, apply in a thin

uniform film to metal surfaces; take great care to
prevent it from entering pipes or blind tapped
holes.

Remove all traces of old jointing materials prior to

reassembly. Do not use a tool which could damage
joint faces.

Inspect joint faces for scratches or burrs and remove

with a fine file or oil-stone; do not allow swarf or dirt to
enter tapped holes or enclosed parts. Blow out any
pipes, channels or crevices with compressed air,
renewing any '0' rings or seals displaced by air blast.

07-07
 GENERAL INSTRUCTIONS

Flexible hydraulic pipes, hoses

Before removing any brake or power steering hose,

clean end fittings and area surrounding them as
thoroughly as possible. Obtain appropriate blanking
caps before detaching hose end fittings, so that ports
can be immediately covered to exclude dirt.

Clean hose externally and blow through with airline.

Examine carefully for cracks, separation of plies,
security of end fittings and external damage. Reject
any hose found faulty.

When refitting hose, ensure that no unnecessary

bends are introduced, and that hose is not twisted
before or during tightening of union nuts.

Containers for hydraulic fluid must be kept absolutely

clean.

Do not store hydraulic fluid in an unsealed container. It

will absorb water, and fluid in this condition would be
dangerous to use due to a lowering of its boiling point.

Do not allow hydraulic fluid to be contaminated with

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mineral oil, or use a container which has previously

contained mineral oil.

Do not re-use fluid bled from system. Always use

clean brake fluid, or a recommended alternative, to
clean hydraulic components.

Fit a blanking cap to a hydraulic union and a plug to its

socket after removal to prevent ingress of dirt.

Absolute cleanliness must be observed with hydraulic

components a t all times.

After any work on hydraulic systems, inspect carefully

for leaks underneath the car while a second operator
applies maximum pressure to the brakes (engine
running) and operates the steering.

07-08
 GENERAL FITTING INSTRUCTIONS

Metric bolt identification

An metric bolt or screw, made of steel and laraer

than 6 in diameter can be identified by either of
symbols M or M embossed or indented on top of
the head (Fig. 1).

In addition to marks to identify the manufacture, the

head is also marked with symbols to indicate the
strength grade e.g. 8.8, 10.9, 12.9, or 14.9, where
the first the minimum tensile strength of
the bolt tens of

Zinc plated metric bolts and nuts are chromate

passivated, a greenish-khakito gold-bronzecolour.

507 004
Metric nut identification

A nut with an metric thread is marked on one face

Fig. 2) or on one of the flats (2, Fig. 2) of the
hexagon with the strength grade symbol 8, 12 or 14. Fig. 1
Some nuts with a strength 4, 5 or 6 are also marked
and some have the metric symbol M on the flat
opposite the strength grade marking.

A clock face system (3, Fig. 2) is used as an alternative

method of indicating the strength grade. The external
chamfers or a face of the nut is marked in a aosition V
relative to the appropriate hour mark on a clock face to
indicatethe strength grade.

A dot is used to locate the 12 o'clock position and a

dash to indicate the strength grade. If the grade is
above 12, two dots identify the 12 o'clock position.
507 0

Fig. 2

07-09
 GENERAL NG INSTRUCTIONS

Hydraulic fittings- Metrification

WARNING: METRIC AND UNIFIED THREADED

HYDRAULIC PARTS -
ALTHOUGH
PIPE CONNECTIONS TO BRAKE
SYSTEM UNITS INCORPORATE
THREADS OF METRICFORM, THOSE
FOR POWER ASSISTED STEERING
ARE OF UNF TYPE. IT IS VITALLY IM-
PORTANT THAT THESE TWO
THREAD FORMS ARE NOT CON-
FUSED, AND CAREFUL STUDY
SHOULD BE MADE FOLLOW-
ING NOTES.

Metric threads and metric sizes are being intro-

duced into motor vehicle manufacture and some
duplication of parts must be expected.
Fitting UNF pipe nuts into metric ports and vice-versa
should not happen, but experience of the change from
BSF to UNF indicated that there is no certainty in
relying upon the difference in thread size when safety
is involved.
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To provide permanent identification of metric parts is

not easy but recognition has been assisted by the 507 006
following means:

All metric pipe nuts, hose ends, unions and bleed

screws are coloured black.
Fig. 1
The hexagon area of pipe nuts is indented with the
letter 'M'.

Metric and UNF pipe nuts are slightly different in shape.

NOTE: In the Figs on this and the following page, 'A'

indicates the metric type and 'B'the UNF type.

The metric female nut is always used with a trumpet

flared pipe and the metric male nut is always used with
a convex flared pipe (Fig. 1).

07-10
 G ENERAL NG INSTR 0NS

Hydraulic fittings - Metrification Continued...

All metric ports in cylinders and calipers have no

counterbores, but unfortunately a few cylinders with
UNF threads also have no counterbore. The situation
is, all ports with counterbores are UNF, but ports not
counterbored are most likely to be metric (Fig.1).

The colour of the protective plugs in hydraulic ports

indicates the size and the type of the threads, but the
function of the plugs is protective and not designed as
positive identification. In production it is difficult to use
the wrong plug but human error must be taken into
account.

The plug colours and thread sizes are:

COLOUR UNF

RED 3/8 in x 24 UNF

GREEN 16 in x 20 UNF Fig. 1
YELLOW 1/2 in x 20 UNF

METRIC
BLACK 1
GREY 1 rnm
BROWN

Hose ends differ slightly between metric and UNF (Fig.

Gaskets are not used with metric hoses.

The UNF hose is sealed on the cylinder or caliper face

by a copper gasket but the metric hose seals against
the bottom of the port and there is a gap between
faces of the hose end and cylinder (Fig. 3).

Pipe sizes for UNF are 3/16 in, in, and 16 in outside
diameter.

Metric pipe sizes are and 8 mm. Fig. 2

mrn pipe is exactly the same as 16 in pipe.

6 pipe is 0.014 in smaller than 1 in pipe.

Fig. 3

07-1 1
 GENERAL INSTRUCTIONS

Hydraulicfittings- Continued...

8 pipe is 0.002 in larger than 5/16 in pipe. Convex

pipe flares are shaped differently for metric sizes and
when making pipes for metric equipment, metric pipe
flaring tools must be used.

The greatest danger lies with the confusion of

and 3/8 in UNF pipe nuts used for 3/16 in (or
pipe. The 3/8 in UNF pipe nut or hose can be
screwed into a port but is very slack and easily
stripped. The thread engagement is very weak and
cannot provide an adequate seal. The opposite
condition, a nut in a 3/8 in. port, is difficult and
unlikely to cause trouble. The nut will screw in
1 or two turns and seize. It has a crossed thread 'feel'
and it is impossible to force the nut far enough to seal
507 010
the pipe. With female pipe nuts the position is of
course reversed.

The other combinations are so different that there is no

danger of confusion.
Fig. 1

Keys and keyways

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Remove burrs from edges of keyways with a fine file

and clean thoroughly before attempting to refit key.

Clean and inspect key closely; keys are suitable for

refitting only if indistinguishable from new, as any
indentation may indicate the onset of wear.

Split pins

Fit new split pins throughout when replacing any unit

Always fit split pins where split pins were originally

used. Do not substitute spring washers; there is
always a good reason for the use of a split pin.

All split pins should be fitted as shown in Fig. 1 unless

otherwise stated.

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 GENERAL FITTING INSTRUCTIONS

Tab washers

Fit new tab washers in all where thev are used.

Never replace a used tab washer.

Ensure that the new tab washer is of the same design

as that replaced.

Special fixings

Bolts are used in various areas of the vehicle with a

blue coating applied to the thread. Should any of these
bolts be moved or removed they MUST be REPLACED
with a NEW bolt.

Bolts are used in various areas of the vehicle with a

nylon insert. If removed these MUST be REPLACED.

Nyloc nuts are used in various areas of the vehicle. If

removed these MUST be REPLACED

Nuts

When tightening up a slotted or castellated nut neve;

slacken it back to insert split pin or locking wire except
in those recommended cases where this forms part of
an adjustment. If difficulty is experienced, alternative
washers or nuts should be selected, or washer
thickness reduced.

Where self-locking nuts have been removed it is

advisable to replace them with new ones of the same

NOTE: Where bearing pre-load is involved nuts should

be tightened in accordance with special instructions.

Locking wire

Fit new locking wire of the correct type for all

assemblies incorporating it.

Arrange wire so that its tension tends to tighten the

bolt heads, or nuts, to which it is fitted.

07-13
 GENERAL FITTING INSTRUCTIONS

Screw threads

Both UNF and Metric threads to standards are

used. See below for thread identification.

Damaged threads must always be discarded. Cleaning

up threads with a die or tap impairs the strength and
closeness of fit of the threads and is not recommended.

Always ensure that replacement bolts are at least

equal in strength to those replaced.

Do not allow oil, grease or jointing compound to enter

blind threaded holes. The hydraulic action on screwing
in the bolt or stud could split the housing.

Always tighten a nut or bolt to the recommended

torque figure. Damaged or corroded threads can affect
the torque reading. -
3
507
To check or re-tighten a bolt or screw to a specified
torque figure, first slacken a quarter of a turn, then
re-tighten to the correct figure. Always oil thread Fig. 1
lightly before tightening to ensure a free running
thread, except in the case of self-locking nuts.
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Unified thread identification bolts

A circular recess is stamped in the upper surface of the

Nuts

A continuous line of circles is indented on one of the

flats of the hexagon, parallel to the axis of the nut (2,
Fig. 1)

Studs, brake rods, etc.

The component is reduced to the core diameter for a

short length at its extremity (3, Fig. 1).

07- 14
 GENERAL FITTING INSTRUCTIONS

TAPER ROLLER BEARING-FAULT DIAGNOSIS

CONDITION OF BEARING

Fig 1
Good Bearina

CAUSE CONDITION OF BEARING

Improper handling or tool usage

REMEDY
Replace the bearing

Fig 2
Bent

CAUSE CONDITION OF BEARING

Improper handling or tool usage

REMEDY
Replace the bearing

Fig 3
Bent cage

CAUSE CONDITION OF BEARING

Marks on roller ends due to overheating
Lubricant failure or overloading

REMEDY
Replace the the seals and
ensure that the bearing is properly lubricated

Fig 4
Galling

07-15
 GENERAL INSTRUCTIONS

TAPER ROLLER BEARING-FAULT DIAGNOSIS

CAUSE CONDITION OF BEARING

Wear on the roller ends caused by fine abrasives

REMEDY
Clean all components and the seals and
bearings and replace if leaking, rough or noisy

Fig 1
Step wear

CAUSE CONDITION OF BEARING

The bearina surfaces are arev or arevish black in
colour, the rollers track material being
etched away usually related to roller spacing

REMEDY
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Replace the bearings, check the seals and also ensure

there is adequate lubrication.

Fig 2

CAUSE CONDITION OF BEARING

Outer track misalignment usually due to a foreign body
under the track

REMEDY
Clean all components and replace the bearing and
ensure that the new track is correctly seated.

Fig 3
Misalignment

CAUSE CONDITION OF BEARING

Surfaces are depressed on the race and the track
caused by hard particles of foreign material

REMEDY
Clean all parts and housings, check the seals and
replace if rough or noisy

Fig 4
Indentations

07-16
 GENERAL FITTING INSTRUCTIONS

TAPER ROLLER BEARING-FAULT DIAGNOSIS

CAUSE CONDITION OF BEARING

Flaking of the surface material due to fatigue

REMEDY
Replace the bearing and clean all related components

Fig 1

CAUSE CONDITION OF BEARING

Surface indentations in track caused by rollers
either vibrating or impact loading while the
bearing is not rotating

REMEDY
Replace the bearing if rough or noisy

Fig 2
Indentations

CAUSE CONDITION OF BEARING

Wear around the outside diameter of the cage and
roller pockets caused by poor lubrication and abrasive
material
-
REMEDY
Replace the bearings and check the conditions of the
seals

Fig 3
Cage wear

CAUSE CONDITION OF BEARING

Marks on track and rollers caused bv fine abrasives

REMEDY
Clean all components and housings. Check the seal
and bearing condition and replace if leaking or noisy

Fig 4
Roller wear

07-17
 GENERAL INSTRUCTIONS

TAPER ROLLER BEARING-FAULT DIAGNOSIS

CAUSE CONDITION OF BEARING

Discolourationranges from black to light brown
caused by moisture or incorrect use of lubricants

REMEDY
Re-use bearings if stains can be removed by light
polishingor if no evidence of overheating is
apparent. Check the seal and other component part
condition.

Fig 1
Discolouration

CAUSE CONDITION OF BEARING

Heat discolouration ranges from blue to faint yellow
resultingfrom overload or incorrect lubricant. As
excessive heat can cause softening of tracks and
rollers, check by drawing a fine file over a softened
area. If faulty, file with grab and cut metal; if it
remains hard the file will skid over the surface without
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removing any material.

REMEDY
Replace the bearings and seals if any heat damage is
evident.

Fig 2
Heat discolouration

CAUSE OF BEARING
Race cracked due to incorrect fitment to shaft,
tipping or poor seating.

REMEDY
Replace the bearing and check the condition
of the seals.

Fig 3
Cracked race

CAUSE CONDITION OF BEARING

Removal of material due to slippage. This can
be caused by poor fits, incorrect lubrication,
overheating. overloading and poor assembly.

REMEDY
Replace bearings and clean all related parts, check
the fit and ensure the replacement bearings are the
correct type. Replace the shaft or housing if damaged.

Fig 4
Rotating track and inner race

07-18
 GENERAL NG I NS

TAPER ROLLER BEARING-FAULTDIAGNOSIS

CAUSE CONDITION OF BEARING

Corrosion caused by small movement of components
with no lubrication

REMEDY
Replace the bearing, check the seals for leakage and
ensure there is adequate lubrication.

8.063

Fig 1
Fretting

CAUSE CONDITION OF BEARING

Caused by lack of lubrication, excessive loads
on the ingress of foreign matter

REMEDY
Change the bearings. Check the seals for wear
and ensure there is adequate lubrication

Seizure

07-19
 JACKING, LIFTING ANDVEHICLE RECOVERY

LIFTING AND JACKING

Stands

When carrying out any work on the vehicle which

requires a wheel to be raised (apart from a simple
wheel change) it is essential that the jack is replaced by
a stand, located by the jacking spigot, to provide a
secure support for the car.

Jacking Points (Fig. 1)

The jack provided in the vehicle's tool kit engages with

spigots situated below the body side members, in
front of the rear wheels and behind the front wheels.

Always chock wheels as well as applying handbrake

when using the jack.
Fig. 1

Workshop Jack

Front - one wheel (Fig. 2)

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Jack under the lower spring support pan, using a

suitable wooden block on the jack head. Place a stand
in position at the adjacent jacking spigot when the
wheel is raised.

Rear - one wheel (Fig. 3)

Locate the jack with a wooden block on its head, under

the outer fork of the wishbone a t the wheel to be
raised. Take care to avoid damage to the aluminium
alloy hub carrier or to the grease nipple fitted to it.
Place a stand under the adjacent jacking spigot when
005
the wheel is raised.

Fig. 2

Fig. 3

08-01
 JACKING, LIFTING AND VEHICLE RECOVERY

LIFTING AND JACKING continued...

Front - both wheels (Fig. 1)

Place the jack, with a wooden block on its head,

centrally under the front suspension crossmernber.
Place stands under both front jacking spigots when the
car is raised.

Rear- both wheels (Fig. 2)

Place a suitable shaped wooden block between the

jack head and the plate in the centre of the rear
crossbeam, ensuring that the jacking load is not
applied to the flanges of the plate. Place stands under
both rear jacking spigots when the car is raised.

Lifting
Fig. 1
Locate lifting pads at the four jacking spigots.

Fig. 2

08-02
 JACKING, LIFTING AND VEHICLE RECOVERY

VEHICLE RECOVERY

General

The preferred method of vehicle recovery is by flat bed

transporter or suspended tow. The towing loops are
primarily for emergency use when being towed for
SHORT DISTANCES, e.g. removing the vehicle if it is
causing an obstruction or winching the vehicle on to a
recovery

Transporting (Fig. 1)

If the vehicle is being transported on a trailer or vehicle

flatbed transporter, the handbrake must be applied,
the wheels chocked and (if fitted with automatic
transmission) the gear selector lever moved to or
’D’ but NEVER to ’P’.

There are four transporter tie down brackets provided

on the vehicle axles. These are NOT suitable for solid Fig. 1
bar towing.
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Vehicles with defective Automatic Transmission

The vehicle must be carried on a transporter or towed

with the rear wheels clear of the ground (see
suspended towing) or towed with the the propeller
shaft disconnected at the final drive input flange. If the
propeller shaft is disconnected it must be firmly
secured away from the final drive flange.

08-03
VEHICLE RECOVERY continued ...
Suspended Towing

Do NOT tow with sling-type equipment since damage

t o the bodywork may result.

Ensure that the recovery team follow these instructions:

Front suspended (Fig.

1. Remove the ignition key from the ignition/

steering lock.

2. Vehicles with automatic transmission:

Disconnect the propeller shaft at the final drive
input flange. Ensure the propeller shaft is firmly
secured away from the final drive input flange
or altenatively --
Providing a distance of 48 (30 miles) is not
to be exceeded, add an extra 1.7 litres (3
pints) of the recommended fluid t o the Fig. 1
automatic transmission through the filler tube.

Before the vehicle is driven again the

excess fluid must be drained and the level
checked.

3. Raise the vehicle using a 'spectacle frame'

type lifting device where a cradle is positioned
under each front wheel as indicated in Fig.

Rear suspended (Fig.2)

1. Remove the ignition key from the ignition/

steering lock.

2. Raise the vehicle using a 'spectacle frame'

type lifting device where a cradle is positioned
under each rear wheel as indicated in Fig.2.

Fig. 2

08-04
 JACKING, LIFTING RECOVERY

VEHICLE RECOVERY continued ...

Towing Recovery - (Non-preferedrecovery method)

Adhere to towing regulations:

In certain countries the registration number of the

towing vehicle and an ’ON TOW’ sign or warning
triangle must be displayed in a prominent position at
the rear of the vehicle being towed.

WARNING: WHEN THE ENGINE IS NOT RUNNING,

THE STEERING WILL NO LONGER BE
ASSISTED AND THE BRAKE SERVO WILL
BECOME INEFFECTIVE AFTER A FEW APPLI-
CATIONS OF THE BRAKES. THEREFORE, BE
PREPARED FOR RELATIVELY HEAVY STEERING
AND THE NEED FOR GREATLY INCREASED
BRAKE PEDAL PRESSURE.

The vehicle may be towed SHORT DISTANCES by

another provided a speed of 48 (30 mph) is not
exceeded. When being towed, the vehicle‘s gear lever
(manual gearbox) or gear selector lever (automatic
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transmission) must be in neutral or position with

the ignition key turned to position to release the
steering lock and render the indicators, horn and brake
lights operational.

Care must be taken to avoid damaging the front air

spoiler.

08-05
 RECOMMENDED LUBRICANTS, FLUIDS CAPACITIES AND DIMENSIONS

Recommended Lubricants and Fluids 3.6

SAE Approved Brands (UK) Temperatures

Component Specification Viscosity above-1 (14°F)
Ratina
Engine
or
Oil Can CCMC G3 See Fig. 1 for range

If the above
are not
available use
A.P.I.

Manual A.P.I. GL4 EP 8 0 Gear 8 0 EP; Castrol

Gearbox Hypoy Light; Duckhams Hypoid 80;
Mobilube Shell Spirax 80EP
Automatic Dexron D Autran DX; Castrol Dexron;
Transmission Duckhams Esso ATF
Dexron; Dexron; Shell
ATF Dexron; Texaco Texamatic
Fluid 6673
Powr-Lok
Differential A.P.I. GL5 90 Shell Spirax Super 90
- Refill

- Top Up only A.P.I. GL5 EP 90 Gear Oil SAE 90 EP; Castrol

if above Hypoy B - Duckhams
oil is not Hypoid 90; Esso Gear Oil
available. Mobilube Shell
Spirax Texaco Multigear
Lubricant EP 90
Power Dexron D See automatic transmission fluids
Assisted or and Autran G; Castrol TQF;
Steering Duckhams Esso Glide
33G) Type G; Fina 33F;
Mobil ATF 2 10; Shell TF;
Texaco Texamatic Type G
Grease Multipurpose Energrease L8; Castrol LM;
Points Lithium Grease Duckhams LB
N.L.G.I. Esso Multipurpose H; Fina
Consistency Mobilgrease MP;
No.2 Shell A; Texaco

Engine Oil-Recommended Scale

-30 - 20 -10 0 10 20 30

Fig. 1

09-0 1
 RECOMMENDED LUBRICANTS, FLUIDS CAPACITIES AND DIMENSIONS

Synthetic Oils

When synthetic oils are used, must conform t o BLS.22.OL.07 standards. The ambient
chart applies equaily to synthetic and mineral oils.

Synthetic and mineral oils are completely miscible and may be used separately or mixed.

Cooling System

Always top up the cooling system with recommended strength of anti-freeze, NEVER with water only. The
correct concentration for all vehicles is 5 0 per cent, with a specific gravity of 1.079 (taken from the radiator
header tank). This solution is suitable for temperatures to -36°C (-33°F).

Should protection to (-40°F) be required the anti-freeze concentration must be increased to 55 per cent
with a specific gravity of 1.086.

Additive ‘Jaguar Radiator Leak Sealer’ or ’Barrs Leaks’.

In XJ-S 3.6 use one bottle per vehicle.
In XJ-S V 12 use t w o bottles per vehicle.

Anti-freeze Jaguar Universal

Should this not be available then phosphate free anti-freeze

conforming to specification BS 3 150 or 3 152 may be used.
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Hydraulic Fluid

Braking System

Use only Jaguar Brake Fluid or Castrol Girling Universal.

These are conventional brake fluids conforming to DOT 4 specification.

Clutch System - (Where fitted)

Use only Jaguar Fluid or Castrol Girling Universal.

These are conventional fluids conforming t o DOT 4 specification.

Convertible Hood Hydraulic System

Use Esso Univis J 13.

09-03
 RECOMMENDED LUBRICANTS, FLUIDS CAPACITIES AND DIMENSIONS

Capacities 3.6

Litres Imperial
Pints Quarts
Engine refill (including filter) 14.1 8.5
(excludingfilter) 13.1 7.9
Manual gearbox
-Drain and refill 2.5 1.5
Automatic transmission:
-From dry 14.1
-Drain and refill 5.3 3.2
- Top up 0.4 0.26

Final drive unit -from dry 2.8 I

Cooling system, including
reservoir and air conditioning:
- Initialfill from dry 20.5 12.3
-Drain and refill 17.5 10.5
Windscreen washer reservoir:
- Non-headlamp 4.6 2.7
- Withheadlamp 9.5 5.7
All vehicles from MY 7.0 12.3 7.4

Litres Imperial
Gallons Gallons
Fuel tank - Coupe 91,0 20.0 24.0
Fuel tank - Cabriolet 82.0 18.0 21.6
Fuel tank- Convertible 18.0 21.6

09-04
 RECOMMENDED LUBRICANTS, FLUIDS CAPACITIES AND DIMENSIONS

DIMENSIONS
Dimensions (Approximate) Metric imperial (in)

Overall length - North American vehicles

(andthose with energy absorbing bumpers) ........... 4869 191.7
Overall length -Rest of the World ............. ......... 4764 187.6

Overall width ..................................................... 1793 70.6

Overall height at kerb weight

Before MY vehicles ............................. 126 1 49.6

After MY vehicles

V 12 - With 2 15/70 tyres ................................ 126 1 49.6

V 12 - With tyres ................................ 1254 49.4
3.6 - With
(Sportspack suspension) .................................. 1247 49.1

............ 102.0
58.6
59.2
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Ground clearance (kerb weight):

Before MY vehicles .................. 140 5.5

After MY vehicles

V 12 - With 21 5/70 tyres ..................... 140 5.5

..................... 133 5.2
3.6 - With tyres
(Sportspack suspension) .......... ........... 126 5.0

Turning circle (kerbto kerb)

- with tyres ........................ metre
- with 2 15/70 tyres ........................ metre
Turning circle (wallto wall)
- with tyres ........................ metre 9 in
- with 2 15/70 tyres ........................ metre

09-06
 RECOMMENDED LUBRICANTS, FLUIDS CAPACITIES AND DIMENSIONS

W ElGHTS
Coupe

European models (Approximateweights)

NOTE: Weight quoted is for heaviest variant

XJ-S 3.6 XJ-S 2

Kerb weight - including options ........................... 1680 (3704) 1800 (3968)

Kerb weight -front axle ...................................... 880 (1 940) (2207)
Kerb weight -front axle ...................................... 800 (1764) 799 (1761)

Gross vehicle weight .......................................... 2030 (4475) 2150 (4740)

'Gross vehicle combination weight ....................... 3530 (7782) 3650 (8047)
Maximum permitted front axle load ....................... 980 (2160) (2425)
Maximum permitted rear axle load ........................ 11 (2447) (2447)

Gross combination weight is the gross vehicle weight plus maximum recommendedtrailer weight.

USA models (Approximateweights)

NOTE: Weight quoted is for heaviest variant.

XJ-S V12

Kerb weight - including options ........................... 1832 (4040)

Kerb weight -front axle ...................................... 1012 (2232)
Kerb weight - rear axle ....................................... 820 (1808)

Gross vehicle weight .......................................... 2 159 (4760)

'Gross vehicle combination weight ....................... 3659 (8067)
Maximum permitted front axle load ....................... 1080 (2380)
Maximum permitted rear axle load ........................ 1080 (2380)

Gross combination weight is the gross vehicle weight plus maximum trailer weight

09-07
 RECOMMENDED LUBRICANTS, FLUIDS CAPACITIES AND DIMENSIONS

Coupe continued

Canadian models (Approximateweights)

NOTE: Weight quoted is for heaviest variant.

XJ-S V12

Kerb weight - including options ......................... 1832 (4040)

Kerb weight -front axle ................................... 1012 (2232)
Kerb weight - rear axle .................................... 820 808)

Gross vehicle weight ............................... 2159 (4760)

"Gross vehicle combination weight .................... 3659 (8067)
Maximum permitted front axle load .................... 1079 (2379)
Maximum permitted rear axle load ..................... 1079 (2379)

Gross combination weight is the gross vehicle weight plus maximum trailer weight.

Cabriolet
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European models (Approximateweights)

NOTE: Weight quoted is for heaviest variant.

XJ-S 3.6 XJ-S 2

Kerb weight - including options ......................... 1690 (3726) 1830 (4034)

Kerb weight -front axle ................................... 882 1003 (221
Kerb weight - rear axle .................................... 808 (1781) 827 (1823)

Gross vehicle weight ....................................... 1900 (4189) 2040 (4497)

'Gross vehicle combination weight .................... 3400 (7496) 3540 (7804)
Maximum permitted front axle load .................... 930 (2050) 1065 (2348)
Maximum permitted rear axle load ..................... (2204) 1020 (2248)

Gross combination weight is the gross vehicle weight plus maximum recommendedtrailer weight.

09-08
 RECOMMENDED LUBRICANTS, FLUIDS CAPACITIES AND DIMENSIONS

Cabriolet continued...

USA models - (Approximate weights)

NOTE: Weight quoted is for heaviest variant.

XJ-S V12

Kerb weight - including options ........................... 1832 (4040)

Kerb weight - front axle ...................................... 101 1 (2230)
Kerb weight - rear axle ....................................... 82 1 (1810)

Gross vehicle weight .......................................... 2068 (4560)

"Gross vehicle combination weight ....................... 3523 (7767)
Maximum permitted front axle load ....................... 1052 (2320)
Maximum permitted rear axle load ........................ 10 16 (2240)

Gross combination weight is the gross vehicle weight plus maximum recommended trailer weight.

Canadian models (Approximate weights)

NOTE: Weight quoted is for heaviest variant.

XJ-SV12

Kerb weight - including options ........................... 1832 (4039)

Kerb weight - front axle ...................................... 101 1 (2230)
Kerb weight - rear axle ....................................... 821 (1810)

Gross vehicle weight .......................................... 2068 (4559)

*Gross vehicle combination weight ....................... 3568 (7866)
Maximum permitted front axle load ....................... 1052 (23 19)
Maximum permitted rear axle load ........................ 1016 (2240)

Gross combination weight is the gross vehicle weight plus maximum recommended trailer weight.

09-09
 RECOMMENDED LUBRICANTS, FLUIDS CAPACITIES AND DIMENSIONS

Convertible

European models (Approximate weights)

NOTE: Weight quoted is for heaviest variant.

XJ-SV12

Kerb weight - including options ......................... 900 (4188)

Kerb weight - front axle ................................... 05 7 (2330)
Kerb weight - rear axle .................................... 843 (1858)

Gross vehicle weight ....................................... 2 1 10 (4652)

"Gross vehicle combination weight .................... 3600 (7936)
Maximum permitted front axle load .................... 1 (2425)
Maximum permitted rear axle load ..................... 1040 (2293)

Gross combination weight is the gross vehicle weight plus maximum trailer weight
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USA models (Approximate weights)

NOTE: Weight quoted is for heaviest variant.

XJ-S 2

Kerb weight - including options ......................... 1900 (4190)

Kerb weight - front axle ................................... 1057 (2331)
Kerb weight - rear axle .................................... 888 (1859)

Gross vehicle weight ....................................... 2 136 (4710)

*Gross vehicle combination weight .................... 3636 (8017)
Maximum permitted front axle load .................... 1098 (2420)
Maximum permitted rear axle load ..................... 1038 (2290)

Gross combination weight is the gross vehicle weight plus maximum trailer weight

09-10
 RECOMMENDED LUBRICANTS, FLUIDS CAPACITIES AND DIMENSIONS

Convertiblecontinued...

Canadian models (Approximateweights)

NOTE: Weight quoted is for heaviest variant.

XJ-SV12

Kerb weight - including options ......................... 1900 (4 190)

Kerb weight -front axle ................................... 1057 (233 1)
Kerb weight - rear axle .................................... 843 (1858)

Gross vehicle weight ....................................... 2 136 (4710)

'Gross vehicle combination weight .................... 3636 (8017)
Maximum permitted front axle load .................... 1098 (2420)
Maximum permitted rear axle load ..................... 1038 (2290)

Gross combination weight is the gross vehicle weight plus maximum trailer weight.

All Markets and Models

Trailer weight maximum:

-Braked (recommended) .................

-Braked (permissable)
but with an eight percent
gradient qualification ..................... 900 (4188)
- Unbraked .................................... 750 653)

Roof rack capacity including weight

of rack (not applicable to Cabriolet
and Convertible models) ..................................... 80

Maximum permitted luggage compartment load ..... 70

FUEL REQUIREMENTS

General

The use of either leaded or unleaded fuel depends on the type of emission control system fitted to the engine
and the legislative requirements in the country for which the vehicle is manufactured.

Vehicles with engines designed to use unleaded fuel are clearly marked 'UNLEADED FUEL ONLY' adjacent to
the fuel filler cap.

09-1 1
 RECOMMENDED LUBRICANTS, FLUIDS CAPACITIES AND DIMENSIONS

Leaded Fuel

All vehicles supplied for use in the United Kingdom and certain Overseas markets have engines which are
designed to use leaded fuel only. It is important to realise that unleaded fuel although labelled 'PREMIUM' is
not the same as 4-Star leaded fuel, and that THE USE OF A FUEL WITH A LOWER OCTANE RATING CAN
CAUSE SERIOUS ENGINE DAMAGE and could result in loss of warranty coverage.

Use leaded fuel with an octane rating of at least 97 in vehicles with high compression engines

When refuelling, ensure that the petrol pump is clearly marked 'LEADED FUEL', if any doubt exists consult the
service station operator for further advice.

Unleaded Fuel

Engines fitted with catalytic converters in the exhaust system are designed to use only unleaded fuel.
Unleaded fuel must be used for the emission control system to operate properly. Its use will also reduce spark
plug fouling, exhaust system corrosion and engine oil deterioration.

Using leaded fuel will damage the emission control system and could result in loss of warranty coverage. The
effectiveness of the catalyst in the catalytic converter decreases after the use of as little as one tank of leaded
fuel. Also, the vehicle is equipped with an electronic fuel injection system, which includes an oxygen sensor.
Leadedfuel will damage the sensor, and deteriorate emission control.

Only petrol pumps delivering unleaded fuel have nozzles which fit the filler neck of the vehicle'sfuel tank.
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Using unleaded fuel with an octane rating lower than recommendedcan cause persistent, heavy 'spark knock'
(a metallic rapping noise). If severe, this can lead to engine damage. However, occasional light 'spark knock'
for a short time while accelerating or driving up hills may occur. Although this noise should not give cause for
concern, it may be eliminated by the use of a fuel of a higher octane rating than that recommended.

Unleaded Fuels Containing Alcohol

Some fuel suppliers sell fuel containing alcohol without advertising its presence. Where uncertainty exists
check with the service station operator.

Ethanol:

Fuels containing up to 10% ethanol may be used. Ensure the fuel has octane ratings no lower than those
recommended for unleaded fuel. Most driver's will not notice any operating difference with fuel containing
ethanol, but some may, in which case the use of conventional unleaded fuel should be resumed if preferred.

09-12
RECOMMENDED LUBRICANTS, FLUIDS CAPACITIES AND DIMENSIONS

Unleaded Fuels ContainingAlcohol Continued . ..

Methanol:

Some fuels contain methanol (methyl or wood alcohol). DO NOT USE fuels containing methanol that do not
also contain and corrosion inhibitors for methanol. Also, DO NOT USE fuels that contain more than
3% methanol even if they contain and corrosion inhibitors. Fuel system damage or vehicle
performance problems resulting from the use of such fuels is not the responsibility of Jaguar Cars Limited and
may not be covered under the warranty.

CAUTION: Take care to not spill fuel during refuelling. Fuel containing alcohol can cause paint
damage, which may not be covered under the warranty.

Components of Emission Control Systems

The component with most impact on the running of the vehicle is the catalytic converter which, when fitted,
always requires the use of unleaded fuel.

The specifications of vehicles depend on the country legislation and/or option level chosen at the time of
purchase. The following cross reference list will help to ascertain the components.

Market Specification

MARKET AIR FUELOCT

Australia
5.3 X 91 Plus fuel evaporative
loss control system.

Austria
3.6 X X X 91
5.3 X X X 91
Belgium
3.6 X X 95 Customer option.
5.3 X 95 Alternative as Europe.

Canada (up 144700)

5.3 X 91 Plus fuel evaporative
loss control system.

Canada (from VIN 144700)

5.3 X X X 91 Plus fuel evaporative
loss control system.

Europe
3.6 97 L High
5.3 97 L compression.

Germany
3.6 X X 95 Customer option.
5.3 X 95 Alternative as Europe.

09- 13
 RECOMMENDED LUBRICANTS, FLUIDS CAPACITIES AND DIMENSIONS

Market Specification (Continued)

MARKET AIR INJ. D.P.C. FUELOCT

Japan
5.3 X Plus fuel evaporative
loss control system.

Middle East
3.6 Low compression plus
5.3 fuel evaporative loss
control system.

Netherlands
3.6 X X Customer option.
5.3 X Alternative as Europe.

Sweden
3.6 X X X Plus fuel evaporative
5.3 X X X loss control system.

Switzerland
3.6 X X X 95
5.3 X X X 95
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United Kingdom
3.6 High
5.3 compression.

U.S.A.
5.3 X X X Plus fuel evaporative
1 loss control system.

Rest of World
3.6 High
5.3 compression.

3.6 Low
5.3 compression.

Key to system legend

AIR INJ - Air Injection.

DPC - Down Pipe Catalyst.
UFC - Under Floor Catalyst.
FUEL OCT - Fuel Octane.
RON - Research Octane Number
L - Leaded.
U -Unleaded.

Exhaust Emission -Testing

In order that exhaust emissions are kept within the legislated limits, an exhaust emission test with the engine
running at idling speed MUST be carried out after any unscheduled service operations which might affect the
emission control system.

09- 14
 MAINTENANCE SUMMARY

The Maintenance Schedules and Maintenance Operations on the following pages, assume an annual mileage
of 24 000 (15 000 miles). For vehicles driven less than this annual rate it is recommended that the
12 000 (7 500 miles) and 24 000 (15 000 miles) services are carried out a t 6 and 12 month intervals
respectively.
The Maintenance Schedules may be revised from time to time. Jaguar Dealers will be notified of revisions by
Service Policy Letters or Technical Bulletins.

SERVICE INTERVALS

Distance x 1000 in miles and kilometres

The period between services should not exceed
12 months or 15 000 miles (24 000
Miles 1

Miles 7.5 22.5 37.5 52.5 67.5 82.5

12 36 60 84 108 132

Miles 15 30 45 60 75 90

24 48 72 96 120 144

10-01
 MAINTENANCE SUMMARY

MAINTENANCE SCHEDULE
EXCEPT NORTH AMERICA
NOTE: An indicates Option Service, refer to page 10-7 for further details

Operation Description Every Every

1000 7500 1 5 000
miles miles miles
(1500 km) 2 000 km) 24 000

Fit vehicle protection kit. X X X

INTERIOR

1 Check condition, security and operation of seats and

seat belts - front and rear. X X X
2 Check operation of seat belt warning system. X X X
3 Check footbrake operation. X X X
4 Check operation of lamps. X *
5 Check operation of horns. X *
6 Check operation of warning indicators. X *
7 Check operation of windscreen wipers. X *
8 Check operation of windscreen washers and
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headlamp (where fitted). X

9 Checkanti-lock brakes (ABS) low pressure warning
system ( 1 model year). X X X
Check security of handbrake, release fully after
checking. X X X
1 Check rear view mirrors for security and function. X X X
12 Check operation of window controls. X *
13 Check operation of all door, bonnet and luggage
compartment locks. X *
14 Check power operated hood reservoir fluid level
(Convertible). X X
15 Check operation of power operated hood
(Convertible). X X

EXTERIOR

16 Lubricate all locks, hinges and door check

mechanisms (not steering lock. X * X
17 Clean radio aerial. *
18 Check windscreen wiper blades and arms, renew
if necessary. X X
19 Mark stud to wheel relationship and remove the front
road wheels. X
2 0 Mark stud to wheel relationship and remove the road
wheels - front and rear X
2 1 Check that tyres are correct size and type. X X X
 MAINTENANCE SUMMARY

Operation Description Every Every

7500 1 5 000
miles miles miles
500 2 000 krn) (24 000

EXTERIOR (Continued)

22 Check tyre tread depth:

Note on service sheet. X X X
2 3 Check tyres for uneven and excessive wear and
damage including sidewall. X X X
24 tyre pressures. X X X
2 5 Inspect front brake wear and
condition. X X
2 6 Ajust front hub bearing end float. X
2 7 Grease hubs. X
2 8 Check for oil leaks from steering and fluid leaks from
suspension system. X X X
29 Check condition and security of steering unit joints
and gaiters. X X X
30 Refit road wheels in original position. X X
3 1 Check tightness of road wheel nuts. X X X

UNDERBODY

32 Drain engine oil. X X X

33 Renew engine oil filter. X X
34 up manual gearbox oil. X
35 Renew manual gearbox oil. X X
36 Drain automatic transmission fluid 30 000
miles
000 krn)
37 Renew automatic transmission filter 30 000
miles
(48 000 krn)
38 up rear axle oil X X X
39 Renew rear axle oil. 30 000
miles
(48 000 km)
40 Refit engine drain plug. X X X
41 Check for oil leaks - engine and transmission. X X X
42 Grease all points excluding hubs. X X
43 Visually check brake hydraulic hoses, pipes and
unions for chafing, cracks, leaks and corrosion. X X X
4 4 Visually check exhaust system for leakage and
security. X X X
4 5 Lubricate handbrake mechanical linkage and cables. X X X

10-03
 MAINTENANCE SUMMARY

Operation Description Every Every

1000 7500 1 5 000
miles miles miles
(I 500 (12 000 km) 000 km)

UNDERBODY [Continued)

$6 Inspect rear brake pads for wear and discs for

condition. X X
F7 Check condition of handbrake pads. X
Renew brake fluid. 30 000
miles
(48 000
Lubricate automatic transmission exposed selector
linkage. X X X
50 Check tightness of propshaft coupling bolts. X X
51 Check security of accessible engine mountings. X
Check condition and security of steering unit joints
and gaiters. X X X
Check security and condition of suspension fixings. X X X
54 Check steering rack for oil leaks. X X X
Check power steering hydraulic pipes and unions for
leaks, chafing, corrosion and security. X X X
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56 Check shock absorbers for fluid leaks. X X X

57 Check the general condition of the underbody
anti-corrosion protection. X

ENGINE COMPARTMENT

58 Fill engine to the correct level with oil. X X X

59 Fill automatic transmission to the correct level
with fluid. 30 000
miles
(48 km)
6 0 Lubricate accelerator control linkage and pedal pivot. X
6 1 Renew air cleaner X
62 Check security of accessible engine mountings. X
63 drive belts tension.
Renew if necessary. X X
6 4 Clean and adjust spark plugs. X
65 Renew spark plugs. X
66 brake fluid reservoir. X X X
67 clutch fluid reservoir (where applicable). X X X
 Every Every
7500 15 000
miles miles miles
500 2 000 km) (24000 km)

TME
68 Check brake servo accumulator hoses
for security and condition X X X
69 up windscreen washer reservoir X X
70 Check conditioning system for leaks
and hoses for security and condition X X X
7 1 Change coolant ensuring that the anti-freeze content
is 50 per cent 30 000
miles
(48 000 km)
72 up cooling system.
Check specific gravity. X * X
73 Clean engine breather filter (XJ-S V 12). X
74 Check crankcase breathing system for leaks;
hoses for security and X X
75 up power steering reservoir. X X X
76 Run engine. Check for sealing of oil filter. Stop engine. X X
77 up engine oil. X X X
Check leaks. X X X
79 Connect electronic instruments and check
underbonnet label data (XJS V 12 only). X X
80 Lubricate distributor (not cam wiping pad) 22 500
(XJS 12 only). miles
(36 000
isconnect vacuum pipe; check dwell angle; adjust
as necessary (XJS 12 only). X X
82 Check ignition timing (at normal operating temperatur
O R HE models) (XJS V 12 only). X X X
83 Check distributor automatic advance (XJS only). X X
84 Check distributor advance increases as vacuum pipe
is reconnected only), X X
85 engine idle speed; stop engine;
disconnect instruments (XJS only). X X
86 Check power steering system for leaks; hydraulic
pipes and unionsfor chafing and corrosion, X X X
 MAINTENANCE SUMMARY

Operation Description Every

7500 15 000
miles miles miles
500 12 000 km) 24 000 krn)

ENGINE COMPARTMENT (Continued)

Check for oil leaks from engine. X X X

38 Re-check tension if driving belt has been renewed X X
39 up automatic transmission fluid. X X X

LUGGAGE COMPARTMENT

90 Check operation of luggage compartment lamp. X *

91 up battery electrolyte. X X X
92 Clean and grease battery connections X X X
93 Remove spare wheel. X X X
94 Check that spare tyre is the correct size and type X X X
95 Check tyre tread depth:
Note on service sheet. X X X
9 6 Check tyre for uneven and excessive wear
and damage including sidewall. X X X
97 tyre pressure. X X X
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9 8 Renew fuel filter. 30 000

miles
(48000
99 Check for fuel leaks. X X X
Refit spare wheel. X X X

GENERAL

101 X X
headlamp alignment.
front wheel alignment X * X

ROAD TEST

103 Carry out test. X X X

104 Ensure cleanliness of controls, door handles,
steering wheel, etc. X X X

10-06
 MAINTENANCE SUMMARY

NTENANCE SC HEDULE
EXCEPT NORTH AMERICA
OPTION SERVICE

Operation Description Every Every

7500 15 000
miles miles
2 000 km) 000

INTERIOR

4 Check operation of lamps. X

5 Check operation of horns. X
6 Checkoperation of warning indicators. X
7 Check operation of windscreen wipers. X
8 Check operation of windscreen washers and
headlamp (where fitted). X
1 1 Check rear view mirrors for security and function X
12 Check operation of window controls. X X
13 Check operation of all door, bonnet and
luggage compartment locks. X X

EXTERIOR

16 Lubricate all locks, hinges and door check mechanisms

(not steering lock). X
17 Clean radio aerial. X

ENGINE COMPARTMENT

69 up windscreen washer reservoir. X

72 up cooling system.
Check specific gravity. X X

LUGGAGE COMPARTMENT

90 Check operation of luggage compartment lamp. X

GENERAL

101 headlamp alignment. X

102 front wheel alignment. X
- Check sunroof and controls for correct operation
(where fitted).
- Check operation of speed (cruise) control (where fitted) X

10-07
 MAINTENANCE SUMMARY

MAINTENANCE SCHEDULE
EXCEPT NORTH AMERICA
At 2 years or 30 000 miles (48000 intervals- whichever is the sooner

Renew brake fluid.

Change coolant ensuring that the anti-freeze content is 50 per cent.

At 3 years or 45 000 miles (72 000 km) intervals - whichever is the sooner

Renew all fluid seals in hydraulic system; examine and renew if necessary all flexible hoses.
Examine working surfaces of master cylinder and calipers. Renew if necessary.
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10-08
 MAINTENANCE SUMMARY

MAINTENANCE SCHEDULE
NORTH AMERICA ONLY

Operation Description Every Every

1000 7500 15 000
miles miles miles
(1500 km) 2 000 000 km)

Fit vehicle protection kit X X X

INTERIOR

Check condition, security and operation of seats and

seat belts - front and rear. X X X
Check operation of seat belt warning system. X X X
Check audible warning system: Seat belt Door open. X X X
Check operation of inertia switch (vehicle fitted with
passive restraint seat belts). X
Check operation of seat belt warning light (vehicle fitted
with passive restraint seat belts). X
Check operation of reverse gear inhibit switch (vehicle
fitted with passive restraint seat belts). X
Check footbrake operation. X X X
Check function of all original equipment, lights, warning
indicators, radio, etc. X X X
Check operation of horns. X X
Check operation of windscreen wipers. X X X
Check operationof windscreen washers. X X X
Check anti-lock brakes (ABS) low pressure warning
system. X X X
Check security of handbrake, release fully after checking. X X X
Check operation of window controls. X X X
Check operation of sunroof controls (where fitted). X X X
Check operation of all door, bonnet and luggage
locks. X X X
Check power operated hood reservoir fluid level
(Convertible). X X
Check operation of power operated hood (Convertible). X X

EXTERIOR

Lubricate all locks, hinges and door check mechanisms

(not steering lock). X X X
Clean radio aerial. X X X
Mark stud to wheel relationship and remove the front
road wheels. X
Mark stud to wheel relationship and remove the road
wheels - front and rear. X
Check that tyres are correct size and type. X X X
Check tyre tread depth. X X X
Check tyres for uneven and excessive wear and damage
including sidewall. X X X
tyre pressures. X X X
Inspect front brake wear and discs for conditior X X
Adjust front hub bearing end float X
Lubricate wheel hubs. X
Refit road wheels in original position. X X
Check tightness of road wheel nuts. X X X

10-09
 MAINTENANCE SUMMARY

NORTH AMERICA ONLY (Continued)

Operation Description Every Every

7500 15 000
miles miles miles
(1500 km) 2 000 km) (24 000 km)

UNDERBODY

Drain engine oil. X X X

Renew engine oil filter canister. X X X
Drain automatic transmission fluid 30 000 miles
(48000 km)
Renew automatic transmission filter 30 miles
(48000 km)
up rear axle oil. X X X
Refit engine oil drain plug. X X X
Check for oil leaks - Engine and transmission. X X X
Lubricate all grease points excluding hubs. X X
Visually check brake hydraulic hoses, pipes and unions
for chafing, cracks, leaks and corrosion. X X X
Visually check exhaust system for leakage and security. X X X
Lubricate handbrake mechanical linkage and cables. X X X
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Inspect rear brake pads for wear and discs for condition
(including handbrake pads). X X
Renew brake fluid. 30 000 miles
(48000 km)
Check tightness of propshaft coupling bolts. X X
Check condition and security of steering unit
joints and gaiters. X X X
Check security and condition of suspension fixings. X X X
Check power steering hydraulic pipes and unionsfor
leaks, chafing, corrosion and security. X X X
Check shock absorbers for fluid leaks. X X X
Check the general condition of the underbody
anti-corrosion protection. X

ENGINE COMPARTMENT

Fill engine to the correct level with oil. X X X

Fill automatic transmission to the correct level with fluid. 30 000 miles
(48000 km)
Lubricate accelerator control linkage and pedal pivot X
Renew air cleaner elements. 30 000 miles
(48 000 km)
drive belts tension. Renew if necessary. X X X
Renew spark plugs. 30 000 miles
(48 000 km)
Run engine. Check for sealing of oil filter.
Stop engine. X X X
up engine oil. X X X
up automatic transmission fluid. X X X
up brake fluid reservoir. X X X
Change coolant ensuring that the anti-freeze content
is 50 per cent. 30 000 miles
(48 000 km)
up cooling system. X X X
Check brake servo accumulator hoses for
security and condition X X

10-10
 MAINTENANCE SUMMARY

NORTH AMERICA ONLY (Continued)

Operation Description Every Every

7500 1 5 000
miles miles miles
(1500 km) (12 000 km) (24000 km)

ENGINE COMPARTMENT (Continued)

up windscreen washer reservoir. X X X

Check control system for leaks
security and condition. X X X
Check cruise control system vacuum hose for security
and general condition. X X X
Check crankcase breathing system and evaporative loss
control system. 60 000 miles
(96 000 km)
up power steering fluid reservoir. X X X
Check for fuel leaks. X X X
Check power steering system for leaks; hydraulic pipes
and unions for chafing and corrosion. X X X
Clean out radiator matrix and condenser to remove dirt
accumulation, etc. 30 000 miles
(48 000
Renew oxygen sensor (Pre 1987 model year). 52 500 miles
(84000 km)

LUGGAGE COMPARTMENT

up battery electrolyte. X X X
Clean and grease battery connections. X X X
Remove spare wheel. X X X
Check that spare tyre is the correct size and type. X X X
Check tyre tread depth. X X X
Check tyre for uneven and excessive wear and damage
including sidewall. X X X
tyre pressure. X X X
Renew fuel filter. 52 500 miles
(84000 km)
Check for fuel leaks X X X
Refit spare wheel. X X X

GENERAL

headlamp alignment. X X X
front wheel alignment. X X X

ROAD TEST

Carry out test. X X

Ensure cleanliness of controls, door handles,
steering wheel, etc. X X X

At 18 months or 30 000 miles 000 km) intervals -whichever is the sooner.

Renew brake fluid.

Change coolant ensuring that the anti-freeze content is 50 per cent.

At 3 years or 45 000 miles (72 000 km) intervals - whichever is the sooner.

Renew all fluid seals in the hydraulic system; examine and renew if necessary all flexible hoses
Examine working surfaces of master cylinder and calipers. Renew if necessary.

10-1 1
 MAINTENANCE

MAINTENANCE PROCEDURE
The maintenance schedule lists on pages 10-2 to
1 give details of mile and kilometre intervals for
the following operations. The figure to the left of each
heading refers to the item number on the maintenance
schedule.

Fit vehicle protection kit

Cover the seats, carpets and steering wheel with

protective covers and polythene sheets. Wear clean
overalls and wash hands or wear gloves before
working inside the vehicle. Always fit covers to
protect the wings before commencing work in the
engine compartment.

INTERIOR
1. Check condition, security and operation of
seats and seat belts - front and rear

Check operation of front seat adjustment (forward,

rearward and seat reclining mechanism) and
security of fixings.
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Check the webbing on the seat belt for

imperfections, cuts, fraying or damage. Sit in the
seat, fasten the seat belt and grip the shoulder belt
at approximately shoulder level with the opposite
hand. Puli the belt sharply in a downwards
direction, the belt should lock.
Repeat the above procedure for all the other seat
belts.
If any seat belt is found to be damaged or the
inertia mechanism is not working correctly, the
seat belt must be replaced. Report if necessary.
 Y

2. operationof seat elt warning system

anual inertia Reel Type

Sit the driving position and ensure that the seat

belt tongue is disconnected from the buckle unit.
Close the driver's door.
Turn ignition key to position '2' and observe that
the warning light is illuminated [on North American
vehicles a continuous high pitched tone will
operate for approximately six seconds).
Push the seat belt tongue into the buckle unit, the
warning light should be extinguished.
Switch ignition OFF and release the seat belt
harness.

Passive Restraint System Market Coupe/

Cabriolet Vehicles Only

Check operation of warning light

(vehiclefitted with passive restraint seat belts

Sit in the seat with the key in the ignition

and with both doors closed The diagonal belt
should automatically deploy t o the rear dock
(restraining position) Turn on the ignition (position
the warning light should not be illuminated
Remove diagonal seat
assembly The seat belt warning light should
illuminate If it does not, locate and correct the
fault Suspect rear dock switch,
restraint ECU common connector pin No 2, LH
side connector pin No 7

NOTE: The audible warning will only operate for

approximately six seconds after the key IS turned
position '2'

10-13
 MAINTENANCE SUMMARY

2. Continued

Check operation of inertia switch (vehicle

fitted with passive restraint seat belts

The inertia switch is located in the driver's

on the door pillar.
Sit in the driving position. Ensure the gear selector
lever is not in the reverse position. Close the
driver's door and insert the ignition key into the
ignition switch. The passive diagonal belts should
move to the restraining position.
Switch on the ignition (position Raise the
button which protrudes through the top
of the inertia switch cover.
Open the doors, the diagonal belts should not
move from the restraining position. Remove the
ignition key, the diagonal belts should not move
from the restraining position. To exit from the
vehicle release the seat belt buckle from the
travelling mechanism by operating the red 'Press'
button. Once outside the vehicle observe that the
assemblies remain in the restraining
position.
Re-enter the vehicle, leave the door open, reset the
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inertia switch by depressing the button. Observe

that the runners move t o the unrestraining
position. Re-attach the belt buckle t o the
assembly with the red 'Press'
button facing inboard.
If the passive belt fails t o comply with the above,
locate and correct the fault. Suspect: inertia
switch; passive restraint ECU common connector
pin

Check operation of reverse gear inhibit switch

(vehiclefitted with passive restraint seat belts

Sit in the driver's seat, close both doors, insert the

key in the ignition and turn it to position '2'. The
diagonal seat belt should automatically deploy to
the rear dock (restraining position) and the warning
light should not be illuminated.
Select reverse gear and open the driver's door.
The diagonal seat belt should remain in the
restraining position. If the seat belt travels to the
unrestraining position, locate and correct the fault.
Open the driver's door and ensuring body or limbs
are not in the path of deploying seat belt,
disengage reverse gear. The seat belt should
travel to the front dock (unrestraining position). If it
does not, locate and correct the fault. Suspect:
reverse inhibit relay.
 MAINTENANCE SUMMARY

3. Check footbrake operation

the footbrake and observe the brake pedal
Report if pedal movement IS excessive.

4. Checkoperation of lamps

Check operation of all exterior lamps, i.e.,

Front side light.
Headlamps on both main and dip beam positions.
Front flasher lamp.
Flasher side repeaters.
Side marker (where fitted).
Number plate lamp.
Tail lamp.
Stop lamp.
Reverse lamp.
High mounted stop lamp (where fitted).
Front and rear fog lamps.
Check operation of all interior lamps, i.e.,
Door guard lamps.
Map lights.
Rear side interior lights.
Roof light

5 . Checkoperation of horns

Turn ignition key to position 1 or '2'

Press the steering wheel :entre pad to sound the
horns.
Switch ignition OFF.

10-15
 MAINTENANCE SUMMARY

6. Checkoperationof warning indicators

Direction Indicator Monitors

Left-hand warning light flashes when the steering

column combination switch is moved to signal a
left-hand turn. Right-hand warning light flashes
when the steering column combination switch is
moved to signal a right-hand turn.

Heated Rear Screen and Heated Door Mirrors

Illuminates when the heated rear screen and

heated door mirrors are in operation.

Rear Fog Lamp

Illuminates when the rear fog lamps are on.

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Headlamp Main Beam

Illuminates when the headlamps are on main

beam.

Volts - Pre model year.

Illuminates to indicate battery overcharge (mal-

function of alternator).

Anti-lock Braking System (ABS) - Post

model year.

The 'ABS' electronics monitor the entire anti-lock

electrical system from ignition switch ON to
ignition switch OFF.
Should the ABS warning light fail to go out on
start-up turn the ignition OFF (position '0') and
then restart the engine. If the light continues to
stay on, or comes on again report the fault for
investigation.

10-16
 MAINTENANCE SUMMARY

6. Continued

Ignition

Illuminates when the ignition is switched ON and

should extinguish when the engine is running. If the
warning light remains ON when the engine is
running, stop the engine and report the fault for
investigation.

Seat Belt

Illuminates when the driver's or front seat

passenger's seat belt is not fastened (Inertia reel
seat belts) and with passive restraint belts is
illuminated until the belt is located in the
'restraining' position.

ExhaustTemperature - Japan only

Illuminates if the exhaust temperature becomes

excessive.

Caravan

This will only illuminate if the vehicle is equipped

for towing and a caravan or trailer electrical cable is
connected to the vehicle.

Low Coolant Level

Illuminates when the coolant level in the radiator is

too low.

Windscreen Washer Reservior Level

Illuminates when the fluid level in the windscreen

washer reservoir is too low.
 MAINTENANCE SUMMARY

6. Continued.

Low Brake Fluid Accumulator

Pressure Low

When the warning light is illuminated it indicates

that the brake fluid level has fallen below a
pre-determined level.
When the warning light is illuminated in conjunction
with the anti-lock failure warning light (where
fitted) it warns of very low brake fluid level or low
boost pressure. In these cases partial or complete
restriction of the anti-lock function may have
occurred or loss of boost may be imminent.
The light should illuminate only when the ignition
switch is in position '3' (start), this provides a
check that the warning circuit is operating
satisfactorily. Failure to do so indicates a bulb or
electrical circuit fault.
if the light remains illuminated when the ignition
switch is returned to position '2' (ignition), then a
brake fault is indicated and the vehicle MUST NOT
be driven until the fault has been rectified.

Low Oil Pressure

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Illuminates when the ignition is switched ON and

should extinguish when the engine is running. If the
warning light remains ON when the engine is
running, loss of oil pressure is indicated. Stop the
engine immediately and rectify before restarting.

Handbrake

Illuminates when the handbrake is applied and the

ignition is switched ON.

Low Fuel Level

Illuminates to indicate low fuel level in the tank

 MAINTENANCE SUMMARY

6. Continued

Hazard

Flashes simultaneously with the front and rear

direction indicator lamps, when the hazard
warning switch is operated.

Bulb Failure

Should illuminate for approximately 15 to 30

seconds with the master light switch in any
position other than OFF. If the light fails to go out
then there is a fault or bulb failure in one or more of
the following circuits:
Front parking lamp, tail and number plate lamp.
With the master lighting switch in the OFF
position, the stop lamp circuit can be checked.
Switch the ignition ON (position apply the
handbrake and the footbrake pedal. The
bulb failure warning light should illuminate. If it
does not, then there is a fault or bulb failure in the
stop lamp circuit.

7.
Check operation of windscreen wipers

NOTE: If any of the windscreen wiper switch

positions do not operate, report the fault for
investigation
Turn ignition key to position ’2’
Push the wiper switch lever up one position for
normal speed operation
Push the wiper switch lever fully up for high speed
operation
Push the wiper switch lever to position to
cancel the function and park the wiper blades
For intermittent operation, push the wiper switch
lever down.
The wiper blades will perform a single sweep then
there be a delay period of approximately five
seconds before the blades sweep the windscreen
again
Push the wiper switch lever to position to
cancel the function and park the wiper blades
To obtain a single sweep of the wiper blades, pull
the wiper switch lever towards the steering wheel
and release
Switch the ignition OFF

10-19
 AINTENA MMARY

windscreen washers and

e (where fitted)

Switch lights to headlamp position (if headlamp

is fitted).
ignition key to position
Push the wiper switch lever up one position.
Press the end of the wiper switch lever to operate
the washer switch.
Observe the cycle on the windscreen
and the headlamps (when fitted).
If the windscreen washer jets are obstructed they
can be cleared using a suitable implement.

NOTE: The headlamp washer jets are not

adjustable.
Reposition the windscreen washer jets if necessary
by a suitable implement into the jet orifice
and moving the jet to the required position.

brakes (ABS) low pressure

system (Post model year)

Switch the ignition ON (position ‘2’) and check that

the ABS warning and Low Brake Pressure warning
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lights extinguish.
Switch the ignition OFF. Remove the auxiliary fuse
box cover (passenger‘s side) and remove the ABS
pump motor fuse (Fuse No 8).
Switch the ignition ON (position Slowly
depress and release the brake pedal, counting the
number of applications until the Low Brake
Pressure warning illuminates.
Continue to depress and release the brake pedal,
counting the number of applications it takes before
there is no longer any power assistance, i.e., the
pedal goes hard.
If the vehicle warning system is operating correctly
there should be a of 7 applications
before the warning light is displayed and a
of 14 applications in total will be
required before the pedal goes ’hard’.
Switch the ignition OFF. Refit the ABS fuse (Fuse
No 8) and replace the auxiliary fuse box cover.
Switch the ignition ON (position ’2‘) and check the
time delay before the warning light is illuminated,
this should be approximately 20 seconds.
 MAINTENANCE SUMMARY

Check security of handbrake, release fully after

checking

Check operation of handbrake; if a normal hand

load causes the brake handle to move more than
(8 inches) adjustment is necessary;
proceed as follows:
Move driver’s seat fully forward.
Chock wheels and set handbrake fully off.
Raise carpet at rear of driver’s seat (Pre 1988
model year vehicles) or remove screw and
handbrake shroud (Post 1988 model year vehicles)
t o give access to adjusting nuts (1).
Slacken locknut.
Screw up adjuster nut until only a slight amount of
slack is apparent in the cable.

NOTE: Do not eliminate all slack from the cable

Tighten locknut.
Lightly smear undersurface of carpet with adhesive
and replace in position (Pre 1988 model year
vehicles) or refit the handbrake shroud and secure
with the screw (Post 1988 model year vehicles).

rear view mirrors for security and

function

Check interior and exterior rear view mirrors for

security.
Check the operation of the external mirrors by
moving the control knobs as follows:

R.H. Stg. Vehicles

Front knob adjust L.H. mirror.

Rear knob adjust R.H. mirror.

L.H. Stg. Vehicles.

Front knob adjust R.H. mirror.

Rear knob adjust L.H. mirror.

1
 MAINTENANCE SUMMARY

12. Check operation of window controls

Check electrically operated windows for smooth-

ness of operation and complete closure.

operation of all door, bonnet and

luggage compartment locks

Check door and luggage compartment locks for

correct operation including central locking system
(On Post model year vehicles the central
locking system incorporates the luggage compart-
ment lock).
If door closing requires noticeable effort, or is in
any way unsatisfactory the door lock will require
adjustment.

14.Check power operated hood reservoir fluid

level (Convertible)

Ensure that the power operated hood is in the fully

closed position.
From inside the vehicle, open the rear storage
compartment.
Access to the reservoir is gained by turning the
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two slotted fasteners and removing the trim panel

located on the right-handside.
Check the fluid level against the level indicator
mark on the pump casing.
Any loss of fluid will indicate a fluid leak in the
system, report for further investigation.
Slide the trim panel back into position and secure
with the two slotted fasteners. JIO

10-22
 MAINTENANCE SUMMARY

operation of power operated hood

(Convertible)

Apply the handbrake, move the gear selector to

'Park' or 'Neutral' and turn the ignition key to
position 1 or '2'.
Release both hood handles by pressing the button _-_-
(A, on the end of the handle Pull
the handle down to release the hook (C, Fig. 1) and
then push the handle back into position. Repeat this
procedure other hood handle.
Press and hold the rear of the hood operating
switch until the hood is fully lowered (the rear
quarter windows automatically lower with the
hood).
Press and hold the front of the hood operating
2
switch until the hood is fully raised and the rear
quarter windows are closed.
Switch ignition OFF.
Press the button (A, Fig.2) on the end of the handle Fig. 1
(B, Fig.2)and pull the handle down. Engage the hook
(C, Fig.2) in the latch and then push the handle back
into position. Repeat this procedure for the other
hood handle.

Fig.2

10-23
 MAINTENANCE SUMMARY

EXTERIOR
16. Lubricate all locks, hinges and door check
mechanisms (not steering lock)

Open all doors and clean the door check

mechanism and hinges, then lightly lubricate using
a multipurpose lithium base grease (refer to
Recommended Lubricants and Fluids in Section
09).

17. Clean radio aerial

Turn ignition key to position 1

Switch radio ON and allow the aerial to extend.
Clean the aerial by wiping the mast with a clean
cloth in an upwards direction.
Switch radio OFF, and allow the aerial to retract.
Switch ignition OFF.

18. Check windscreen wiper blades and arms,

renew if necessary
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Lift the wiper blades clear of the windscreen, wipe

clean and check for wear, cracks or damage.
Replace the wiper blades on the windscreen.
If a wiper blade is damaged, lift the blade clear of
the windscreen.
Depress the retaining clip and withdraw the wiper
blade.
After fitting the new blade, check that it is held
firmly in the wiper arm. Return the wiper arm and
blade to the windscreen.

Headlamp Wiper Blades

Lift the wiper blades clear of the headlamps, wipe

clean and check for wear, cracks or damage.
Replace the wiper blades on the headlamp.
If a wiper blade is damaged, move the wiper arm
away from the headlamp into the service position
and carefully lever the blade securing ball from the
wiper arm socket.
Fit a new blade to the arm and return the blade and
arm assembly to the side of the headlamp.
 MAINTENANCE SUMMARY

Drive the vehicle onto a suitable wheel-free lift and

raise t o a convenient height (waist high) with the
wheels free to rotate.

19. Mark stud to wheel relationship and remove

the front road wheels

Slacken the road wheel nuts a quarter of a turn

each.
Remove one road wheel securing nut, mark the
road wheel relative to the stud and remove the
remaining nuts.
Repeat the procedure for the other front road
wheel.

20. Mark stud to wheel relationship and remove

the road wheels -front and rear

Slacken the road wheel nuts a quarter of a turn

each.
Remove one road wheel securing nut, mark the
road wheel relative to the stud and remove the
remaining nuts.
Repeat the procedure for the other road wheels
which are to be removed.

21. Check that tyres are the correct size and type

Check all tyres as follows:

Sports Alloy roadwheel - XJS -

Post 1987 model year

Pirelli VR 15 (Tubeless)

5 spoke 'Starfish' Alloy roadwheel - XJS 3.6

Dunlop SP Super Sport D7, VR 15 or

Pirelli Cinturato 15/70 VR 15 .

Perforated Alloy roadwheel - XJS 3.6 - Pre

1987 model year

Dunlop SP Super Sport D7. VR 15 or

Pirelli Cinturato P5, 2 15/70 VR 15.

10-25
 MAINTENANCE SUMMARY

22.Check tyre tread depth: Note on service sheet

Visually check the tyre tread depth indicators on all
tyres including the spare.
The minimum depth allowed is 1 (0.039 in)
over three quarters of the tread width around the
entire circumference.

23.Check tyres for uneven and excessive wear

and damage including sidewall

Check each tyre for wear and damage

Visually inspect sidewalls and tread for signs of
damage, uneven and excessive wear, exposure of
ply or cord structure and for sharp objects
embedded in the tread.
Remove any objects found in the tread with a small
blunt tool.
The following information details some of the
causes of irregular wear and tyre damage:

Misalignment Wear.

Rasped and feathered tread condition is caused by

wheel misalignment and results in very rapid tread
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wear.
’Fins’ on the inside edges of the pattern ribs,
particularly on the nearside tyre, indicate toe-in.
‘Fins’ on the outside edges, particularly on the
offside tyre, indicate toe-out.

10-26
 MAINTENANCE SUMMARY

23. Continued

Incorrect Tyre Pressures.

Under-inflation (a) is a frequent cause of severe

tyre damage, resulting from the excessive flexing
of the tyre. Under-inflation builds up internal heat
which eventually weakens the casing. It also
causes rapid and irregular tread wear.
Over-inflation (c) leads to shortened tyre life with
tread wear concentrated on the centre section in
contact with the road. The cushioning effect of the
tyre is impaired, resulting in a hard and
able ride. The tyre is also susceptible to impact a b C
fracture and casing damage.
Correct inflation (b).

Camber Wear.

One shoulder more severely worn than the other.

This type of wear is accentuated by mechanical
irregularities of steering or suspension, or by high
speed cornering.

Irregular Wear

Caused by mechanical irregularity of the vehicleas,

for example, worn bearings, steering joints or
badly adjusted brakes.

10-27
 MAINTENANCE

23. Continued

Deflation Damage.

Breakdown of the tyre casing structure which can

arise from under-inflation, over-loading or running
on a flat tyre.

Neglected Cut

Damage through accidental cuts or penetrations

will extend in use due to continued flexing and/or
of moisture and road matter.

impact Fractures.
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Resultant damage from impact fractures is not

always visible externally and, therefore, as a safety
precaution the tyre should be removed and
examined.
(a) Casing fracture caused by severe localised
impact through driving over kerbs, hitting
pot-holes and/or objects in the roadway.
(b) A double fracture is caused by crushing the
sidewall of the tyre between an object and the
rim flange.

NOTE: In both instances such damage can lead to

sudden and dangerous tyre deflation some time
impact occurred.
a

Age Deterioration.

Cracking and crazing of the tread and sidewall

rubber, sometimes accompanied by carcase
deformation. An indication that tyres have been in
service for an extremely long time.
 ANCE SUMMARY

24. tyre pressures

Unscrew the dust cap from valve of the tyre to

be tested and check the pressure using an
accurate tyre pressure gauge. Refit the dust cap.

XJ-S 3.6

Cold inflation pressures for 2 15/70 size tyres:

Front Rear

32 32
2.21 bar 2.21 bar

Pressures may be reduced by (6

0.41 bar) on front and rear tyres to obtain
maximum comfort provided the speed does not
exceed

Cold inflation pressures for size tyres:

Front Rear

34 36
2.35 bar 2.48 bar

Pressures may be reduced by (8

0.55 bar) on front and rear tyres to obtain
maximum comfort provided the speed does not
exceed

XJ-S 2

Cold inflation pressures for 2 15/70 size tyres:

Front Rear

32
2.2 I bar bar

Pressures may be reduced

by 0.42 (6 0.41 bar) on front
and rear tyres to obtain maximum comfort provided
the speed does not exceed 160

Cold inflation pressures for size tyres:

Front Rear

36 36
2.48 bar 2.48 bar

Pressures may be reduced by (8

0.55 bar) on front and rear tyres to obtain
maximum comfort provided the speed does not
exceed
 MAINTENANCE SUMMARY

25. Inspect front brake pads for wear and discs for
condition

Visually inspect the brake pads which should be

evenly worn; if the minimum thickness of pad
material is less than 4 (0.2 in) a new set of
brake pads MUST be fitted.
Discs must be free from deep scoring and signs of
distortion or uneven wear.

26. Adjust front hub bearing end float (Fig 1)

Using a dial indicator positioned on the hub flange

measure and record the end float.
If the recorded end float is (0.006 in) or
more reset the clearance.
To adjust, remove the front hub grease cap
Remove the split pin (2) from the hub and
remove the nut cover (4).
Using a dial indicator positioned on the hub flange
tighten the nut to obtain an end float of
Fig 1
rnm - (0.002in - 0.006 in).
Align the hub nut cover and secure with a new split
pin.
Clean the hub grease cap and refit to the hub.
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 MAINTENANCE SUMMARY

27. Grease hubs

Front hubs (Fig. 1)

Wipe the grease nipples clean and using a

grease gun apply a multi-purpose lithium base
grease (refer to Recommended Lubricants and
Fluids in Section 09) to each grease nipple until
grease exudes from the bleed holes at the hub
centres.

Rear hubs (Fig.2)

Clean the dust caps (A) and adjacent areas of the

hub carriers.
Prise the caps out of the hub carriers and using a
grease gun inject a multi-purpose lithium base
grease (refer to Recommended Lubricants and
Fluids in Section 09) into the hubs until no more
will enter; do not build up pressure in the hubs.
Refit the dust caps.

Fig 1

Fig 2

10-31
 MAINTENANCE SUMMARY

28. Check for oil leaks from steering and fluid leaks
from suspension system

Visually check the ends of the steering rack for

signs of any oil leakage.
Visually check underneath the wheel arches and
around the suspension sytem for any signs of fluid
leakage.
Report if any leaks are evident.

29. Check condition and security of steering unit

joints and gaiters

Visually check the steering unit joints and gaiters

including top and bottom ball joints for condition
and security.

30. Refit road wheels in original position

Lift the road wheel and tyre assembly the

hub, align the wheel with the marked stud and
secure with the wheel nuts.
Lightly tighten the wheel nuts alternately using the
sequence shown in the illustration.
Ensure that the taper on the wheel nuts is seated
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fully onto the taper faces of the wheel disc.

Repeat the above procedure for the remaining
wheels which are to be fitted.

3 Check tightness of road wheel nuts.

Operate the lift to prevent the road wheels from
rotating.
Check the tightness of all road wheel nuts as
follows:
Torque tighten the wheel nuts alternately (using
the sequence shown in the illustration) to 88 - 102

CAUTION: Do not exceed a torque of 102 Nm (75

Ibf

10-32
 MAINTENANCE SUMMARY

UNDER BODY
Raise the lift to a convenient working height

32.Drain engine oil

Preferably this should be done when the engine oil
is warm and therefore the oil drains more readily.

XJ-S 3.6

Place an open container with a capacity of a t least

10 litres (1 7.5 pints) under the sump drain plug.
Before removing the drain plug wipe clean the area
of the sump surroundingthe plug.
Using a 30 ring spanner or socket, remove the
sump drain plug, discard the copper washer and
collect the oil in the container.

XJ-S 2
Place an open container with a capacity of at least
12 litres (21 pints) under the sump drain plug.
Before removing the drain plug wipe clean the area
of the sump surrounding the plug.
Using a in AF ring spanner or socket, remove
the sump drain plug, discard the copper washer
and collect the oil in the container.

10-33
 MAINTENANCE SUMMARY

33. Renew engineoil filter

Place an open container under the filter and

remove the filter canister using a suitable oil filter
removal tool, catch the oil in the container.
Clean the oil filter mounting face and lubricate the
rubber seal on the new filter with clean engine oil.
Fit and tighten the filter canister using only hand
pressure and on no account use an oil filter
removal tool.

NOTE: Normal tightening torque of the oil filter is

to turn after initial contact with the mounting
face.

XJ-S 3.6
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\ JHB

10-34
 MAINTENANCE SUMMARY

34. up manual gearbox. oil

Wipe clean the area of the gearbox surrounding

the filler plug (1) and remove the plug.
Top up the gearbox with a recommended SAE
EP80 oil (refer to Recommended Lubricants and
Fluids in Section 09) the bottom of the thread
in the filler plug hole.
Fit and tighten the filler plug.

35. Renew manual gearbox oil

Preferably this should be done when the gearbox

oil is warm and therefore the oil drains more
readily.
Place an open container with a capacity of at least
2 litres (4.5 pints) under the gearbox drain plug.
Before removing the drain and filler plugs wipe
clean the area of the gearbox surrounding the
plugs.
Remove the gearbox filler plug then remove
the drain (2) and collect the oil in the
container.
Refit and tighten the drain plug.
Fill the gearbox with a recommendedSAE EP80 oil
(refer to Recommended Lubricants and Fluids in
Section 09) the bottom of the thread in the
filler plug hole.
Gearbox capacity is 1,4 litres (2.5 pints).
Fit and tighten the filler plug.

36.Drain automatic transmission fluid

Preferably this should be done when the
transmission fluid is warm and therefore the fluid
drains more readily.

XJ-S 3.6- ZF Transmission

Place an open container with a capacity of at least

4 litres (9 pints) under the transmission drain plug

Before removing the drain plug wipe clean the area

of the transmission surrounding the plug.
Remove the drain plug and collect the fluid in the
container.
Fit and torque tighten the drain plug to 15 Nm 1
Ibf.ft) .
Reposition the container under the dipstick tube
union nut (2).
Disconnect the dipstick tube union nut and the
tube from the transmission
Drain the remaining fluid into the container.
Allow the transmission to drain for at least
minutes (approximately 3 litres (5.3 pints) of fluid
will drain).
Clean the tube unions and fit the dipstick tube to
the transmission sump, torque tighten the union

10-35
 MAINTENANCE SUMMARY

36. Continued.

XJ-S 2- 400 Transmission

Place an open container with a capacity of a t least

9 litres 6 pints) under the vacuum capsule.
Remove the vacuum capsule clamp bolt and clamp

Disconnect the capsule (2) and drain the fluid into

the container.
Reconnect the capsule.
Refit the clamp and tighten the clamp bolt.
Reposition the container under the transmission
sump.
Remove ten sump bolts, leaving two at the front
and one at the rear.
Slowly slacken the remaining sump bolts, allowing
the fluid to drain into the container.
Remove the remaining sump bolts and carefully
remove the
Drain the fluid from the sump.
Remove and discard the sump gasket, clean the
sump pan and mating faces.
Fit a replacement gasket to the sump pan, lift the
pan into position and secure with the bolts.
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Torque tighten the sump pan bolts to 16 Nm (12

XJ-S 2 - BW Model 12 Transmission

Place an open container with a capacity of at least
9 litres (16 pints) under the tube
union nut.
Unscrew the union nut securing the
tube to the transmission sump.
Drain the fluid into the container.
Clean the tube unions and fit the dipstick tube to
the transmission sump, torque tighten the union
 MAINTENANCE SUMMARY

37.Renew automatic transmission filter

XJ-S 3.6 - Transmission

Drain the automatic transmission fluid as detailed

in operation 25, but do not refit the dipstick tube.
Remove the sump pan securing bolts ( 1) and
clamps.
Displace and remove the sump pan (2) and drain
off any remaining fluid.
Remove and discard the gasket, clean the sump
pan, magnets and mating faces.
Remove the filter securing screws remove the
filter (4)and discard the ring (5).
Clean the filter mating faces, fit a new '0' ring to
the new filter and secure with the screws.
Fit a replacement gasket to the sump pan, lift the
pan into position and secure with the clamps and
bolts.
Torque tighten the sump pan bolts to 8 Nm (6
Ibf .
Clean the tube unions and fit the dipstick tube to
the transmission sump, torque tighten the union
nut t o 20 Nm.

XJ-S 2- 400 Transmission

Remove the transmission sump pan as detailed in

operation 25.
Remove the filter securing bolt (2).
Remove thefilter (1).
Clean the filter mating faces and fit a new filter.
Refit and tighten the filter securing bolt.
Refit the transmission sump pan as detailed in
operation 25.

10-37
 37. Continued

XJ-S V12 - BW Model 12 Transmission

Drain the automatic transmission fluid as detailed

in operation 25, but do not refit the dipstick tube
(1, Fig. 1).
Remove the nut (2, Fig. 1) securing the collision
plate to the rear engine mounting.
Remove the nuts (3, Fig. 1) securing the collision
plate t o locating studs, lower the plate noting fitted
position of washers.
Remove stud nuts, bolts and washers (4,
securing the sump pan t o the transmission case;
manoeuvre the pan clear of the exhaust system.
Remove and discard the gasket.
Remove pan head screws (1, Fig.2) securing filter 5
to the valve block; detach the filter.
Fit a new filter and secure with the pan head
screws. 1
Fit a replacement gasket to the sump pan, lift the
pan into position and secure with the stud nuts,
bolt and washers.
Torque tighten the sump pan bolts t o 14 - 17 Nm
( 10 -
Fig 1
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Clean the tube unions and fit the dipstick tube to

the transmission sump, torque tighten the union

Refit the collision plate and secure with nuts to the

locating studs and rear engine mounting.

10-38
 MAINTENANCE SUMMARY

38. up rear axle oil

Wipe clean the area of the rear axle surrounding

the filler plug and remove the plug.
Top up the axle with a recommended SAE 90 oil
(refer to Recommended Lubricants and Fluids in
Section 09) the bottom of the thread in the
filler plug hole.
Fit and tighten the filler plug.

39. Renew rear axle oil

Preferably this should be done when the rear axle

oil is warm and therefore the oil drains more
readily.
Place an open container with a capacity of a t least
2 litres (4.5 pints) under the axle drain plug.
Before removing the drain and filler plugs wipe
clean the area of the axle surrounding the plugs.
Remove the axle filler plug then remove the
drain plug (2)and collect the oil in the container.
Refit and tighten the drain plug.
Fill the axle with a recommended SAE 90 oil (refer
t o Recommended Lubricants and Fluids in Section
09) the bottom of the thread in the filler plug
hole.
Rear axle capacity is approximately 1,6 litres (2.8
pints).
Fit and tighten the filler plug.

10-39
 MAINTENANCE SUMMARY

40. Refit engine drain plug

XJ-S 3.6

Clean the sump drain plug and fit a new copper

washer.
Fit the drain plug into position on the sump and
using a 30 socket and torque wrench, torque
tighten the plug to a torque of 41 - 47 Nrn (30 -
34

XJ-S 2

Clean the sump drain plug and fit a new copper

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washer.
Fit the drain plug into position on the sump and
using a in AF ring spanner or socket tighten the

774

4 1 . Check for oil leaks - Engine and Transmission

Check the underside of the engine, manual

gearbox, automatic transmission and rear axle for
any signs of oil leakage.

Report if any leaks are evident

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 MAINTENANCE SUMMARY

42. Grease all points excluding hubs

Use only a multi-purpose lithium base grease (refer
to Recommended Lubricants and Fluids in Section
09) and always wipe the nipples clean before
injecting grease.
Inspect the delivery end of the grease gun to
ensure that no dirt or other contaminant is present
on the nozzle. Locate the nozzle securely on each
nipple before operating the grease gun, and watch
carefully for grease escaping between nozzle and
nipple; this indicate damage to the nipple,
which must then be renewed.
Do not over-grease; an excess of grease may
distort seals, and escaped grease retains dirt and
dust, therefore wipe off surplus grease.

Front suspension (Pre 1988 model year

vehicles only):

Lubricate the front upper and lower swivel joints (4

nipples) on each side of the vehicle until grease just
appears between the plastic cover and joint.

Rear suspension (Fig.2):

Lubricate the rear suspension outer bearings (2 Fig 1

nipples), rear suspension inner bearings (4 nipples) and
rear axle universal joints (4 nipples). Access to these
joint nipples is obtained by removing rubber plugs
from joint covers. Ensure that plugs are correctly
refitted after greasing. Before greasing outer sus-
pension bearings ensure that bleed holes, diametrically
opposite to grease nipples are clear; when sufficient
grease has been applied to the joints any excess will
appear a t the bleed holes.

Fig 2
 MAINTENANCE SUMMARY

43. Visually check brake hydraulic hoses, pipes

and unions for chafing, cracks, leaks and
corrosion

Visually check all brake hydraulic hoses, pipes and

unions for signs of chafing, cracks, leaks and
corrosion.
Hoses should be flexed by hand to ascertain their
condition and checked for cracks and cuts
particularly a t junction ends.
Metallic pipes should be checked for corrosion
especially where they have been covered by
etc.
Report if any faults are evident.

44. Visually check exhaust system for leakage and

security

Check exhaust system and joints for leaks and

general condition.
Check security of exhaust mountings.
Report if any faults are evident.

45. Lubricate handbrake mechanical linkage and

cables
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Lightly apply a multi-purpose lithium grease (refer

t o Recommended Lubricants and Fluids in Section
09) to the cables and lever pivots.

46 Inspect rear brake pads for wear and discs for

condition

Visually inspect the brake pads which should be

evenly worn; if the minimum thickness of pad
material is less than 4 (0.2 in) a new set of
brake pads MUST befitted.
Discs must be free from deep scoring and signs of
distortion or uneven wear.

47. Check condition of handbrake pads

Visually inspect the handbrake pads which should

be evenly worn; if the minimum thickness of pad
material is less than 4 a new set of handbrake
pads MUST be fitted.

10-42
 MAINTENANCE SUMMARY

48. Renew brake fluid

WARNING: DURING OPERATIONS WHICH

NECESSITATE THE HANDLING OF BRAKE
FLUID, EXTREME CARE MUST BE OBSERVED:
BRAKE FLUID MUST NOT BE ALLOWED TO
CONTACTTHE VEHICLE PANTWORK.

CAUTION: DO NOT 'top up' the fluid reservoir

with fluid which has been bled through the
system, as it will have become aerated.
Always use fresh, clean fluid from a new tin.

NOTE: It is vital that absolute cleanliness is

maintained throughout the entire bleeding operat-
ion. Always use lint free cloths and ensure that dirt
or grit does not enter the system.

Use only new Jaguar Brake Fluid or Castrol Girling

Universal.

Renew the brake fluid and bleed the braking system

as detailed in Section 70 under the headings
and 'Brake Hydraulic System - Bleed'
or 'Brake Hydraulic System - ABS - Bleed.'

49. Lubricate automatic transmission exposed

selector linkage

Lightly apply a multi-purpose lithium grease (refer

to Recommended Lubricants and Fluids in Section
09) to the exposed selector linkage.

50. Check tightness of propshaft coupling bolts

Torque tighten the propshaft coupling bolts to 3 6

51. Check security of accessible engine mountings

Clean the area around the engine mountings.

Inspect rubber mountings for signs of deterioration
or distortion and check fixings for security.

52. Check condition and security of steering unit

joints and gaiters

Visually check ball joint and

steering rack bellows to ensure that they are
seated and sealing correctly.
Report if any faults or leaks are evident.

53.Check security and condition of all suspension

fixings

Clean areas of front and rear crossbeam and

suspension attachments. Inspect rubber mountings
and bushes for signs of deterioration or distortion
and check all fixings for security.

10-43
 MAINTENANCE SUMMARY

54. Check steering rack for oil leaks

Visually check the steering rack for signs of any oil

leakage.
Report if any leaks are evident.

55. Check power steering hydraulic pipes and

unions for leaks, chafing and security

Visually check and report if any faults are evident.

56. Check shock absorbers for fluid leaks

Visually check all shock absorbersfor fluid leaks

Report if any leaks are evident.

57. Check the general condition of the underbody

anti-corrosion protection
Visually check and report on the general condition
of the underbody anti-corrosion protection.
If any areas are damaged or flaking then new
anti-corrosion sealant will have to be applied.
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 MAINTENANCE SUMMARY

ENGINE COMPARTMENT
Lower the lift.

Do not attempt to start the vehicle until item 58 (fill

with engine oil) and item 59 (fill automatic
transmission with fluid, where applicable) have
been completed.
Operate the bonnet release from within the
vehicle, open the bonnet and fit protective covers
to the front wings.

58. Fill the engine to the correct level with oil

XJ-S 3.6(Fig. 1)

Remove the filler cap adjacent to the left-hand

cam cover.
If the oil filter has been replaced add litres
(14.1 pints) of approved oil (refer t o
Recommended Lubricants and in Section
09).
Replace the oil filler cap.

XJ-SV12 (Fig.2)

Remove the oil filler cap (B) on the left-hand cam

cover.
If the oil filter has been replaced add litres (17.5
pints) of approved engine oil (refer to Recom- Fig 1
mended Lubricants and Fluids in Section 09).
Replace the oil filler cap.

Fig 2
 MAINTENANCE SUMMARY

59. Fill automatic transmission with fluid

XJ-S 3.6

A combined filler tube and dipstick is located on

the rear left-hand side of the engine adjacent to the
engine oil dipstick.
Remove the automatic transmission dipstick and
add approximately 3 litres (5.3 pints) of Dexron D
automatic transmission fluid (refer to Recom-
mended Lubricants and Fluids in Section 09).
Using a lint free cloth, wipe the dipstick and
replace.

XJ-S 2 (Fig.2)

A combined filler tube and dipstick is located on

the rear right-hand side of the engine.
Remove the dipstick and add approximately
litres (16 pints) of Dexron D automatic
transmission fluid (refer to Recommended Lubri-
cants and Fluids in Section 09). Fig 1
Using a lint free cloth, wipe the dipstick and
replace
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60. Lubricate accelerator control linkage and pedal

pivot

Lightly lubricate the linkage and pedal pivot with

clean engine oil.

Fig 2
 MAINTENANCE SUMMARY

6 Renew air cleaner

XJ-S 3.6

Release the t w o spring clips disconnect the

hose and withdraw the air cleaner assembly
from the engine compartment.
the three spring clips (3) and remove the
end assembly (4).
Remove the air cleaner element and discard.
Clean the air cleaner body and end cover
assembly.
Position a new element in the body, refit the end
assembly and secure with the three
spring clips.
Refit the air cleaner assembly by pushing the air
intake pipe into its location hole and then
positioning the air cleaner body on the air
flowmeter.
Refit the hose, locate the t w o spring clips and snap
into position.
Fig
XJ-SV12 (Fig.2)

Detach the air temperature sensor connector

the L.H. air cleaner intake pipe.
Release the t w o spring clips (2) on each air cleaner,
detach the covers and withdraw the paper
elements (1).
Clean the covers and mating faces.
Position the new elements in the air cleaners and
ensure that they are inserted with the metal plates
opposite the entry holes to the throttle housings.
Refit the covers, locate the spring clips and snap
into position.
Refit the connector to tne sensor in the L.H. air
cleaner intake pipe. Fig 2

10-47
 MAINTENANCE SUMMARY

62. Check security of accessible engine mountings

Clean the area around the engine mountings.

Inspect rubber mountings for signs of deterioration
or distortion and check fixings for security.

63. drive belts tension. Renew if

necessary

Inspect the drive belts for general condition before

checking the tension. If the belt shows signs of
'shredding' - the local separation of strands of
material from the body - it must be replaced.
To check the tension apply a known pressure at
right angles to the belt in its longest straight run
between pulleys, and measure the deflection
caused in the belt.

Data for each belt as follows:

XJ-S 3.6

Driving belt Deflecting Deflection

force
in
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Air pump 1,5 3.3 4.6 0.18

(wherefitted)
Compressor, 2,9 6.4 4,4 0.17
Alternator. 1,5 3.3 4,4 0.17

XJ-S 2

Driving belt Deflecting Deflection

force
in
Power assisted
steering pump and
water pump. 6.5 4,1 0.16
Alternator. 1,0 3.2 4,4 0.17
Compressor and
air delivery pump 2,9 6.4 5,6 0.22
(where fitted).
Fan belt. 2,9 6.4 3,3 0.13

10-48
 MAINTENANCE SUMMARY

63. Continued.

If a belt requires to be adjusted observe the

following procedures given for each drive belt.
Report if a belt is found to be faulty and requires
6
replacing.

drive belt-XJS 3.6 (wherefitted)

Slacken the link arm trunnion bolt (4).link arm pivot

bolt, air pump pivot (6) and link arm
adjuster locknut.
Tighten lower adjusting nut (3) to obtain the

arm ana air pump pivot

Re-check the belt tension

Compressor drive belt 3.6

Slacken the drive belt upper adjusting nut
adjusting rod securing bolt (3) and adjusting
trunnion block securing bolt (1).
Raise the front of the vehicle and position on t w o
axle stands or raise the vehicle on the lift.
From below the vehicle, slacken the compressor
pivot bolts.
Tighten the lower adjuster nut to obtain the correct
belt tension.
Tighten the upper nut trunnion bolt (1) and
pivot bolts.
Lower the vehicle and tighten the adjuster anchor
bolt (3).
Re-check the tension.

Alternator drive belt - XJS 3.6

Slacken the alternator pivot bolt locknut

trunnion block securing bolt (2). alternator upper
adjusting nut (1) and adjusting rod to water pump
securing nut (4).Tighten lower adjusting nut (5) to
obtain the correct belt tension.
Tighten upper adjusting nut trunnion securing
bolt adjusting rod to water pump securing nut
(4)and pivot bolt locknut (3).
Re-check the belt tension.

10-49
 MARY

Continued

Front belt - Driving, fan 2

Slacken the bolt (2) securing the jockey pulley

carrier and the nuts a t the adjusting link (4) and
trunnion (5 and 6).
Wind back the adjusting nut (6) sufficiently to
enable the belt to be removed from the pulleys,
and manoeuvre past the fan blades.
If necessary fit a new belt then set the tension,
tighten adjusters and fixings.

Second belt - Driving, power steering pump

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and water pump 2

Remove the fan belt as detailed previously, then
slacken the nuts securing the pivot bolt, trunnion
adjuster link
Wind the inner lock nut down the thread to the
link, to enable the steering pump to swing towards
the engine and allow the belt t o be removed
If necessary fit a new belt then set the
tighten adjusters and fixings
Replace the front belt

Third belt - Driving, air conditioning compressor

and air delivery pump (where fitted) - XJS 2
Remove the fan belt and pump belt as detailed
previously
Slacken the nut securing the adjuster pulley or air
pump (when fitted) mounting bolt (1) and the
adjusting link securing bolt (2).
CAUTION: Ensure that the head of the
adjusting link bolt does not contact the pulley.
Slacken the adjusting link locknut (3)and move the
adjuster pulley towards the engine, by slackening
the adjusting link nut (4) and winding along the
thread.
Ease the belt off the pulleys.
If necessary fit a new belt then set the tension,
tighten adjusters and fixings.
Replace the front belts.

10-50
Continued

Carefully remove the three belts as detailed

previously, inspect and lay aside for refitting.
Raise the front of the vehicie and position on t w o
axle stands or raise the vehicle on the lift.
From below the vehicie, slacken the alternator
pivot bolt ( I ) , adjuster and trunnion
securing nuts (3 and 4).
Wind the adjusting nut (4) along the threads
towards the alternator, until the belt can be
removed.
If necessary fit a new belt then set the tension,
tighten adjusters and
Lower the vehicle.
Replace the front belts.

Ensure that all H.T. leads are clearly identified by

cylinder number at front of engine) before
detaching them.
On 3.6 six cylinder engines:
Remove the spark plugs using a special, long 10
spark plug socket.
On 5.3 V 12 engines:
Remove the spark plugs using spark plug tool 18G
1364.
Clean and test the spark plugs on a spark plug
machine.
Set the gap between the two electrodes (by
bending the side electrode) as follows:
3.6 engines:
5.3 2 engines:
Before replacing the spark plugs, wipe clean the
seatings in the cylinder head and check the sealing
washers (3.6 engine only).
Lightly screw in all plugs using the special plug
socket (3.6 engines) or spark plug tool 18G 1364
(5.3 and then torque each
spark plug
3.6 enqines: 23 - 28 Nm 7 - 2 0
5.3 10- (7 - 9
Replace the H.T. leads as identified, ensuring that
each lead is securely connected t o the spark plug.

enew spark plugs

Remove and replace the spark plugs as detailed on
operation 64, but omit the cleaning process.
It is important that only the correct type of spark
plug is used as a replacement, otherwise the
engine running and exhaust emission levels could
be adversely affected.

1
 MAINTENANCE SUMMARY

65. up brake fluid reservoir

WARNING: DURING OPERATIONS WHICH

NECESSITATE THE HANDLING OF BRAKE
FLUID, EXTREME CARE MUST BE OBSERVED;
BRAKE FLUID MUST NOT BE ALLOWED TO
CONTACT THE VEHICLE PAINTWORK.

CAUTION: DO NOT 'top up' the fluid reservoir

with fluid which has been bled through the
system, as it will have become aerated.
Always use fresh, clean fluid from a new tin.

Vehicles with servo assisted brakes

The fluid level is visible through the translucent

casing of the
Check that the brake fluid level is on the 'Max'
mark on the reservoir.
If necessary, top up as follows:
Before removing the cap, clean the reservoir and
cap thoroughly with a lint free cloth to ensure that
no dirt enters the reservoir.
Hold the cable (brake fluid level warning light) and
unscrew the filler cap.
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Top up t o the 'Max' level using new, unused

approved brake fluid (refer t o Recommended
Lubricants and Fluids in Section 09).
Refit the filler cap.
If any brake fluid is spilt, replace the cap on the
reservoir before rinsing it away, to avoid
contamination.
The brake fluid level in the reservoir is initially
nearly full, but the level will drop as the brake pads
wear. If the level appears exceptionally low,
location of the fluid leakage must be found and
reported.

10-52
 MAINTENANCE SUMMARY

66. Continued

Vehicles with Anti-lock Braking System (ABS)

The fluid level is visible through the translucent

casing of the reservoir and must be between the
'Max' and 'Min' marks on the reservoir.

NOTE: There are two 'Max' marks on the

reservoir, always use the higher mark when
checking the level and topping up.

Ensure the vehicle is parked on level ground before

checking the brake fluid level.
Pump brake pedal a t least 20 times (ignition OFF),
or until pedal travel becomes restricted.
Switch ignition ON (position '1' or
Wait until the 'Anti-lock Braking System' pump
stops running.
Check that brake fluid level is on the higher 'Max'
mark.
If necessary, top up as follows:
Before removing the cap, clean the reservoir and
cap thoroughly with a lint free cloth to ensure that
no dirt enters the reservoir.
Unscrew the filler cap.
Top up to the higher 'Max' level using new, unused
approved brake fluid (refer to Recommended
Lubricants and Fluids in Section 09). do not
overfill.
Refit the filler cap.
If any brake fluid is spilt, replace the cap on the
reservoir before rinsing it away, t o avoid
contamination.
The brake fluid level in the reservoir is initially
nearly full, but the level will drop as the brake pads
wear. If the level appears exceptionally low,
location of the fluid leakage must be found and
reported.

10-53
 MAINTENA

67. up clutch fluid reservoir - XJS 3.6

(where fitted)

OPERATIONS
THE HANDLING OF BRA
, EXTREME CARE MUST
OBSERVED; BRAKE FLUID MUST NOT BE
CONTACT THE VEHICLE

NOT 'top up' the fluid reservoir

with fluid which has been bled through t
system, as it will have become aerat
Always use fresh, clean fluid from a new tin.

Before removing the cap (A), clean the reservoir

and cap thoroughly with a lint free cloth to ensure
that no dirt enters.
Unscrew the filler cap, check the level and top up if
necessary, t o the base of the filler neck using new,
unused approved fluid (refer to
Recommended Lubricants and Fluids in Section
09).
Refit the filler cap.
If any fluid is spilt, replace the cap on
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the reservoir before rinsing it away, to avoid

contamination.
 brake s o
hoses for

Visually check the hoses for signs of leakage or

damage
Report if any faults are evident

69. up washer reservoir

Fluid is visible through the walls of the container If

necessary, remove the cap and top up with clean,
preferably soft water. Jaguar Windscreen Washer
Fluid should also be added to assist cleaning The
reservoir should be filled to just below the neck
(Fig 1 - Pre model year) or just below the
filler cap (Fig 2 - Post model Refit
the cap
In winter add Jaguar Windscreen Washer Fluid to
prevent possible damage to the pump under
freezing conditions
UNDER NO CIRCUMSTANCES must cooling
system anti-freeze be used, since this will damage
paintwork
After adding screen washer anti-freeze to the
reservoir, operate the pump until untreated water
is purged from the pipes and jets.
/
70.Check stem for
I

Visually check the hoses for signs of leakage or

damage. Check for frosting on the connector union
housing; the region around the suction part is
normally cold and slight frosting is permissible. Fig 2
Check by feel along pipe lines for sudden
temperature changes that would indicate a
blockage at that point.
Report if any faults are evident.
 71. Change coolant ensuring that the anti-freeze
content is 50 per cent

Use Jaguar Universal anti-freeze. Should this not

be available, then phosphate free anti-freeze
conforming to specification B.S. 3 1 5 0 or 3152
may be used.
The correct concentration for all vehicles is 5 0 per
cent with a Specific Gravity of 1.079 (taken from
the radiator header tank). This mixture is suitable
for -36°C (-33°F).
Should protection to -40°C (-40°F)be required the
anti-freeze concentration must be increased to 55
per cent with a Specific Gravity of 1.086.
A 135 bottle (3.6 engines) or t w o 135
bottles (5.3 2 engines) of 'Jaguar Radiator Leak
Sealer' or 'Barrs Leaks' must also be mixed with
fresh anti-freeze.

WARNING: DO NOT REMOVE THE ENGINE

HEADER TANK FILLER CAP (3.6engines) OR
HEADER TANK CAP AND
ENGINE FILLER CAP engines) WHILST
THE ENGINE IS HOT. IF THE MUST BE
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REMOVED PROTECT THE HANDS AGAINST

ESCAPING STEAM, AND SLOWLY TURN
THE HEADER TANK CAP ANTI-CLOCKWISE
UNTIL THE RESISTANCE OF THE SAFETY
STOP IS FELT. LEAVE THE CAP IN
POSITION UNTIL THE PRESSURE
RELEASED, THEN PRESS DOWN AND TURN J26 057
TO REMOVE.
Fig 1
Drain and Refill- 3.6engines (Figs. I and 2)

The cooling system refill capacity is 9,9 litres

(17.5 pints).

CAUTION: Anti-freeze will damage paintwork.

Avoid spillage.

Place a drain tray in position under the radiator

Remove the header tank cap, open

the radiator drain tap (2, and drain the
coolant.
Close the radiator drain tap.
Reposition the drain tray and remove the cylinder
block drain plug (1, Fig.2). Allow the remaining
coolant to drain, then refit the cylinder block drain

NOTE: On catalyst cars, access may be limited. If Fig 2

so, remove the catalytic convertor 17.50.01.
Fill the cooling system with the correct solution of
anti-freeze and water, and a 135 bottle of
'Jaguar Radiator Leak Sealer' or 'Barrs Leaks'.
Refit the header tank cap and run
the engine until correct operating temperature is
reached, ie the thermostat is open, set the air
conditioning controls to 'Defrost' and '85'.

10-56
 MAINTENANCE SUMMARY

71. Continued

Switch OFF the engine, carefully remove the

header tank cap and top up with
anti-freeze solution, if necessary.
Check for water leaks from drain and
retighten if necessary.

Drain and Refill - 5.3 2 engines.

The cooling system refill capacity is litres (35

pints).

CAUTION: Anti-freeze will damage paintwork.

Avoid spillage.

Place a drain tray in position radiator.

Remove the engine filler (A) and remote header
tank caps, open the radiator drain tap.

NOTE: On later H.E.engines the drain tap has

been omitted. To drain the radiator, the bottom
hose must be removed.
Allow the coolant to drain from the system. This
will allow approximately 14 litres (25 pints) to
drain without disconnecting hoses.
Close the radiator drain tap or refit the bottom
hose.
Fill the system with plain water using the engine
filler pipe, fit both filler caps. Set the air
conditioning controls t o 'Defrost'. Run the engine
at for 5 minutes. Open both filler
caps and turn the radiator drain tap on (or remove
the bottom hose) to drain the water as before.
Close the radiator drain tap (or refit the bottom
hose).
Fill the cooling system with the correct solution of
anti-freeze and water, and t w o 135 bottles of
'Jaguar Radiator Leak Sealer' or 'Barrs Leaks'.
Refit the header tank cap and run
the engine until correct operating temperature is
reached, ie the thermostat is open, set the air
conditioning controls to 'Defrost' and '85'.
Switch OFF the engine, carefully remove the
header tank cap and top up with
anti-freeze solution, if necessary.
Check for water leaks from the drain tap and/or
bottom hose, retighten if necessary.
 MAINTENANCE SUMMARY

72. Continued

72. up cooling system. Check specific

gravity

The coolant level must only be checked when the

engine is cold.

WARNING: OBSERVE THE WARNING

DETAILED IN OPERATION 71.

up coolar (3.6engine:

Refer to coolant specification given in operation 7 1

for recommended anti-freeze and correct
concentration.
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CAUTION: Anti-freeze will damage paintwork.

Avoid spillage.

Remove the header tank cap. The

coolant level in the header tank should just reach
the mark a t the base of the filler neck, top up if
necessary.
Refit the filler cap.

up coolant (5.3

Refer to coolant specification given in operation 7 1

for recommended anti-freeze and correct con-
centration.

CAUTION: Anti-freeze will damage paintwork.

Avoid spillage.

COLD
Remove the cap (A) from the engine filler pipe. If the
coolant level is below 7 (3 in) from the seal
face, top up as necessary.
Refit the filler cap.

10-58
7 2 . Continued

it is necessary to check the coolant level when

hot use a cloth or gloves to protect the hands.
Carefully remove the cap on the header tank (B),
this will release the pressure in the system. The
engine filler pipe cap (A) may then be removed. If
the coolant level is below 7 (3 in) from the seal
face, top up as necessary
Refit both caps.

The correct concentration for all vehicles is 50 per

cent with a Specific Gravity of 1.079 (taken from
the radiator header tank). This mixture is suitable

Should protection to -40°C (-40°F) be required the

anti-freeze concentration must be increased to 55
per cent with a Specific Gravity of

Remove the header tank cap.

Use an approved coolant hydrometer to check the
Specific Gravity as follows:
insert the rubber tube of the hydrometer below the
coolant level, squeeze the bulb and release to draw
a sample of coolant into the instrument.
Repeat this procedure three times to the
instrument.
With the coolant sample drawn into the
so that the liquid is between the two lines on
the glass, check the coolant temperature on the
in the upper section of the instru-
ment.

: It is not recommended that anti-freeze

tests are carried out in coolant temperatures
below (60°F). Warm up th engine for a few
minutes if necessary,
Hold the instrument verticallyand at eye level, then
note the Specific Gravity reading on the float stern
a t liquid level. It is advisable to fold over the rubber
tube and grip it between the fingers. This prevents
air ingress which causes the float to bounce, and
makes a steady reading difficult to obtain.
necessary, add the correct quantity of anti-
freeze.
Replace the header tank cap.
 MAINTENANCE SUMMARY

73. Clean engine breather filter (5.3V12 engines)

Remove the clip (1) securing the rubber cover (2)

to the breather housing.
Disconnect the breather pipe (3) from the rubber
cover.
Remove the rubber cover and lift out the filter (4).
Wash the breather filter in clean fuel and blow dry
using a low pressure air blast.
Refit the filter and rubber cover and secure with the
clip.
Refit the breather pipe to the rubber cover.

74. Check crankcase breathing system for leaks;

hoses for security and condition

Visually examine the crankcase breathing system

and hoses for any signs of leakage, damage,
cracking, chafing, etc. Ensure the connections are
secure.
Report if any faults are evident.

75. up power steering reservoir

Wipe clean and remove the combined filler cap

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and dipstick from the power steering fluid

reservoir; take great care t o prevent any foreign
matter from entering the reservoir. Using a lint free
cloth, wipe the dipstick clean, refit the filler cap
then remove and inspect the oil level shown on the
dipstick and if necessary, top up with power
steering fluid Dexron D or Type G (refer to
Recommended Lubricants and Fluids in Section
09) and replace the filler cap.

NOTE: The 'COLD' side of the dipstick should only

be used if the level is being checked before the
power steering system has reached normal
operating temperature. The 'HOT' side of the
dipstick should be used once normal operating
temperature has been reached.
If the fluid level is low report for further
investigation.

76. Run engine. Check for sealing of filter. Stop

engine

Start the engine; allow it to run at idling speed and

check below the vehicle for signs of any oil leakage
at the new oil filter. Stop the engine.
If the filter is leaking, wipe clean and tighten (use
hand pressure only).

10-60
 MAINTENANCE SUMMARY

77. up engine oil

XJ-S 3.6(Fig.1)

Use an approved engine oil (refer to Recommended

Lubricants and Fluids in Section 09)
If necessary, stop the engine and wait one minute
Remove the dipstick and wipe clean Replace and
withdraw the dipstick
If oil is on the knurled area, no oil is required
If oil is on the knurled area - add 1 litre (1 8 pints)
and recheck
Replace the dipstick
If the vehicle has stood overnight before the is
checked observe the following procedure
If oil is above the mark 'M' - no oil is required
If oil IS below 'M'- add 1 litre ( 1 8 pints) and
recheck

XJ-S 2 (Fig 2)

Use an approved engine oil (refer to

Lubricants and Fluids in Section 09). Fig 1
If necessary, stop the engine and wait one minute.
Remove the dipstick (A) and wipe clean.
and withdraw the dipstick.
If oil is on the knurled area with the engine hot
cold, no additional oil is required.
Replace the dipstick.

Fig 2

10-6 1
 78. Check for fuel leaks

Visually check ail fuel pipes and unions for leaks,

check tightness of connecting nuts, if necessary.
Check fuel rails and injectors for
Report if any leaks are evident.

79. Connect electronic instruments and check

underbonnet label data 2 engine only]

Connect the electronic tuning equipment to the

engine and check underbonnet label data.

80. Lubricate distributor (not cam wiping pad)

engines

Remove the moulded cap a t the top of the

distributor by removing the three screws, lift off
the rotor arm and remove the four screws securing
the anti-flash shield.
Apply few drops of engine oil to the felt pad
reservoir in the rotor shaft.

NOTE: The centrifugal advance mechanism, pick

up plate centre bearing and the vacuum unit
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connecting peg, are lubricated on assembly with a

light grease.
Refit the anti-flash shield and the distributor cap.

isconnect vacuum pipe; check dwell angle;

adjust as necessary 2 engines only)

Disconnect the vacuum pipe and check the dwell

angle.

82. Check ignition timing (at normal operating

temperature on HE models) 2 engines only)

Check the ignition timing which should be between

16" to 18" a t 3000
83.Check distributor automatic advance
engines only)

Check the centrigual advance in crankshaft

degrees and as follows:

HE engines only

20" to 24" at 6200

18" to 22" at 4000
12" to at 2000
No advance below 9 0 0

Pre HE engines only

34" to 38" at 6200

29" to 33" at 4000
22" to 26" at 2000
No advance beiow 900

84. Check distributor adwance increases as vacuum

pipe is reconnected engines only)

Reconnect the vacuum pipe and check that the

distributor advance increases.

engine idle speed; stop engine;

c t instruments 2 engines only)

Set the engine idling speed to 750

Stop the engine and remove the electronic tuning
equipment.

86.Check power steering system for leaks;

hydraulic pipes and unions for chafing and
corrosion

Visually inspect the power steering system for any

signs of fluid and examine the hydraulic pipes
and unions for chafing and corrosion.
Report if any faults are evident.

87. Check for oil leaks from engine

Visually check for any signs of leakage from the

engine.
Report if any leaks are evident.

88. Re-check tension if driving

renewed

If any any of the driving belts checked in operation

63 have been renewed, run the engine for a few
minutes then re-check the tension and adjust if
necessary.
 MAINTENANCE SUMMARY

up automatic transmission fluid

A combined filler tube and dipstick is located on

the rear left-hand side of the engine adjacent to the
engine oil dipstick (XJ-S 3.6, Fig. 1) or located on
the rear right-hand side of the engine (XJ-S V12,

Before checking the fluid level the vehicle must be

on level ground.
Firmly apply the handbrake and position the
selector lever in ’P’ (Park).
Start the engine and allow it to run at idling speed
for a few minutes.
Apply the footbrake and pass the selector lever
through the entire range to ensure that the
transmission system is primed.
Return the selector lever t o ’P’ (Park); withdraw the
dipstick. me40 ’95
Using a lint free cloth, wipe the dipstick clean and
immediately check the fluid level by replacing the
dipstick and withdrawing it. Fig
If necessary, add Dexron D automatic trans-
mission fluid (refer to Recommended Lubricants
and Fluids in Section 09) to bring the level to the
‘MAX’ mark on the dipstick.
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The ‘COLD’ side of dipstick should only be used if

the level is being checked before the vehicle has
reached normal operating temperature, e.g. first
thing in the morning.
The ‘HOT’ side of the dipstick should be used once
normal operating temperature has been reached.
After topping-up (if required), repeat the above
procedure. Be not t o overfill.

Fig 2

10-64
 MAINTENANCE SUMMARY

LUGGAGE COMPARTMENT
90. Check operation of luggage compartment
lamp

Open the luggage compartment lid and check if the

is illuminated.
Report if the lamp fails to illuminate.

91. up battery electrolyte (Figs 1 and 2)

To check electrolyte, remove the battery cover,

use a coin to release the t w o slotted fasteners.
Gently prise off the vent covers (A) taking care not
to strain the rubber vent pipe
Inspect the electrolyte level. This should be 4 t o
(0.15 t o 0 . 3 5 in) above the top of the plates. Fig 1
necessary, top up with distilled water.
Refit the vent covers, ensuring that the vent pipe is
correctly fitted.
Refit the outer cover and secure with the
slotted fasteners.

92. Clean and grease battery connections. (Figs 1

and 2)

Remove the battery cover, use a coin to release

the t w o slotted fasteners.
Ease back battery terminal covers (C), slacken
pinch bolts (13 spanner required) and
disconnect battery leads.

NOTE: Disconnect the negative lead (earth

terminal) first.
Clean battery posts and coat with petroleum jelly.
Reconnect the positive lead, tighten the pinch bolt
and fit the terminal cover.
Reconnect the negative lead, tighten the pinch bolt
and fit the terminal cover.
Refit the outer cover and secure with the t w o
slotted fasteners.

Fig 2

10-65
 MAINTENANCE SUMMARY

93. Remove the spare wheel

Remove the carpet cover and unscrew the knob

retaining the spare wheel in an anti-clockwise
direction. Lift out the wheel.

94. Check that spare tyre is the correct size and

Check the spare tyre as detailed in operation 2 1

95. Check tyre tread depth: Note on service sheet

Visually check the tyre tread depth indicators on all

tyres including the spare.
The minimum depth allowed is 1 over three
quarters of the tread width around the entire
circumference.

tyres for uneven and excessive wear

and damage including

Check the spare tyre as detailed in operation 23

97. pressure
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Check the spare tyre pressure as detailed in

operation 24.
 MAINTENANCE SUMM

98. Renew fuel filter

WARNING: THIS OPERATION RESULTS IN

FUEL AND FUEL VAPOUR BEING RELEASED
WHICH IS EXTREMELY FLAMMABLE, GREAT
CARE MUST BE TAKEN WHEN WORK IS
BEING CARRIED OUT ON THE FUEL SYSTEM
AND THE FOLLOWING PRECAUTIONS MUST
BE STRICTLY ADHERED TO:
NO SMOKING WARNING SIGNS MUST BE
POSTEDAROUNDTHE AREA.
A FIRE EXTINGUISHER MUST BE
CLOSE AT HAND.
DRY SAND MUST BE AVAILABLE TO SOAK
UP ANY SPILLAGE.
THE WORKING AREA MUST BE WELL
VENTILATED.
ENSURE THE FUEL IS EMPTIED INTO AN
AUTHORISED EXPLOSION PROOF CON-
TAINER.

Remove the spare wheel if it is still in position in the

vehicle.
Depressurize the fuel system as follows: Remove
the right-hand luggage compartment trim.
Pull cable from terminal 85 of fuel pump relay.
Disconnect HT lead from ignition coil.
Switch ignition ON and crank engine for a few
seconds.
Re-connect HT lead to ignition coil.
Re-connect cable t o terminal 85 of fuel pump
relay.
Refit right-hand luggage compartment
Remove the battery cover, use a coin to release
the two slotted fasteners.
Disconnect the battery.
Remove the luggage compartment floor carpet
and rear trim carpet from around the fuel filter.
Place a suitable container below the filter.
Fit pipe clamps t o the outlet and inlet hoses,
disconnect the hose clips remove the hoses
from the fuel filter and fit plugs to the hoses and
filter.
Remove the t w o screws (2) securing the filter to
the mounting bracket, remove the fuel filter (3).
Position the new filter on the mounting bracket and
secure with the two retaining screws.
Fit the inlet and outlet hoses and tighten the hose
clips.
Reconnect the battery positive lead, tighten the
pinch bolt and fit the terminal cover.
Reconnect the battery negative lead, tighten the
pinch bolt and fit the terminal cover.
Refit the outer cover and secure with the t w o
slotted fasteners.

10-67
 MMARY

check all fuel hoses for signs of leakage.

if any leaks are evident.

Lift the spare wheel into the luggage compart-

ment.
in position against the rear panel with the
bolt passing through a wheel stud hole.
Fit and tight the securing knob.
Fit the spare wheel cover.

alignment

beam setting should only be carried

with approved beam setting apparatus.

only:

emove the screw securing the top of finisher

to top of lamp housing.
Ease top of finisher (2) away from lamp unit and
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lift bottom locating spigots from housing.

erican vehicles only:

three screws securing the finisher.

ttom screw it may be necessary to
ease bumper sleeve away from lamp unit finisher.
Remove the finisher.
The adjustment screws are set diagonally
opposite each other. The upper screw is for
vertical alignment, the lower screw for horizontal

Turn the top screw anti-clockwise to lower the

clockwise to raise the beam.
Turn the side screw anti-clockwise to,
to move the beam to the right.
Refit the lamp unit finsisher and secure with the

10-68
 djust front wheel alignment

Set the front wheels in the straight ahead

the grease nipple (early vehicles) or plug

ter vehicles) from the rack adjuster pad
the centralizing tool 18G 1466 (2) and
adjust the position of the rack until the reduced
tip of the tool enters the locating hole in the rack.
Check the alignment by using light beam
equipment or an approved track setting gauge.

Slacken the tie-rods outer ball joint locknut.

Release the clip securing the gaiters outer end to
the tie-rods.
Turn the tie-rods by an equal amount until the
alignment of the wheels is correct. Torque
tighten the locknut to 52 to 68 Nm (38.5 50.4
while holding the tie-rod end spanner fiats.
the alignment.
Ensure the gaiters are not twisted and re-tighten
the clips.
Remove the centralizing tool and refit the
grease nipple.

RO
103. out test

Carry out road or roller test as detailed. Remove

the wing covers and close the bonnet.

oad test procedure

Before driving the vehicle check the

(a] Vehicle meets current roadworthiness legis-
lation.
(b) On automatic transmission models; check
that the vehicle will only start in Park or
Neutral
(c) The starter motor operates smoothly.
(d) Engine starts easily.
(e) Low oil pressure and ignition warning lights
extinguish on starting.
Oil pressure gauge and battery condition
indicator register.
(g) Tachometer operates.
Engine runs smoothly and quietly without
undue noise levels.
Foot and handbrake operate.
(k) On automatic transmission models; checking
parking pawl for engagement.

10-69
 SUMMARY

103. Continued

When driving the vehicle on the road check the

following:
(a) Manual gear or automatic drive selection and
noise levels throughout the range.
(b) If fitted; clutch for free play, slipping or
judder.
(c) Engine drive performance is normal, without
excessive noise levels.
(d) The throtrle operates smoothly.
(e) Speedometer for steady operation, and that
the distance recorder operates.
(f) Indicators for self cancelling.
(g) Steering for noise, effort required, free play,
wander and castor action.
(h) Check suspension for noise, irregularity in
ride and road whee! imbalance.
Footbrake pedal for effort, travel, braking
efficiency, pulling and binding.
(k) Operation of all instruments and optional
equipment.
(I) Abnormal body and wind noise.
If fitted; operation of cruise control.
(n) Webbing and operation of seat belts includ-
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ing inertia reels.

Handbrake ratchet and hold.
(r) Report on road test findings.

10-70
 MAINTENANCE SUMMARY

103. Continued

Roller test procedure

Before running the vehicle on the roller equip-

ment, check the following:
(a) On automatic transmission models; check
that the vehicle will only start in Park (P) or
Neutral (N).
(b) The starter motor operates smoothly.
(c) Engine starts easily.
(d) Low oil pressure and ignition warning lights
extinguish on starting.
(e) Oil pressure gauge and battery condition
indicator register.
(f) Tachometer operates.
Engine runs smoothly and quitely without
undue noise levels.
(h) Foot and handbrake operate.
On automatic transmission models; checking
parking pawl for engagement.

When running the vehicle on the roller equipment,

check the following:
(a) Manual gear or automatic drive selection and
noise levels throughout the range.
(b) Engine drive performance is normal, without
excessive noise levels.
The throttle operates smoothly.
(d) Speedometer for steady operation, and that
the distance recorder operates.
(e) Indicators for self cancelling.
Footbrake pedal for effort, travel, braking
efficiency, pulling and binding.
Operation of all instruments and optional
equipment.
(h) Handbrake ratchet and hold.
Report on road test findings.

104.Ensure cleanliness of controls, door handles,,

steering wheel, etc.

Remove vehicle protection kit. Ensure that all

controls, door handles and steering and
carpets are clean.
 SERVICE TOOLS

3.6ENGINE
MS 204

support bracket Adjustable valve seat cutter

MS 768 18G 1436

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1 . Timing damper oil pressure simulator tool and

Basic handle set crank pulley remover

JD 550-3

Small moulded plastic case to take

MS and four cutters Crankshaft rear seal replacer adaptor

MS 150-8

Expandable pilot Valve guide

11-01
 SERVICE TOOLS

3.6ENGINE Continued

Front pulley lock Dummy caps

Jackshaft power steering and

timing cover bush Camshaft timing tool

18G 55A JD 118

Piston ring compressor Auxiliary drive oil seal remover

,
Valve spring compressor Auxiliary drive oil seal replacer

1 1-02
 SERVICE TOOLS

3.6 .

JD 1016)

Crankshaft front oil seal replacer Clutch spring compressor

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Crankshaft front sealer remover Gearbox mounting centraliser

JD 1151)

Chain link

Engine lifting brackets

1 1-03
 SERVICE TOOLS

5.3ENGINE
MS

Valve spring compressor Additional hook assembly

JD 40

Camshaft sprocket retainer Oil seal packing pre-sizing tool

JD41

Cylinder liner retainers Adaptor crankshaft rear oil seal are-size

Engine support bracket Damper setting

 5.3ENGINE Continued
18G 55A (38113)

Piston ring compressor

JD 39
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Jack shaft sprocket holder

Tirnina chain tension retainer

c 3993

Valve timing gauge

1 1-05
 SERVICE TOOLS

AUTOMATIC TRANSMISSION

JD 138 18G 195

Rear hub end float gauge Compressor piston accumulator control valve

Extractor bolt oil sump Replacer oil and rear extension oil seals

1298 18G 1309

Forward and Intermediate clutch piston replacer Intermediate clutch inner seal protector sleeve

18G 1310 18G

Band application pin selection gauge Pressure test equipment

 SERVICE TOOLS

AUTOMATIC TRANSMISSION Continued ...

18G 18G

Replacer front clutch piston rear clutch

18G 68 1 (CBW 548) and (CBW 548-

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Toraue screwdriver set Screwdriver bit adaotor

18G 1004 (7066)

Front servo adiuster adaptor pliers

18G 1004

Pointsfor 18G 1004 Points for 18G 1004

11-07
 SERVICE TOOLS

AUTOMATIC TRANSMISSION Continued

CBW 35-65 JD 107 (18G 1016)

Bench cradle Clutch spring compressor

Tension wrench Auto tool kit

Front and rear oil seal replacer Selector linkage setting gauge

JD 104 JD 1501)

Extension housing roller bearing Convertor lifting handles

11-08
 SERVICE TOOLS

AUTOMATIC TRANSMISSION Continued ...

JD 106 (LST 11 1) JD 107 (18G 1016)

Oil pump rotation sleeve Clutch spring compressor

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Adaptor clutch spring compressor '0' ring and snap ring replacer

Gear train Kickdown cable remover

JD 11 1 (LST 1 18)

Transmission holding fixture Control unit oil seal

1
 SERVICE TOOLS

PROPSHAFT AND FINAL DRIVE

1 (GKN 47-3)

Pinion setting gauge Pinion bearing cone

(GKN GKN

drive inner Reolacer differential bearina cone

Propellor shaft flange wrench Torque screwdriver set

11-10
 PROPSHAFT AND FINAL DRIVE Continued

Drive shaft bearing nut wrench Propellor shaft flange wrench

(GKN 18G 47 (MS

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drive pinion inner bearing cup Multi-purpose hand press

-3

Output shaft outer bearina

bearing Adaptor remover differential bearing cone

JD SL 550-8 GKN

Rear wishbone shaft drive outer bearina

1
 SERVICE TOOLS

STEERING AND

606602

Ring expander for steering box valve and worm seals Power steering pump

18G 1259 s 355

Assembly pilot steering rack pinion Pow-A-Rak nut wrench

JD 36A JD 24

Steering rack checking fixture Steering joint taper separator

Ring compressor for steering box valve

and worm seals Steering rack alignment pin

11-12
 SERVICE TOOLS

STEERING AND FRONT SUSPENSION Continued

JD 100 (1 8G 1063) JD 10-2

(Supercedes JD 24)

Remover - steerina arm and swivel hub ball points Adaptor pressure test
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Adaptor power Front coil spring compressor

JD 20A

Steerinq pump drive dog remover Bearing remover main tool

JD 10 JD 20A- 1

152
Rear hub inner and outer cup
Power steering test set remover adaotor

1 1 -1 3
 REAR SUSPENSION

JD 15

Adaptor dismantler damper spring unit rear Replacer - Rear hub master spacer and bearing

16C

rear hub outer bearing cone Torque arm bush rear

14 JD 1

Rear wishbone pivot dummy shaft Hub

138

Rear hub end float gauge

11-14
 SERVICE TOOLS

Rear camber setting links

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Realacer rear hub bearina cone and CUD

14-7

Remover rear hub bearina cone

11-15
 SERVICE TOOLS

BRAKES

Replacer disc brake piston seal

Protector seal installer (Sanden compressor)

JD 146 JD 149

102

Clutch front plate and rotor kit

(Sanden compressor) Dipstick oil level (Sanden

JD 147

100

Seal retainer tongs (Sanden compressor) Seal (Sanden compressor)

~-

11-16
 SERVICE TOOLS

ELECTRICAL

18G

Fuel tank sender unit wrench

BODY
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Rubber basic too!

GENERAL

370 134 (MS 550)

Adaptor plates Driver handle

All service tools listed are available from:

V L Churchill Limited
PO Box 3
Daventry
Torx screw wrench Northamptonshire 1 1 4NF

11-17
 ENGINE 5.3

CONTENTS
DESCRIPTION OPERATION OPERATION PAQE
No No

CAMSHAFTS ......... ........... RENEW ....................... 12.13.01

CAMSHAFT PIPES
CONNECTING ROD BEARING - EN
CRANKSHAFT ... ...... RENEW ....................... 12.21.33 .......... 12-62

CRANKSHAFT MAIN BEARING - ENGINE SET ........ RENEW ...

CYLINDER HEADS .... OVERHAUL .................. 12.29.21 .......... 12-31

CYLINDER HEAD G .......................
........ RENEW 12.29.01
CYLINDER HEAD G ............... RENEW ...............
....... 12.25.27 .......... 12-57
CYLINDER PRESSURES ._. CHECK ........................ 12.25.01 .......... 12-39
DRIVE PLATE ................ .......... RENEW ....................... 12.53.13 .......... 12-66
ENGINE ............... .................................... DESCRIPTION ..

ASSEMBLY .....
ENGINE ASSEMBLY ...............
ENGINE MOUNTING

FLYWHEEL .................................
OIL COOLER . .
OIL COOLER R
OIL COOLERS .................................. RENEW ....................... 12.60.74

OIL PICK UP STRAINER

OIL PRESSURE RELIEF V

.......................................................... RENEW ....................... 12.60.44 .......... 12-73

PISTON ROD SET ...... RENEW ....................... 12.17.01 .......... 12-51
PISTON ROD-ENGINE SET ...... OVERHAUL .................. 12.17.10 .......... 12-53
SANDWICH PLATE ASSEMBLY .................... RENEW .......................
SPARK PLUG INSERTS ........................................ FITTING ...........
TIMING CHAIN ................................................... RENEW ............ 12.65.12

12.65.50 .......... 12-47

TIMING CHAIN ........ RENEW 12.65.28 .......... 12-49
.................... ......... 12.29.48 .......... 12-19

12-01

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 ENGINE 5.3
12-02
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 ENGINE 5.3

GENERAL DESCRIPTION 12.00.00

Set in a 60 degree ’Vee’ formation, the engine consists of twelve cylinders - six in each bank -each with a
bore of and a stroke of giving a n overall capacity of 5343 cubic centimetres. On each bank, a
single overhead camshaft drives two valves per cylinder. Petrol is supplied to each cylinder via ihjectors fed
from a regulated fuel rail. Clean air is supplied by t w o paper element air cleaners, one per bank.

CONSTRUCTION

The skirted design crankcase is manufactured in cast alloy, and its open top deck houses slip fit wet cast iron
cylinder liners.

Housed in the crankcase is the forged steel crankshaft, which is nitro-carburise treated to enable a very high
quality finish on bearing surfaces and help increase the life of the bearing journals. The crankshaft is supported
by seven main bearing caps, which have bearings of lead bronze on split steel backed shells with a lead indium
overlay. Any crankshaft is controlled by half thrust washers fitted on each side of the centre main
bearing. The gears and pulleys which drive the timing chain and external drive belts are keyed on to the
crankshaft nose and held captive by a single bolt fitted into the end of the crankshaft.

The connecting rods in ’H’ section are manufactured in forged steel. They contain small end bushes
manufactured in lead bronze with steel backing, and are machined to size after being pressed into the
connecting rod. Big end bearings are made from lead bronze on split steel backed shells with lead indium
overlay.

Pistons are manufactured from aluminium alloy and have varying degrees of dished crown to suit high or
standard compression ratios depending upon market requirements. Three rings are fitted to each piston, t w o
upper compression rings and one lower oil control scraper ring. The pistons run on hardened steel gudgeon
pins, which are offset from the centre line of the piston towards the thrust face.

A major feature of this engine is the cylinder head which is manufactured from aluminium alloy. It utilises the
’May’ design combustion chamber which has been used for its lean burn qualities, thus aiding fuel economy
and helping to meet stringent emission regulations worldwide. The cylinder head also houses the two steel
in-line valves per cylinder which run in cast iron guides.
Twin valve springs and chilled cast iron bucket tappets are operated by a single overhead camshaft running
directly in the tappet block. Manufactured in cast iron with chilled cams, the camshafts are retained by
machined aluminium caps.
The tappet block is manufactured in cast aluminium alloy and is topped by a cover of the same material, which
carries the emblem.

Camshaft drive is by a single ‘duplex’ chain, which also incorporates the auxilliary shaft in its drive line. Drive
for the chain is provided b y the crankshaft. A tensioner blade and three damper blades are used to control the
chain.
The distributor is driven by the auxilliary shaft via a set of spiral reduction gears.

Four external drive belts situated a t the front of the engine are operated by a pulley on the crankshaft nose.
The four belts drive the following:

1 Alternator.
2 Air conditioning compressor and air pump.
NOTE: On non-air injection engines, an idler pulley is fitted in place of the air

3 Water pump and power steering pump.

4 Cooling fan.

Below the line of the crankcase are t w o windage trays; these prevent oil being sucked up and thrown into the
crankcase, thereby alleviating windage and power loss. Bolted on to the bottom of the crankcase is the
aluminium sandwich plate, the front part of which forms the base of the engine, with the rear part opening out
to let oil reach the pressed steel sump. The sump is bolted t o the sandwich plate.

12-03
 Oil is drawn from the sump via a gauze filter fitted in the suction hose. Pressurised oil is fed via internal galleries
in the cylinder block to the filter head. The oil is then regulated by a relief valve fitted in the filter head. Any relief
oil is returned to the suction side of the oil pump via an oil cooler, with a balance valve diverting oil back t o the
sump in the event of an oil cooler blockage.
After the relief valve, the main oil is fed to the oil filter, and this is again regulated and in the event of a
blockage, the filter is bypassed. Oil is hereafter fed into the main oil gallery for distribution to the various parts
of the engine.

FULL FL

This system is the same as the relief flow oil cooler system up to the regulation by the relief valve. Any relief
here is returned directly to the suction side of the oil pump. The main oil is then fed to the oil filter, is again
regulated, and in the event of a blockage the system is bypassed. After the filter, the main oil is sent through
an oil cooler which is regulated to guard against blockage. After cooling. the main oil is fed into the main oil
gallery for distribution to the various parts of the engine.

Pressurised and filtered is fed from the main oil gallery to the seven main bearings, and then via crankshaft
drillings t o the big end bearings.
An oil feed pipe connecting t o the rear of the block feeds the camshaft bearings, taking oil from the main
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gallery. The auxilliary shaft is fed with oil taken from the main gallery via drillings at the front of block.

gases are recycled via the induction system to maintain a crankcase depression, and so prevent their
to the atmosphere. These gases are taken from the crankcase by a vent pipe attached to the front of
the left hand tappet block, and are fed to a positive crankcase ventilation (PCV)valve housed in the left hand air
cleaner. At closed or part throttle, blowby gases are pulled into the plenum chamber of the inlet manifold.
With a wide open throttle, the blowby gases are pulled into the clean side of the left hand air cleaner. The
purpose of the PGV valve is to protect the crankcase against too high a depression being generated by either
the induction manifold or the air cleaner, and will restrict any such depression accordingly. In this way, a
suitable depression is maintained in all throttle conditions, ranging from closed to wide open.

TE

The engine is cooled by a mixture of water and antifreeze circulating around the coolant passages. The water
pump is mounted directly above the crankshaft and is driven from the crankshaft nose by a three point drive
(including the power steering pump). The coolant is fed into the block via external delivery pipes and is drawn
from the engine via a thermostat back to the radiator, or is recirculated according to the thermostat position.

12-04
 ENGINE 5.
SYMPTON POSSIBLE CAUSE CHECK REMEDY
Engine spits back Excessively weak Check CO reading of gases See Engine Management
into air boxes mixture leaving the exhaust pipes

Air leaking into induction Listen for leaks (whistling), spray

manifolds 'easy start' around suspect area,
.the engine speed will increase
should an air leak be present
Engine backfires Air leakage Check for leaks or blows in the Repair leaks or replace
the exhaust system system system if necessary

Leakage past valves Check HC reading of exhaust Remove the cylinder

and guides gases and also check for and overhaul
crankcase fumes

Ignition timing retarded Check ignition timing See Engine Management

Mixture too weak Check CO level from exhaust See Engine Management

Incorrect valve timing Check camshaft timing Adjust camshaft timing

Valves sticking open Check valve clearances Adjust valve clearances

Check for wear or gum in Replace guides or

valve guides Decarbonise the

cylinder head
Check for poor seating of valves Overhaul the cylinder

Engine fails to die Incorrect ignition timing Check ignition timing

Valve clearances Check clearances Adjust clearances
insufficient

Faulty cylinder head Check for leaks into the oil Replace the
gasket and water

Exhaust system Check for restrictions Remove the restrictions

blocked or replace components
as necessary

fails to rotate Batterv leads loose or Check the condition of the leads Clean and tiqhten
attempting to terminal corroded and terminals necessary
start
Battery discharged Check condition of battery with Charge or replace as
hydrometer necessary

Starter motor If the lights dim when ignition Remove starter motor,
inoperative switch is operated, the starter free off pinion and refit
may be jammed in the starter ring

loose and dirty

connections to the starter motor

12-05
 ENGINE 5.
SYMPTON POSSIBLE CAUSE CHECK REMEDY
Engine rotates but Starter motor speed Check battery leads and Tighten and clean leads
not fire too low terminals as necessary

Check the state of the battery Charge battery or fit

charge replacement

Faulty ignition system Using plug lead pliers, hold the If no spark, a yellow or
plug lead approx. from the white spark is evident,
cylinder head and crank the engine, check the ignition
check that a good blue spark system
jumps the gap between the end of
the plug lead and the cylinder head

If the spark is inadequate, remove Clean and the

the sparking plugs sparking plugs, replace
if worn out

Fuel system defect Check the injectors are Refer to Fuel Injection
'clicking'. Check the fuel and Engine Management
pressure. Check the voltage sections.
a t the fuel pump.
Overheating Thermostat stuck Remove thermostat and carry out Change thermostat
closed boiling water check
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Faulty gauge Check with equipment Fit new guage

Faulty transmitter If other equipment in circuit OK Fit new transmitter

fit new transmitter

Radiator blocked Check for uneven heat in radiator Flush or change radiator
i.e. hot and cold spots plus
water emission from overflow pipe

Too high concentration Remove the heater tank cap and Drain coolant and fill
of anti-freeze check concentration with a with correct
hydrometer concentration

Fan belt slack Check tension Retension the belt

Fan belt broken Open bonnet and check visually Fit new belt

Water pump seized Remove drive belt and turn pulley Change water pump

Insufficient coolant Remove header tank cap and Top-up coolant

check coolant level visually

Incorrect ignition timing Check ignition timing See Engine Management

mixture Check levels See Engine Management

too weak

incorrect thermostat Remove thermostat and visually Change thermostat

check temperature reading

Collapsed hoses Start engine, run until normal Fit new hoses
temperature is attained and
visually check the hoses for
collapsing

12-06
 E REMEDY
Cylinder head Remove head tank cap, fill tank Change head
leaking with water. Run engine until hot
rev engine and return to idle;
check for bubbles in water

Incorrect valve timing Check valve timing with Service Reset valve timing
Tool

adiator cap spring Fit cap to pressure Fit new cap

weak equipment and check spring
release pressure
At tick over Torquatrol Run engine and visually check Fit new torquatrol unit
that large fan is turning
No oil pressure Faulty oil pump drive Strip oil pump and check visually Fit pump
gear

indicator Check with equipment Change indicator

No oil in Dip oil Fill with oil

Blocked pick-up pipe Remove sump and pick-up pipe Clean pick-up strainer

Too cold Thermostat stuck open Remove thermostat Fit new thermostat

uxiliaryfan remains Check relay circuit Fit new relay

operational

Check radiator fan thermostat Fit new fan thermostat

Check diode Fit new diode

Faulty indicator Check with equipment Change indicator

Faulty transmitter If all other equipment fit Fit new transmitter

new transmitter

Thermostat missing Remove thermostat housing Fit new thermostat

Wrong temperature Remove thermosrat housing and Fit correct thermostat

rated thermostat visually check rate
Losing oil Worn front oil seal Wipe clean, run engine and Fit new seal
(leaking) visually check

Worn rear seal Wipe belt housing clean, run Remove gearbox and fit
engine and visually clean new seal

Leaking gaskets Visual (except head Change or

see head blown) reseal

Cylinder block cracked Visual Change cylinder block

12-07
 ENGINE 5.3

SYMPTON POSSIBLE CAUSE CHECK REMEDY

Detonation knock Ignition timing too far Check ignition timing See Engine Management
(pinking) advanced

Head blown Dip engine oil and check for Change head
ingress of water. Remove header tank cap, rev engine and
check for bubbles in water

Thermostat Remove thermostat and carry out Fit new thermostat

overheating boiling water test
Mixture too weak Check with meter See Engine Management
No water in engine/ Remove header tank cap and with water
radiator water level

Engine running too hot See overheating fault

finding

No water in engine/ Remove header tank cap and with water

radiator water level

Valve timing incorrect Check valve timing Adjust valve timing

Incorrect octane fuel If all other checks OK, this Fill with correct octane
could be the cause fuel
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Excessive noise from Excessive valve Check valve clearances Adjust valve clearances
valve gear clearance

Broken valve Remove valves and check springs Replace as necessary

Broken valve guide Remove valves and check guides Replace as necessary

Broken valve seat insert Remove valves and check inserts Replace as necessary

Lack of lubrication Check oil pressure See insufficient oil

pressure fault finding

Valve clash Check valve timing Adjust valve timing

Worn camshafts Valve clearances and lack of Adjust valve clearances

lubrication - see insufficient oil
pressure

Worn camshaft drive Remove front timing cover and Replace as necessary
check for wear
Insufficient oil Oil requires changing Dip oil, check colour and Change oil
pressure viscosity

Worn crankshaft Listen for rumble or knock Change crankshaft

journals

Excessive crankshaft Fit dial gauge and measure Remove sump and fit
oversize thrust washers

Worn main bearing Listen for rumble Check crankshaft

shells journals for wear and fit
new shells

Worn oil pump Remove oil pump and check the Fit new oil pump
clearances

12-08
 ENGINE 5.3

SY MPTON POSSIBLE CAUSE CHECK REMEDY

Insufficient Oil pressure relief valve Remove valve and check for Fit new valve
pressure sticking open sticking

Oil pressure relief valve Remove spring and check spring Fit new
too weak rates assembly

Insufficient oil in sump Dip oil Top-up as required

Faulty gauge Check gauge with fast check Fit new gauge
equipment

Engine overheating See overheating fault

finding

Wrong specification oil Dip oil and check viscosity Change oil and filter
(too thin)

Water in oil Dip oil and check if oil is a Change oil and check for
blown milky white colour head

Cracked oil pump Remove sump and check visually Change the pump
housing

Blocked oil pick-up pipe Remove sump and check visually Remove oil pick-up pipe
strainer and clean strainer

Oil pump pipe '0' rings Remove sump and pipe and check Fit new rings

Main oil gallery seals Eliminate other poss. causes Fit new rings or clear
leaking or gallery gallery
blocked
Oil pressure too high Relief valve stuck shut Remove valve and check for Clean or replace the
sticking valve

Wrong pressure relief Remove spring and check the rate Fit new spring
valve

Incorrect grade engine oil Drain engine oil and fill

with correct oil

Gauge or transmitter Check gauge, of O.K. fit new Fit new gauge or
fault transmitter transmitter

Engine temperature too Check operation of the thermostat Fit new thermostat or
low valve (stuck open) or oil cooler
valve stuck open
Loss of power Burned valves Check compressions Remove cylinder
and change valves

Sticking valves Check compressions Remove cylinder

and replace valves/
guides or springs

Poor engine tune Check engine tune Adjust as necessary

Insufficient valve Check valve clearance Adjust as necessary

clearance

12-09
 EN
POSSIBLE CAUSE CHECK REMEDY
Loss of power Fuel injection fault Refer to fuel injection section
L o w compression in Check compressions as
cylinders necessary
Ignition fault Refer to electrical section
Camshaft timing timing using Adjust camshaft timing
incorrect Service Tool C 3993
grade fuel Drain fuel and refill with
correct octane
Partial seizure of engine Remove spark plugs and rotate Overhaul engine as
necessary
Worn Remove and check for Replace
wear
Rough running normal Sticking valves Check compressions Change valve, springs
engine speed (less or guides
than 12 cylinders)
Broken valve springs Check compressions Change valve springs
and check for bent
valves

Piston fault Check compressions Change pistons

Head blown Check compressions and water Change head

level
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Valve burned out Check valve

Valve seat burned Check compressions Cut or change valve seat

ignition fault Refer t o electrical section

Fuel injection fault Refer t o fuel injection section

Air leaking into inlet Run engine and listen for Change gasket oi
manifold easy start around manifold
suspect area. If engine speed
increases, confirmed

Blowing exhaust Run engine and check for leaks Repair leak or change
exhaust
Noisy Chains L o w oil pressure Take reading from gauge when See insufficient oil
engine is hot pressure

Tensioners not released Remove and check Insert 3 Allen key

tension of chain (topchain) and turn tensioner
Remove cover to check clockwise, compress
b o t t o m chain tensioner tensioner to release
b o t t o m chain

Chains worn Check check Replace as necessary

for wear

Sprockets worn Check visually as necessary

Tensioner worn Check visually as necessary

 5.3
SYMPTON POSSIBLECAUSE CHECK REMEDY
Insufficient oil Oil pressure relief valve Remove valve and check for Fit new valve
Rough idle Valve timing incorrect Check camshaft timing using Adjust camshaft timing
Service Tool

Incorrect mixture Check reading for exhaust See Engine Management

Incorrect ignition timing Check ignition timing See Engine Management

Valve clearances Check valve clearances Adjust valve clearances

insufficient

Valve burned out Check compressions Change valve

Ignition fault Refer to electrical section

Fuel injection fault Refer to fuel ignition section

Burning oil Worn cylinder bores Check wear with a comparitor Rebore cylinders as
necessary

Worn valve guides Insert valve in guide and check Change valve guides
side movement as necessary

Worn inlet valve seals Remove seals and check for splits Replace in sets
or wear

Worn piston rings Measure rings in bore Replace rings in sets

and rebore as necessary

Leaking cylinder head Check for blue smoke from Replace head
exhaust

Engine oil wrong Drain oil and refill

specification with correct viscosity oil

12-1 1
 ENGINE 5.3

CAMSHAFT COVER GASKET LEFT HAN

RENEW 12.29.40

Open the luggage compartment and remove the right

hand side trim.
Disconnect the cable from the fuel pump relay terminal
Fig
Open the bonnet. Disconnect the HT lead from the
ignition coil. Switch on the ignition and crank the
engine for approximately five seconds.
Switch off the ignition. Reconnect the pump terminal
and refit the luggage compartment trim.
Remove the battery cover, disconnect the battery.
Disconnect the air temperature sensor Fig 2).
Release the clips ( 1 Fig 3) and remove the air cleaner
cover. Remove the element (2 Fig 3).
Disconnect the auxiliary air valve hose from the air
cleaner back plate.
Disconnect the auxiliary air vaive hose feed pipe. 1
Disconnect the crankcase breather hose.
Remove the air cleaner backplate bolts (3 Fig 3).
Remove the backplate from the throttle housing.
complete with overrun vaive hose.
Remove and discard the overrun valve hose and air
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cleaner gasket.
Disconnect the fuel pipes from the overrun valves
(retrieve the spacer from the LH valve). Fig 2
Disconnect the regulator hose from the fuel rail.
Disconnect the crossover pipe from the fuel
Disconnect the pressure hose from the manifold
Disconnect the vacuum hose from the throttle housinq
(FEDERAL ONLY).
Disconnect the terminals from the kickdown switch
(LH DRIVE ONLY).
Disconnect the throttle cable from the throttle pedestal
(LH DRIVE ONLY).
Release the throttle rod from the the bell-crank.
Release the harness to fuel rail securing clips.
Disconnect the fuel injectors (Fig 4) and cold start
injector (1 Fig 1 page 13).
Disconnect the brake vacuum hose from the non-r
valve.
Remove the throttle return spring.
Disconnect the rubber elbow from the manifold bleed
pipe.
Remove the twelve manifold nuts and washers.
Remove the t w o screws securing the air rail clips t o the
manifold ram tubes (FEDERALONLY).
Disconnect the air rail. Remove and discard the
rings (FEDERALONLY).
Remove the EGR valve securing bolts, and remove the
EGR valve from the throttle housing flange (FEDERAL
ONLY).
Remove the six manifold stud spacers.
Remove the manifoid assembly from the cylinder
head, carefully easing aside fuel and air pipes.
Remove and discard the manifold gaskets, fit blanking
plugs to the inlet ports.
Re-position the harness clear of the cam cover.
Disconnect the cross pipe hose from the auxiliary air
valve.
Remove the cam securing nuts, bolts and
washers ( 1 Fig page
Remove the cam cover. Discard the qasket and half
moon seal (2 Fig page
12-12
 ENGINE 5.3

Apply sealant to the radial edge of a new half moon

seal (Fig 3). Fit the seal to the carrier.
Fit the cam cover using a new gasket.
Fit and torque tighten the securing
Reconnect the cross pipe hose to the auxiliary air
valve.
Re-position the wiring harness to the cam cover, and
reconnect the coolant temperature sensor.
Remove the blanking plugsfrom the inlet ports.
Refit the induction manifold, using new gaskets.
Refit the manifold stud spacers.
Refit the EGR valve (FEDERALONLY).
Refit the air rail, using new ’0’ rings (FEDERAL ONLY).
Refit the air rail to the-manifold ram tubes
(FEDERALONLY).
Fit and torque tighten the manifold securing nuts and
washers
Refit the rubber elbow to the manifold bleed pipe
Fit the throttle return spring Fig 1
Reconnect the brake vacuum hose the non-return
valve
Reconnect the fuel and cold start injector terminals
Secure the harness to the fuel rail, using new plastic

Fit the throttle rod to the bell crank

Refit the throttle cable assembly to the
pedestal (LH DRIVE ONLY)
Reconnect the kickdown switch terminals (LH DRIVE
ONLY)
Refit the vacuum hose t o the throttle housing
(FEDERALONLY).
Reconnect the manifold pressure hose to the manifold
Reconnect the fuel cross-over pipe t o the fuel rail
Reconnect the pressure regulator return hose to the
fuel rail
Reconnect the fuel pipe to the overrun valves, ensuring
that the spacer is fitted to the LH valve
Refit the air cleaner Reconnect the battery
Close the bonnet

DATA
TORQUE FIGURES

Cam cover 1 1Nm

Inlet manifold to cylinder head (nuts)23-27Nm
Inlet manifold to cylinder head (bolts)
EGR valve to throttle housing 9.5- 12Nm
Elbow to inlet manifold
Hose clips

SPANNER SIZES

16” A F

Half moon seal

Fig 3

12-13
 Depressurise the air system (if fitted)

the luggage and remove the right

hand side trim
Disconnect cable from the fuel relav terminal
85 Fig 1). Fig 1
Open the bonnet. 3
Disconnect the HT iead from the ignition coil.
Switch on the ignition and cran the engine for
five seconds.
witch off the ignition.
econnect the fuel terminal and refit the luggage
compartment trim.
Remove the battery cover, and disconnect the battery.
Reiease the toggle clips Fig 2) and remove the air
cleaner cover.
Removethe air cleaner element (2 Fig 2).
Remove the air cleaner backplate securing bolts (3 Fig

Remove the backplate from the throttle housing,

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with overrun valve hose

Remove and discard the overrun valve hose and air
cleaner gasket
filter bracket from the manifold ram

fuel pipes from the overrun valves

{retrieve the spacer from the LH valve)
Disconnect the manifold pressure hose from the
manifold and ‘T‘ piece
Disconnect the fuel cross-over pipe from fuel rail
Disconnect the terminals from the kickdown switch

cable from the throttle pedestal

rod from the the bell-crank.

Disconnect the vacuum hoses from the throttle
housing.
Disconnect the rubber elbow from the air balance pipe.
Reiease the harness to fuel rail securing ciips.
Disconnect the terminals from the fuel injectors (Fig 4)
and cold injector Fig 1 page
the harness earth strap from the manifold
ram tube.
Disconnect the brake vacuum hose from the non-r
valve.
Disconnect the vacuum hose from the manifold
stub pipe.
the valve vacuum hose from the
manifold stub pipe (FEDERAL ONLY).
Disconnect the automatic transmission vacuum hose
from the connecting
emove the throttle
ernove the twelve manifold securing nuts and
washers.
Disconnect the a Remove and discard the
rings FEDERAL 0
Disconnect the fuel cross-over pipe from the fuei rail.

12-14
ONLY).
Remove the six manifold stud

plugs to the inlet ports.

securing bolt Fig

Slacken off, but do not remove, the silencer union to
compressor securing
Withdraw the union, discard the sealing ring, and fit
blanking plugs to the union and
Remove the cam cover securina nuts. bolts and
washers Fig 3)
Remove the cam cover the gasket arid half
Fig 1
e radial edge of a new half moon
seal (Fig 4). Fit the seal to the cam carrier.
Fit the replacement cam cover
Fit and torque tighten the secu
Refit the siiencer union to the
sealing ring.
Fit and tighten the silencer to securing
bolt.
Remove blanki
Refit the induction
Refit the manifold s
Refit the EGR valv
the fuel cross-over pi
Refit the air raii, using new
Fit and torque tighten the ts and
washers.
Fit the throttle return spring,
Reconnect the automatic vacuum pi
Reconnect the valve vacuum hose the

Reconnect the heater valve hose

Reconnect the brake vacuum hose to the non-return
valve
Refit the harness earth strap
Reconnect the fuel and cold start injector terminals
Secure the harness to the fuel rail, using new plastic

Reconnect ?heair balance pipe

Reconnect the vacuum hoses t o the throttle housing
Fit the throttle rod to the
Refit the throttle to the throttle

terminals (R

Reconnect the fuel cross pipe to the fuel rail

Reconnect the manifold pressure hose to the manifold
and ‘T’ piece
Reconnect the fuel to the valves ensurina

82 30 06 and 3

Close the

12-15
 ENGINE 5.3

DATA
n
TORQUE FIGURES

Cam cover I I Nm
manifold to cylinder head (nuts) 23-27Nm
lnlet manifold to cylinder head (bolts)23-27Nm
EGR valve to throttle housing 9.5-
Elbow to inlet manifold
clips
Silencer to compressor union

SPANNER SIZES

6 " AF

Half moon seal

CAMSHAFTS
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RENEW 12.13.01

Removethe LH camshaft cover

Remove the camshaft cover
NOTE: Camshafts may be renewed individually.
Remove the rubber grommet from the front of the
timing cover.
Insert Service Tool 5 0 (Release Tool) through the
timing cover (1 Fig and release the locking catch on
the timing chain tensioner.
Fit Service Tool JD 50 (Chain Tension Retainer), and
retract the timing chain tensioner until the locking catch
is engaged (2 Fig 1). Fig
Remove Service Tools JD 50.
Rotate the engine to the cam removal position until
Timing Gauge C 3993 can be inserted into the recess
in the LH camshaft (Fig 2).
Note the t w o uppermost camshaft sprocket retaining
bolts. Remove Timing Gauge C 3993.
Rotate the engine until the two LOWER
sprocket retaining bolts become accessible.
Push back the lock tabs and remove the t w o retaining
bolts.
Rotate the engine to the camshaft removal position
and refit Timino 3993.
Remove the t w o camshaft sprocket bolts
and fit Service Tool JD 40 (1 Fig 3).
CAUTION: DO NOT ROTATE THE ENGINE WHILE THE
CAMSHAFT IS DISCONNECTED.

Gradually slacken off each camshaft cap securing nut Fig 3

(1 Fig 1 page 17) turns a t a time until the valve
springs are fully relaxed.
Note the cap to carrier relationship.
Remove the and lift off the bearing caps
(2 Fig 1 page
Remove the LH camshaft (3 Fig 1 page 17).
Clean all components thoroughly. Examine all
component parts for wear and damage.
Replace worn or damaged components as necessary.

12-16
 ENGINE 5.3

Ensure that all are not obstructed.

Lubricate the camshaft journals with clean engine oil.
Fit the replacement camshaft to the camshaft carrier,
using C 3993 to position the camshaft correctly (Fig

Fit the bearing caps, washers and securing nuts.

Progressively tighten the securing nuts to the correct
torque (see DATA), working from the centre
outwards.
Check that Timing Gauge C 3993 is in position.
Engage the camshaft sprocket to the camshaft, fit and
tighten one retaining bolt.
Remove Service Tool JD 40.
Remove Service Tool C 3993.
Rotate the engine and fit the remaining sprocket
retaining bolts. Lock over the tabs.
Repeat the procedurefor the camshaft.
Fit Service Tool JD 50 (Chain Tension Retainer) and
raise the timing chain tensioner slightly.
Insert Service Tool JD 50 (Release Tool) through the
timing cover. Release the locking catch and allow the
tensioner to expand.
Remove both Service Tools. Refit the rubber grommet
to the front of the timing cover. Fig 1
Adjust the valve clearances 12.29.48.
Refit the cam covers and induction manifolds.
Evacuate and charge the air conditioning system
82.30.06 and
Refit the air cleaner. Reconnect the battery.
Close the bonnet.

DATA
Valve clearances:
Inlet
Exhaust

SERVICE TOOLS

C 3993 Timing Gauge

JD 40 Camshaft Retainer
JD 50 Chain Tension Tool

TORQUE FIGURES

Bearing caps to carrier 1 I

Camshaft sprocket to camshaft 23-27Nm
Camshaft cover 1 1
EGR valve to throttle housing 9.5-
Elbow to inlet manifold
Hose clips
Inlet manifold to cylinder head (nuts)
Inlet manifold to cylinder head (bolts)
Silencer compressor union

SPANNER SIZES
Fig 2
AF

7 AF

Half moon seal

12-17
 www.JagDocs.com

Fi
Fig 2
Remove the camshaft covers 1 (LH) and
12.29.44
Rotate the engine as necessary and measure the valve
clearances between the heel of the camshaft and the
cam followers (2 Fig 1
Make a note of each reading.
The correct clearance is:

INLET: 0 . 0 1 2-0.01
0.01

Should the clearances be incorrect,

follows:
Remove the rubber grommet from the front of the
timing cover.
Service Tool 5 0 (Release Tool) through the
timing cover ( 1 Fig and release t e locking on
the timing chain tensioner. 1
Fit Service Tool 5 0 (Chain Tension
retract the timing chain tensioner
locking catch is engaged.
Remove Service Tools JD 50.
Rotate the engine to the
until Timing Gauge 39
recess in the camshaft
Note the two uppermost camshaft sprocket retaining

Remove Timing Gauge

Rotate the engine until
sprocket retaining become accessible.
Push back the lock tabs and remove the two retaining

otate the engine to the camshaft removal position

and refit Timing Gauge C 3993.
Remove the remaini two camshaft sprocket

DO NOT ROTATE T INE

Gradually slacken off each camshaft cap securing nut

Fig 1 page 20) two turns at a time until the valve
springs are fully relaxed.
ote the cap to carrier relationship.
/washers and off the bearing caps

mshaft (3 Fig 1 page 20).

Remove the cam followers (3 Fig
Remove each shim (5 Fig in turn, check the size wit
a and note the reading.
Caiculate the size of him required the

There are shims available, each

b y a letter of the alphabet, starting at
increasing in 0.001in stages to 0.1
W h e n the correct shim sizes have been
shims and cam followers to the cam carrier.
Lubricate the camshaft journals with clean engine
the camshaft to the camshaft carrier,
to position the camshaft correctly,
 ENGINE 5.3
2
Fit the bearing caps, washers and securing nuts.
Progressively tighten the securing nuts to the correct
torque (see DATA), working from the centre
outwards.
the valve clearances. Repeat the adjustment
procedure if necessary.
Check that Timing Gauge C 3993 is in position.
Engage the camshaft sprocket to the camshaft, fit and
tighten one retaining bolt.
Remove Service Tool JD 40.
Remove Service Tool 3993.
Rotate the engine and fit the remaining sprocket
retaining bolts. Lock over the tabs.
Repeat valve clearance adjustment procedure for
the camshaft.
Fit Service Tool JD 50 (Chain Tension Retainer) and
raise the timing chain tensioner slightly.
Insert Service Tool JD 50 (Release Tool) through the 2 ,/’ J.2

timing cover. Release the locking catch and allow the Fig 1
tensioner to expand.
Remove both Service Tools. Refit the rubber grommet
to the front of the timing cover.
Refit the camshaft covers using a new gasket and half
moon seal (2 Fig Apply sealant to the radial edge of
a new half moon seal (Fig 3). Fit the seal to the cam
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carrier.
Fit and tighten the securing (1 Fig 2 ) Refit
the induction manifolds.
Evacuate and charge the air conditioning system
82.30.06 and 82.30.08.
Refit the air cleaner. Reconnect the battery.
Close the bonnet

DATA
Valve clearances:
Inlet
Exhaust 0.0 12-0.0 14in
Fig 2
EXCESSIVE CLEARANCE INCHES

Size of existing shim 0.100

Plus the actual clearance noted
0.219

Less the specified valve

clearance 0.013
= required shim size 0.106

INSUFFICIENT CLEARANCE INCHES

Size of existing shim 0.107

Plus the actual clearance noted 0.0 10
0.1 17

Less the specified valve

clearance 0.013
= required shim size 0.104 Fig 3

12-20
 ENGINE 5.3

DATA

Letter Thickness

A 0.085 in
B 0.086 in
in
D in
E in
F in
G in
H 0.092 in
0.093 in
0.094 in
K 0.095 in
L 0.096 in
M 0.097 in
in
0 0.099 in
in
in
0.102 in
S 0.103
T 0.104 in
U 0.105 in
in
W in
X in
Y in
Z 0.1 in

SERVICE TOOLS

C 3993 Timing Gauge

Camshaft Sprocket Retainer
JD 50 Timing Chain TensionRetainer and Release Tool

TORQUE FIGURES

Bearing caps to carrier 1 1-

Camshaft sprocket to camshaft
Camshaft cover 1Nm
EGR valve to throttle housing 9.5-
Elbow to inlet manifold
Hose clips
Inlet manifold to cylinder head (nuts)
Inlet manifold to cylinder head (bolts)
Silencer to compressor union 34Nm

SPANNER SIZES

16" A F

AF

Half moon seals

1
 ENGINE 5.3

CYLINDER HEAD GASKET- LEFT HAND

RENEW 12.29.02

Remove the left hand camshaft cover

Remove the right hand camshaft cover
Disconnect the thermostat housing to cross-over pipe
hose.
Remove the bolts securing the thermostat housing,
auxiliary air valve and lifting eyes to the cylinder head.
Reposition the housing clear of the cylinder head.
Remove and discard the gaskets.
Remove unit
Rotate the engine and fit Timing Gauge C 3993 to the
right hand camshaft recess (Fig 1).
Remove the rubber grommet from the front of the
timing cover.
Service Tool JD 50 (Release Tool) through the
timing cover (1 Fig 2). and release the locking catch on
the timing chain tensioner.
Fit Service Tool JD 50 (Chain Tension Retainer), and
retract the timing chain tensioner (2 Fig 2) until the
locking catch is engaged.
Remove Service Tools JD 50.
Remove Timing Gauge
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Note the t w o uppermost camshaft sprocket retaining

bolts.
Rotate the engine until the t w o LOWER camshaft
sprocket retaining bolts become accessible.
Push back the lock tabs and remove the two retaining
bolts.
Rotate the engine to the camshaft removal position
and refit Timing Gauge C 3993.
Remove the remaining t w o camshaft sprocket bolts
and fit Service Tool JD 40 (1 Fig 3).

CAUTION: DO NOT ROTATE THE ENGINE WHILE THE

CAMSHAFT IS DISCONNECTED.

Jack up the vehicle and support with axle stands.

Remove the steering rack gaiter heat shield (1 Fig 4).
Remove the front heat shield.
Remove the LH exhaust down pipe heat shield.
Disconnect the LH exhaust down pipe from the
manifold. Discard the sealing rings.
Remove the LH exhaust manifold heat shield (2 Fig 1 Fig 3
Disconnect the EGR pipe (FEDERALONLY)
Remove the axle stands and lower the vehicle
Remove the gearbox dipstick tube clamp (1 Fig 1 page
23)) (AUTO ONLY)
Re-position the tube away from the engine (AUTO
ONLY)
Disconnect the fuel hoses from the cooler
Fit blanking plugs to all disturbed connections
Disconnect the camshaft feed pipe assembly (1 Fig
2 page 23) Discard the sealing washers
NOTE Place cloths or similar below the working area
to catch any leaking oil
Remove the three cylinder head t o timing cover
securing nuts and washers
Progressively slacken off the cylinder head nuts,
commencing a t the outer edges and working towards
the centre of the head

12-22
 IN

Remove the securing nuts and washers and remove

the cylinder head assembly
NOTE Always support the cylinder heads on blocks of
wood This will prevent damage to the valves which,
when open, protrude below the cylinder head face
CAUTION Do not remove Timing Gauge 3993 from
the camshaft
CAUTION If for any reason engine rotation becomes
necessary (cylinder bore examination, do not
rotate the engine until Service Tool 41 Retaining
Brackets have been fitted to the cylinder liners Fig
Clean all components thoroughly Examine all
parts for wear and damage
Replace worn or damaged components as necessary
Ensure that the cylinder head and block mating faces
are clean, and all galleries are not obstructed
Fit a new gasket to the cylinder block, ensuring that the
side marked ‘TOP’ is uppermost
CAUTION Do not use any grease or
compound on the cylinder head gasket
Fit the cylinder head
Fit the cylinder head securing nuts and washers
Tighten the cylinder head t o block securing nuts in the
correct sequence (Fig 3) to the torque figures given in
DATA
Tighten the cylinder head to cover securing nuts
083
4 Fig 3) to the torque in
Remove Service Tool JD 40 Fig 4) and check the 2
alignment of the retaining bolt
If the camshaft and sprocket holes are
alignment, remove the coupling to sprocket retaining
circlip Fig 4), and disengage the coupling from the
splines. at the same time pressing the sprocket on to
the camshaft shoulder
Rotate the coupling until alignment IS obtained 14
Engage the splines, and fit t w o securing bolts using a
new tab washer (3 Fig 4)
Lock over the tabs and refit the retaining circlip
Remove Timing Gauge C 3993 (4 Fig
Rotate the enqine until the remaininq sprocket securinq
can be fitted. Fig 3
Tighten the bolts and lock overthetabs.
Refit the camshaft oil feed pipe assembly, using new
sealing washers. Refit the amplifier unit.
Remove the blanking piugs and reconnect the fuel
hoses to the cooler.
Refit the gearbox dipstick tube (AUTO ONLY).
Refit the rear exhaust manifold and heat shield.
Jack up the vehicle and support with axle stands.
Refit the EGR pipe (FEDERALONLY).
Refit the exhaust down pipe, using new sealing rings.
Refit the heat shield.
Refit the front heat shield.
Refit the steering rack gaiter heat shield.
Remove the axle stands and lower the vehicle.
Fit Service Tool JD 50 (Chain Tension Retainer) and
raise the timing chain tensioner slightly.
Insert Service Tool JD 50 (Release Tool) through the
timing cover. Release the locking catch and allow the
tensioner t o expand.

Fig 4

12-23
 Remove both Service Refit the rubber grommet
to the front of the timing cover.
Adjust the valve clearances
Refit the assembly. Ensure that the paint
marks align (Fig 1).
Refit the thermostat valve assembly, using
new gaskets.
Reconnect the cross-over pipe hose to the thermostat
housing.
Refit the camshaft covers.
Refit the induction manifolds.
Evacuate and charge the air conditioning system
82.30.06 and 82.30.08.
Refit the air cleaner. Reconnect the battery.
up the engine oil (Fig 2).
Check the ignition timing
Carry out EGR emission test 17.00.00 (FEDERAL
ONLY).
Close the bonnet.

DATA
Valve clearances:
Inlet 0.01
Exhaust 0.0 12-0.0
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SERVICE TOOLS

3993 Timing Gauge

J D 4 0 Camshaft Sprocket Retainer Fig 1
JD 4 Cylinder Liner Retaining Brackets
JD 50 Chain Tension Retainer and Release Tool

TORQUE FIGURES

Banjo connector bolts 14Nm

Bearing caps to carrier 1 1 -
Camshaft sprocket to camshaft 23-27Nm
Camshaft cover 1 1Nm
Cylinder head to block (9/ 36Nm
Cylinder head t o block 70Nm
EGR valve to throttle housing 9.5-
Elbow to inlet manifold
Exhaust manifold to cylinder head 23-27Nm
to water pump 23-27Nm
Exhaust downpipe to manifold 30-35Nm
Heat shield to manifold 23-27Nm
Hose clips
lnlet manifold to cylinder head (nuts)23-27Nm
Inlet manifold to cylinder head (bolts) 23-27Nm
Silencer to compressor union 34Nm
Thermostat housing to cylinder head 23-27Nm

SPANNER SIZES

F
Fig 2
16" A F

Half moon seal

Exhaust down pipe 5696

12-24
 ENGINE 5.3

CYLINDER HEAD GASKET - RIGHT

HAND
RENEW

Remove the right hand camshaft cover

Remove the unit 26.25.2 1.
Disconnect the thermostat housing to cross-over pipe
hose.
Remove the bolts securing the thermostat housing,
auxiliary air valve and lifting eyes to the cylinder head.
Re-position the housing clear of the cylinder head.
Remove and discard the gaskets.
Slacken off the air pulley adjusting bolt
lock nuts.
582
Remove the adjusting bolt bracket from the cylinder
head (2 Fig Fig 1
Remove the compressor securing bolts, disengage the
drive belt (1 Fig 1) from the pulley, and re-position the
compressor (3 Fig 1) away from the working area
CARS ONLY).
Rotate the engine and fit Timing Gauge C 3993 to the
right hand camshaft recess (Fig 2).
Remove the rubber grommet from the front of the
timing cover.
Insert Service Tool JD 50 (Release Tool) through the
timing cover (1 Fig 3), and release the locking catch on
the timing chain tensioner.
Fit Service Tool JD 50 (Chain Tension Retainer), and
retract the timing chain tensioner (2 Fig 3) until the
locking catch is engaged.
Remove Service Tools JD 50.
Remove Timing Gauge C 3993.
Note the t w o uppermost camshaft sprocket retaining
bolts.
Rotate the engine until the t w o LOWER
sprocket retaining bolts become accessible.
Push back the lock tabs and remove the t w o retaining
bolts.
Rotate the engine t o the camshaft removal position
and refit Timing Gauge C 3993.
Remove the remaining t w o camshaft sprocket bolts
and fit Service Tool JD 4 0 (1 Fig 4).
CAUTION: DO NOT ROTATE THE ENGINE WHILE THE
CAMSHAFT IS DISCONNECTED.
Jack up the vehicle and support with axle stands.
Remove the exhaust down pipe heat shield (3 Fig 1
page 26).
Disconnect the exhaust down pipe from the
manifold. Discard the sealing rings.
Remove the exhaust manifold heat shield (2 Fig 1
page 26).
Disconnect the EGR pipe (WHERE FITTED).
Remove the axle stands and lower the vehicle.
Disconnect the camshaft oil feed pipe assembly ( 1 Fig
2 page 26). Discard the sealing washers.
NOTE: Place cloths or similar below the working area
to catch any leaking oil.
Remove the three cylinder head to timing cover
securing nuts and washers. Re-position the cable clips
away from the studs.
Progressively slacken off the cylinder head nuts,
commencing at the outer edges and working towards
the centre of the head.
Remove the securing nuts and washers and remove
the cylinder head assembly.
12-25
 NOTE Always support the cylinder heads on blocks of
wood This prevent damage to the valves which,
when open, protrude below the cylinder head face

CAUTION Do not Timing Gauge 3993 from

the camshaft

CAUTION If for any reason engine rotation becomes

necessary bore examination, etc), do not
rotate the engine until Service Tool 41 Retaining
Brackets have been fitted to the cylinder liners

Clean all components thoroughly Examine all

component parts for wear and damage
Replace worn or damaged components as necessary
Ensure that the cylinder head and block faces
are clean, and all galleries are not obstructed.
Fit a new gasket to the cylinder block, ensuring that the
side marked 'TOP' is uppermost. Fig
CAUTION: Do not use any grease or jointing
compound on the cylinder head gasket.

Fit the cylinder head.

Fit the cylinder head securing nuts and washers.
Tighten the cylinder head to block securing nuts in the
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correct sequence (Fig 3) to the torque figures given in

DATA.
Tighten the cylinder head to timing cover securing nuts
(14 Fig 3) to the torque figures given in DATA.
Remove Service Tool JD 40 Fig 4) and check the
alignment of the sprocket retaining holes.
If the and sprocket holes are not in
alignment, remove the coupling to sprocket retaining
Fig 4), and disengage the coupling from the ,112
splines, at the same time pressing the sprocket on to Fig 2
the shoulder.
Rotate the coupling until alignment is obtained.
Engage the splines, and fit t w o securing bolts using a
new tab washer (3 Fiq 4).
Lock over the tabs refit the circlip.
Remove Timing Gauge 3993 (4 Fig 4). 14
Rotate the engine until the remaining sprocket securing
washer can be fitted.
Tighten the bolts and lock over the tabs.
Refit the camshaft oil feed pipe assembly, using new
sealing washers.
Refit the rear exhaust manifold and heat shield. Fig 3
Refit the starter motor and heat shield.
Jack up the vehicle and support with axle stands.
Refit the EGR pipe (FEDERALONLY).
Refit the exhaust down pipe, using new sealing rings.
Refit the heat shield.
Remove the axle stands and lower the vehicle.
Fit Service Tool JD 50 (Chain Tension Retainer) and
raise the timing chain tensioner
Insert Service Tool (Release Tool) through the
timing cover. Release the locking catch and allow the
tensioner to expand.
Remove both Service Tools. Refit the rubber grommet
t o the front of the timing cover.
Refit the compressor and drive belt CARS
ONLY).
Refit the air pulley adjusting bolt
bracket. Adjust the pulley and tighten the locknuts.

Fig 4
12-26
 ENGINE 5.3

Adjust the valve clearances 12.29.48.

Refit the assembly. Refit the fan/
torquatrol assembly. Ensure that the paint marks align
(Fig 1).
Refit the thermostat valve assembly, using
new gaskets.
Reconnect the cross-over pipe hose to the thermostat
housing.
Refit the camshaft covers.
Refit the induction manifolds.
Evacuate and charge the air conditioning system
82.30.06 and
Refit the air cleaner. Reconnect the battery.
up the engine oil (Fig 2).
Check the ignition timing
Carry out EGR emission test 17.00.00 (WHERE
APP CAB LE)

DATA
Valve clearances:

Exhaust

SERVICE TOOLS

C 3993 Timing Gauge

JD 40 Camshaft Sprocket Retainer
JD 41 Cylinder Liner Retaining Brackets Fig 1
JD 50 Timing Chain Retainer and Release Tool

TORQUE FIGURES

Air pump 20-27Nm

Banjo connector bolts 12- 14Nm
Bearing caps to carrier 1 I -
Camshaft sprocket to camshaft 23-27Nm
Camshaft cover I 1Nm
Cylinder head to block 16"AF) 36Nm
Cylinder head to block
EGR valve to housing 9.5-
Elbow to inlet manifold
Exhaust manifold to cylinder
to water pump 23-27Nm
Exhaust downpipe to manifold 30-35Nm
Heat shield to manifold 23-27Nm
Hose clips
Inlet manifold to cylinder head (nuts)23-27Nm
Inlet manifold to cylinder head (bolts)23-27Nm
Silencer to compressor union 34Nm Fig 2
Starter motor bolts 32-39Nm
Thermostathousing to cylinder

SPANNER SIZES

AF
AF
AF

moon
Exhaust down pipe Tivoli Kay Adhesives 5696

12-27
 ENGINE 5.

CYLINDER HEAD GASKET- ENGINE SET

RENEW 12.29.01
Remove the left hand camshaft cover
Remove the right hand camshaft cover
Remove the unit 26.25.2 1.
Disconnect the thermostat housing to cross-over pipe
hose.
Remove the bolts securing the thermostat housing,
auxiliary air valve and lifting eyes to the cylinder head.
Re-position the housing clear of the cylinder head.
Remove and discard the gaskets.
Slacken off the air pulley adjusting bolt
lock nuts.
Remove the adjusting bolt bracket from the cylinder
head (2 Fig 1).
- - . $ 582

Fig I
Remove the compressor securing bolts, disengage the
drive belt Fig from the pulley, and re-position the
compressor Fig 1) away from the working area
CARS ONLY).
Rotate the engine and fit Timing Gauge C 3993 to the
right hand camshaft recess (Fig 2).
Remove the rubber grommet from the front of the
timing cover.
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Service Tool JD 50 (Release Tool) through the

timing cover (1 Fig 3), and release the locking catch on
the timing chain tensioner.
Fit Service Tool JD 50 (Chain Tension Retainer), and
retract the timing chain tensioner (2 Fig 3) until the
locking catch is engaged.
Remove Service Tools JD 50.
Remove Timing Gauge C 3993.
Note the t w o uppermost sprocket retaining bolts on
both camshafts.
Rotate the engine until the t w o LOWER sprocket
retaining bolts become accessible on both camshafts.
Push back the lock tabs and remove the four
accessible retaining bolts.
Rotate the engine to the camshaft removal position
and refit Timing Gauge C 3993 t o the camshaft.
Remove the remaining t w o camshaft sprocket
bolts and fit Service Toot JD 40 (1 Fig 4).
Remove the remaining two camshaft sprocket
bolts and fit Service Tool JD 40 (1 Fig 4).
CAUTION: DO NOT ROTATE THE ENGINE WHILE THE
CAMSHAFT IS DISCONNECTED.

Jack up the vehicle and support with axle stands.

Remove LH and (3 Fig 1 page 29) exhaust down
pipe heat shields.
Disconnect LH and exhaust down pipes. Discard
the sealing rings. Fig 3
Remove LH (2 Fig 2 page 29) and (2 Fig 1 page 29)
exhaust manifold heat shields.
Disconnect the EGR pipe [WHERE FITTED),
Remove the axle stands and lower the vehicle.
Remove the gearbox dipstick tube clamp (1 Fig 2 page
29) (AUTO ONLY).
Re-position the tube away from the engine (AUTO
ONLY)
Disconnect the fuel hoses from the cooler
Fit blanking plugs t o all disturbed connections
Disconnect the camshaft oil feed pipe assembly Fig
3 page 29)
Fig 4

12-28
 ENGINE 5.3

Discard the sealing washers

NOTE Place cloths or similar below the working area
to catch any leaking oil

Remove three LH cylinder cover

securing nuts and washers. Re-position the cable clips
away from the studs
Progressively off the LH cylinder head nuts,
commencing a t the outer edges and working towards
the centre of the head
Remove the securing nuts and washers and remove
the LH cylinder head assembly
Immediately the cylinder head has been removed,
Service Tool JD 41 Cylinder Liner Brackets must be
fitted t o the engine (Fig 4) Failure t o carry out this
operation will result in the Hylornar sea! being broken,
causing water leakage into the sump
Repeat the procedure to the cylinder head
Fit Service Tool JD 41 Brackets
NOTE Always support the cylinder on blocks of
wood This will prevent damage to valves which,
when open, protrude below the cylinder head face

Clean all components thoroughly Examine all

component parts for wear and damage
Replace worn or damaged components as
Ensure that the cylinder heads and block mating face
are clean, and all galleries are not obstructed
Fit a new gasket to the LH cylinder ensuring that
the side marked 'TOP' is uppermost Fig 2
CAUTION Do not use any grease or
compound on the cylinder head gasket

Fit the LH cylinder head

Fit the cylinder head securing nuts and washers
Tighten the cylinder head t o block securing nuts in the
correct sequence (Fig 1 page 30) to the torque figures
given in DATA
Tighten the cylinder head to timing cover securing nuts
(14 Fig 1 page 30)to the torque figures given in DATA
Repeat the procedure to refit the cylinder head
Fit Timing Gauge C 3993 to the camshaft
Remove Service Tool JD 40 (2 Fig 2 page 30) from the
LH camshaft sprocket and check the alignment of the
sprocket retaining bolt holes 283
If the camshaft and sprocket holes are not in Fig 3
alignment, remove the coupling to sprocket retaining
circlip (1 Fig 2 page and disengage the coupling
from the splines, at the same time pressing the
sprocket on to the camshaft shoulder
Rotate the coupling alignment is obtained
Engage the splines, and fit two securing bolts using a
new tab washer (3 Fig 2 page 30)
Lock over the tabs and refit the retaining
Repeat the procedure for the camshaft sprocket
Remove Timing Gauge C 3993 (4 Fig 2 page 30)
Rotate the engine until the remaining sprocket securing
washers can be fitted
Tighten the bolts and lock over the tabs
Refit the camshaft oil feed pipe assembly, using new
sealing washers

12-29
 ENGINE 5.3

Refit the amplifier unit.

Remove the blanking plugs and reconnect the fuel
hoses to the cooler.
Refit the exhaust manifold heat shields. 14
Refit the gearbox dipstick tube (AUTO ONLY).
Jack up the vehicle and support with axle stands.
Refit the EGR pipe (WHERE FITTED).
Refit the exhaust down pipes, using new sealing rings
Refit the heat shields.
Refit the steering rack gaiter heat shield. Fig 1
Remove the axle stands and vehicle.
Service Tool JD 50 (Chain Tension Retainer) and
raise the timing chain tensioner slightly.
Insert Service Tool JD 50 (Release Tool) through the
timing cover. Release the locking catch and allow the
tensioner to expand.
Remove both Service Tools. Refit the rubber grommet
to the front of the timing cover.
Refit the compressor and drive belt CARS
ONLY).
Refit the air pulley adjusting bolt
bracket. Adjust the pulley and tighten the locknuts.
Adjust the valve clearances
Refit the assembly. Ensure that the paint
marks align (Fig 3).
www.JagDocs.com

Refit the thermostat valve assembly, using

new gaskets.
Reconnect the cross-over pipe hose t o the thermostat
housing.
Apply sealant to the radial edge of a new half moon
seal (Fig 4). Fit the seal to the carrier.
Fit the cam cover using a new gasket.
Fit and tighten the securing
Refit the induction manifolds.
Evacuate and charge the air conditioning system Fig 2
82.30.06 and
Refit the air cleaner.
Reconnect the battery.
up the engine oil (Fig 1 page
Check the ignition timing
Carry out EGR emission test 17.00.00 (WHERE
AP PLI CAB LEj .
Close the bonnet.

DATA
Valve clearances:
Inlet
Exhaust Fig 3

SERVICE TOOLS
C 3993 Timing Gauge
JD 40 Camshaft Sprocket Retainer
JD Liner Retaining Brackets
JD 50 Chain Tensioner Retainer and Release

TORQUE FIGURES

Air pump adjuster

Banjo connector bolts 7 2- 14Nm
caps to
Camshaft sprocket to camshaft 23-27Nm
Camshaft cover 7
Fig 4

12-30
 ENGINE 5.3

Cylinder to block 36Nm

Cylinder head block 70Nm
EGR valve to throttle housing 9.5-
Elbow to inlet manifold
Exhaust manifold to cylinder head23-27Nm
to waterpump 2 3 - 2 7 N m
Exhaust downpipe to manifold 3 0 - 3 5 N m
Heat shield to
Hose clips
manifold to cylinder head (nuts)2 3 - 2 7 N m
lnlet manifold to cylinder h 23-27Nm Fig 1
Silencer to compressor
Thermostat housing to cylinder head 2 3 - 2 7 N m

SPANNER SIZES

AF
16" AF
AF

0I B R CANTS
Half moon seal 702
Exhaust downpipe Kay Adhesives 5696
Fig 2

CYLINDER HEADS 1 2 3

OVERHAUL 12.29.21

Remove left and right hand cylinder heads 12.29.0 1.

Immediately each cylinder head has been removed,
Service Tool JD 41 Cylinder Liner Brackets must be
fitted t o the engine (Fig 2). Failure to carry out this
operation will result in the Hylomar seal being broken,
causing water leakage into the sump.
NOTE: Always support the cylinder heads on blocks of
wood. This will prevent damage to the valves which, Fig 3
when open, protrude below the cylinder head face.
Remove the spark plugs and exhaust manifolds from
the LH cylinder head.
Gradually slacken off each camshaft cap securing nut
(two turns at a time) until the valve springs are fully
relaxed.
Note the cap to carrier relationship.
Remove the (1 Fig 3) and lift off the
bearing caps (2 Fig 3).
Remove the LH (3 Fig 3).
Using a magnet, lift out the cam followers (Fig 4).
Remove the camshaft carrier.
Support the valves using wooden blocks.
Remove the valve springs, using Service Tool JD
6 1 18C and adaptor JD 6 1 18C-2 (Fig 1 page 32).
 ENGINE 5.3

Retrieve the collars (2 Fig 2), cotters (1 Fig 2), and

spring retaining plates (4 Fig 2).
Remove the valves (5 Fig noting the relationship
between valve and guide t o ensure correct pairing
during re-assembly.
Remove the seals from the inlet valve guides.
Clean all component parts.
Check for wear and burning of valves or seats.
Check the cylinder head face for distortion.
If distortion is evident, a maximum of 0.025
(0.010 in) may be removed by skimming the cylinder
head.
Taking care not to damage the inside surface of the
combustion chambers, remove all traces of carbon
from the inlet and exhaust ports. Fig 1
NOTE: When using scrapers or wire brushes for
removing carbon deposits, avoid scratching the valve
faces and seats. A soft wire brush is the most suitable
implement for this purpose.

Clean all carbon and other deposits from the valve

guides using a suitable valve guide brush.
Thoroughly wash the cylinder head to ensure that all
loose carbon is removed and dry the head with a high
pressure air line.
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Clean and polish each valve.

Examine the stems for straightness and wear, using a
suitable dial gauge and V-block arrangement (Fig 3).
Examine the valve faces for burns, pitting and
distortion.
Renew any valves that are excessively worn, bent, or
too badly pitted t o be salvaged by refacing.
NOTE: No attempt should be made to clean up a burnt
or badly pitted valve face by extensive 'grinding in' of
the valve to the seat.

Lightly lap the valves into the seats with a fine grinding
compound. The reseating operation should leave the
finished surfaces smooth. Excessive lapping will
groove the valve face resulting in a poor seat when the
engine is hot.

Fig 4 shows:
'A' Correctly seated
Undesirable condition
'C' Method of rectification.

To test the valves for concentricity with their seats,

coat the face of the valve with 'Engineers Blue' or
similar, and rotate the valve against the seat.
If the valve face is concentric with the valve stem, a
mark will be made all around the face. Should a mark
be made on only one side of the face, the face is not
concentric with the valve stem.
Clean the valve and again coat with 'Engineers Blue'
and rotate the valve against the seat.
Check that the valve guide is concentric with the valve
seat, if not, the seat must be recut.
Whenever valves are replaced, the seats must be recut
prior t o lapping of the valves.
Check valve guide wear by inserting a new valve into
the guide to be checked, lift it 3 from its
seat and rock it sideways. Movement of the valve
across its seat must not exceed 0.5 (0.020in) (A
Fig 1 page 33). Fig
 ENGINE 5.3
A
Should the movement exceed this tolerance, the valve
guide must be replaced, using Service Tool 18G 1432
to drift out the old guide (Fig 2). Ensure that the
relevant valve guide is selected prior to fitting (see
DATA).

DATA
Replacement guides are available in t w o sizes and have
identification grooves machined in the shank. Sizes are
as follows:

First 2 grooves 12.88 to

(0.507 to
diameter. Fig 1

Second 3 grooves 13.00 to

(0.5 12 to 0.5 1 1in)
diameter

When new guides are to be fitted they should always

be one size larger than the old guide.
Cylinder head bores will require reaming as follows:

Remove the old valve guide and ream the cylinder head
to the following dimensions:

First (2 grooves) + 0.0

+ Fig 2

Second (3 grooves) + 0.01 2mm

(0.5 +

Immerse the cylinder head in boiling water for 30

minutes.
Coat the guide with graphite grease, and, using Service
Tool 18G 1432, drift in the guide from the
side until the circlip is seated in the groove (Fig 3).
NOTE: To fit the guide correctly, the interference
should not be sufficient to cause the use of excessive
force.

NOTE: After fitting a valve guide, the valve seat must

be using Service Tool MS 6 2 1 (Fig4).

Examine the valve seat inserts for pitting or excess

wear. If renewal is necessary, proceed as follows:
Remove the inserts by machining, leaving
approximately 0.25 of metal which can
easily be removed by hand without damaging the
cylinder head.
Measure the diameter of the insert recess in the
cylinder head.
Grind down the outside diameter of the new insert to a
dimension 0.08 (0.003 in) larger than the insert
recess.
Heat the cylinder head for 30 minutes from cold to a
temperature of 150°C (300°F).
Fit the insert ensuring that it beds evenly in the recess.
Fig 4
 5.3

when the cylinder head has cooled using Service

Tool MS 6 2 1.

Correct valve seat angles are:

Exhaust I
44.1 degrees 44. degrees

NOTE: If new valve inserts have been fitted, the

clearance between valve stem and cam must be
checked; this should be 8.13 (0.320 in) plus the
valve clearance.

The dimension must be taken between the valve stem

and the back of the cam.
Should this dimension not be obtained, metal must be
,
2

ground from the valve seat of the insert. Fig 1

NOTE: Use only suitable grinding equipment.
Remove only very small amounts of metal from the
valve seat at one time before re-checking the
clearance.
Examine the cam followers for wear on the top face, ,

these should be perfectly flat.

Check for any sign of barrelling on the side faces (Fig
1). Replace all followers that are worn or suspect.
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Wash the valves, springs, collets, followers and air

dry.
After the valve springs have been thoroughly washed,
they must be examined for fatigue and distortion.
Test the valve springs either by comparison with the
figures given below, or by comparison with a new
Fig 2
valve spring (using a recommended valve spring
testing machine).

DATA
Valve spring wire
diameter:
Inner
Outer

diameter inner
outer
Total No. of coils 6 inner: 5 outer
Free length inner

outer
Rate Def inner Fig 3
Def outer
Helix Right hand

To test against a new valve spring, insert both valve

springs end t o end between the test equipment .
Apply a load to partly compress the springs and
measure their comparative lengths (Fig 2).
NOTE: 'A' is the old spring.
If the distance a t 'A' is smaller than the distance at
then ' A ' must be replaced.
Spring distortion is determined by positioning the
spring upright on a surface plate and checking the
squareness of each end with a set square (Fig 3).
All valve springs which have diminished in length
are not square must be discarded and
replacements fitted.

12-34
 ENGINE 5.3

Fit the valves into the guides and place the cylinder
head on wooden blocks.
Fit the valve spring seats, inlet valve guide oil seals,
springs and collars.
Compress the springs using Service Tool J 6 1 and
Adaptor J6 1 and insert the cotters.
Refit the cam carrier.
Refit the original shims in the valve collar recesses (1
Fig 1).
Ensure that the shims are seated correctly (not as
shown in Fig 2).
Fit the cam followers.
NOTE: If the cylinder head has been overhauled to the
extent of having the valve seats each shim
should beO.O1O in. smallerthan the original. I
Fig 1
Lubricate the camshaft and fit to the cam carrier
ensuring that it is fitted with the slot t o the top.
Fit the camshaft caps and torque tighten the securing
bolts in the sequence shown in Fig 3.
Measure the valve clearance between the heel of the
camshaft and the cam followers (Fig 4), turning the
camshaft as necessary to measure all the clearances.
The correct clearance should be:

INLET VALVES 0.012 -

EXHAUST VALVES 0.012

Make note of the actual clearances.

Should any of the clearances be incorrect, remove the
camshaft caps, the camshaft and the cam followers.
Remove all the shims requiring adjustment, check with
a micrometer the size of the existing shims and note
the reading. Calculate the size of the shim required,
following the examples below. Fig 2

EXCESSIVE CLEARANCE INCHES

1 3 5 7 6 4 2
Size of existing shim 0.100
Plus the actual clearance noted
0.1 19
Less the specified valve
clearance 0.013
= required shim size 0.106

INSUFFICIENT CLEARANCE INCHES

Size of existing shim 0.107

Plus the actual clearance noted
0.1 17

Less the specified valve

clearance 0.013
= required shim size 0.104

NOTE: A list of available shim sizes is given in DATA

Fig 4

12-35
 ENGINE 5.3

Fit the cam followers, refit the camshaft, the camshaft

caps and the valve clearances.
NOTE: A final check of the valve clearances should be
done when the cylinder head is fitted and torque
tightened to the cylinder block. 14
Clean the cylinder head thoroughly and check the
cylinder head and cylinder block for warping, bowing
or cracks. 15
Ensure that the cylinder heads and block mating faces 13 11 9 8 10 12
are clean, and all galleries are not obstructed.
Fig 1
Repeat the overhaul procedure for the cylinder
head.

Fit a new gasket to the LH cylinder block, ensuring that

the side marked 'TOP' is uppermost.
CAUTION: Do not use any grease or
compound on the cylinder head gasket.

Fit the LH cylinder head.

Fit the cylinder head securing nuts and washers.
Tighten the cylinder head t o block securing nuts in the
correct sequence (Fig 1) to the torque figures given in
DATA.
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Tighten the cylinder head to timing cover securing nuts

(14 Fig 1) to the torque figures given in DATA.
Repeat the procedure to refit the cylinder head.
Remove Service Tool JD 40 (2 Fig 2) from the LH
camshaft sprocket and check the alignment of the
sprocket retaining bolt holes.
If the camshaft and sprocket holes are not in
alignment, remove the coupling to sprocket retaining
circlip ( 1 Fig 2), and disengage the coupling from the
splines, at the same time pressing the sprocket on to
the camshaft shoulder. Fig 2
Rotate the coupling until alignment is obtained.
Engage the splines, and fit t w o securing bolts using a
new tab washer (3 Fig 2).
Lock over the tabs and refit the retaining circlip.
Repeat the procedure for the camshaft sprocket.
Remove Timing Gauge C 3993 (4 Fig 2).
Rotate the engine until the remaining sprocket securing
washers can be fitted.
Tighten the bolts and lock over the tabs.
Refit the camshaft oil feed pipe assembly Fig
using new sealing washers.
Refit the amplifier unit.
Remove the blanking plugs and reconnect the fuel
hoses to the cooler.
Refit the exhaust manifold heat shields.
Refit the gearbox dipstick tube (AUTO ONLY).
Jack up the vehicle and support with axle stands.
Refit the EGR pipe (FEDERALONLY).
Refit the exhaust down pipes, using new sealing rings.
Refit the heat shields.
Refit the steering rackgaiter heat shield. J12
Remove the axle stands and lower the vehicle.
Fit Service Tool JD 50 (Chain Tension Retainer) and
raise the timing chain tensioner slightly. Fig 3
Insert Service Tool JD 50 (Release Tool) through the
timing cover. Release the locking catch and allow the
tensioner to exoand.

12-36
Remove both Service Tools. Refit the rubber grommet
t o the front of the timing cover.
Refit the compressor and drive belt CARS
ONLY).
Refit the air pulley adjusting bolt
bracket. Adjust the pulley and the locknuts.
Adjust the valve clearances 12.29.48.
Refit the assembly. Ensure that the paint
marks align (Fig 1).
Refit the thermostat valve assembly, using
new gaskets.
Reconnect the cross-over pipe hose to the thermostat
housing.
Apply sealant to the radial edge of a new half moon
seal (Fig 2). Fit the seal to the carrier.
Fit the replacement cam cover using a new gasket.
Fit and torque tighten the securing
Refit the induction manifolds.
Evacuate and charge the air conditioning system
82.30.06 and 82.30.08.
Refit the air cleaner.
Reconnect the battery.
the oil
Check'the ignition
Carry out EGR test 17.00.00 [FEDERAL
ONLY).
Close the bonnet.
Fig 1
DATA
VALVE CLEARANCES:

Exhaust 0.012-0.0

SIZES

Letter Thickness

A in
B 0.086 in
C 0.087 in
D 0.088 in
E 0.089 in
F in
in \ \\ \ \
H 0.092 in Fig 2
0.093 in
J 0.094 in
K 0.095 in
0.096 in
M 0.097 in
N 0.098 in
in
P in
Q 0.101 in
R 0.102 in
S 0.103
T 0.104 in
U 0.105 in
V 0.106 in
W 0.107 in
0.108 in
Y Fig 3
Z 0.1

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 spring compressor
Valve spring compressor adaptor

valve rhrot
Elbow to inlet
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3.19 9 G
 1

Run the engine until it reaches its normal operating

temperature.
Stop the engine.
Open the bonnet.
Disconnect the sparking plug leads from the sparking
plugs.
sparking plugs.
Fit a compression test gauge No.1 plug hole

are numbered from the front,

radiator end, of the engine.
Turn the ignition to position 3 (start) and crank the
engine over with the motor for seconds.
NOTE: THE CRAN
BELOW 300 RPM,
WIDE OPEN.
Make a note of the test gauge reading (Fig
Remove the compression gauge and release the
pressure from the gauge.
Repeat the procedure for the remaining eleven Fig 1

Check the spark plug ga Refit the spark

Refit the plug leads.
Close the bonnet.

Pressure

Low

Firing order 1A 6 6A
(A = bank; E
from the front o f t

Sparking plug gap

TORQUE FIGURES

Sparking plug to cylinder head

 ENGINE 5.3

SPARKING PLUG INSERTS

FITTING 12.29.78

Remove the cvlinder head - 12.29.11

-
Immediately each cylinder head has been removed,
Service Tool JD 41 Cylinder Liner Brackets must be
fitted to the engine (Fig Failure to carry out this
operation will result in the Hylomar seal being broken,
causing water leakage into the sump.
NOTE: Always support the cylinder heads on blocks of
wood. This will prevent damage to the valves which, Fig 1
when open, protrude below the cylinder head face.
Remove the spark plugs and exhaust manifolds from
the cylinder head.
Gradually slacken off each cap securing nut
(two turns at a until the valve springs are fully 1 2 3
relaxed.
Note the cap to carrier relationship.
I
Remove the Fig 2) and lift off the
bearing caps (2 Fig 2).
Remove the camshaft (3 Fig 2).
Using a magnet, remove the cam followers (Fig 3).
Remove the camshaft carrier.
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Remove the valve springs, using Service Tool JD

6 1 18C and adaptor JD 6 1 18C-2 (Fig4).
Retrieve the collars (2 Fig 1 page cotters ( 1 Fig 1 Fig 2
page and spring retaining plates (4 Fig 1 page 41).
Remove the valves (5 Fig 1 page noting the
relationship between valve and guide to ensure correct
pairing during re-assembly.
Remove the seals from the inlet valve guides.
Referring to Fig 2 page 41: Bore out the stripped
thread to 19.05 (0.750 in) diameter and tap out to
16 UNF - 2B (Dimension 'A').
Counter bore to (Dimension 'B').
Dimension 'C' =
Dimension 'D' = -

Dimension 'E' =
Dimension 'F' =
Dimension 'G' = 1 1.81 -

Fit the screwed insert ensuring that it sits firmly at the Fig 3
bottom of the thread.
Drill and ream a 3.17 in) diameter hole
deep, between the side of the insert
and the head.
Drive in a locking pin and secure by peening the edge
of the insert and the locking pin.
Dimension 'H' = (Fig 3
Refit the valves. Refit the cylinder head.
Refit the cam covers.
Refit the induction manifolds.
Evacuate and charge the air conditioning system
82.30.06 and
Refit the air cleaner. Reconnect the battery.
up the engine oil.
Check the ignition timing
Carry out EGR emission test 17.00.00 (FEDERAL
ONLY).
Fig 4

12-40
 ENGINE 5.3

DATA
SERVICE TOOLS

C 3993 Timing Gauge

JD 40 Camshaft Sprocket Retainer
JD 4 1 Cylinder Liner Retaining Brackets
JD 50 Timing Chain Retainer and Release Tool
J 61 Valve spring compressor
J Valve spring compressor adaptor

TORQUE FIGURES

Air pump adjuster

Banjo connectorbolts Fig 1
Bearing caps to carrier
Camshaft sprocket to
Camshaft cover 1
Cylinderheadto block
Cylinder head to block
EGR valve to throttle housing 9.5-
Elbow to inletmanifold
Exhaust manifold to cylinder
to waterpump
Exhaust downpipe to manifold
Heat shield to
Hose clips
Inlet manifold to cylinder head (nuts)
Inlet manifold to cylinder head (bolts)
Silencer to compressor union 34Nm
Starter motor bolts 32-39Nm
Spark plugs (taper seat)
Thermostat housing to cylinder head

SPANNER SIZES

AF
AF
16" AF

KEY)

Half moon seal

Exhaust down pipe Kay Adhesives 5696

Fig 3
 Remove the assembly
Fit the assembly t o a suitable stand.
unit
Remove the camshaft covers
Disconnect the thermostat housing to cross-over pipe
hose.
Remove the bolts securing the thermostat housing,
auxiliary air valve and lifting eyes to the cylinder head.
Re-position the housing clear of the cylinder head.
Remove and discard the gaskets.
Slacken off the air pulley adjusting bolt
lock nuts.
Remove the adjusting bolt bracket from the cylinder
head.
Remove the compressor securing bolts, disengage the
drive belt from the pulley, and re-position the
compressor away from the working area
CARS ONLY).
Rotate the engine and fit Timing Gauge C 3993 to the
right hand camshaft recess (Fig 1).
Remove rubber grommet from the front of the
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timing cover.
Service Tool JD 50 (Release Tool) through the
timing cover, and release the locking catch on the
timing chain tensioner (1 Fig
Fit Service Tool JD 50 (Chain Tension Retainer), and
retract the timing chain tensioner (2 Fig 2) until the
locking catch is engaged.
Remove Service Tools JD 50.
Remove Timing Gauge C 3993.
Note the t w o uppermost sprocket retaining bolts on
both camshafts.
Rotate the engine until the t w o LOWER sprocket
retaining bolts become accessible on both camshafts.
Push back the lock tabs and remove the four
accessible retaining bolts.
Rotate the engine to the camshaft removal position
and refit Timing Gauge C 3993 to the camshaft.
Remove the remaining two LH camshaft sprocket
bolts and fit Service Tool JD 40 (1 Fig 3).
Remove the remaining t w o sprocket
bolts and fit Service Tool JD 40 Fig 3).
CAUTION: DO NOT ROTATE THE ENGINE WHILE THE
CAMSHAFT IS

Remove the gearbox dipstick tube clamp Fig 4).

(AUTO ONLY).
Re-position the tube away from the engine (AUTO
ONLY).
Disconnect the camshaft oil feed pipe assembly (Fig 1
page 43). Discard the sealing washers.
Remove the three LH head cover
securing nuts and washers. Re-position the cable clips
away from the studs.
Progressively slacken off the LH cylinder head nuts,
commencing at the outer edges and working towards ,
the centre of the head
Remove the securing nuts and washers and remove
the LH cylinder head assembly

Fig 4

12-42
 ENGINE 5.3

Immediately the cylinder head has been removed,

Service Tool JD 41 Cylinder Liner Brackets must be
fitted to the engine (Fig 2). Failure t o carry this
operation will result in the Hylomar seal being broken,
causing water leakage into the sump.
Repeat the procedure to remove the cylinder head.
Fit Service Tool JD 4 1 Cylinder Liner Brackets.
NOTE: Always support the cylinder heads on blocks of
wood. This will prevent damage t o the valves which,
when open, protrude below the cylinder head face.

Remove the sump plug and drain the into a suitable

container.
Remove the sump pan securing bolts (2 Fig Fig 1
remove the sump pan (1 Fig 3).
Remove the suction elbow (2 Fig 4). remove the
sandwich plate securing bolts (1 Fig 4), and remove
the plate, noting the different stud lengths.
Remove the alternator.
Remove the PAS pump.
Remove the emission control air pump pulley and
remove the air pump (FEDERALONLY).
Remove the air conditioning compressor and bracket
(AIRCONONLY).
Remove the water pump.
Remove the crankshaft cone and woodruff key.
Remove the alternator and air pump mounting bracket.
Remove the timing cover securing boits and serrated Fig 2
washers Fig 1 page noting the different bolt
lengths and dowel locations.
Remove the timing cover (2 Fig 1 page 44). Discard the
gasket (3 Fig page 44) and oil seal (4 Fig 1 page 44).

Clean all components thoroughly, and examine all

component parts for wear and damage. Replace worn
or damaged components as necessary.
Ensure mating faces are clean and grease-free.
Immerse the new oil seal in clean engine oil.
Press the oil seal into the timing cover.
Refit the timing cover to the engine, using a new
gasket. Ensure the oil seal is not damaged or distorted.
Fit and tighten the securing bolts.
Refit the air pump and aiternator mounting bracket.
Refit the crankshaft cone.
Refit the water pump.
Refit the air conditioning compressor and bracket Fig 3
(AIRCONONLY).
Refit the emission control air pump pulley and remove
the air pump (FEDERALONLY).
Refit the PAS pump.
Refit the alternator.
Refit the sandwich plate assembly.
Refit the sump pan.
Ensure that the cylinder heads and block mating faces
are clean, and a!! galleries are not obstructed.
Fit a new gasket to the LH cylinder block, ensuring that
the side marked 'TOP' is uppermost.
CAUTION: Do not use any grease or jointing
compound on the cylinder head gasket.

Fig 4

12-43
 ENGINE 5.3

Fit the LH cylinder head.

Fit the cylinder head securing nuts and washers.
Tighten the cylinder head t o block securing nuts in the
correct sequence (Fig 2) t o the torque figures given in
DATA.
Tighten the cylinder head t o timing cover securing nuts
(14 Fig 2) to the torque figures given in RATA.
Repeat the procedure to refit the cylinder head.

Fit Timing Gauge C 3993 (4 Fig 3) to the camshaft.

Remove Service Tool JD 40 (2 Fig 3) from the LH
camshaft sprocket and check the alignment of the
sprocket retaining bolt holes.
If the camshaft and sprocket holes are not in
alignment, remove the coupling to sprocket retaining
circlip (1 Fig and disengage the coupling from the
splines, at the same time pressing the sprocket on to
the shoulder. Fig 1
Rotate the coupling until alignment is obtained.
Engage the splines. and fit t w o securing bolts using a
new tab washer (3 Fig 3).
Lock over the tabs and refit the retaining circlip.
Repeat the procedure for the camshaft sprocket. 14
Remove Timing Gauge C 3993.
Rotate the engine until the remaining sprocket securing
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washers can be fitted.

Tighten the bolts and lock over the tabs.
Refit the camshaft oil feed pipe assembly Fig 4).
using new sealing washers. Fig 2
Refit the gearbox dipstick tube (AUTO ONLY).
Fit Service Tool JD 5 0 (Chain Tension Retainer) and
raise the timing chain tensioner slightly.
Service Tool JD 5 0 (Release Tool) through the
timing cover. Release the locking catch and allow the
tensioner to expand.
Remove both Service Tools. Refit the rubber grommet
the front of the timing cover.
Refit the compressor and drive belt CARS
ONLY).
Refit the air pulley adjusting bolt
bracket. Adjust the pulley and tighten the locknuts.
Adjust the valve clearances
Refit the assembly.
Refit the thermostat valve assembly, using
new gaskets.

Apply sealant to the radial edge of a new half moon

seal (Fig 1 page 45). Fit the seal to the carrier.
Fit the replacement cam cover using a new gasket.
Fit and torque tighten the securing
Refit the induction manifolds.
Refit the assembly.
Evacuate and charge the air conditioning system
82.30.06 and
Refit the air cleaner.
Reconnect the battery.
Refill the engine clean oil (Fig 2 page 45).
Refill the cooling system.
Check ?heignition timing
Carry out EGR emission test 17.00.00 (FEDERAL
ONLY).
Close the bonnet.

12-44
 ENGINE 5.3

Valve clearances:

MS Engine support Tool.

3993 Timing Gauge
J D 4 0 Camshaft Sprocket Retainer
JD41 Cylinder Liner Retaining Brackets
JD 5 0 Timing Chain Tensioner Retainer and Release
Tool

TORQUE FIGURES

Banjo connector bolts 72- I

Camshaft sprocket t o cams
Camshaft cover 1 Nm
Cylinder head t o block 1
Cylinder head t o block
EGR valve to housing 9.5- Fig 1
Elbow to inlet manifold
Engine mounting bracket t o crossmember 7 9-2
Engine mounting tie bolts 34-40Nm
Exhaust down pipe to manifold
to waterpump
Fuel pipe unions (5/ dia.)
Fuelpipeunions
unions
Heat shield to manifold 23-27Nm
Hose clips
lnlet manifold to cylinder head (nuts)23-27Nm
lnlet manifold t o cylinder head (bolts) 23-27Nm
Oil coolerpipes
to mounting bracket 50Nm
Rear engine mounting peg 34-40Nm
Rear engine mounting rubbers 36-43Nm
Rear engine mounting t o body 16 bolt) 7
Rear engine mounting t o body bolt)36-43Nm
Silencer to compressor union 34Nm
set screws 7 6-20Nm
Thermostat housing to cylinder head

SPANNER SIZES

6 AF
1/2 AF
16"AF
AF
I 16" AF

Fig 2
Half seal
Exhaust down pipe Kay Adhesives 5696
 Retainer to

Fig

tat valve assembly,

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e covers.

the air system

efit the air cleaner.

anjo

Fig 3
 ENGINE 5.3

DATA
TORQUE FIGURES

Engine mounting bracket to crossmember 19-24Nm

Engine mounting tie bolts 34-40Nm
Exhaust down pipe to manifold 30-35Nm
to waterpump 23-27Nm
Fuelpipe unions (5/
Fuelpipe unions 17-
Fuelpipe unions 27-33Nm
Heat shield to manifold 23-27Nm
Hose clips
lnlet manifold to cylinder head (nuts)23-27Nm
lnlet manifold to cylinder head (bolts)23-27Nm
Oil cooler pipes 54-60Nm
to mounting bracket 50Nm
Rear engine mounting peg 34-40Nm
Rear engine mounting rubbers 36-43Nm
Rear engine mounting to body (5/ 16 bolt) 7 9-24Nm
Rear engine mounting to body bolt) 36-43Nm
Silencer to compressor union 34Nm
Sump setscrews
Thermostat housing to cylinder head 23-27Nm Fig 1

SPANNER SIZES

AF
AF
16" AF
AF
1 16" AF

Half moon seal

Exhaust down pipe Tivoli Kay Adhesives 5696

TIMING CHAIN DAMPERS

RENEW 12.65.50

Remove the timing cover

Fit Service Tool JD 39 Sprocket Retainer to the
Fig 1).
Disconnect the timing chain from the camshaft and
jackshaft sprockets.
Withdraw the crankshaft sprocket and timing chain.
Remove the oil pump securing bolts and remove the oil
pump (1 Fig 2).
CAUTION: DO NOT ROTATE THE ENGINE WHILE THE
ARE DISCONNECTED.
Remove the timing chain hanger Fig 2
securing bolts.
Remove the sprocket hangers and dampers.
Examine all components for wear and damage.
Replace worn or damaged components as necessary.
Fit the replacement dampers and sprocket hangers to
the cylinder block. Fit the securing bolts, do not fully
tighten at this stage.
Note the position of JD 39 Sprocket Retainer Tool
relative to the jackshaft sprocket.

12-47
 ENGINE 5.3
2
Remove JD 39 Sprocket Retainer Tool.
Position Service Tool JD 38 Damper Setting Jig on to
thefrontof Fig
Fit the damper bolts (finger tight + 1 turn).
Position the sprocket hangers and camshaft dampers
so that they are in contact with the jig locating dowels

Fully tighten the sprocket damper

securing bolts.
Remove Service Tool JD 3 8 Damper Setting Jig.
Refit JD 39 Sprocket Retainer Tool.
Refit the oil pump. 2
Engage the crankshaft sprocket in the timing chain.
Fit the assembly to the camshaft and
jackshaft sprockets.
Remove Service Tool JD 39 Sprocket Retainer.
Refit the timing cover 12.65.01.
Refit the cylinder heads.
Adjust the valve clearances
Refit the assembly. Ensure that the paint
marks align (Fig 2).
Refit the thermostat valve assembly, using Fig 1
new gaskets. Refit the camshaft covers.
Refit the induction manifolds.
Refit the assembly.
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Evacuate and charge the air conditioning system

82.30.06 and 82.30.08.
Refit the air cleaner. Reconnect the battery. 6
Refill the engine with clean oil (Fig 3).
Refill the cooling system.
Check the ignition timing 86.35.29.
Carry out EGR emission test 17.00.00 (FEDERAL
ONLY).
Close the bonnet.

DATA
Valve clearances:

Exhaust

SERVICE TOOLS

538 Engine Support Tool.

3993 Timing Gauge
JD 38 Damper Setting Jig
JD 39 Jackshaft Retainer Tool
camshaft Sprocket Retainer
JD 4 1 Cylinder Liner Retaining Brackets
JD 50 Timing Chain Tensioner Retainer and Release
Tool 2

TORQUE FIGURES

Air
connectorbolts 72- 14Nm
Camshaft sprocket to camshaft 23-27Nm
Camshaft cover 1
head to block 36Nm
Cylinder head to block
EGR valve to throttle housing 9.5-
Elbow inlet manifold
Engine mountingbracket to crossmember
Engine mounting tie bolts
Exhaust downpipe to Fig 3
to waterpump
 ENGINE 5.3

DATA
TORQUE FIGURES

Heat shield to manifold 23-27Nm

Hose clips
Inlet manifold to cylinder head (nuts)23-27Nm
Inlet manifold to cylinder head (bolts)23-27Nm
to mounting bracket 50Nm
Rear engine mounting peg 34-40Nm
Rear engine mounting rubbers 36-43Nm
Rear engine mounting to body bolt) 79-24Nm
Rear engine mounting to body bolt) 36-43Nm
Silencer to compressor union 34Nm
Thermostat housing to cylinder head

SPANNER SIZES

AF

16"AF
Fig 1
BR ANTS

Half moon seal

Exhaust down pipe Kay Adhesives 5696

TIMING CHAIN
RENEW 12.65.28

Remove the timing cover 12.65.01.

Move the chain tensioner (2 Fig 1) clear of the locating
bracket and slide the tensioner off the dowel pin.
CAUTION: DO NOT ROTATE THE ENGINE WHILE THE
IS DISCONNECTED.
Examine all components for wear and damage.
Replace worn or damaged components as necessary.
Fit the new tensioner to the dowel pin.
Refit the timing cover Fig 2
Refit the cylinder heads.
Adjust the valve clearances
Refit the assembly.
Refit the thermostat valve assembly. using
new gaskets.
Apply sealant to the radial edge of a new half moon
seal (Fig 2). Fit the seal to the carrier.
Fit the replacement cam cover using a new gasket.
Fit and torque tighten the securing
Refit the induction manifolds.
Refit the assembly.
Evacuate and charge the air conditioning system
82.30.06 and
Refit the air cleaner.
Reconnect the battery.
Refill the engine with clean oil (Fig 3).
Refill the cooling system.
Check the ignition timing
Carry out EGR emission test 17.00.00 (FEDERAL
ONLY).
Close the bonnet. Fig 3

12-49
 www.JagDocs.com

Half

12-50
 INE

RENE 12.17.01

Remove the
Fit the assembly a suitable stand.
Remcve the cylinder heads 12.29.01
Fit JD 41 Cylinder Liner Brackets (Fig
NOTE: Always support the cylinder heads on blocks of
wood. This will prevent damage t o the valves which,
when open, protrude below the cylinder head face.

Remove the sump plug and drain the oil into a suitable 3
container
Remove the sump pan securing bolts (2 Fig
remove the sump pan ( I Fig 2)
Remove the suction elbow (2 Fig 3), remove the
sandwich plate securing bolts Fig 3), and remove
the plate, noting the different stud lengths
Rotate the crankshaft Numbers 1 and 5 journals
are outermost
Remove the securing nuts Fig bearing cap (2
4) and shell from one rod, noting the cap to
Connecting rod relationship
Remove any carbon deposits from the top of the
cylinder bore.
Push the connecting rod up the cylinder bore and Fig 2
withdraw the assembly Fig I page 52).
Remove the connecting rod bearing shell.
Repeat the procedure to remove the remaining 3
connecting assemblies.
Thoroughly clean all components and examine for
wear and damage. Replace worn or damaged
components as necessary.
Clean bearing surfaces and
Coat the piston rings, gudgeon pins and cylinder bore
with clean engine
Ensure that the piston ring gaps are correctly spaced
around the piston (Fig 2 page 52).

Compress the piston rings using Service Tool

55A (Fig 3 page 52).
Enter the rod assembly into the
cylinder bore, ensuring that 'FRONT' (stamped on the
piston) faces the front of engine.
Firmly, but without undue force, push the piston/
connecting rod assembly down the cylinder bore.
Coat the connecting rod bearing surface liberally with
clean engine oil.
Fit a new bearing shell half (2 Fig 4 page 52) into the
connecting rod, ensuring that the bearing shell tab is
correctly located in the connecting rod (1 Fig 4 page
52).
Coat the bearing shell with oil.
Pull the connecting rod down on to the crankshaft
journal.
Coat the connecting rod cap bearing surface liberally
with clean engine oil.
Fit a new bearing shell half (3 Fig 4 page 52) into the
connecting rod cap, ensuring that the bearing shell tab
is correctly located.
Coat the bearing shell wit
Fig 4

12-5 1
 ENGINE 5.3

F i t the connecting rod cap. Fit and torque tighten the

securing nuts.
Repeat the procedure t o refit the remaining connecting
assemblies.
Refit the sandwich plate.
Refit the sump.
Remove Service Tool JD 41 Cylinder Liner Brackets.
Refitthecylinder heads
Remove the engine from the engine stand.
Refit the gearbox, and refit t h e
assemblyto thevehicle 12.37.01.
Evacuate and charge the air conditioning system ,_- ,
82.30.06 and Fig I
Refit the air cleaner.
Reconnect the battery.
Refill t h e engine with clean oil.
Refill t h e cooling system.
Check the ignition
Carry out EGR emission test 17.00.00 (FEDERAL
ONLY).
Close the bonnet.

DATA
Valve clearances:
www.JagDocs.com

Inlet
Exhaust 0.0 12-0.014in

SERVICE TOOLS

535 Engine support Tool.

C 3993 Timing Gauge
J D 4 0 Camshaft Sprocket Retainer
JD 4 1 Cylinder Liner Retaining Brackets
JD 50 Timing Chain Tensioner Retainer and Release
Tool
18G 55A Piston Ring Compressor
TORQUE FIGURES

Air pump
Banjo connectorbolts 12-
Camshaft sprocket camshaft
Camshaft cover 1
036
Connecting rod cap nuts
Cylinderhead t o block 36Nm Fig3
Cylinder head t o block
EGR valve t o throttle housing 9.5-
Elbow inlet manifold
Engine mounting bracket to crossmember
Engine mounting tie bolts
Exhaust down pipe t o manifold 30-35Nm
t o waterpump
Fuelpipe unions
Fuelpipeunions dia.)
Fuelpipe unions 27-33Nm
Heat shield to
Hose clips
Inlet manifold to cylinder head (nuts)
Inlet manifold to cylinder head (bolts) 23-27Nm
Oil coolerpipes
t o mounting bracket
Rear engine mounting peg
Rear engine mounting rubbers
Fig 4
 5.

DATA
TORQUE FIGURES

Rear engine mounting to body bolt)

Rear engine mounting to body bolt) 36-43Nm
Silencer to compressor union
Sump set screws
Thermostat housing to cylinder

SPANNER SIZES
Fig 1

16 AF

3/4 AF

ITS

Half moon seal

Exhaust downpipe 5

'I
PISTON AND CONNE Fig 2
ENGINE SET
OVERHAUL

Remove the assembly

Fit the assembly to a suitable stand.
Remove thecylinder heads
Fit JD41 Cylinder Liner Brackets (Fig I ) .
NOTE: Always support the cylinder heads on blocks of
wood. This will prevent damage to the valves which,
when open, protrude below the cylinder head face.

Remove the sump plug and drain the oil into a suitable
container.
Remove the sump pan securing bolts (2 Fig
remove the sump pan (1 Fig 2).
Remove the suction elbow (2 Fig 3), remove the
sandwich plate securing bolts ( 1 Fig 3). and remove Fig 3
the Plate, noting the different stud lengths.
Rotate the crankshaft until Numbers-1 and 5 journals
are outermost.
Remove the securing nuts (1 Fig 4), bearing cap (2 Fig
4) and shell from one connecting rod, noting the cap to
connecting rod relationship.
Remove any carbon deposits from the top of the
cylinder bore.
Push the connecting rod up the cylinder bore and
withdraw the assembly Fig 1 page 54).
Remove the connecting rod bearing shell.
NOTE: Pistons are supplied complete with gudgeon
pins, and are matched assemblies. It is not possible to
interchange component parts.
Pistons are available in selective grades, identified by
'A' or 'B' stamped on the piston crown and the
adjacent face of the cylinder liner.
Fig 4

12-53
 and is
is

lop nn
www.JagDocs.com

small flat file or

1

Fig 2

ntil it reaches its

clearance

Fig 3
Fit the piston to the connecting , so that the large
chamber on the rod f es the crankshaft
web, and the piston 'F I'mark faces the front of

Fig

rod, that the tab is seated the

n on to the
journal.
Coat the rod cap bearing su
with clean engine
Fit a new bearing shell half (3 Fig the connecting
, ensuring the tab is correctly
located.

Refit sandwich

Refit the Ensure the

marks align (Fig 4).
Remove the engine from the engine stand.
Refit the gearbox, and refit the

Fig
Refill the cooling system.
Check the timinq
17.
ONLY).

Valve clearances:

Fig 4
 DATA
Piston
clearance
ring side clearances:
T o p ring -
Second ring
Bottom ring - Nil (self-expanding)
bush bore

SERVICE TOOLS

MS 53B Engine support Tool.

3993 Timing Gauge
JD 40 Camshaft Sprocket Retainer
JD 4 Cylinder liner Retaining Brackets
JD 50 Timing Chain Tensioner Retainer and Release
Tool
55A Piston Ring Compressor

TORQUE FIGURES

Air pump 20-27Nm

Banjo connector bolts Fig 1
Camshaft sprocket to camshaft 23-27Nm
www.JagDocs.com

Camshaft cover Nm
Connecting rod cap nuts
Cylinder head to block (9/ 36Nm
Cylinder head to block 70Nm
EGR valve to throttle housing
Elbow to manifold
Engine mounting bracket to crossmember 19-24Nm
Engine mounting tie bolts 34-40Nm
Exhaust down pipe to manifold 30-35Nm
to waterpump 23-27Nm
unions
Fuel pipe unions dia.) 1 I -
Fuel pipe unions dia.) 27-33Nm
Heat shield to manifold
Hose clips
Inlet manifold to cylinder head (nuts) 23-27Nm
manifold to cylinder head (bolts) 23-27Nm
Oilcooler pipes 54-60Nm
to mounting bracket 50Nm
Rear engine mounting peg 34-40Nm
Rear engine mounting rubbers 36-43Nm
Rear engine mounting to body I 6 bolt)
Rear engine mounting to body bolt) 36-43Nm
Silencer to compressor union 34Nm
set screws
Thermostat housing to cylinder head 23-27Nm

SPANNER SIZES

16" A F

AF

AF

Half moon seal

Exhaust down pipe Tivoli Kay Adhesives 5696

12-56
 ENGINE 5.3

CYLINDER LINERS
RENEW 12.25.26
Removethe assembly 12.37.0
Fit the assembly to a suitable stand.
Removethe cylinder heads
Fit JD 41 Cylinder Liner Brackets (Fig 1).
NOTE: Always support the cylinder heads on blocks of
wood. This will prevent damage to the valves which,
when open, protrude below the cylinder head face.

Remove the sump plug and drain the oil into a suitable Fig 1
container.
Remove the sump pan securing bolts (2 Fig 2) and
remove the sump pan (1 Fig 2).
Remove the suction elbow (2 Fig 3), remove the
sandwich plate securing bolts (1 Fig 3). and remove
the plate, noting the different stud lengths.
Rotate the crankshaft until Numbers 1 and 5 journals
are outermost.
Remove the securing nuts (1 Fig 4), bearing cap (2 Fig
4) and shell from one connecting rod, noting the cap to
connecting rod relationship.
Remove any carbon deposits from the top of the
cylinder bore.
Push the connecting rod up the cylinder bore and
withdraw the assembly (Fig page 58). Fig 2
Remove the connecting rod bearing shell.
Repeat the procedure t o remove the remaining
connecting assemblies.
Remove Service Tools JD 41 Cylinder Liner Brackets.
Remove the cylinder liners, noting their location
relative to the cylinder block.
NOTE: Liners are graded, and are stamped 'A' (RED -
ID) or 'B' (GREEN - ID). New
liners MUST be the same grade as the old ones.

Thoroughly clean the crankcase and all components,

ensure that all galleries are clear and unobstructed.
Blow through with dry, clean compressed air.
Examine all components for wear and damage.
Replace worn or damaged components as necessary. Fig 3
Fit the new cylinder liners using a thin seal of Hylomar
between liner and block. Ensure both sealing surfaces
are clean.
Refit Service Tools JD 4 1 Cylinder Liner Brackets.
Clean all bearing surfaces and cylinder bores.
Coat the piston rings, gudgeon pins and cylinder bore
liberally with clean engine oil.
Ensure that the piston ring gaps are correctly spaced
around the piston (Fig 2 page 58).
Compress the piston rings using Service Tool 18G
55A (Fig 3 page 58).
Enter the rod assembly into the
cylinder bore, ensuring that 'FRONT' (stamped on the
piston)faces the front of the engine.
Firmly, but without undue force, push the piston/
connecting rod assembly down the cylinder bore.

Fig 4

12-57
 half (2 Fig 4) into the connectin

Coat the connecting rod cap bearing surface

with clean engine oil.
Fit a new bearing shell hall (3 Fig 4) into the connectin
rod that the bearing shell tab is

it and torque tighten the

ocedure to refit the remaining piston/

connecting rod assemblies.

efit the sandwich plate.

Refit the

marks align (Fig 1 page 59).

www.JagDocs.com

Remove the engine from the engine stand.

Refit the gearbox, and refi the
12.37.
he air conditioning system

Reconnect the battery.

Refill the engine with clean oil (Fig 2 page 59).
Refill the cooling system.
Check the ignition timing
Carry out EGR emission test 17.00.00 (FEDERAL
ONLY),
Close bonnet.

Valve clearances:
Inlet 0.012-0.0

Top compression ring gap 1

Piston skirt
clearance

Piston ring side clearances:

Top ring

Bottom ring - Nil

Small end bush bore

Fi

12-5
DAT

MS Engine
3993 Timing Gauge
JD 40 Camshaft Sprocke
d D 4 1 Cylinder Liner Reta
50 Timing Chain Tens
Tool
5.4 Piston Ring

Air pump adjuster

Banjo connector bolts 1
Camshaft sprocket
Camshaft cover I 1
Connecting rod cap nuts
Cylinder head to block
Cylinder head to block
valve to hous
Elbow to inlet manifold 12.
Engine mounting bracket to
Engine mounting tie bolts
Exhaust down pipe to ma U
to waterpump
Fuelpipe unions Fig
Fuelpipe unions 1
Fuelpipe unions 2
Heat shield to
Hose clips
manifold cylinder head (nuts)
Inlet manifold to cylinder head
Oil coolerpipes
to mounting
Rear engine mounting peg
Rear engine mounting rubbers
Rear engine mounting to body
Rear engine mounting to bod
Silencer to compressor union
Sump set screws
Thermosrat housing to cylinder head

SPANNER SIZES Fig 2

AF

16" A F

moon seal
Cylinder liner to block
Exhaust down pipe

12-59
 A

NOTE
This operation should only be carried out if crankshaf?
damage IS not suspected, and the problem IS due to
bearing shell wear or failure
If, upon inspection, journals are found to be damaged,
the engine must be removed and ?he crankshaft
renewed
Fig 1
Raise the vehicle on a ramp
Remove the sump plug and drain the oil into a suitable
container
Remove the sump pan securing bolts (2 Fig
remove the sump pan ( 1 Fig
Remove the suction (2 Fig 2), remove the
plate securing bolts Fig and remove
the plate, noting the different stud lengths , ,

Remove the pipe securing bolts (1 Fig 3). and

disconnect the suction pipe (2 Fig 3) from ?he elbow
Remove the delivery securing bolts,
and draw the undershield clear
www.JagDocs.com

Rotate the crankshaft until two journals are outermost

Remove the securing nuts Fig bearing caps (2 Fig
and shells from the connectinq rods on one

WHILE THE BEARING CAPS ARE DISCONNECTED

Fig 2
Clean all components and bearing surfaces
Coat the connecting rod bearing surface liberally with
clean engine oil
Fit a n e w bearing shell half into the connecting rod,
ensuring that the bearing tab IS correctly located
in the connecting rod
Coat the bearing shell with oil
Pull the connecting rod d o w n o n to the crankshaft
journal
Coat the connecting rod cap bearing surface liberally
with clean engine oil
Fit a new bearing shell half into the connecting rod cap,
ensuring that the bearing shell tab is correctly located
Coat the bearing shell with Fig 3
Fit the connecting rod cap Fit and torque tighten the
securing nuts.
Repeat the operation o n the other accessibiejournal.

Rotate the crankshaft until two more journals are

outermost.
Repeat the bearing renewal procedure.
Rotate the crankshaft until two remaining journals
are outermost.
Repeat the bearing renewal procedure.
Refit the suction and delivery pipes, using a new
suction pipe ring.
Clean the oil strainer.
Refit the sandwich plate.
the sump.
Refill theengine with clean oil

Fig 4
 ENGINE 5.3

ATA
T FIGURES

Connecting rod cap nuts

Oil cooler pipes 54-6ONm
Sandwich plate to block 16.5-21Nm
Sump set

SPANNER SIZES

6” AF

AF

n
RENEW

NOTE
This operation should only be carried out if 312 072
damage is not suspected, and the problem IS due
bearing shell wear orfailure. Fig 1
If, upon inspection, journals are found to be damaged,
the engine must be removed and the crankshaft
renewed

Raise the vehicle on a ramp. 3

Remove the sump plug and drain the oil into a suitable
container.
Remove the sump pan securing bolts (2 Fig
remove the sump pan Fig 1).
Remove the suction elbow (2 Fig remove the
sandwich plate securing bolts Fig 2), and remove
the plate, noting the different stud lengths.
Remove the suction pipe securing bolts (1 Fig 3). and
disconnect the suction pipe (2 Fig 3) from the elbow.
Remove the delivery securing bolts,
and draw the undershield clear.
Remove the and securing the
delivery pipe elbow to the oil pump casing. Fig 2
NOTE: Leave the bolt at the outboard fastening in
position in the oil pump casing. If the bolt is removed
for any reason, it must be refitted from a downward
direction.
Draw the delivery downwards from the
bore in the crankcase and the oil pump casing.
Remove and discard the gasket.
Draw the undershield clear.

CAUTION: DO NOT ROTATE THE CRANKSHAFT

WHILE THE BEARING CAPS ARE DISCONNECTED.

NOTE: The centre and rear bearing shells cannot be

interchanged; the rear main bearing shell has an oil
groove, the centre main bearing shell is of plain
construction.
NOTE: The rear main bearing (6 Fig 1 page 62) is
secured with four small and t w o large Fig 3

12-6 1
 e not to mark the

efit

Fig 1
www.JagDocs.com

block I
Sump set screws

AF

Remove plug and the oil into a suitable

container. Fig 2
Remove the torque converter 44.17.07 (AUTO

the drive plate (AUTO ONLY}.

the clutch 1 ONLY).
Withdraw the spacerfrom the crankshaft.
Move the chain tensioner clear of the locating bracket
and slide the tensioner off the dowel
Disengage the timing chain the sprockets and
remove.
Invert the engine, remove the sump pan securing bolts
(2 Fig 2) and remove the sump pan 1 Fig 2).
Remove the suction elbow (2 Fig 3), remove the
sandwich plate securing bolts Fig 3), and remove
the plate, noting the different stud lengths.
Remove the suction pipe securing bolts ( 1 Fig 41, and
disconnect the suction pipe (2 Fig 4) from the elbow.
Remove the delivery securing bolts.
Remove the and securing the
delivery pipe elbow to the oil pump casing.
NOTE: Leave the bolt at the outboard elbow fastening
in position in the oil pump casing. If the bolt is removed
for any reason, it must be refitted in a downward
direction.

Draw the delivery downwards from the Fig 1

bore in the pump casing.
Remove and discard the gasket.
Draw the undershield clear. \
Withdraw the crankshaft sprocket and Woodruff key.
Remove the oil pump securing bolts Fig page 64)
and remove the pump, drive and Woodruff key.
Rotate the crankshaft until Numbers and 5 journals
are outermost.
Remove the securing nuts Fig 2 page bearing
caps (2 Fig 2 page 64) and shells from the connecting
rods on one journal noting the cap to connecting rod
relationship.
Remove and discard the shell.
Displace the connecting rod away from the crankshaft, 072
remove and discard the bearing shell.
Remove the remaining connecting rods, caps and Fig 2
bearing shells.

Remove the UNF main bearina nuts.

from the centre bearing and working outwards.
Remove the 1/2" UNF main bearing cap nuts and pillar
nuts, starting from the centre bearing and working
outwards. Note the location of the pillar nuts.
Lift off the bearing caps, remove and discard the
shells.
Slide the rear main bearing casting out of the cylinder
block, remove and discard the bearing shell and seals.
Lift the crankshaft out of the cylinder block, remove
and discard the upper bearing shell halves.
Thoroughly clean all components and examine for
wear and damage. Replace worn or damaged Fig 3
components as necessary.
Clean all bearing surfaces and cylinder bores

Fig 4

12-63
 ENGINE 5.3

Fit new sealing strips to the grooves of the rear main

bearing casting.
Apply one drop of Red Hermatite (or similar) into the
crankshaft rear oil seal grooves (top and bottom), and
fit new crankshaft rear oil seal halves (2 Fig 3).
Fit the rear main bearing casting to the cylinder block ( 1
Fig 3), fit and tighten the securing nuts (3 Fig 3).
Pre-size the rear oil seal using Service Tool JD 178 and
adaptor JD 1 78- 1 (4 Fig 3).
Remove the rear main bearing casting.
Liberally oil the upper main bearing shells and fit to the
cylinder block. Smear the rear oil seal with Dag
Colloidal Graphite.
NOTE: The centre and rear bearing shells cannot be
interchanged; the rear main bearing shell has an oil Fig 1
groove, the centre main bearing shell is of plain
construction.

Position the crankshaft in the cylinder block.

Liberally oil the main bearing cap shells and fit to the
main bearing caps.
Fit the caps to the crankshaft, fit and tighten the
securing nuts and pillar nuts.
NOTE: It is not necessary t o fit the centre bearing cap
prior to checking the crankshaft end float.
www.JagDocs.com

Check the crankshaft end float Fig 4).

The end float must be
Thrust washers are available in sizes

Fit the selected washers to the groove in the cylinder

block (2 Fig 4).
NOTE: The grooved side of the thrust washers must
face outwards.
Re-check the end float. Re-adjust as necessary.
Lubricate and fit the centre main bearing cap. fit and
tighten the securing nuts.
NOTE: Ensure the reference marks on the caps align
with the marks on the cylinder block.

Coat the connecting rod bearing surface liberally with

clean engine oil.
Fit a new bearing shell half Fig 1 page 65) into the
connecting rod, ensuring that the bearing shell tab is
correctly located in the connecting rod Fig 1 page
65). Fig 3
Coat the bearing shell with oil.
Pull the connecting rod down on to the crankshaft
journal
Coat the connecting rod cap bearing surface liberally
with clean engine oil.
Fit a new bearing shell half (3 Fig 1 page 65) into the
connecting rod cap, ensuring that the bearing shell tab
is correctly located.
Coat the bearing shell with oil.
Fit the connecting rod cap. and torque tighten the
securing nuts.
Repeat the procedure t o refit the remaining piston/
connecting rod assemblies.
Refit the oil pump drive gear, Woodruff key and oil
pump. Fit and tighten the securing bolts.
Fit a new Woodruff key to the crankshaft and refit the
crankshaft sprocket.

12-64
 ENGINE 5.3

Refit the undershield.

Refit the delivery pipe elbow, using a new 0 ring.
Refit the delivery
Refit the suction pipe, using a new 0 ring.
Clean the oil strainer.
Refit the sandwich plate assembly
Refit the sump.
Refit the timing chain and tensioner assembly.
Refit the timing cover, using a new oil seal.
Refit the cylinder heads.
Adjust the valve clearances
Refit the camshaft covers.
Refit the induction manifolds.
Refit the clutch 33.10.01 (MANUAL ONLY).
Refit the drive plate and torque converter 44.17.07
(AUTO ONLY).
Refit the assembly. Ensure that the paint
marks align (Fig2).
Refit the assembly. Fig 1
Evacuate and charge the air conditioning system
82.30.06 and 82.30.08.
Refit the air cleaner.
Reconnect the battery.
Refill the engine with clean oil (Fig3).
Refill the cooling system.
Check the ignition timing
Carry out EGR emission test 17.00.00 (FEDERAL
ONLY).

DATA
SERVICE TOOLS

MS 538 Engine Support Tool.

3993 Timing Gauge
JD 1 78 Oil Seal Pre-sizing Tool
JD 178- 1 Pre-sizing Tool Adaptor
JD 39 Jackshaft Retainer Tool
Camshaft Sprocket Retainer
41 Cylinder Liner Retaining Brackets
JD 50 Timing Chain Tensioner Retainer and Release
Tool

TORQUE FIGURES

adjuster
Banjo connector bolts
Camshaft sprocket to
Camshaft cover 1 Fig 2
Connecting rod cap nuts
Cylinder head to block 36Nm
Cylinder head to block
EGR valve to throttle housing 9.5-
Elbow to inlet manifold
Engine mounting bracket to crossmember
Engine mounting tie bolts
Exhaust down pipe to
to waterpump
Flywheel bolts
Fuelpipe unions
Fuelpipe unions II-
Fuelpipeunions 27-33Nm
Heat shield to
Hose clips
Inlet manifold to cylinder head (nuts)

12-65
www.JagDocs.com

from drive plate Fig

components, replace as
necessary.

Fig
 IN

DAT

bolts

Removethe
Push back the lock tabs and remove the flywheel
securing Fig
Remove the tab washer and stiffener plate.
Draw two locating dowels from the drive plate (2 Fig

If a draw bolt is to be used, turn the

so that the draw bolt reacts against the rear
main bearing cap, NOT the cylinder block.
Clean and examine all components, as
necessary.
Thoroughly clean all mating faces.
Fit the replacement flywheel to the crankshaft.
Fit a NEW lock washer. Fit and tighten the securing
bolts. Lock over the tabs.
Refit the clutch.

AT

Fig
SPANNER SIZES

12-67
 ENGINE 5.3

CRANKSHAFT DAMPER AND PULLEY

3
RENEW 12.21.01

Remove the radiator 26.40.04.

Remove the torquatrol unit 26.25.21.
Remove the PAS pump drive belt 57.20.02.
Remove the alternator drive belt 86.10.03.
Remove the compressor air pump drive belt 82.10.02
CARS ONLY).
Remove the pulley securing bolts (1 Fig 1) and
withdraw the pulley.
Remove the crankshaft damper bolt (2 Fig 1).
Loosen off the damper by striking with a hide mallet.
Withdraw the damper and cone (3Fig retrieve both
Woodruff keys from the cone and crankshaft Fia 1 \
Examine all components for wear and Fig 1
Replace worn or damaged components as necessary.
Fit t w o NEW Woodruff keys to the cone and
crankshaft.
Fit the replacement fit and tighten the
crankshaft damper bolt.
Fit the pulley, fit and tighten the securing bolts.
Refit the compressor air pump drive belt 82.10.02
(AIRCONCARS ONLY).
www.JagDocs.com

the alternator drive belt 86.10.03,

the PAS pump drive belt 57.20.02.
Refit the torquatrol unit 26.25.21,
NOTE: Ensure that the paint marks on the torquatrol
unit align (Fig 2).
Refit the radiator 26.40.04.
Refill the coolant system.
Evacuate and charge the air conditioning system
82.30.06 and 82.30.08.
Refit the air cleaner.

DATA
TORQUE FIGURES

pivot 20-27Nm
Crankshaft damper bolt 1 72-206Nm
Crankshaft pulley to damper Nm
Fan cowl bracket to lower crossmember
Fan cowl to body
Fan mounting to
Mounting bracket to fan motor
cooler pipes 54-60Nm
SPANNER SIZES Fig 2

16" AF

12-68
 INE

RENE

Remove the crankshaft damper and pulley 12.2

Prise the seal from the timing cover. Discard the seal
Fig
Withdraw the crankshaft spacer (2 Fig 1).
Ensure that the seal recess is absolutely clean.
Smear the new seal with clean engine oil.
Position the seal squarely in the recess and tap gently
home with a hide
Refit the crankshaft damper and pulley.
Refit the compressor air pump drive belt 82.10.02
CARS ONLY).
the alternator drive belt 86.10.03.
the PAS pump drive belt
torquatrol unit
NOTE: Ensure that the paint marks on the torquatrol 6
unit align (Fig
Refit the radiator
Refillthe coolant system.
Evacuate and charge the air conditioning system
and 82.30.08.
Refit the air cleaner.

DATA
TORQUE FIGURES

pump pivot
Crankshaft damper bolt
Crankshaft pulle to damper 16.5-2 1N m
Fan cowl bracket to lower crossmember 8-9
Fan cowl to body
Fan mounting to
Mounting bracket to far,
Oil cooler pipes 54- 60N m

SPANNER SIZES

16" A F Fig 2

AF

CRANKSHAFT REAR
RENEW 12.21.20

Remove the assembly

Fit the assembly to a suitable stand.
Remove the sump plug and drain the oil into a suitable
container.
Remove the torque converter 44.17.07 (AUTO
ONLY).
Remove the drive plate (AUTO ONLY).
Remove theclutch 33.10.01 (MANUALONLYJ.
Remove the timing cover
Withdraw the spacer from the crankshaft.
Move the chain tensioner clear of the locating bracket Fig 3
and slide the tensioner off the dowel pin (2 Fig 3).

12-69
 the chain the sprockets and
remove.

e the suction

Fig 1

Draw clear.
www.JagDocs.com

are

Fig 2

NF main bearing cap nuts, starting

Fig 3

Fig 4
 TE: is not to fit the centre bearing ca

Thrust

it camshaft
 Refit the torquatrol unit.
NOTE: Ensure that the paint marks on the torquatrol
unit align (Fig 1).
Refit the assembly.
Evacuate and charge the air conditioning system
82.30.06 and 82.30.08.
Refit the air cleaner.
Reconnect the battery.
Refill the engine with clean oil (Fig2).
Refill the cooling system.
Check the ignition timing 86.35.29.
Carry out EGR emission test (FEDERAL
ONLY).

DATA
SERVICE TOOLS

MS 5 3 8 Engine Support Tool.

3993 Timing Gauge
JD 1 7 8 Oil Seal Pre-sizing Tool
JD Pre-sizing Tool Adaptor
JD Retainer Tool
JD 40 Camshaft Sprocket Retainer
JD 4 Cylinder Liner Retaining Brackets
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JD 50 Timing Chain Tensioner Retainer and Release

Tool

TORQUE FIGURES Fig 1

Air pump adjuster 20-27Nm

Banjo connector bolts 12-
Camshaft sprocket to
Camshaft cover 1 Nm
Connecting rod cap nuts
Cylinder head to block 36Nm
Cylinder head to block
EGR valve to throttle housing 9.5-
Elbow to inlet manifold
Engine mounting bracket to crossmember
Engine mounting tie bolts
Exhaust down pipe to manifold 30-35Nm
to water pump 23-27Nm
Flywheel bolts maximum
Fuel pipe unions (5/ dia.)
Fuel pipeunions
Fuel pipe unions dia.)27-33Nm
Heat shield to manifold
Hose clips
Inlet manifold to cylinder head (nuts) Fig 2
Inlet manifold to cylinder head (bolts)
Main bearing cap nuts 84Nm maximum
Main bearing cap nuts
Oil coolerpipes
to mounting bracket
Propeller shaft bolts 36.5-43Nm
Rear engine mounting peg
Rear engine mounting rubbers
Rear engine mounting body (5/ bolt) 19-24Nm
Rear engine mounting to body bolt) 36-43Nm
Sandwichplate to block 16.5-2 I Nm
Silencer to compressor union
Sump set screws
Torque converter bolts
Thermostathousing to cylinder head
 ENGINE 5.3

DATA
SPANNER SIZES

16" AF

CANTS
Half moon seal
Exhaust down pipe Adhesives 5696
Crankshaft rear oil seal Dag Graphite

0'72

RENEW 12.60.44
Fig 1
Remove the sump plug (1 Fig 1) and drain the oil into a
suitable container.
Remove the sump pan screws and serrated washers
(2 Fig I). Note the position of the transmission oil
cooler pipe clip.
Lower the
Clean all components thoroughly and examine for
wear or damage. Replace worn or damaged
components as necessary.
Lightly coat the new gasket with Hylomar.
Fit the replacement sump and gasket, fit and tighten
the securing screws and serrated washers.
Secure the transmission oil cooler pipe clip.
Refill the engine with oil (Fig 2).

DATA
TORQUE FIGURES

Sump set screws

SPANNER SIZES

AF
AF Fig 2
 To remove the plate the
splaced for access

Fig 1

unions from the elbow and delivery pipe

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Remove the by-pass housing securing screws

Remove the by-pass valve assembly from the housing,
clean and examine components, replace as
necessary

s Use

ndwich replacement

pipes the s

Fill the engine with (Fig 4)

Fig 3

set

Fi
AF

1
 anners, one on the cooler the

Drain the engine oil.

Remove the splash panel securing
Disconnect the return hose union
NOTE: spanners, one on the oil coder the
her on the hose union, must be used.
 OIL COOLER SU E
RENEW 12.6

Drain the engine oil.

Remove the splash panel securing screws.
Disconnect the supply hose union (2 Fig
NOTE: T w o spanners, one on the oil cooler union the
other on the hose union, must be used.

Disconnect the supply hose from the oil cooler Fig

Plug all broken connections to prevent dirt ingress.

Connect the replacement supply hose to the oil cooler.
Connect the supply hose union. Fig 1
Refit the lower splash panel.
Refill the engine with clean oil (Fig 2).

TORQUE

Oil coolerpipes

SPANNER SIZES
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7
AF

Fig 2
OIL SSE

Open the bonnet.

Release the toggle clips Fig 3) and remove the LH air
cleaner cover.
Remove the air cleaner Fig 3).
Disconnect the auxiliary air valve hose from the air
cleaner back plate.
Disconnect the auxiliary air valve hose feed pipe.
Disconnect the crankcase breather hose.
Remove the air cleaner backplate securing bolts (3 Fig

Remove the backplate from the throttle housing, 2

complete with overrun valve hose. Fig 3

Remove and discard the overrun valve hose and air
cleaner gasket.
Remove the eight securing the LH down
pipe to the exhaust manifold.
Disconnect the EGR pipe from the manifold (FEDERAL
ONLY).
Remove the down pipe flange and
remove the down pipe. Discard the sealing rings.
NOTE: On drive vehicles, the steering to full left
lock, this will enable the down pipe to be manoeuvred
clear.
Disconnect the oil cooler supply pipe union Fig

12-76
 ENGINE 5.3

Cut the clip on the pressure relief valve vent hose (1 Fig

Remove the bowl (1 Fig 2).

Remove the LH front heatshield.
he four filter retaining screws (2 Fig 2).
not possible to fully withdraw the lower
screw (3 Fig 2).

Carefully break the filter head to cylinder block seal,

and press the filter head upwards until the by-pass
valve stub pipe clears the housing.
Separate the vent pipe from the relief valve.
Manoeuvre the filter head clear.
Clean and examine all components, replace as Fig 1
necessary.
Thoroughly clean all mating faces.
Fit a new 0 ring to the by-pass valve stub pipe.
Fit a new gasket to the cylinder block, and offer up the
filter head into position.
Press the stub pipe down
housing and locate one screw.
Fit and tighten the remaining screws and washers.
Fit a new clip to the relief valve vent hose.
Reconnect the oil cooler supply pipe.
Refit the bowl, ensure
ring is new or undamaged.
Refit the heat shield.
Refit the exhaust down pipe, using new sealing rings.
Refit the air cleaner.
Run the engine, up the oil level (Fig 3).
Carry EGR emission test 17.00.00 (FEDERAL
ONLY).
Close the bonnet. Fig 2

DATA

Exhaust down pipe to manifold

Filter bowl bolt
Filter - 8- I
Heat shield to
Oilcoolerpipes
Oil filter head to block

SPANNER SIZES

-
Fig 3
3/4 AF

12-77
 ing the suction pipe clips

lean or

,fit the pipe clips

the
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Fig 2

relief valve vent hos Fig 3)

and unscrew from the filter

Fig 3

1
 ENGINE 5.3

OIL PUMP
RENEW 12.60.26

Remove the engine/gearbox assembly 12 .37 .01.

Fit the engine/gearbox assembly to a suitable stand .
Remove the sump plug and drain the oil into a suitable
container.
Remove the t iming cover 12.65 .01 .
Withdraw the spacer from the cra nkshaft.
Move the chain tensioner clear of the locating bracket
and slide the tensioner off the dowel pin (2 Fig 1).
Disengage the timing chain from the sprockets and
remove .
Invert the engine, remove the sump pan bolts (2 Fig 2)
and remove the sump pan (1 Fig 2) .
Remove the suct ion elbow (2 Fig 3). remove the
sandwich plate securing bolts (1 Fig 3). and remove
the plate, noting the stud lengths.
Remove the suction pipe securing bolts (1 Fig 4). and Fig 1
disconnect the suction pipe (2 Fig 4) from the elbow.
Remove the delivery pipejundershield securing bolts.
Remove the bolt/washer and nut/washer securing the
delivery pipe elbow to the oil pump casing .
NOTE: Leave the bolt at the outboard elbow fastening
in position in the oil pump casing. If the bolt is removed
for any reason, it must be refitted in a downward
direction .

Draw the delivery pipe/elbow downwards from the

bore in the crankcase/oil pump casing.
Remove and discard the gasket.
Draw the undershield clear.
Withdraw the crankshaft sprocket/Woodruff key.
Remove the oil pump securing bolts (1 Fig 1 page 80)
Fig 2
and remove the pump, drive and Woodruff key.

Thoroughly clean all components and examine for 3

wear and damage. Replace worn or damaged
components as necessary. Clean all bearing surfaces .
Fit the oil pump drive gear, Woodruff key and
replacement oil pump. Fit and tig hten the securing
bolts.
Fit a new Woodruff key to the crankshaft and refit the
crankshaft sprocket.
Refit the undershield.
Refit the delivery pipe elbow, using a new 0 rin g
Refit the delivery pipe/undershield .
Refit the suction pipe, using a new 0 ring .
Clean the oil strainer. Fig 3
Refit the sandwich plate assembly 12.60.45.
Refitthe sump.
Refitthe timing chain and tensioner assembly.
Refit the tim ing cover, using a new oil seal. 2
Refit the cylinder heads.
Adjust the valve clearances 12.29.48.
Refit the camshaft covers.
~----------',j;~i li~
Refit the induction manifolds.
Refit the torquatrol unit .
NOTE: Ensure that the paint marks on the torquatrol
unit align (Fig 2 page 80).
Refit t he engine/gearbox assembly.

Fig4

12-79
 ENGINE 5.3

Evacuate and charge the air conditioning system

82.30.06 and
Refit the air cleaner. Reconnect the battery.
Refill the cooling system.
Refill the engine with clean oil (Fig 3).
Check the ignition timing 86.35.29.
Carry out EGR emission test 17.00.00 (FEDERAL
ONLY).

DATA

MS 538 Engine Support Tool.

3993 Timing Gauge Fig 1
JD 39 Jackshaft Retainer Tool
40 Camshaft Sprocket Retainer
47 Cylinder Brackets
JD 50 Timing Chain TensionerRetainer and Release
Tool

TORQUE FIGURES

20-2
Banjo connectorbolts 12-
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Camshaft sprocket to
Camshaft cover 1 1Nm
Cylinder head to block (9/ 36Nm
Cylinder head to block
EGR valve to throttle housing 9.5-
Elbow to inlet manifold
Engine mounting bracket to crossmember 19-24Nm
Engine mounting tie bolts
Exhaust downpipe to manifold
to waterpump
Fuel pipe unions (5/ dia.)
Fuel pipe unions dia.) 1 -
unions dia.)27-33Nm
Heat shield to manifold
Hose clips
Inlet manifold to cylinder head (nuts)
Inlet manifold to cylinder head (bolts)
Oil cooler pipes
to mounting bracket
Propeller shaft bolts 36.5-43Nm
Rear engine peg Fig 2
Rear engine mounting rubbers 36-43Nm
Rear engine mounting to body (5/ 16bolt)
Rear engine mounting to body bolt) 36-43Nm
Sandwichplate to block
Silencer to compressor union
Sump set screws
Thermostathousing to cylinder head

SPANNER SIZES

AF

6" AF
AF
7

Fig 3
Half moon seal
Exhaust down pipe Kay Adhesives 5696
12-80
 ENGINE 5.3

OIL PUMP
OVERHAUL 12.60.32

Remove the oil pump

Remove the eight bolts and lock washers and detach
the pump cover from the gear housing.
Mark the drive gear relationship (1 Fig
to ensure correct re-assembly.
Remove both gears, wash all parts in clean paraffin or
petrol and dry with compressed air.
Check the condition of all gear teeth and remove any
burrs with a fine file.
Refit the driven gear and check the radial clearance Fig 1
between the gear and housing (2 Fig
NOTE: Checks should not be made at the six radial flats
on the gear.
Radial clearance must not exceed

Refit the drive gear and check the radial clearance

between gear and crescent (3 Fig 1).
Radial clearance must not exceed
Check the gear end float using a straight edge across
the joint face. Measure the clearance between the
straight edge and gears (1 Fig 2).
End float must not exceed
If any of the tolerances are outside the figures given
then the oil pump must be replaced.
1 12
Re-assemble the pump. Note the drive Fig 2
gear relationship.
Fit new lock washers. Fit and tighten the securing
bolts.
Refit the oil pump

DATA
SERVICE TOOLS

MS 538 Engine Support Tool.

3993 Timing Gauge
J D 39 Jackshaft Retainer Tool
40 Camshaft Sprocket Retainer
Cylinder Liner Retaining Brackets
J D 50 Timing Chain Tensioner Retainer and Release
Tool

TORQUE

Air pump 20-27Nm

Banjo connectorbolts 12-14Nm
Camshaft sprocket to
Camshaft cover I 1Nrn
Cylinder head to block (9/ 36Nm
Cylinder head to block
EGR valve to throttle housing 9.5- 12Nm
Elbow to inlet manifold
Engine mounting bracket to crossmember 19-24Nm
Engine mounting tie bolts 34-40Nm
Exhaust downpipe to
to waterpump 23-27Nm

1 2-8 1
 ENGINE 5.3

DATA
TORQUE FIGURES

Fuel pipe unions (5/16" dia.) B.5-9.5Nm

Fuel pipe unions (3/8" dia.) 11-13.5Nm
Fuel pipe unions (1/2" dia.) 27-33Nm
Heat shield to manifold 23-2 7Nm
Hose clips 2. 5Nm
Inlet manifold to cylinder head (nuts) 23-27Nm
Inlet manifold to cylinder head (bolts) 23-27Nm
Oil cooler pipes 54-60Nm
PAS pump to mounting bracket 50Nm
Propeller shaft bolts 36. 5-43Nm
Rear engine mounting peg 34-40Nm
Rear engine mounting rubbers 36-43Nm
Rear engine mounting to body (5/ 16 bolt) 19-24Nm
Rear engine mounting to body (3/ 8 bolt) 36-43Nm
Sandwich plate to block 16.5-21 Nm
Silencer to compressor union 34Nm
Sump set screws 16-20Nm
Thermostat housing to cylinder head 23-2 7Nm

SPANNER SIZES
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7/16"AF
1/ 2 " AF
9/ 16 " AF
5/ 8 " AF
11/ 16" AF

OILS/ SEALANTS/LUBRICANTS

Half moon seal Hylosil1 02

Exhaust down pipe Tivoli Kay Adhesives 5696

0099C

12-82
 ENGINE 5.3

ENGINE MOUNTING-LEFT HAND

RENEW 12.45.01

Remove the radiator grille securin g screws, and

remove the grille.
Remove the bumper front centre section securing
nuts/bolt, and remove t he section.
Open the bonnet.
Remove the bonnet stay to bonnet secu ring screws,
and remove the stay clamping pieces .
Fully open the bonnet.
Remove the fan assembly securing securing bolt, and
remove the fan from the spindle.
Remove the fuel fi lter bracket to manifold screw (1 Fig
1), remove the spacing washer, and move the Filter
clear of the engine lifting eye.
Release the toggle clips (1 Fig 2) and remove the LH air
cleaner cover.
Remove the air cleaner element (2 Fig 2).
Remove the air cleaner backplate securing bolts (3 Fig
21 Fig 1
Remove the backplate from the throttle housing
complete with overrun valve hose.
Remove and discard the overrun valve hose and air
cleaner gasket .
Remove the securing nuts/washers from the LH
engine mounting (Fig 3) and crossmember bracket.
Attach suitable lifting equipment to the engine . Raise
the engine sufficiently to f ree the mounting.
Retrieve the fibre washer.
Fit t he replacement mounting and fibre washer to the
crossmember.
Fit and t ighten the securing nuts/washers.
Lower the engine int o posit ior on the mounting,
Fit and tighten the mounting secu ri ng nuts/washers. J I2-58 ,)

Re move tho lifting oquipmont. Fig 2

Rofit the fuel filter to the manifold.
Refit t he fa n to the spindle.
Careful ly lower the bonnet and refit the bonnN stays.
Refit the bumper centre section.
Refitthe radiator grille.
Refit the air cleaner.
Close the bonnet.

DATA

TORQUE FIGURES

Engine mounting to crossmember 19-24Nm

Engine mounting to engine 19-24Nm

SPANNER SIZES

7/16"AF
1/2" AF
9/16"AF
Fig 3

12-83
 5.

ENGINE MOUNTING - RIGHT HAND

RENEW 12.45.03

Remove the radiator grille securing screws, and

remove the grille.
Remove the bumper front centre section securing
and remove the section.
Open the bonnet.
Remove the bonnet stay to bonnet securing screws,
and remove the stay clamping pieces.
Fully open the bonnet.
Remove the fan assembly securing securing bolt, and
remove the fan from the spindle.
Remove the fuel filter bracket to manifold screw (1 Fig
remove the spacing washer, and move the filter
clear of the engine lifting eye.
Release the toggle clips Fig 2) and remove the air
cleaner cover.
Remove the air cleaner element (2 Fig 2).
Disconnect the auxiliary air valve hose from the air
cleaner back plate.
Remove the air cleaner backplate securing bolts (3 Fig Fig 1
Remove the backplate from the throttle housing,
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complete with overrun valve hose. 3

Remove and discard the overrun valve hose and air
cleaner gasket.
Remove- the securing from the
engine mounting (Fig 3) and crossmember bracket.
Attach suitable lifting equipment to the engine. Raise
the engine sufficiently to free the mounting.
Retrieve the fibre washer.
Fit the replacement mounting and fibre washer to the
crossmember.
Fit and tighten the securing
Lower the engine into position on the mounting.
Fit and tighten the mounting securing
Remove the lrfting equipment.
Refit the fuel filter t o the manifold.
Fig 2
Refit the fan to the spindle.
Carefully lower the bonnet and refit the bonnet stays.
Refit the bumper centre section.
Refit the radiator grille.
Refit the air cleaner.
Close the bonnet.

TORQUE FIGURES

Engine mounting to crossmember 7

Engine mountingto engine

SPANNER SIZES

AF

AF

12-84
 .
MOUNTING- REA
RENEW \
Drive the vehicle on to a ramp.
Open the bonnet.
Fit Service Tool MS 53B across the engine (Fig
Fit the support hook to the engine lifting eye. Take the
weight of the engine and tighten the
Raise the ramp.
Disconnect the exhaust down pipes from the
intermediate pipes (Fig 2).
Remove the left and right hand heat shields.
Remove the collision plate 1 Fig 3).
Position a jack under the rear engine mounting plate.
Locate a suitably formed block of wood between jack
and plate to prevent
Remove the‘mounting t o securing bolts (2 Fig 3).
Lower the jack. Remove the mounting assembly, Fig
noting the positions of spacers (if fitted) and bolts of
different length.
Remove the stud and seating plate.
Thoroughly clean all components and examine for
wear and damage. Replace worn or damaged
components as necessary.
Check the condition of the mounting rubbers, replace if
necessary (MANUAL ONLY).
Refit the stud and seating plate.
Fit the assemblv. raise the iack and the
mounting bolt
Fit and tighten the securing bolts.
Refit the collision plate.
Refit the heat shields.
Refit the exhaust pipes.
Lower the vehicle and remove Service Tool MS
Close the bonnet.
Fig 2
DATA
SERVICE TOOLS

MS Engine support bracket

TORQUE FIGURES

Rear mounting stud

Rear mounting rubbers 36.5-43Nrn
Tie bolts 34-40Nm

SPANNER SIZES

AF
16“ AF

I
Fig 3
 ENGINE ASSEMBLY
RENEW 12.37.01

Drive the vehicle on to a ramp.

Open the bonnet.
Depressurise the fuel system
Disconnect the battery.
Removethe bonnet76.16.01.
Remove the lower grille
Drain the coolant system 1.
Depressurise the air conditioning system 82.30.05
CARS ONLY).
Slacken off the hose clips Fig disconnect the
hoses from the fuel cooler and air conditioning unit
Fig 1). IMMEDIATELY plug all broken connections
using clean, dry blanking plugs (AIRCONCARS ONLY).
Release the clips securing the harness to the wing
valance stay.
Remove the left (with hose) and right hand wing
valance stays.
Disconnect the ambient and coolant temperature
sensors Fig 2).
Release the clips securing the cold start relay harness
to the LH fuel rail and cross over pipe.
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Disconnect the throttle switch and trigger unit feed

wires.
Disconnect the kickdown switch feed wires. Fig 2
Disconnect the earth leads from the induction
manifold.
Release the main harness securing clips. Re-position
the harness away from the engine.
Release the wing valance harness securing clips.
Withdraw the harness.
Disconnect the harness block connector.

Remove the relay cover, situated on the wing

valance Fig 3).
Disconnect the cold start injection relay, manoeuvre
the harness through the valance bracket.
Disconnect the water feed rail pipe from the heater
valve.
Disconnect the brake vacuum pipes from the left and
right hand induction manifolds.
Disconnect the heater vacuum pipe from the right hand
induction manifold. Fig 3
Disconnect the throttle cable from the throttle
pedestal.
Disconnect the starter solenoid and starter motor feed
cables from the bulkhead connector. 3
Remove the left and right hand air cleaner covers
securing clips (1 Fig 4). covers and elements (2 Fig 4).
Release the clips securing the pressure sensor feed
pipe. Disconnect the pipe from the tee piece, plug the
broken connection.
Slacken off the hose clips (2 Fig 1 page
disconnect the hoses (1 Fig 1 page 87) from the fuel
filter, plug the broken connections.
Disconnect the air conditioning silencer pipe (2 Fig 2
page 871, IMMEDIATELY the broken connections
using clean, dry blanking plugs (AIRCONCARS ONLY).
Disconnect the fuel pipe from the cooler (Fig plug
the broken connections.
Fig 4

12-86
 ENGINE 5.3

Disconnect the left and right radiator top hoses from

the thermostat
Disconnect the header tank hose.
Disconnect the heater return hose from the tee piece.
Disconnect the transmission oil cooler hoses (1 Fig 3),
plug broken connections (AUTO ONLY).
Disconnect the alternator harness block connectors (2
Fig 3).
Disconnect the thermostatic switch Fig 4). Release
the harness securing clips.
Disconnect the fan motor line fuse, release the
retaining clip.
Disconnect the smaller of t w o block connectors a t the
front of the wing valance.
Disconnect the expansion pipe banjo bolt, union and
washer.
Remove the radiator top rail, note positions of earth
lead terminals and harness clip.
Disconnect the outlet pipe from the receiver drier unit,
IMMEDIATELY plug the broken connections using Fig 1
clean, CARS ONLY).
fan to top rail securing nuts and
washers.
Remove the bonnet stays
Release the condenser pipe securing clip.
Lift off the radiator top rail complete with the
evaporator and receiver drier units.
Retrieve the two copper (banjo bolt) washers from the
top of the radiator.
Fit Service Tool MS 53B engine support bracket
across the wing channels (Fig 1 page 88)). Align the
hook to the lifting eye. Tighten the hook to support the
engine.
Disconnect the low coolant sensor located in the
side of the radiator.
Disconnect the bottom hose (2 Fig 2 page 8 8 ) .
Lift the radiator slightly to facilitate access to the oil
cooler connections.

Disconnect the oil cooler pipes. Plug the broken

connections.
NOTE: Two spanners, one on the oil cooler union the
other on the hose union, must be used.

Carefully out the radiator, fan cowl and electric fan.

Raise the ramp. 1
Disconnect the exhaust intermediate and down pipes
Fig 3 page 8 8 ) .
Remove the left and right hand front heat shields.
Remove the rear heat shields (2Fig 4 page 88).
Remove the intermediate heat shields (1 Fig 4 page 427
88).
Remove the collision plate from the transmission unit.
Position a transmission under the
transmission.
Remove the mounting to body securing bolts.
Lower the transmission Remove the
mounting assembly, noting the positions of spacers (if
fitted) and bolts of different length.
Remove the stud and seating plate.
Disconnect the propeller shaft.
Lower the ramp.

12-87
 ENGINE 5.3

CARS ONLY:
Remove the gear lever knob.
Remove the rubber gaiter securing screws, remove the
gasket and gaiter.
Move the gear lever to first gear position.
Raise the ramp.
Disconnect the pipe from the clutch slave cylinder or, if
fitted, at the bulkhead bracket. Plug the broken
connections.

AUTO TRANSMISSION CARS ONLY:

Raise the ramp.
Disconnect the selector cable from the trunnion block.
Remove the selector lever to shaft Fig 1
page 89).Slide the lever off the shaft.
Disconnect the outer cable ( 1 Fig 2 page 89).

ALL CARS:
Disconnect the speedometer cable. Re-position the
cable to the side of the transmission tunnel.
Disconnect the torque housing earth
strap Fig 3 page 89).
Remove the steering gaiter heat shields. Carefully
withdraw the shields, avoid damage t o the gaiters.
Remove the LH exhaust manifold heat shield.
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Remove the LH exhaust down pipes, remove and

discard the sealing rings.
Remove the exhaust manifold heat shield.
Remove the exhaust down pipes, remove and
discard the sealing rings. 2
NOTE: Rotate the down pipe through 180 degrees
t o facilitate withdrawal.

Disconnect the EGR pipe from the manifold (WHERE

APPLICABLE).
Remove the PAS oil cooler from the mounting bracket.
Swing the cooler away from the engine.
Remove the PAS pump (2 Fig 4 page 89) from the
mounting bracket.
Release the drive belt, and lay the pump aside in an
upright position, away from the engine.
Lower the ramp. Move the car off the ramp into a
vehicle bay.
Position a jack under the transmission.
Take the weight of the transmission with the jack. 423

CAUTION: ON CARS FITTED WITH AUTOMATIC Fig 3

TRANSMISSION, THE JACK MUST BE LOCATED
UNDER THE REAR EXTENSION HOUSING, NOT
UNDER THE OIL PAN. \
Attach lifting chains to the front and rear engine lifting
eyes (Fig 1 page 90).
NOTE: The removal operation will be made easier if the
rear lifting chains are approximately 6” (1
longer than the front chains.
Remove the engine, taking care to ensure that the
engine does not foul or damage any components.
Ensure that the gear lever is below the console and
clear of the transmission tunnel before the engine is
lifted out (MANUAL TRANSMISSION CARS ONLY).
CAUTION: MAINTAIN A CONTINUAL WATCH ON
THE STEERING RACK, PIPES AND ANY
COMPONENTS LIABLE TO FOUL THE ENGINE. J 12-130
Fit the assembly to an engine stand.
Fig 4
 ENGINE 5.3

REFITTING
Fit new exhaust sealing rings (chamfered side
upwards) to the exhaust down pipes.
Position the down pipes in the engine compartment.
Locate the foam pad on top of the transmissiom
casing. Secure with string.
Attach lifting chains to the front and rear engine lifting
eyes.
NOTE: The removal operation will be made easier if the
rear lifting chains are approximately 6” ( 1
longer than the front chains.
Remove the assembly from the
engine stand. Fig 1 431
Transport the assembly to the
vehicle.
Lower the assembly into the engine
compartment until a trolley jack can be positioned
beneath the transmission casing.
CAUTION: ON CARS FITTED WITH AUTOMATIC
TRANSMISSION, THE JACK MUST BE LOCATED
UNDER THE REAR EXTENSION HOUSING, NOT
UNDER THE OIL PAN.

Continue lowering the engine and raising the jack until

the engine can be located on mounting studs. Fit and
tighten the securing
CAUTION: MAINTAIN A CONTINUAL WATCH ON
THE STEERING RACK, PIPES AND ANY
COMPONENTS LIABLE TO FOUL THE ENGINE.

Fit Service Tool MS 53B engine support bracket

across the wing channels (Fig 2 page 90). Align the
hook to the lifting eye. Tighten the hook t o support the
engine.
Loosely secure the down pipe to the exhaust
manifold. DO NOT attempt t o fully tighten the nuts a t
this stage.
Move the vehicle on to the ramp.
Raise the ramp.
Tighten the down pipe securing nuts by diagonal
selection.
Reconnect the EGR pipe to the manifold (WHERE
APPLICABLE).

Lower the ramp.

Position the fan and cowl assembly in the engine
compartment.
Refit the PAS pump. Tension the PAS pump drive belt
57.20.01.
Refit the radiator and reconnect the oil cooler pipes.
NOTE: T w o spanners, one on the oil cooler union the
other on the hose union, must be used.
Loosely fit the fan cowl t o the radiator.
Raise the ramp.
Reconnect the propeller shaft. Fit and tighten the bolts
( 1 Fig 3 page 90).
Reconnect the speedometer drive cable (2 Fig 3 page 1
90).

Select ‘D’ (AUTO ONLY).

Move the selector lever until the selector
cable can
Refit the trunnion block securing bolt
Fig 4

12-89
 Remove any traces of Loctite from the threaded
portion of the rear engine stud.
Smear the threads of the stud with Loctite Grade AV.
Screw the stud and seating washer into the
transmission.
Reassemble the rear engine mounting. DO NOT fit the
collision plate a t this stage.
Position the jack and formed of wood
beneath rear engine mounting.
Raise the jack until the rear can be bolted t o
the body. Tighten the securing bolts by diagonal
selection.
Remove the jack, remove the self-locking nut from the
centre stud and refit the collision bracket. Fig 1
Refit the own pipe, tighten nuts by
diagonal selection.
Reconnect the EG pipe to the manifoid (FEDERAL
ONLY).
Refit and rear heat shields.
Reconnect earth strap.
Reconnect the left and right hand intermediate pipes to
the down pipes. Smear the joints with
ten securing clamp nuts by
NOT avertighten.
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Reconnect the radiator hose.

to mounting brackets.
engine support bracket.
end of the angled front strut.
Refit the top rail assembly ensuring that copper
washers and not displaced. Fig 2
NOTE: A thin assed through the above
components assist in this operation

Fit the banjo bolt, pipe

Reconnect the le
Fit and tighten the top
Refit the upper cross strut and upper end of the angled
cross strut
Reconnect the receiver drier unit (AIRCON CARS
ONLY)
Secure the fan cowl fuse and harness clip,
reconnect the harness at the snap connector
Reconnect the switch at the water pump
(1 Fig Ensure a new seal is fitted (2 Fig 4)

Reconnect the heater and expansion

Reconnect the air hoses CARS
ONLY)
Reconnect the radiator top hoses
Reconnect all fuei pipes
Reconnect all vacuum hoses
Refit left and right air cleaner elements and
covers
Reconnect the alternator (2 Fig 1 page 9 1)
the throttle cable
Refit the valance stays
onnect harnesses
air system
CON CARS ONLY)
Refit the gear lever rubber boot, gasket and gear knob J25

(MANUAL ONLY)
Fig 4
 ENGINE 5.3

Bleed the clutch 35.15.01 (MANUAL ONLY).

Reconnect the battery.
Refill the engine with clean engine oil (Fig 2).
Adjust kickdown switch 44.30.09 (AUTO ONLY).
Check the ignition timing
Carry out EGR emission test 17.00.00 (WHERE
APPLICABLE).
Run engine and check for leaks.
Bleed power assisted steering by turning steering from
lock to lock with engine running. Top up reservoir.
the coolant, engine and transmission oil
levels.
Refit the bonnet and lower grille. Close the bonnet.

DATA
J12 427

SERVICE TOOLS Fig 1

MS 53B Engine Support Tool.

TORQUE FIGURES

20-27Nm
Banjo connector bolts 12- 14Nm
EGR valve to throttle housing 9.5-
Elbow to inlet manifold
Engine mounting bracket to crossmember 19-24Nm
Engine mounting tie bolts 34-40Nm
Exhaust down pipe to manifold 30-35Nm
to water pump 23-27Nm
Fuelpipe unions (5/ dia.)
Fuel pipe unions dia.) I 1 -
Fig 2
Fuelpipe unions 27-33Nm
Heat shield to 23-27Nm
Hose clips
Oil coolerpipes
to mounting bracket 50Nm
Propeller shaft bolts
Rear engine mounting peg 34-40Nm
Rear engine mounting rubbers 36-43Nm
Rear engine mounting to body (5/ 16bolt) 79-24Nm
Rear engine mounting to body bolt) 36-43Nm
Silencer to compressor union 34Nm

SPANNER SIZES

1/2 AF
AF

3/4 AF

Half moon seal

Exhaust down pipe Kay Adhesives 5696
Crankshaft rear oil seal Dag Colloidal Graphite

12-9
 ENGINE 5.

ENGINE ASSEMBLY
OVERHAUL

NOTE: All instructions, unless otherwise stated, apply

t o both 'A' bank and LH 'B' bank cylinder head
assemblies.

Remove the assembly 12.37.01.

Fig 1
Remove the assembly 33 01
(MANUAL CARS ONLY)
Remove the torque assembly
4 4 17 07 (AUTO CARS ONLY)

Fit the engine t o an engine stand

Remove the left and right hand induction manifolds
Remove the left and right hand exhaust manifolds
Remove the hose clip securing the oil pressure relief
valve bleed pipe to the top of the sandwich plate
Remove the setscrews securing the clips on the oil
cooler feed pipe
Disconnect the cooler feed pipe at the pipe union
Release the bolt at the base of the oil filter bowl and
remove the filter element (early cars), or unscrew and
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discard the filter element (later cars) Fig 1)

Remove three setscrews securing the by-pass valve
union t o the sandwich plate
Remove four setscrews securing the filter head to
cylinder block (2 Fig 1)
Release the oil cooler suction pipe union nut
Slacken the fan belt and remove the 1
the fan belt idler assembly Remove the

Remove the PAS bolts and remove the

pump Fig 2).
Remove the PAS pump mounting bracket and
adiustment link . -
Remove four setscrews securing the compressor
CARS
Remove the compres'sor mounting bracket (AIRCON
CARS ONLY).
Remove the air pump (IF FITTED).
Remove the air pump mounting bracket and adjust-
ment link (IF FITTED).
Release the transmission oil cooler pipe clips and
remove the pipesfrom engine.
Remove the starter motor.
Remover four bolts securing the crankshaft pulley to
withdraw the pulley.
Remover bolt (2 3), strike the damper
sharply with hide mallet and withdraw the damper.
Recover the Woodruff key ( 4 Fig 3).
Remove the damper cone (3 Fig 3), recover the
Woodruff (4 Fin 3).
Remove the retaining the ter
inlet spout to the water pump. Carefully break the seal.
Remove the setscrews, studs and bolt retaining the
water pump (2 Fig 4). break the seal and
remove the water assembly complete
with the engine cross pipe Fig 4).

12-92
 ENGINE 5.3

Remove the distributor and the amplifier unit.

Remove the banjo bolts securing the camshaft oil feed
pipes to the rear of the tappet blocks and oil gallery (1
Fig
Remove the throttle pedestal, amplifier bracket, heater
return pipe and engine cable.
Remove the alternator and bracket.
Remove the domed head nuts, copper washers and
setscrews securing ?he camshaft cover to the cylinder
head (1 Fig 2); lift off the cover.
Remove and discard the gaskets and half moon seals
(2 Fig 2).
Bend back the locking tabs securing the camshaft 083
sprocket retaining bolts. Fig 1
Remove two bolts from each sprocket. Use timing
chain tensioner retractor tool JD 50 to fully extend the
tensioner Fig 3).
Rotate the engine until the t w o remaining bolts are
accessible. Remove the bolts Fig 4).
Fit retaining tool JD 40 to each sprocket (2 Fig 4) and
remove JD 50.
Slacken off the camshaft bearing cap n u t s Fig 1
page 94) working from the centre outwards.
Remove the camshaft (3 Fig 1 page 94).

Remove the securing the tappet

to the cylinder head; remove the tappet block together
with tappets.
Retrieve the valve adjusting pads. Note location.
Fig 2
Progressively slacken off the cylinder head nuts,
working from the centre outwards.
Lift off the cylinder head and place on blocks of wood.
Fit cylinder liner retainers JD 4 1 (Fig2 page 94).
Remove the bolts ( 1 Fig 3 page 94) securing the timing
cover to the cylinder block noting relative positions of
long, short and dowelled bolts.
Remove the timing cover (2 Fig 3 page lift off
gaskets (3 Fig 3 page 94) and discard.
Remove and discard the timing cover oil seal (4 Fig 3
page 94).
Withdraw the spacer from crankshaft.
Move the chain tensioner clear of the locating bracket
and slide off the dowel pin.
Disengage and remove the timing chain from the
sprockets.
Remove the bolts securing the jackshaft cover t o
cylinder block, lift off cover.
Note the position of spacing bolts (NON
AIR CONDITIONED CARS ONLY).

Remove the engine mounting brackets, invert the

engine and remove the sump pan bolts. Note the
position of the oil cooler pipe clip.
Remove the bolts securing the sandwich plate baffle
and sandwich plate; recover the crankshaft angle
indicator scale.
Carefully break the joint and remove all traces of
gasket. Remove the suction union elbow from
sandwich plate.
Remove four setscrews and washers securing the
suction pipe clips and bracket. Draw the suction pipe
from the 0 ring at the elbow.
Remove t w o securing the
crankshaft undershield and delivery pipe clips. Draw
the undershield clear.

12-93
 ENGINE 5.3

Remove the securing the oil delivery 1 2 3

pipe elbow to the oil pump casting. Lift the oil deliverv I
pipe from the crankcase and discard the
gasket
Withdraw the crankshaft sprocket and Woodruff key
Remove four bolts securing the oil pump to cylinder
block ( 1 Fig 4) Withdraw the pump, drive gear and
Woodruff kev
Remove setscrews (1 Fig 1 page 95) and
tabwasher (2 Fig 1 page 95) securing the sprocket (3 Fig 1
Fig 1 page 95) t o the jackshaft; withdraw the sprocket,
discard the tabwasher.
Remove the bolts ( 4 Fig 1 page 95) securing the
jackshaft locking plate (5 Fig 1 page 95) to the cylinder
block; lift the plate out of the groove in the jackshaft
flange.
Withdraw the jackshaft (6 Fig 1 page 95).
NOTE: Care must be taken to identify pistons with their
respective bores. Big end caps should be fitted to
connecting rods immediately after removal.

Remove the nuts securing the connecting rod bearing

cap; lift off the cap together with the shell bearing.
Remove carbon deposit from the top of the bore; push
the connecting rod and piston up the cylinder bore and
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Fig 2
withdraw.
Repeat the procedure for the remaining piston/
connecting rod assemblies. Fig 2
Remove the bolts on the locking plate securing the
drive plate to the crankshaft.
Lift off the drive plate.
Remove the small nuts securing the main bearing caps,
starting from the centre bearing.
Remove the pillar nuts and large nuts securing the main
bearing caps starting from the centre bearing.
NOTE: Note location of pillar nuts t o assist
replacement.
Lift off the bearing caps and shells, slide the rear main
bearing casting out of the cylinder block, remove and
discard the seals.
Lift the crankshaft out of the cylinder block, retrieve the
upper halves of the main bearing shells.
NOTE: If for any reason cylinder liners are to be
removed and re-used, they should be marked ‘FRONT‘
and refitted in their original bore.
Remove cylinder liner retaining tools JD
Fig 3
Following crankshaft removal, journals should be
checked in accordance with dimensions given in
Section 04.
NOTE: Due to the extemely hard surface of crankshaft
journals, it is not possible to grind crankshafts
satisfactorily.
CAUTION: Ensure that all components are scrupulously
clean, blow out all oil galleries in crankshaft, camshafts
etc. with dry clean compressed air.
Smear the shoulders of cylinder liners with Hylomar
and fit them into cylinder block. Remove any excess
sealant.
NOTE: Cylinder liners must be fitted dry.
Ensure the liners are correctly seated and fit retaining
tools JD 41.

Fig 4

12-94
 ENGINE 5.3

Fit new sealing strips to the grooves of the rear main

bearing casting Fig 2).
Fit a new crankshaft rear oil seal, applying one drop of
red (or similar) into both sealing grooves, 4
top and bottom, before fitting the seal halves into the
grooves (2 Fig 2).
casting to the cylinder block and
tighten the retaining nuts (3 Fig 2).
Pre-size the rear oil seal using Service Tool JD 17B
together with adaptor JD 17B-1 ( 4 Fig 2).
Remove the rear main bearing casting.
Liberally oil the upper main bearing shells and fit to the
cylinder block. Smear the rear oil sea! with Dag
Colloidal Graphite.
CAUTION: Centre and rear main bearing shells must
not be confused with each other; the rear main bearing
shell has an oil groove whereas the centre main
bearing shell is plain.

Position the crankshaft in

Fit new bearing shells t o the caps; the caps, using
pillar nuts as noted.
Fit and torque tighten the securing nuts.
Check the crankshaft end float Fig 3 ) .
The end float must be
Thrust washers are available in sizes

Fit the selected washers to the groove in the cylinder

block (2 Fig 3).
NOTE: The grooved side of the thrust washers must
face outwards. Fig 2
Fit new bearing shells t o the caps, oil the shells and
crankshaft journals.
Fit the main bearing caps and nuts; smear the oil seals
in the rear main bearing casting with clean engine oil
before assembly.
NOTE: Ensure that the reference marks on the bearing
caps face the marks on the cylinder block.

Torque tighten the bearing caps one at a time, working

from the centre outwards.
Liberally smear the bore of number one cylinder with
clean engine oil.
Ensure that the piston ring gaps of number one piston
are evenly spaced around the circumference of the
piston (1 Fig 4).
Smear the piston rings with oil and compress using
Service tool 18G 55A (Fig 1 page 96).
Enter the rod assembly into the top
of bore, ensuring that ‘FRONT’ stamped on piston
faces forward. DO NOT use undue force when fitting Fig 3
the piston.
Fit the big end bearing shell to the connecting rod and
bearing cap (2.3 Fig 2 page ensure that the tabs
on the shells are located (1 Fig 2 page 96).
Oil the shells and crankshaft journal, fit the bearing cap
ensuring that it is the correct way round. Fit and torque
tighten the nuts.
Repeat the procedure for the remaining pistons.
Check that the engine rotates freely.
Refit the oil pump t o the drive gear, fit and tighten the
nuts.
Use ring seals at both ends of the oil delivery

Locate the crankshaft undershield on the nuts, Fig 4

and place the oil delivery pipe into position.
12-95
 ENGINE 5.3

Loosely secure the undershield and delivery pipe using

two washers.
Use a new 0' ring seal at the suction elbow and locate
the suction pipe.
Secure the suction pipe clips and bracket using four
washers.
Fully tighten all six setscrews securing the undershield.
Refit the drive plate to the crankshaft; ensure that the
dowels are located correctly (2 Fig 31.
Use a new locking plate. Fit and tighten the securing
bolts (1 Fig 3).
Refit the crankshaft sprocket.
If the timing chain guide is being renewed, reset all the
guides
Refit the timing chain tensioner (2 Fig 4) ensuring that it
is fully retracted.
Smear the journals of the jackshaft with clean engine
oil and fit the jackshaft.
Refit the jackshaft locking plate.

Reposition the camshaft sprockets using retaining

tools JD 40 (3
Attach a dial gauge to number one 'A' bank cylinder
head stud.
Rotate the crankshaft, and using the dial gauge, set
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number one 'A' piston at TDC (1 Fig 1 page 97).

Refit the iackshaft and timing chain, ensuring
equal amount side of the crankshaft
and jackshaft.
Ensure that the centre punch marks on the sprocket
and jackshaft are 180 degrees apart and that the mark
on the jackshaft is at the top. Fit jackshaft retaining tool
JD 39. Tighten the bolts and lock over the tabs (1 Fig

Remove jackshaft retaining tool JD 39.

CAUTION: The engine must on no account be rotated
until the camshaft sprockets are coupled to the
camshafts.
Refit the timing cover, use a new crankshaft oil seal
and gaskets, tighten the bolts by diagonal selection.
Refit the crankshaft spacer.
If necessary, renew the 0 ring seal in the oil pump
suction elbow.
Fit the sandwich plate to the crankcase, using a new
gasket, and secure using Secure
the crankshaft angle indicator scale.
Fit the baffle plate to the sandwich plate.
Fit the oil sump pan, securing the oil cooler pipe
bracket as noted.
Fit the suction union elbow t o the sandwich plate and
secure. Use a new seal.
Remove cylinder liner retaining tools JD 41 .

Smear the mating faces of the tappet block and

cylinder head with Hylomar.
Refit the tappet block to the cylinder head, tighten the
b y diagonal selection working from
the centre outwards.
Refit the camshafts.
Refit the bearing caps ensuring that reference marks
correspond, tighten nuts by diagonal selection
working from centre outwards.
Adjust the valve clearances
Fit the cylinder head gasket with 'TOP' uppermost. Do
not use jointing compound or grease.

12-96
 ENGINE 5.3

Turn each camshaft until valve timing gauge C 3993

can be fitted to the slot in the front flange (4 Fig 3).
Refit the cylinder heads. Torque tighten the nuts in the
correct sequence (Fig 2).
Reconnect the camshaft oil feed pipes.
Remove retaining tools JD 40 (2 Fig 3).
Remove the circlip retaining the camshaft sprocket
couplings (1 Fig 3), press the sprocket on to the
camshaft shoulder.
Rotate the coupling until t w o bolt holes align with holes
in the
Refit the couplings to the camshaft sprockets, refit the
circlips, remove gauge C 3993.
Fit and tighten the securing washers, lock
over the tabs (3 Fig 3).
Insert screwdriver tool JD 50-2 through the hole in the
timing cover and release the chain tensioner locking
catch; refit the rubber grommet.

Rotate the engine until the remaining bolt holes in the

coupling are visible.
Fit the remaining bolts, secure all bolts with 14
tabwashers.
Apply sealant to the radial edge of a new half moon
(Fig 4). Fit the seal to the carrier.
Fit new camshaft cover gaskets (2 Fig 1 page 98). Refit
the camshaft cover, fit and torque tighten the securing Fig 2
bolts.
Refit the jackshaft cover.
Refit the alternator and bracket.
Refit the distributor and amplifier unit.
Refit the water pump (using a new gasket) and engine
cross pipe. Refit the water inlet pipe t o the water

Fit a new Woodruff key (4 Fig 2 page 98) to the

crankshaft. Refit the damper cone (3 Fig 2 page 98) .
Fit a new Woodruff key t o the crankshaft (3 Fig 2 page
98). Refit the crankshaft damper and pulley. Fit and
tighten the securing bolts Fig 2 page 98).
Refit the starter motor. Fit and tighten the securing
bolts.
Refit the transmission oil cooler pipes to the engine.
Refit the air pump mounting bracket and adjustment
link. Refit the air pump (IF FITTED).

Refit the compressor mounting bracket (AIRCON

CARS ONLY).
Refit the compressor (AIRCONCARS ONLY).
Refit the PAS pump mounting bracket and adjustment
link. Refit the PAS pump. Fig 3
Refit the fan idler pulley assembly. Tension the fan belt.
Reconnect the oil cooler suction pipe union.
Refit the torque converter 44.17.07 (AUTO ONLY).
Refit the clutch 33.10.01 (MANUAL ONLY).
Refit the filter head to the cylinder block.
Refit the bypass valve union to the sandwich plate.
Refit the oil filter
Reconnect the oil cooler feed pipe union.
Reconnect the oil pressure relief valve bleed pipe to the
top of the sandwich plate.
Refit the gearbox 44.20.01 (AUTO ONLY).
Refit the gearbox 33.10.01 (MANUALONLY).

12-97
 Refit the exhaust manifolds.
Refit the left and right hand induction manifolds.
Refit the assembly 12.37.0 1.
Refit the assembly. Ensure that the paint
marks align (Fig 3).
Evacuate and charge the air conditioning system
82.30.06 and 82.30.08 CARS ONLY).
Bleed the clutch 35.15.01 (MANUAL ONLY).
Reconnect the battery.
Refill the engine with clean engine oil (Fig4).
Adjust kickdown switch 44.30.09 (AUTO ONLY).
Check the ignitiontiming

out EGR emission test (FEDERAL

ONLY). Fig 1
Run engine and check for leaks
Bleed power assisted steering by turning steering from
lock to lock with engine running. Top up the reservoir.
the coolant, engine and transmission oil
levels.
Refit the bonnet and lower grille. Close the bonnet

DATA
Valve clearances:
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Exhaust

Top compression ring gap 0.36-0.5 1

Second compression ring gap
Oil control ring gap 0.38-

Piston skirt -
clearance

Piston ring side clearances:

Top ring -
Second ring -

I;
Bottom ring -Nil (self-expanding)

Small end bush bore 23.8

Cylinder Liner bore size:

GRADE 'A' (RED) -
GRADE 'B' (GREEN)-

SERVICE TOOLS
087

MS 538 Engine Tool. Fig 3

C 3993 Timing Gauge
JD I Oil SealPre-sizing Tool
JD 178- 1 Pre-sizing Tool Adaptor
JD 39 Jackshaft Retainer Tool
JD 40 Camshaft Sprocket Retainer
JD 41 Cylinder RetainingBrackets
JD 50 Timing Chain Tensioner Retainer and Release
Tool

Fig 4

12-98
 ENGINE 5.3

DATA
TORQUE FIGURES

Banjo connector bolts 12- 14Nm

Camshaft sprocket to camshaft 23-27Nm
Camshaft cover 1 1 Nm
Connecting rod cap nuts
Cylinder head to block (9/ 36Nm
Cylinder head to block 70Nm
EGR valve to throttle housing 9.5-
Elbow to inlet manifold
Engine mounting bracket t o crossmember
Engine mounting tie bolts 34-40Nm
Exhaust down pipe to manifold 30-35Nm
to waterpump 23-27Nm
Flywheel bolts
Fuelpipe unions
Fuelpipeunions
Fuelpipe unions 27-33Nm
Heat shield to
Hose
Inlet manifold to cylinder head (nuts) 23-27Nm
Inlet manifold t o cylinder head (bolts)23-27Nm
Main bearing cap nuts 84Nm maximum
Main bearing cap nuts 36.5-38Nm
Oil cooler pipes 54-60Nm
to mounting bracket 50Nm
Propeller shaft bolts 36.5-43Nm
Rear engine mounting peg 34-40Nm
Rear engine mounting rubbers 36-43Nm
Rear engine mounting to body (5/ 16 bolt)
Rear engine mounting to body bolt) 36-43Nm
Sandwich plate to block 7 Nm
Silencer to compressor union 34Nm
Sump set screws
Torque converter bolts 55-62Nm
Thermostat housing to cylinder head

SPANNER SIZES

AF

Half moon seal

Exhaust downpipe Kay Adhesives 5696
Crankshaft rear oil seal Colloidal Graphite
 ENGINE 5.3- HE

CONTENTS
DESCRIPTION OPERATION OPERATION PAGE
No No

CAMSHAFT COVER GASKET - LEFT HAND RENEW 12.29.40 12-03

CAMSHAFT COVER GASKET - RIGHT HAND RENEW 12.29.41
CRANKSHAFT FRONT OIL SEAL ......................... RENEW 12.21.14
CYLINDER HEAD GASKET- LEFT HAND REN
CYLINDER HEAD GASKET- RIGHT HAND REN
ENGINE DES
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12-0 1
 ENGINE 5.3- HE

2 5.3 HE ENGINE
GENERAL DESCRIPTION

The V12 5.3 HE engine features a new type of combustion chamber design (May 'Fireball'), which gives more
efficient combustion by controlling the movement of the mixture. It also allows the use of a higher
compression ratio, increased from 10: 1 to 12.5: 1.

The combustion chamber (Fig 1) consists of t w o 'areas', a small one beneath the inlet valve, with a narrow
guide channel leading to a larger area beneath the exhaust valve, where the spark plug is located.

As the piston commences its compression stroke, the mixture is compressed in the inlet valve area, and
swirls along the guide channel to the larger combustion area, where it is ignited.

The strong turbulence and 'squish' effect, produced by the compression and swirling of the mixture from the
small to the large combustion chamber areas, gives better mixing and controlled, even burning. It also
allows the use of a very lean mixture.
The new inlet valve has a flat face and forms the ceiling of the small compression area. The exhaust valve
remains slightly dished.

The pistons are new, and have a dished crown instead of the previously flat face.
A new digital fuel injection system has been fitted to the HE engine, the 'Lucas - P' system, which is more
flexible than the previous D-Jetronic system, and is better suited to the high efficiency cylinder head design.

Fig 1

12-02
 ENGINE

CAMSHAFT C
RENEW

Open the luggage compartment and remove the right

hand side trim.
Disconnect the cable from the fuel pump relay terminal
85 (Fig 1).
Open the bonnet.
Disconnect the HT lead from the ignition coil. Fig 1
Switch on the ignition and crank the engine for
approximately five seconds.
Switch off the ignition.
Reconnect the fuel pump terminal and refit the luggage
compartment trim.
Remove the battery cover, and disconnect the battery.
Remove the LH air cleaner cover and element
19.10.01.
Remove the bolts securing the fuel cooler to the LH air
cleaner back plate.
Disconnect the fuel regulator hose from the fuel cooler.
Fit blanking plugs to the hose and cooler.
Remove the ignition amplifier.
Remove the clip securing the harness to the fuel rail.
Displace the regulator hose from the injector mounting
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position.
Disconnect all the LH injectors (Fig 2) and the cold start
injector Fig 3).
Disconnect the LH throttle rod from the throttle
pedestal.
Disconnect the harness from the coolant temperature
transmitter (Fig4).
Disconnect the hoses from the valve in the air
cleaner back date.
Disconnect the manifold cross pipe from the inlet
manifold.
Re-position the cross pipe awayfrom the area.
Remove the bolt securing the ignition amplifier harness
t o the inlet manifold.
Disconnect the rear balance pipe hose and the auxiliary
air valve hose from the inlet manifold.
Disconnect the auxiliary air valve hose from the air
cleaner back plate.
Remove the throttle return spring.
Disconnect the fuel regulator to LH fuel rail hose.
Slacken the clips and separate the fuel rail halves, fit
blanking plugs to the hoses and fuel rail ends.
Remove the nuts securing the LH inlet manifold, and
remove inlet manifold. Remove and discard all
gaskets.
Fit blanking plugs to the inlet ports to prevent the
ingress of dirt, etc.
Remove the camshaft cover securing Fig
1
Remove the harness clip from the front stud and
remove the camshaft cover. Remove and discard the
cover gasket and half moon seal (2 Fig 1 page 04).
Apply sealant t o the radial edge of a new half moon
seal (Fig 2 page 04).
Fit the seal to the cam carrier.
Refit the camshaft cover using a new gasket.
Fit and torque tighten the securing
Remove the blanking plugs from the inlet ports and
refit the inlet manifolds, using new gaskets.
Refit the fuel rail and fuel regulator.
 ENGINE 5.3- HE

Refit the throttle return spring.

Reconnect the auxiliary air valve hose and the rear
balance pipe hose.
Refit the ignition amplifier harness to the inlet manifold,
Reconnect the manifold cross pipe and valve hose.
Reconnect the coolant temperature transmitter har-
ness.
Reconnect the throttle rod to the throttle pedestal.
Reconnect the injectors and cold start injector.
Position the regulator hose, and secure the harness to
the fuel rail.
Refit the ignition amplifier.
Reconnect the fuel regulator hose to the fuel cooler.
Secure the fuel cooler to the air cleaner backplate.
Refit the air cleaner assembly.
Reconnect the battery.
Close the bonnet.

DATA
TORQUE FIGURES
Fig 1
Cam cover 7 Nm
lnlet manifold to cylinder head (nuts)23-2 7Nm
lnlet manifold to cylinder head (bolts)23-27Nm
Elbow to inlet manrfold
Hose

SPANNER SIZES

16" A F

6 AF

Half moon seal 702

CAMSHAFT COVER GASKET RIGHT

HAND
Fig 2
RENEW 12.29.41

Depressurise the air conditioning system (if fitted)

Open the luggage compartment and remove the right

hand side trim.
Disconnect the cable from the fuel pump relay terminal
85 (Fig 3).
Open the bonnet.
Disconnect the HT lead from the ignition coil.
Switch on the ignition and crank the engine for
approximately five seconds.
Switch off the ignition.
Reconnect the fuel pump terminal and refit the luggage
Compartment trim.
Remove the battery cover, and disconnect the battery.
Remove the air cleaner cover and element.

Fig 3

12-04
 ENGINE 5.3 - HE

Disconnect the fuel feed hose from the engine bundy

pipe; fit suitable blanking plugs to the hose and pipe
ends.
Remove the dump valve from the mounting bracket;
disconnect the coolant temperature and t w o way
solenoid valve feed wires.
Remove the manifold cross pipe from the inlet
manifold.
Disconnect all the injectors (Fig 1) and the cold start
injector.
Remove the clips securing the harness t o the fuel
rail.
Disconnect the throttle cable and throttle rod from
the throttle pedestal.
Disconnect the vacuum pipe from the distributor
vacuum capsule.
Remove the screw securing the solenoid air switch to
the inlet manifold and remove the earth wires.
Remove the nuts and bolts securing the brake fluid
reservoir, disconnect the electrical leads, and carefully
displace the reservoir to one side.
Remove the overrun valve securing screws (1 Fig 2). Fig 1
disconnect the valve (2 Fig 2) from the inlet
manifold. Remove the throttle linkage.
Disconnect the vacuum pipe from the three way
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solenoid valve and disconnect the electrical leads.

Disconnect the electrical leads from the coolant
temperature switch (Fig 3). Remove the throttle return
spring.
Slacken the clips and separate the fuel rail halves, fit
blanking plugs to the hoses and fuel rail ends.
Remove the nuts securing the manifold and remove
the inlet manifold.
Remove and discard all gaskets.
Remove the securing the camshaft cover.
Remove the air conditioning compressor silencer
securing bolt (1 Fig 1 page 06).
Carefully remove the camshaft cover from beneath the
air conditioning pipe (2 Fig 1 page 06) and the rear
coolant hose. Remove and discard the cover gasket
and half moon seal.
Refit the camshaft cover using a new gasket.
Fit and torque tighten the securing
Secure the air conditioning compressor silencer t o the
front of the compressor.
Remove the blanking plugs from the inlet ports and
refit the inlet manifolds, using new gaskets.
Refit the fuel rail and hoses.
Fig 2
Refit the throttle return spring.
Reconnect the water temperature switch.
Reconnect the vacuum pipe and leads to the three way
solenoid valve.
Refit the throttle linkage.
Refit the overrun valve to the inlet manifold.
Refit the brake fluid reservoir.
Refit the solenoid air switch t o the inlet manifold.
Reconnect the throttle cable and throttle rod t o the
throttle pedestal.
Reconnect the vacuum pipe.
Reconnect the injectors and cold start injector.

Fig 3
12-05
 ENGINE 5.3- HE

Position the regulator hose, and secure the harness to

the fuel rail.
Refit the manifold cross pipe to the inlet manifold.
Refit the dump valve. Reconnect the coolant
ature and two way solenoid feed wires.
Reconnect the fuel feed hose.
Refit the air cleaner assembly.
Reconnect the battery.
Close the bonnet.

DATA

Cam cover I Nm
Inlet manifold to cylinder head (nuts) 23-27Nm
manifold to cylinder head (bolts) 23-27Nm
to inlet manifold 182 255
Hose clips

16 F

Half moon

LEFT HAN
RENEW 12.29.02
Remove the LH camshaft cover
Remove the camshaft cover 12.29.41.
Disconnect the thermostat housing to cross-over pipe
hose.
Remove the bolts securing the thermostat housing,
auxiliary air valve and lifting eyes to the cylinder head.
Re-position the housing clear of the cylinder head.
Remove and discard the gaskets.
Remove unit
Rotate the engine and fit Timing Gauge C 3993 to the
right hand camshaft recess (Fig 2).
Remove the rubber grommet from the front of the
timing cover.
Insert Service Tool JD 50 (Release Tool) through the
timing cover Fig and release the locking catch on
the timing chain tensioner.
Fit Service Tool JD 5 0 (Chain Tension Retainer), and
retract the timing chain tensioner (2 Fig 3) until the
locking catch is engaged.
Remove Service Tools JD 50.
Remove Timing Gauge
Note the t w o uppermost camshaft sprocket retaining
bolts.
Rotate the engine until the two LOWER camshaft
sprocket retaining bolts become accessible.
Push back the lock tabs and remove the t w o retaining
bolts.
Fig 3

12-06
 ENGINE 5.3- HE

Rotate the engine to the camshaft removal position

and refit Timing Gauge C 3993.
Remove the remaining two camshaft sprocket bolts
and fit Service Tool JD 40 (1 Fig 1).
CAUTION: DO NOT ROTATE THE ENGINE WHILE THE
CAMSHAFT IS DISCONNECTED.
Jack up the vehicle and support with axle stands.
Remove the steering rack gaiter heat shield (1 Fig 2).
Remove the front heat shield (2 Fig 2).
Remove the LH exhaust down pipe heat shield (3 Fig

Disconnect the LH exhaust down pipe from the

manifold. Discard the sealing rings.
Remove the LH exhaust manifold heat shield.
Disconnect the EGR pipe (FEDERALONLY).
Remove the axle stands and lower the vehicle. Fig 1
Remove the gearbox dipstick tube clamp (1 Fig 3) 1
(AUTO ONLY).
Re-position the tube away from the engine (AUTO
ONLY).
Disconnect the fuel hoses from the cooler Fig 4).
Fit blanking plugs to all disturbed connections.
Disconnect the camshaft oil feed pipe assembly (2 Fig
4). Discard the sealing washers.
NOTE: Place cloths or similar below the working area
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to catch any leaking oil.

Remove the three cylinder head to timing cover
securing nuts and washers.
Progressively slacken off the cylinder head nuts,
commencing at the outer edges and working towards
the centre of the head.
Remove the securing nuts and washers and remove
the cylinder head assembly.
NOTE: Always support the cylinder heads on blocks of
wood. This will prevent damage t o the valves which,
when open, protrude below the cylinder head face. Fig 2
CAUTION: DO NOT REMOVE TIMING GAUGE C 3993
FROM THE CAMSHAFT
CAUTION: IF FOR ANY REASON ENGINE ROTATION
BECOMES NECESSARY (CYLINDER BORE EXAM-
INATION, ETC), DO NOT ROTATE THE ENGINE UNTIL
SERVICE TOOL JD 41 RETAINING BRACKETS HAVE
BEEN FITTED TO THE CYLINDER LINERS.
Clean all components thoroughly. Examine all com-
ponent parts for wear and damage.
Replace worn or damaged components as necessary.
Ensure that the cylinder head and block mating faces Fig 3
are clean, and all galleries are not obstructed.
Fit a new gasket to the cylinder block, ensuring that the
side marked 'TOP' is uppermost.
CAUTION: Do not use any grease or jointing
compound on the cylinder head gasket.
Fit the cylinder head.
Fit the cylinder head securing nuts and washers.
Tighten the cylinder head to block securing nuts in the
correct sequence (Fig 1 page 08) to the torque figures
given in DATA.
Tighten the cylinder head to timing cover securing nuts
(14 Fig 1 page 08) to the torque figures given in DATA.
Remove Service Tool JD 40 and check the alignment
of the sprocket retaining bolt holes.

Fig 4

12-07
 ENGINE 5.3- HE

If the and sprocket holes are not in

alignment, remove the coupling to sprocket retaining
circlip Fig and disengage the coupling from the
splines, a t the same pressing the sprocket (3 Fig
2) on to the camshaft shoulder (2 Fig 2).
Rotate the coupling until alignment is obtained
Engage the splines, and fit two securing bolts using a
new tab washer.
Lock over the tabs and refit the retaining circlip
Remove Timing Gauge C 3993
Rotate the engine until the remaining sprocket securing
washer can befitted
Tighten the bolts and lock over the tabs
Refit the camshaft oil feed pipe assembly, using new
sealing washers
Refit the amplifier unit
Remove the blanking plugs and reconnect the fuel
hoses to the cooler 14
Refit the gearbox dipstick tube (AUTO ONLY)
Refit the rear exhaust manifold and heat shield
Jack up the vehicle and support with axle stands
Refit the EGR pipe (FEDERAL ONLY)
Refit the exhaust down pipe, using new sealing rings
the heat shield Fig 1
Refit the front heat shield
Refit the steering rack gaiter heat shield
Remove the axle stands and lower the vehicle
Fit Service Tool JD 5 0 (Chain Tension Retainer) and
raise the timing chain tensioner slightly 2
Insert Service Tool JD 50 (Release Tool) through the
timing cover.
Release the locking catch and allow the tensioner to
expand.
Remove both Service Tools. Refit the rubber grommet
to the front of the timing cover.
Adjust the valve clearances
Refit the assembly.
Refit the thermostat valve assembly, using
new gaskets.
Reconnect the cross-over pipe hose t o the thermostat Fig 2
housing.
Refit the camshaft covers.
Refit the induction manifolds.
Evacuate and charge the air conditioning system
82.30.06 and
Refit the air cleaner.
Reconnect the battery.
up the engine oil.
Check the ignition timing
Carry out EGR emission test 17.00.00 (FEDERAL
ONLY).
Close the bonnet.

DATA
Valve clearances:
14in.
Exhaust0.012-0.0

SERVICE TOOLS
C 3993 Timing Gauge
JD 40 Camshaft Sprocket Retainer
J D 4 Cylinder Liner Retaining Brackets
JD 50 Timing Chain Tension RetainerandRelease Tool
 ENGINE 5.3- HE

DATA
TORQUE FIGURES

Banjo connector bolts 12- 14Nm

Bearing caps to carrier 1 1
Camshaft sprocket to camshaft 23-27Nm
Camshaft cover 1 1Nm
Cylinder head to block 36Nm
Cylinder head t o block 70Nm
EGR valve to throttle housing 9.5-
Elbow to inlet manifold
Exhaust manifold to cylinder head 23-27Nm
to waterpump 23-27Nm
Exhaust down pipe to manifold 30-35Nm
Heat shield to
Hose clips
Inlet manifold to cylinder head (nuts) 23-27Nm
Inlet manifold to cylinder head (bolts) 23-27Nm
Silencer to compressor union 34Nm
Thermostat housing to cylinder head

SPANNER SIZES

16" A F
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AF
AF

J ! Z 582

BR ANTS
Fig 1
Half moon seal
Exhaust down pipe Kay Adhesives 5696

31

CYLINDER HEAD GASKET - RIGHT

HAND
RENEW 12.29.03

Remove the right hand camshaft cover

Remove the unit 26.25.2
Disconnect the thermostat housing t o cross-over pipe
hose Fig 1).
Remove the bolts securing the thermostat housing,
auxiliary air valve and lifting eyes to the cylinder head.
Re-position the housing clear of the cylinder head.
Remove and discard the gaskets.
Slacken off the air pulley adjusting bolt
lock nuts.
Remove the adjusting bolt bracket from the cylinder
head (2 Fig 1).
Remove the compressor securing bolts, disengage the
drive belt (3 Fig 1) from the pulley, and re-position the
compressor away from the working area
CARS ONLY).
Rotate the engine and fit Timing Gauge 3993 to the
right hand recess (Fig 2).
Fig 2
Remove the rubber grommet from the front of the
timing cover.

12-09
 ENGINE 5.3- HE

Insert Service Tool JD 50 (Release Tool) through the

timing cover, and release the locking catch on the
timing chain tensioner.
Fit Service Tool JD 50 (Chain Tension Retainer), and
retract the timing chain tensioner until the lockingcatch
is engaged.
Remove Service Tools JD 50.
Remove Timing Gauge C 3993.
Note the two uppermost camshaft sprocket retaining
bolts.
Rotate the engine until the two LOWER camshaft
sprocket retaining bolts become accessible.
Push back the lock tabs and remove the two retaining
bolts.
Rotate the engine to the camshaft removal position
and refit Timing Gauge C 3993.
Remove the remaining two camshaft sprocket bolts Fig 1
and fit Service Tool JD 40 1 1
CAUTION: DO NOT ROTATE ENGINE WHILE THE
CAMSHAFT IS DISCONNECTED.
Jack up the vehicle and support with axle stands.
Remove the exhaust down pipe heat shield (3 Fig

Disconnect the exhaust down pipe from the

manifold. Discardthe sealing rings.
Removethe exhaust manifold heat shield (2
Disconnect the EGR pipe (FEDERAL ONLY).
Remove the axle stands and lower the vehicle,
Disconnect the camshaft oil feed pipe assembly (2 Fig
3). Discard the sealing washers.
NOTE: Place cloths or similar below the working area
to catch any leaking oil.
Remove the three cylinder head to timing cover
securing nuts and washers. Re-position the cable clips
away from the studs.
Progressively slacken off the cylinder head nuts,
commencing a t the outer edges and working towards
the centre of the head.
Remove the securing nuts and washers and remove Fig 2
the cylinder head assembly.
NOTE: Alwavs the cvlinder heads on blocks of
wood This prevent damage to the valves which,
when open, protrude below the cylinder head face
CAUTION. DO NOT REMOVE TIMING GAUGE C 3993
FROM THE CAMSHAFT
CAUTION IF FOR ANY REASON ENGINE ROTATION
BECOMES NECESSARY (CYLINDER BORE EXAM-
INATION, ETC), DO NOT ROTATE THE ENGINE UNTIL
SERVICE TOOL JD 41 RETAINING BRACKETS HAVE
BEEN FITTED TO THE CYLINDER LINERS
CLEAN ALL COMPONENTS THOROUGHLY EXAMINE
ALL COMPONENT PARTS FOR WEAR AND
DAMAGE
REPLACE WORN OR DAMAGED COMPONENTS AS
NECESSARY
ENSURE THAT THE CYLINDER HEAD AND BLOCK
MATING FACES ARE CLEAN, AND ALL
GALLERIES ARE NOT OBSTRUCTED
FIT A NEW GASKETT TO THE CYLINDER BLOCK, Fig 3
ENSURING THAT THE SIDE MARKED 'TOP' IS
UPPERMOST.
CAUTION: DO NOT USE ANY GREASE OR
COMPOUND ON THE CYLINDER HEAD GASKET.
Fit the cylinder head.
Fit the cylinder head securing nuts and washers.

12-10
 ENGINE 5.3 - HE

Tighten the cylinder head t o block securing nuts in the

correct sequence (Fig 1) to the torque figures given in
DATA
Tighten the cylinder head to timing cover securing nuts
(14 Fig 1 ) to the torque figures given in DATA
Remove Service Tool JD 4 0 and check the alignment
of the sprocket retaining bolt holes
If the and sprocket holes are not in
alignment, remove the coupling to sprocket retaining
circlip (1 Fig 2), and disengage the coupling from the 14
splines, a t the same pressing the sprocket (3 Fig
on to the camshaft shoulder Fia
Rotate the coupling until alignment obtained.
Engage the splines, and fit t w o securing bolts using a
new tab washer.
Lock over the tabs and refit the retaining circlip. Fig 1
Remove Timing Gauge C 3993.
Rotate the engine until the remaining sprocket securing
washer can be fitted.
Tighten the bolts and lock over the tabs.
Refit the camshaft oil feed pipe using new
sealing washers.
Refit the rear exhaust manifold and heat shield.
Refit the starter motor and heat shield.
Jack up the vehicle and support with axle stands.
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Refit the EGR pipe (FEDERALONLY).

Refit the exhaust down pipe, using new sealing rings.
Refit the heat shield.
Remove the axle stands and lower the vehicle.
Fit Service Tool JD 50 (Chain Tension Retainer) and
raise the timing chain tensioner slightly.
Insert Service Tool JD 50 (Release Tool) through the
timing cover.
Release the locking catch and allow the tensioner to
expand.
Remove both Service Tools. Refit the rubber grommet
t o the front of the timing cover.
Refit the belt ONLY).
Refit the air pulley adjusting bolt
bracket. Adjust the pulley and tighten the locknuts.
Adjust the valve clearances
Refit the assembly.
Refit the thermostat valve assembly, using
new gaskets.
Reconnect the cross-over pipe hose t o the thermostat
housing.
Refit the camshaft covers.
Refit the induction manifolds.
Evacuate and charge the air conditioning system
82.30.06 and
Refit the air cleaner. Reconnect the battery.
up the engine oil.
Check the ignition timing 86.35.29.
Carry out EGR emission test 17.00.00 (FEDERAL
ONLY).
DATA
Valve clearances:
0.012-0.0
Exhaust 0.0 12-0.0
SERVICE TOOLS
C 3993 Timing Gauge
JD 40 Camshaft Sprocket Retainer
Cylinder Brackets
JD 50 Timing Chain Retainer and Release Tool

1
 ENGINE 5.3- HE

DATA
TORQUE FIGURES

Banjo connectorbolts 12- 14Nm

Bearing caps to carrier 1 1
Camshaft sprocket to camshaft 23-27Nm
Camshaft cover 1 I Nm
Cylinder head to block 36Nm
Cylinderhead to block 70Nm
EGR valve to throttle housing 9.5-
Elbow to inlet manifold
Exhaust manifold to cylinder
to waterpump 23-27Nm
down pipe to manifold 30-35Nm
Heat shield to
Hose clips
manifold to cylinder head (nuts) 23-27Nm
manifold to cylinder head (bolts) 23-27Nm
Silencer to compressor union 34Nm
Starter motor bolts 32-39Nm
Thermostat housing to cylinder head 23-27Nm

SPANNER SIZES

16“A F

F
5/8 A F
7

Half moon seal

Exhaust downpipe Kay Adhesives 5696

CRANKSHAFT FRONT
RENEW 12.21
Remove the left and right hand air cleaner covers and
elements. \
Remove the radiator 26.40.04.
Remove the torquatrol unit 26.25.2 1 . Fig 1
Remove the PAS pump drive belt 57.20.02.
Remove the drive belt 86.10.03.
Remove the compressor air pump drive belt 82.10.02
,-
CARS ONLY).
Remove the pulley securing bolts (1 Fig 1) and
withdraw the pulley.
Remove the crankshaft damper bolt (2 Fig 1 ) .
Loosen off the damper by striking with a hide mallet.
Withdraw the damper and cone (3 Fig retrieve both
Woodruff keys (4 Fig 1) from the cone and crankshaft.
Prise the seal Fig 2) from the timing cover. Discard
the seal.
Withdraw the crankshaft spacer (2 Fig 2).
Examine all components for wear and damage.
Replace worn or damaged components as necessary.
Ensure that the seal recess is absolutely clean. Fig 2

12-12
 ENGINE 5.3- HE

DATA
TORQUE FIGURES

Banjo connectorbolts 12- 14Nm

Bearing caps to carrier 1 1
Camshaft sprocket to camshaft 23-27Nm
Camshaft cover 1 I Nm
Cylinder head to block 36Nm
Cylinderhead to block 70Nm
EGR valve to throttle housing 9.5-
Elbow to inlet manifold
Exhaust manifold to cylinder
to waterpump 23-27Nm
down pipe to manifold 30-35Nm
Heat shield to
Hose clips
manifold to cylinder head (nuts) 23-27Nm
manifold to cylinder head (bolts) 23-27Nm
Silencer to compressor union 34Nm
Starter motor bolts 32-39Nm
Thermostat housing to cylinder head 23-27Nm

SPANNER SIZES
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16“A F

F
5/8 A F
7

Half moon seal

Exhaust downpipe Kay Adhesives 5696

CRANKSHAFT FRONT
RENEW 12.21
Remove the left and right hand air cleaner covers and
elements. \
Remove the radiator 26.40.04.
Remove the torquatrol unit 26.25.2 1 . Fig 1
Remove the PAS pump drive belt 57.20.02.
Remove the drive belt 86.10.03.
Remove the compressor air pump drive belt 82.10.02
,-
CARS ONLY).
Remove the pulley securing bolts (1 Fig 1) and
withdraw the pulley.
Remove the crankshaft damper bolt (2 Fig 1 ) .
Loosen off the damper by striking with a hide mallet.
Withdraw the damper and cone (3 Fig retrieve both
Woodruff keys (4 Fig 1) from the cone and crankshaft.
Prise the seal Fig 2) from the timing cover. Discard
the seal.
Withdraw the crankshaft spacer (2 Fig 2).
Examine all components for wear and damage.
Replace worn or damaged components as necessary.
Ensure that the seal recess is absolutely clean. Fig 2

12-12
 ENGINE 5.3 - HE

Smear the new seal with clean engine oil.

Position the seal squarely in the recess and tap gently
home with a hide mallet.
Fit t w o NEW Woodruff keys to the cone and
crankshaft.
Fit the replacement (3 Fig fit and
tighten the crankshaft damper bolt (2 Fig 1).
Fit the pulley, fit and tighten the securing bolts Fig
Refit the compressor air pump drive belt 82.10.02
CARS ONLY).
the alternator drive belt 86.10.03.
the PAS pump drive belt 57.20.02.
Refit the torquatrol unit 26.25.21.
Refit the radiator 26.40.04.
Refill the coolant system.
Evacuate and charge the air conditioning system \
82.30.06 and 82.30.08. Fig I
Refit the air cleaner.

DATA
TORQUE FIGURES

pivot 20-27Nm
Crankshaft damper bolt
Crankshaft pulley to damper Nm
Fan cowl bracket to lower
Fan cowl to body
Fan mounting to
Mounting bracket to fan
coolerpipes

SPANNER SIZES

F
AF
16"AF

12-13
 EMISSION FUEL SYSTEM

CONTENTS

DESCRIPTION OPERATION OPERATION PAGE

No No

ADSORPTION CANISTER .......................... RENEW .........

AIR DELIVERY PUMP ......... ........ 17.25.07 .......... 17-12
AIR DELIVERY PUMP DRIVE
AIR DELIVERY PUMP DRIVE ......................... ................ 17.25.15
AIR RAIL (LEFT-HAND) .......
AIR RAIL (RIGHT-HAND) ............
CATALYTIC CONVERTER (LEFT
CATALYTIC CONVERTER (RIGH
CHECK VALVE ............ ............................ RENEW
CRANKCASE BREATHE
........................
EMISSION CONTROLSYSTEM .................... ....... 17.00.00
EMISSION CONTROL SYSTEM
EMISSION CONTROL SYSTEM ....... .......... TESTING

EGR CONTROL UNIT ....................

EGR VALVE .................... .......................... RENEW 17.45.01 .......... 17-15
EGR VALVETRANSFER PIPE ........ ................... RENEW

EXHAUST GAS SYSTEM

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17-01

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 EMISSION FUEL SYSTEM

EMISSION CONTROLSYSTEM V 12
Description

The emission control system fitted is designed to

comply with local legislative requirements. Some or all
of the following components may be fitted depending
on those requirements. The description that follows
refers to cars with an emission control system that
complies with North American Federal specification.
The system is of the air injection type and comprises
the following major components. The components act
upon the engine and interact with each other as
detailed.

Air injection system

An air delivery pump (A), supplies air under pressure,

through a diverter valve (B), a check valve and air
rails (E) to the exhaust ports just above the exhaust
valve heads.
This air combines with the exhaust gas to continue the
oxidisation process in the exhaust system. The check
valve prevents flow in the air rails when exhaust gas
pressure exceeds air supply pressure.
the diverter valve operates in response t o an abrupt fall
in manifold pressure, i.e.
sudden closure of throttle, and diverts secondary air t o
atmosphere for a period of 2-3 seconds. This reduces
the ratio which would otherwise be too rich t o
burn and would pass through the engine t o mix with
secondary air and become combustible. The next firing Fig 1
cycle would then ignite the mixture causing a backfire Key to illustration
in the exhaust system. The diverter valve is actuated
by manifold pressure via a rubber tube connected to a A Air delivery pump
tapping in the inlet manifold. B valve
C Exhaust gas recirculation (E.G.R.) Valves
Thermostatic Vacuum System D Checkvalve
E
In conjunction with the Emission Control four F Positive crankcase ventilation valve
conditions of the thermostatic vaacuum system are Engine breather filter
fitted:
A For cars to Canada and USA (Federal) except
California. Fig. 2.
B For cars other than A.C.D. Fig. 2.
C For cars to California (1977 and 1978). Fig. 3 4
D For cars to Australia (1977 and 1978). Fig. 4-5.

The various components used in these systems are

described below: A distributor is fitted with a vacuum
retard capsule (1B) for 1977 Australia and California
cars.
A vacuum capsule for 1978
California and Australia cars.
A vacuum advance capsule (1A) for Federal and all
others as B above.

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 EMISSION FUELSYSTEM

Throttle edge ports (2).

Vacuum supply (3).
The PRV incorporated in the valve (4) is
controlled by secondary air supply back pressure, 565
t o 724 bar. The PRV provides the safety for the
secondary air pump protection.
Carbon canister (5) only.
Thermostatic vacuum switch (6) incorporates a
capsule controlled valve sensing engine coolant
temperature. The valve advances ignition timing
should the coolant temperature exceed
At this temperature port D switches from port C t o
port M.
Thermostatic vacuum switch California 1977 only
incorporates a wax capsule controlled valve sensing
engine coolant temperature. The valve inhibits part
throttle ignition retard until the coolant exceeds the
specified temperature.
The switch is controlled by coolant temperature to
switch port 2 from port 3 to port 1 a t (fully open) Fig 1 C Emission Califor
168.8 + or - (76’ or - This was fitted to
1977 California cars only.
Thermostatic vacuum switch (7A) incorporates a wax
capsule controlled valve, sensing engine coolant
temperature which inhibits part throttle ignition
advance until engine coolant exceeds the specified
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temperature. The switch is controlled by engine

coolant temperature and switches port 2 from port 3
to port 1 at (fully open) 169F The use of this
valve improves the efficiency of the exhaust emission
control system during the engine warm up phase by
inhibiting the part throttle vacuum ignition advance.
Air cleaner (8)Full throttle switch (Australia 1977).
The vacuum operated switch initiates a signal to the
ECU at full throttle and modifies the injection pulse.
Thermal vacuum valve (10). controlled by a bimetal
element sensing engine coolant temperature provides
a signal to the vacuum delay valve bypass during fully
warm engine operation so inhibiting the fast idle
system.
Vacuum delay valve (by-pass) (1 1) delays the rise of
the vacuum signal received by the supplementary air Fig 2 C Emission California
valve. Flow in the opposite direction is made possible
by means of a one way valve. A by-pass of the
restriction is present in order to allow the fast idle
function to be inhibited under fully warm conditions.
The delay valve is controlled by inlet manifold vacuum
and engine coolant temperature, without this device
the cold fast idle will not function.
Vacuum delay valve ( 1 2A) (full throttle), delays the fall
of the vacuum signal to the supplementary air valve
when the inlet

Fig 3 D Emission Australia

 EMISSION CONTROL‘D’ FUEL SYSTEM

vacuum drops towards zero, when the throttles

are fully opened, flow in the opposite direction is made
possible by means of a one way valve.
The function of the valve is due to delay operation of
supplementary air valve during short periods of engine
operation a t or near wide open throttle.
Vacuum delay valve (ignition) delays rise of
vacuum signal at ignition advance vacuum capsule
signal port; flow in the opposite direction is made
possible by means of a one way valve. The valve is
controlled by throttle edge (2) vacuum signal. The
function of the valve is to reduce emissions of oxides
of nitrogen during vehicle acceleration.
A Supplementary air valve (13) delivers extra air to
support cold engine fast idle; the operating vacuum is
controlled by a vacuum delay valve.
The valve is controlled by engine coolant temperature,
inlet manifold vacuum and delay valve calibrations. The
supplementary air valve increases the rate of engine
and catalytic converter warm-up so reducing the Fig 1 D Emission Australia
emission of unburnt hydrocarbons.
Ignition retard dump valve 14 senses rising throttle
edge vacuum signal and dumps the vacuum retard
signal.
The valve is controlled by throttle edge (2) vacuum
signal which enables improvements to be made t o part
throttle fuel economy.
A spring throttle valve bleeds air into the inlet manifold
during engine overrun modes. The valve is controlled
by spring setting, atmospheric pressure and inlet
manifold pressure.
The overrun valve opens a t depression 650 bar +
or - 135 milli bar.
The function of the valve is t o reduce emissions of
unburnt hydrocarbons during engine overrun modes.

Fast System (California and Australia)

A vacuum operated supplementary air valve (13)

supplies the extra air required t o support a fast idle of
up to 1200 at coolant temperatures up to
122’F
The control system operates as follows.
The operating vacuum source is the inlet manifold,
therefore in order t o prevent the supplementary air
valve (which is normally open) closing immediately the
inlet vacuum builds up following engine starting, a
vacuum delay valve 1) is fitted to the signal pipe.
In’order to inhibit the operation of the supplementary
air valve, after a hot start, it is necessary t o by-pass the
vacuum delay valve (1 1). This is accomplished by
means of a thermal vacuum valve (10). sensing engine
coolant temperature.

17-04
 EMISSION FUEL SYSTEM

The thermal vacuum valve (10) connects the inlet and

outlet ports of a by-pass incorporated in the delay
1).
A second vacuum delay is placed in the signal
pipe between the supplementary air valve and delay
valve 1) with the resistance to flow in the opposite
direction to that of valve (1 1). The function of this
second valve is to delay the loss of vacuum signal to
the supplementary air valve during short periods of
engine operations at or near wide open throttle.

Part Throttle Vacuum Ignition Retard System

(Australia)

At idle the ignition timing is controlled by a vacuum

operated capsule attached to the ignition distributor
C). The vacuum source is a port located downstream
of or in close proximity to the throttle butterfly. In the
event of the engine overheating the vacuum signal is
dumped by means of a thermostatic vacuum switch
(6). The switch is an valve controlled by a wax
capsule eensing engine coolant temperature. The
valve advances idle ignition timing, hence increasing
idle speed, should the engine coolant temperature
exceed
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Part Throttle Vacuum Ignition

System (California)

At idle the ignition timing is controlled by a vacuum

operated capsule attached to the ignition distributor
(IC). The vacuum source is the inlet manifold (3). via a
0.040 restrictor (16). In the event of the engine
overheating the vacuum signal is dumped by means of
a thermostatic vacuum switch (6) sensing engine
coolant temperature. This results in the ignition timing
being advanced and the idle speed increased. The
ignition vacuum advance system is inhibited by a
second thermostatic vacuum switch (7A) until the
engine coolant temperature exceeds 1 at which
point the vacuum signal sourced at the throttle edge (2)
is connected to the ignition advance capsule via a
delay valve In order to inhibit the vacuum
ignition retard the throttle edge vacuum signal is also
fed to a vacuum switch (14) which bleeds air at
atmospheric pressure into the retard vacuum pipe,
thus destroying the inlet manifold vacuum retard
signal.

Crankcase breather system

To ensure that piston blow-by gas does not escape

from the crankcase to atmosphere, a depression is
maintained in the crankcase under all operating
conditions.

17-05
 EMISSION CONTROL ‘D’ FUEL SYSTEM

This is achieved by connecting the crankcase breather

housing G’ to a chamber F’ in the left-hand air cleaner
backplate; this chamber has two outlets, one of
which is connected to the inlet manifold balance pipe
and the other to the inlet side of the air cleaner. In the
former there is fitted a variable orifice valve that
controls the part throttle crankcase ventilation. A
depression is maintained in the crankcase at full
throttle by the depression on the inlet side of the air
cleaner.

Exhaust gas recirculation(E.G.R.) system

Solenoid operated valves C’ meter a proportion of

exhaust gas into the induction system. The gas
diverted from the exhaust downpipe at a tapping
upstream of the catalytic converters and fed via valves
and fixed orifices in the induction system upstream of
the throttle butterfly valves.
The signal that operates the E.G.R. valves is
determined by the position of the throttle switch, such Fig 1
that there is no recirculationat idle and full throttle.
The E.G.R. valves are further inhibited until engine
coolant temperature exceeds 35‘C (95’9 and at road
speeds in excess of 60-65 mph. These functions are
controlled by the E.G.R. controller mounted inside the
luggage compartment behind the right-hand rear light
cluster.

Catalytic converters

Catalytic converters are fitted into the exhaust system

t o further reduce carbon monoxide and hydrocarbon
emissions. A system maintenance
indicator is built into the centre switch panel. The
indicator illuminates at 25,000 miles to indicate the
necessity for the renewal of catalytic converters and
maintenance t o the E.G.R. system. The switch
mechanism is built into the speedometer flexible drive
line. The unit is a gear driven mechanical reduction
device and is fitted with a magnetically operated reed
switch. The device is re-set t o zero after maintenance M17

has been performed, means of a special key. Fig 2

Unleaded fuel MUST be used on catalyst equipped
cars and labels to indicate this are displayed on the
instrument panel and below the filler flap. The filler cap
is designed to accommodate unleaded fuel pump
nozzles only. Also the anti-surge flap A’ prevents
leaded fuel from being added to the fuel tank in that it
does not open when a leaded fuel pump nozzle is
entered into the filler neck, up to the position of the
restrictor B’ and the pump is switched on.

17-06
www.JagDocs.com
 EMISSION FUEL SYSTEM

FAULT FINDING

Cause
ingine will 1 Low battery or poor connections 1 Check battery, recharge. Clean and secure
start terminals.
Check for low charge from alternator.
2 Start system faulty 2 Clean and check main starter
circuit and connections.
3 Incorrect or dirty fuel 3 Check grade of fuel.
If contamination suspected, drain
and flush fuel tank, flush
through system, renew fuel filter
4 Fuel starvation 4 Check fuel pressure. If not satisfactory,
check feed pipesfor
leaks or blockage.
Renew connectors if damaged or
deteriorated.
5 Fuel injection equipment 5 Ensure that all connector plugs
electrical connections are securely attached. Pull back
rubber boot and ensure that plug
is fully home. While replacing
boot, press cable towards socket.
Ensure ECU multi-pin connector is
fully made. Check that all ground
connections are clean and tight.
6 Auxiliary air valve faulty 6 Remove valve and test.
7 Cold start system faulty 7 Check cold start system.
8 Pressure sensor 8 Ensure manifold pressure pipe is
(part of the ECU) attached to sensor, is not kinked
twisted, or disconnected anywhere
9 Trigger unit 9 Check function of trigger unit
(DType injection)
Temperature sensors 10 Checksensorfor open and short
circuit.
1 1 HT circuit faults 1 1 Check for sparking.
12 Power faults 12 Carry out ignition checks.
13 LT switching fault 13 Check pick-up module.
14 Ignition timing incorrect 14 Check and adjust as necessary.
15 EGR valve malfunction 15 Check function of EGR valve on
vehicle. If not satisfactory
remove manifold and clean ports.
Renew valve if spring is broken,
solenoid failed or other fault
obvious.
16 14 As a last resort check by
substitution
or 17 Check items 13 17 If trouble persists, proceed
above with item 18.
dle 18 Throttle potentiometer 18 Check function of idle and full
load switches.
19 Incorrect idle speed 19 Adjust auxiliary air valve
by-pass bleed screw.
20 Check items 8 and 13 above 20 If trouble still persists,
proceed with item 2
2 1 Ignition system 2 1 Check ignitionwiring for
deterioration
fraying chafing and security.
Inspect distributor cap for
cracks, tracking and check rotor
condition.
22 Spark plug faults 22 Clean, reset and test plugs;
Renew as necessary.
23 Check item 15 23 If trouble still persists,
proceed with item 24.
24 Vacuum system faults 24 Check operation of vacuum unit
and condition of vacuum pipes.
Renew as necessary.

17-08
 EMISSION FUELSYSTEM

FAULT FINDING

oor or Advance or retard Check operation of advance

rratic mechanism faults retard mechanism. Lubricate or
renew as necessary.
16 Throttle by-pass valves 16 Check and adjust as necessary.
Exhaust system leaking or Check and rectify as necessary.
blocked
Incorrect idle mixture Check CO level. Remove the
blanking plug from ECU and with
special tool No. 6073055 1 adjust
to 1 t o 2% CO at 750 rpm.
Air injection system (where
fitted) should be disconnected
for this operation.
29 Poor compressions Check compressions, and rectify
as necessary.
30 Air leaks at inlet Check inlet manifold to cylinder
manifold head joint. Remake with new
gasket if necessary. Check
manifold tappingsfor leaks.
3 1 Check item 6 3 1 If trouble still persists,
proceed with item 32.
32 Engine oil filler cap 32 Check cap for security. Renew
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loose or leaking seal if damaged.

33 Engine breather pipe 33 Check and clear, or renew as
restrictors missing or necessary.
blocked
34 Engine breather hoses 34 Check and clear, or renew as
blocked or leaking necessary.
35 Charcoal canister 35 Inspect, and renew as necessary.
restricted or blocked
36 Check items and 9 36 Check in order shown
37 Check items 3 , 4 and 5 37 If trouble still persists,
flat spot proceed with item 38.
38 Check item 7 with engine 38 If trouble still persists,
cold proceed with item 39.
39 Throttle butterfly 39 Adjust as necessary.
40 Check item 8 $0If trouble still persists,
proceed with item 41.
41 Brakes $ 1 Check for binding brakes.
42 Check items, 13,21,22, 42 If trouble still persists,
14,24,and 25 proceed with item 43.
43 Air cleaner blocked 43 Inspect element, and renew as
necessary.
44 Check items 27,29,30, 44 Check in the order shown.
32,33,33,34,9,10,
16
45 Leaking fuel 45 Check fuel system for leaks,
rectify and renew connectors as
necessary.
46 Check items 18,7,8,41, 46 If trouble still persists,
27,29 and 30 proceed with item 47.
47 Cylinder head gasket 47 Check cylinder head t o block
leaking joint for signs of leakage.
Renew gasket as necessary.
48 Cooling system blocked or 46 Flush system, check for
leaking blockage. Check hoses and
connections for security and
leaks; renew as necessary.
Check functions of thermostats;
Renew if necessary.
49 Check items 28,30,31 , 49 Check in the order shown.
32.33. and 14.

1 7-09
 EMISSION CONTROL 'D' FUEL SYSTEM

FAULT FINDING

Cause Cure
Lack of 50 Air leaks 50 Any air leak into the manifold
engine will appear as an equivalent
braking or throttle opening; correct fuel
high idle then be supplied for that
speed apparant degree of throttle and
the engine will run faster.
Ensure that all hose and pipe
connections are secure. Check
all joints for leakage, and
remake as necessary.
5 1 Throttle sticking 5 1 Lubricate, check for wear and
reset.
52 Check items 14, 52 If trouble still persists,
proceed with item 53.
53 Throttle spindle leaks 53 Check seals, bearing and
spindles for wear; renew as
necessary.
54 Check item 30
Lack of 55 Check items and 7 55 If trouble still persists,
engine proceed with item 56.
power 56 Throttle inhibited 56 Check throttle operation, free
off and reset as necessary.
57Checkitems41.43.8. 57 Check in order shown.
29,
29,
.
34.35.39 and 16.
Engine over- 58 Check items 14, 58 Check in order shown.
heating 24 and 15.
Engine cuts 59 Check items 10, 59 Check in order shown.
out or 13.21.
stalls 22. 18.30.
and
16.
Engine 6 0 Check items 60 Check in order shown.
misfires

15 and 16
Fuel smells 6 1 Check items and 3 4 6 1 If trouble still
proceed with'item 62.
62 Fuel filler cap defective 62 Check seal and cap for
deterioration; renew as
necessary.
63 Check items 63 Check in the order shown
43 and 16.
Engine runs 64 Check items 3, 1, 64 Check in the order shown.
on 14,
and 15
Engine 65 Check items 3, 65 Check in the order shown.
knocking or and 15.

Arcing a t 66 Check items 2 1 and 22. 65 Check in the order shown

the plugs
Lean running 67 Check in the order shown.
(low CO)
and 35.
Rich running 68 Check items 68 Check in the order shown.
(excess CO) and 16

17-10
 EMISSION FUELSYSTEM

FAULT FINDING

Cause Cure
Backfiring 69 Check items 69 If trouble persists, proceed
in exhaust and 32 with item 70.
70 valve faulty 70 Check valve line for condition
and security, rectify as
necessary. Check that air is
dumped on deceleration by
disconnecting air outlet pipe at
valve and feeling
operation of the valve when the
throttle is opened and closed

Noisy air 72 Incorrectly tensioned air 72 Check and adjust drive belt
injection pump drive belt tension; renew belt if necessary
73 Relief valve faulty or low 73 Check that the valve operates.
pump pressure. If pump fails to produce enough
. pressure to lift the valve,
check item 73. If satisfactory,
renew the pump.
74 Check valve sticking 74 Check valve operation and hoses
(Japan and Australia). for security or blockage. Renew
or rectify as necessary.
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17-1 1
 EMISSION CONTROL’D’ FUEL SYSTEM

ENGINE BREATHER FILTER

RENEW 17.10.02

Remove the hose clip securing the rubber cover to

breather housing and disconnect the pipe from the
rubber cover (1 Fig 1).
Remove the rubber cover and lift out the filter (2 Fig 1).
Reverse the above operations t o fit new filter.

ADSORPTION CANISTER
RENEW 17.15.13

Remove the front left-hand road wheel.

Remove the three screws and washers securing the
access cover to spoiler, release tne three studs,
remove cover.
Note the position of and remove the hoses from the
canister stub pipes (1 Fig 2). Fig 1
Remove the screw, nut and washers securing the
canister clamp (2 Fig 2).
Prise open the clamp and remove the canister.
Reverse the above operations to fit new canister.

AIR DELIVERY PUMP

RENEW 17.25.07

No servicing or overhaul of the air delivery

pump is possible. In the event of failure a service
exchange unit must be fitted.

Remove the right-hand air cleaner cover.

Remove the three bolts securing the air pump pulley to
drive shaft (1 Fig 3).
Remove the pump pulley (2 Fig 3).

CAUTION: A screw driver or wedge must not be

used to prise pulley off the drive shaft as extensive
damage t o filter element will result.
Slacken the bolt esecuring the adjuster rod trunnion to
pump (3 Fig 3).
Remove the lock nut from the adjuster rod (4 Fig 3). 074
Slacken the nut securing the air pump mounting bolt
and pivot the pump awayfrom engine (5 Fig 3). Fig 2
Support the pump, remove mounting nut, flat washer
and bolt (6 Fig 3).
Disconnect the vacuum hose from the valve (7
Fig 3).

17-12
 EMISSION FUELSYSTEM

Release the secondary air pipe from the diverter valve

and discard the sealing ring Fig
Remove the air delivery pump.
Remove the two bolts and washers securing the
diverter valve elbow to air pump, remove elbow and
diverter valve (2 Fig 1).
Remove and discard the gasket (3 Fig
Reverse the above operation fitting new air pump
using new gasket and sealing ring.

AIR DELIVERY PUMP DRIVE BELT

ADJUST 17.25.13

Remove the right-handair cleaner cover.

Slacken nut securing air pump mounting bolt Fig 2).
Slacken adjusting link securing bolt (2 Fig 2).

CAUTION: Ensure head of bolt does not foul pulley. 076

Slacken the adjusting link lock nut (3 Fig 2).
Adjust belt tension by means adjusting link nut (4 Fig
correct tension is as follows: Aload of 6.4 (2.9 Fig 1
kg) must give a total belt deflection of 0.22 in (5.6 mm)
when applied a t point A.
Reverse the above operations.
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AIR DELIVERY PUMP DRIVE BELT

RENEW 17.25.15

Remove the right-handair cleaner cover.

Remove the fan belt Fig 3).
Remove the power assisted pump
drive belt (2 Fig 3).
Slacken the nut securing the air delivery pump
mounting bolt (3 Fig 3).
Slacken adjusting link bolt (4 Fig 3).

CAUTION: Ensure head of bolt does not foul pulley.

Slacken adjusting link lock nut (5 Fig 3).
Slacken the adjusting ling nut and wind along thread
until the belt can be manoeuvred clear (6 Fig 3) 077

Manoeuvre the new belt into position.

Fig 2
Set the drive belt tension.
Tighten all nuts and bolts.
Refit drive belts.

Fig 3

17-13
 EMISSION FUELSYSTEM

AIR RAIL
RENEW Left-hand 17.25.17
Right-hand 17.25.18
I
Depressure the fuel system.
Disconnect the battery earth lead.
Remove the power pump drve belt.
Remove the fuel pressure regulator.
Remove the two screws securing the air rail bracket to
inlet manifold ram tubes (1 Fig 1).
Remove the earth strap from the rear inlet manifold
ram tube (right-hand side only).
Remove the six nuts and serrated washers securing air
rail and manifold stud spacers to cylinder head (2 Fig

Release hose clip securing air rail to check valve

connecting hose (3 Fig 1).
Lift out air rail and disconnect from check valve
connecting hose (4 Fig 1).
Remove and discard rubber sealing rings (5 Fig 1).
Fitting a new air rail is the reversal of the above Fig 1
new rubber sealing rings are fitted.

CHECKVALVE
RENEW 17.25.21

Release the hose clips securing the air delivery rail

hoses to non-return valve outlet; slide hoses clear of
valve outlets (1 Fig 2).
Remove lower clip securing hose to check valve inlet
pipe (2 Fig 2).
Remove check valve (3 Fig 2).
Fitting a new valve is the of the removal
procedure.

VALVE
RENEW 17.25.25

Remove air cleaner and element.

Disconnect vacuum hose from diverter valve stub
Fig 2
pipe. Fig 3).
Remove the t w o bolts and spring washers securing
the diverter valve to elbow (2 Fig 3).
Release the air rail pipe from diverter valve (3 Fig 3).
Remove the diverter valve (4 Fig 3). 4
Remove and discard diverter valve to elbow gasket (5
Fig 3).
Remove and discard air rail pipe sealing ring (6 Fig 3).
Remove air rail pipe to diverter valve union from
diverter valve, remove and discard sealing ring (7 Fig

Reverse the above operation fitting a new valve using

new rings and gaskets.

J17-069

Fig 3

17-14
 EMISSION CONTROL'D' FUEL SYSTEM

EXHAUST GAS (EGR)

VALVE
RENEW 17.45.01

Removethe air cleaner cover.

Disconnect the EGR valve transfer pipe from down
pipe take-off stub (1 Fig 1).
Remove the electrical connectors from rear of EGR
valve (2 Fig 1).
Remove the two bolts and spring washers securing
the EGR valve to elbow (3Fig
Remove and discard EGR valve to elbow gasket (4 Fig

Removethe transfer pipe from EGR valve (5 Fig 1).

Reverse the above operation fitting a new gaskets
transfer pipe.

EGR CONTROL UNIT

RENEW 17.45.07
Fig 1
Disconnect the battery earth lead.
Remove two nuts and washers securing right-hand
rear light cluster.
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Disconnect the earth lead from light cluster stud.

Remove the light cluster from housing.
Remove the two nuts and bolts securing EGR control
unit to body.
Disconnect the EGR control unit block connector,
removethe EGR control unit.
Revers the above operation fitting new unit.

EGR VALVE TRANSFER PIPE

RENEW 17.45.11

Remove the air cleaner cover.

Slacken nuts securing EGR valve transfer pipe clamps
(1 Fig 2). Jl7-078
Release transfer pipe from EGR valve and down pipe
take-off stub.
Clean the EGR valve and down pipe take-off stub Fig 2
connections.
Reverse the above operations fitting new trnsfer pipe.

CATALYTIC CONVERTER
RENEW Left-hand 17.50.01
Right-hand 17.50.03

Remove air cleaner element.

Slacken the nut securing the EGR valve transfer pipe
clamp at take-off pipe.
Disconnect the EGR valve transfer pipe from take-off
pipe.
 EMISSION FUELSYSTEM

beneath the vehicle remove the bolts and spring

washers securing power steering bellows heatshield,
remove heat shield.
Remove nuts, plain washers and bolts securing
flanges, separate intermediate pipe from down pipe.
Ensure intermediate pipe is adequately supported.
Remove nuts and plain washers securing heatshield
and down pipe to exhaust manifolds; withdraw
heatshield.
Withdraw the down assembly.
NOTE: This operation will be greatly facilitated if the
steering is turned when manoeuvring the assembly
clear.
Fitting a new catalyst is the reversal of the removal
procedure coating all joints with suitable
Tighten down pipe and clamping flange fixing by
diagonal selection to avoid distortion.

06551)

17-16
 EMISSION 2
CONTENTS

DESCRIPTION OPERATION OPERATION PAGE

NO NO

17.15.13 .......... 17-07

................... DESCRIPTION 17.00.00 .......... 17-02
AIR DELIVERY PUMP ... RENEW ................ 17.25.07 .......... 17-07
AIR DELIVERY PUMP DRIVE BELT ......... ......... ADJUST 17.25.13 .......... 17-08
AIR DELIVERY PUMP DRIVE BELT .................. .... RENEW ......... 17.25.15 .......... 17-08
AIR INJECTION ........... ... 17.00.00 .......... 17-05
AIR RAIL (LEFT HAND) ......... ............................. RENEW ................ 17.25.17 .......... 17-09
AIR (RIGHT HAND) ............... ..................... RENEW ................ 17.25.18 .......... 17-09
.................. DESCRIPTION ....... 17.00.00 .......... 17-02
CATALYTIC CONVERTER (LEFT HAND) 17.50.01 .......... 17-12
17.50.03 .......... 17-12
CHECKVALVE ................... RENEW ................ 17.25.21 .......... 17-10
D EMISSIONS ........................ ....................... DESCRIPTION ....... 17.00.00 .......... 17-04
VALVE ........................... 17.25.25 .......... 17-1 1
ENGINE BREATHER FILTER .................... 17.10.02 .......... 17-07
... RENEW ........... 17.45.01 .......... 17-1 1
EGR CONTROL .... RENEW ................ 17.45.07 .......... 17-1 1
EGR VALVE TRANSFER RENEW ................ 17.45.11 .......... 17-12
17.00.00 .......... 17-06
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17-01
 EMISSION 2
EMISSIONS

COUNTRY
...................................................

................................... A 14
.................................................... F 14
E 3
F 13
G 12

'B' EMISSIONS 2
Ignition advance operation with engine coolant
temperature below 38" and below 4000
With the coolant temperature below 38' C the 3 way
solenoid valve (1 Fig the 2 way solenoid (2Fig 1) is
energised for 15 minutes via the time delay module (3
Fig 1) and the coolant temperature switch (4 Fig 1).
At idle speed vacuum is not available a t the throttle
edge tapping (5Fig 1) therefore, when cold there is no
vacuum advance. To compensate for this, the solenoid
air switch (6 Fig 1) is energised open for 15 minutes to
give a steady idle speed during the warm-up period, by
drawing air directly from the air cleaner into the inlet
manifold. 'B' bank manifold is fed by the engine
balance pipe.
With a light throttle and the coolant temperature below
38'C, the throttle edge tapping (5 Fig send a vacuum
signal th