service repair manual

1. Published by JaguarCars .im
.I.a.
BY APPOINTMENT TO
HER MAJESTY QUEEN ELIZABETW
THE QUEEN MOTHER
MANUFACTURERS OF DAIMLER AND JAGUAR CARS
JAGUAR CARS LIMITED COVENTRY ENGLAND
JAGUAR
VOLUME 2
Contains Sections
12. ENGINE 2.9
12. ENGINE 3.6
17. EMISSION CONTROL
18. ENGINE MANAGEMENT 2.9
18. ENGINE MANAGEMENT 3.6
19. FUEL SYSTEM
26. COOLING SYSTEM 2.9
26. COOLING SYSTEM 3.6
30. EXHAUST SYSTEM 2.9
30. EXHAUST SYSTEM 3,6
2.9 - 3.6
SERVICE MANUAL
ted Publication Part NO JJM IO 04 05

2. ENGINE2.9
CONTENTS
DESCRlPTlON OPERATION OPERATION PAGE
No No
AUXILLIARY SHAFT .................................................... RENEW .................... 12.10.30 .... 12-04
AUXILLIARY SHAFT REARSEAL ................................... RENEW .................... 12.10.32 .... 12-07
CAMSHAFT ................................................................ RENEW .................... 12.13.02 .... 12-08
CAMSHAFT CARRIER .................................................. RENEW .................... 12.13.24 .... 12-144
CAMSHAFT COVER GASKET ........................................ RENEW .................... 12.29.39 .... 12-12
CONNECTINGRODBEARING-ENGINESET ....................... RENEW .................... 12.17.16 .... 12-13
CRANKSHAFT ............................................................ RENEW .................... 12.21.33 .... 12-15
CRANKSHAFT DAMPER ............................................... RENEW .................... 12.21.09 .... 12-22
CRANKSHAFT ENDFLOAT ........................................... CHECK&ADJUST ..... 12.21.26 .... 12-28
CRANKSHAFTFRONTOILSEAL .................................... RENEW .................... 12.21.14 .... 12-38
CRANKSHAFTPULLEYAIR CONDITIONINGDRIVE ........... RENEW .................... 12.21.08 .... 12-112
CRANKSHAFTPULLEYAIR CONDITIONINGDRIVE
(AIRCONDITIONINGFITTED) ...................................... RENEW .................... 12.21.08 .... 12-124
CRANKSHAFTREAROILSEAL ...................................... RENEW .................... 12.21.20 .... 12-34
CRANKSHAFTTIMING GEAR ........................................ RENEW .................... 12.65.25 .... 12-85
CYLINDERHEADCASTING ........................................... RENEW .................... 12.29.15 .... 12-116
CYLINDERHEAD-COMPLETE ...................................... RENEW .................... 12.29.10 .... 12-124
CYLINDERHEADGASKET ............................................. RENEW .................... 12.29.02 .... 12-127
CYLINDERHEAD .......................................................... OVERHAUL .............. 12.29.19 .... 12-129
CYLINDERPRESSURES ................................................. CHECK ..................... 12.25.01 .... 12-33
ENGINE ....................................................................... DESCRIPTION ........... 12.00.00 12-03
ENGINEASSEMBLY ...................................................... RENEW .................... 12.41.02 .... 12-148
ENGINEOIL ................................................................. DRAIN&REFILL ........ 12.60.00 .... 12-31
ENGINEMOUNTINGBRACKET-LEFTHAND ................... RENEW .................... 12.45.15 .... 12-49
ENGINEMOUNTINGBRACKET- RIGHTHAND ................. RENEW .................... 12.45.15 .... 12-48
ENGINEMOUNTING-ENGINESET ................................. RENEW .................... 12.45.13 .... 12-114
ENGINEREAR/GEARBOX ADAPTOR PLATE .................... RENEW .................... 12.53.03 .... 12-31
FLYWHEEL ................................................................. RENEW .................... 12.53.07 .... 12-32
FRONTENGINEMOUNTING-LEFTHAND ....................... RENEW .................... 12.45.01 .... 12-50
FRONTENGINEMOUNTING-RIGHTHAND ..................... RENEW .................... 12.45.03 .... 12-49
INTERMEDIATESPROCKET ........................................... RENEW .................... 12.65.26 .... 12-76
LOWER TIMINGCHAIN ................................................. RENEW .................... 12.65.16 .... 12-80
LOWER TIMINGCHAINTENSIONER ............................... RENEW .................... 12.65.30 .... 12-66
MAINBEARING-ENGINESET ......................................... RENEW .................... 12.21.39 .... 12-56
OILCOOLER ................................................................ RENEW .................... 12.60.68 .... 12-52
OILCOOLERHOSE-VEHICLESET .................................... RENEW .................... 12.60.73 .... 12-55
OILCOOLERRETURNHOSE ........................................... RENEW .................... 12.60.76 .... 12-52
OILCOOLERSUPPLY HOSE ........................................... RENEW .................... 12.60.74 .... 12-54
OILFILTERCANISTER ................................................... RENEW .................... 12.60.04 .... 12-42
OILFILTERHEADGASKET ............................................ RENEW .................... 12.60.03 .... 12-41
OILPICK UPSTRAINER ................................................. RENEW .................... 12.60.20 .... 12-47
OILPRESSURERELIEFVALVE ASSEMBLY ....................... CHECK&OVERHAUL. 12.50.56 .... 12-42
OILPRESSURETRANSMITTER ...................................... RENEW .................... 12.60.50 .... 12-39
OILPUMP ................................................................... OVERHAUL .............. 12.60.32 .... 12-24
OILPUMP ................................................................... RENEW .................... 12.60.22 .... 12-26
OILPUMPDRIVECHAINAND DAMPER ........................... RENEW .................... 12.60.31 .... 12-137
OILPUMPDRIVECHAINDAMPER .................................. RENEW .................... 12.60.29 .... 12-62
OILPUMPDRIVESPROCKET ......................................... RENEW .................... 12.60.30 .... 12-45
OILPUMPPIPE '0' RINGS .............................................. RENEW .................... 12.60.27 .... 12-141
OILSUMP ................................................................... RENEW .................... 12.60.44 .... 12-40
OILSUMPGASKET ....................................................... RENEW .................... 12.60.38 .... 12-44
PISTONANDCONNECTING RODENGINESET .................. RENEW .................... 12.17.01 .... 12-36
REAR ENGINEMOUNTING ............................................. RENEW .................... 12.45.04 .... 12-113
SPARKINGPLUGINSERTS ............................................ FITTING ................... 12.29.78 .... 12-142
TIMINGCHAINDAMPER-VEHICLESET ........................... RENEW .................... 12.65.48 .... 12-90
TIMING CHAIN-ENGINESET .......................................... RENEW .................... 12.65.14 .... 12-95
TIMING CHAIN, GEAR AND TENSIONER-ENGINESET ........ RENEW .................... 12.65.13 .... 12-106
TIMINGCOVER GASKET ............................................... RENEW .................... 12.65.04 .... 12-59
....
12-1

3. ENGINE2.9
DESCRIPTION OPERATION OPERATION PAGE
No No
TIMINGGEAR-ENGINESET ........................................... RENEW .................... 12.65.22 .... 12-100
UPPERTIMINGCHAIN .................................................. RENEW .................... 12.65.15 .... 12-73
UPPERTIMINGCHAINTENSIONER ................................. RENEW .................... 12.65.29 .... 12-69
VALVE CLEARANCES ................................................... CHECK ..................... 12.29.47 .... 12-51
VALVECLEARANCES ................................................... CHECK& ADJUST ..... 12.29.48 .... 12-146
16958
12-2

4. ENGINE2.9
2.9 ENGINE
CUTAWAY
12-3

5. ENGINE2.9
AUXILLIARY DRIVESHAFT
RENEW 12.10.22
Openand removethe bonnet.
Removecylinder head, operation 12.29.02.
Removeanddiscardthe headgasket.
Remove the damper woodruff key and remove the oil
seal spacerfrom the crankshaft.
Remove the elastic band from the upper dampers,
knock down the lock tabs on the bolts securing the
tensionerpedestal.
Removethe pedestal bolts and tab washer (3 Fig 1).
Remove the pedestal/tensioner assembly and chain
damper (1 Fig 1).
Remove the tensioner pivot pin (2 Fig 1) and remove
the tensioner from the pedestal, clean the pivot pin.
Knockdown the lock tab ears of the bolts securingthe
upperstatic damper.
Removethe bolts (5 Fig I), tab washer, upper damper,
damper (4Fig 1) pedestal and upper timing chain (6
Fig 1).
Removethe bolts (10Fig 1) securingthechaintensioner
and removethe assembly.
Removethe chain (8Fig 1) from intermediatesprocket
(9Fig 1) and remove.
Removethe power assisted steering pump housingto
auxilliaryshaft housingsecuringbolts (1 Fig2),remove
the power-assisted steering pump drive coupling and
remove the auxilliary shaft rear oil seal using Service
Tool JD 118(18G1468).
Using right-angledcirclip pliers remove the drive shaft
securing circlip (1 Fig 3), lift the timing chain (8Fig 1)
off the shaft gear (7 Fig I), remove the shaft (2Fig ?)
andcollect the thrust washer (3Fig2).
Clean all component parts removed and check for
wear or damage, should any of these conditions
prevailthenthe component mustbe replaced.
Cleanthe auxilliarybearinghousing.
Check for wear and if necessary change the auxilliary
shaft bushes(5Fig2)usingServiceTool 18G 1434.
Refit the housing (4 Fig 2) with new gasket (6 Fig 2)
and secure with the bolts (1 Fig2).
Lubriucatethe shaft and refitthe shaft into the housing,
engaging the chain with the gear as it is fitted.
Lubricateand fit the thrust washer (3Fig2) and secure
with the Girlcip (1 Fig3).
Lubricate new oil seal and using Service Tool 18G
1469,fit andseat the shaft rear oil seal (2Fig3).
NOTE: Under no circumstances must the plastic seal
insertberemovedpriorto fittingthe seal.
Fit the drive coupling to the power assisted steering
pump, align the pump shaft with the auxilliary shaft,
connect the pump shaft to the drive shaft and tighten
the pumphousingsecuringbolts (1 Fig2).
Lubricate the intermediate sprocket bearing, lift the
chain (8Fig 1) and engage the sprocket fully in the
chainand seat into the bearing.
19 18 i7 J12-540
Fig 1
Fig2
Fig3

6. ENGINE2.9
Assemble the plunger, spring and base to the guide,
lubricatethe assembly.
Fit the guide assembly to the tensioner housing,
reposition the chain damper for access ensuring that
no loose links are left below the crankshaft, fit the
tensioner assembly (10 Fig 1 page 12-4) to the
cylinderblock with the guidefacingdownwards.
Fit but do not tighten the uppertensioner securing bolt
(11 Fig 1 page 12-4), push the guide into the housing
to releasethe baseandalignwith the damper.
Align the damper with the lower bolt hole, fit and
tightenthe lower bolt (11Fig 1page 12-4).
Finally tighten the upper bolt, fill the tensioner oil
reservoirwith oil and work the tensionerto prime with
oil.
Refill the reservoir with oil and ensure that the
tensionerisfully primed.
Lubricate the upper timing chain (6 Fig 1 page 12-4)
andfit to the intermediatesprocket, fit the upper static
damper, fit the tab washer, secure with the bolts and
knockupthe locktab ears.
Fit a new tensioner (1 Fig 1 page 12-4)to the pedastal
andfit thetensioner pivot pin(2Fig 1page 12-4).
Align a new tab washer to the tensioner and fit the
securing bolts (3Fig 1page 12-4).
Align the damper to the tensioner and fit the
damper/tensioner assembly to the engine ensuring
that the damper does not foul the the distributor drive
shaft sprocket.
Finallytightenthe securing bolts and knock upthe lock
tab ears.
Repositionthe uppertensionerand secureto the upper
damperswith anelastic band.
Remove the oil seal (1 Fig 1) from the timing cover,
clean all of the gasket surfaces, oil seal spacer, pointer
and crankshaftdamper.
Fit a new oil seal to the timing cover ensuring that the
front of the seal isflush with the front face of the timing
cover (1Fig2).
Apply 'Hylosil 102' to the timing cover gasket faces
andthe outer edgeof the sumpface.
Reverse the timing cover and cylinder head removal
proceduresto reassemble.
Ensure that the cooling system is fitted with the
correct solution of anti-freeze and water and that the
engine oilisfree of water. Shouldthis condition prevail,
the oil filter must be replaced and the engine oil
drained; refillwith new engineoil.
Refitthe bonnet.
Fig 1
Fig2
12-5

7. ENGINE2.9
DATA
SERVICETOOLS
JD 118(18G 1468)Auxilliary drives oil sealremover
C3993Camshaft timing tool
18G 1436Crankshaftpulley remover
18G 1437Frontpulley lock
JD 101 Timingchain tensionreleasehook
1861434Timingcoverbushremover replacer
186 7469Auxilliary driveoil seal replacer
TORQUE FIGURES
Adjustment trunnion to alternator securing bolt
23-27Nm
Alternator adjustment bolt to timing cover nut
23-27Nm
Alternator adjustment bolt-trunnion lock nuts 12-
14Nm
Alternator pivot bolt 23-27Nm
Alternatorpivot bolt nut 23-27Nm
Banjobolt tocylinder head 13-16Nm
Dipstick tobracket5-8Nm
Camshaftcover to camcarrier (nut)23-27Nm
Camshaftcover to cam carrier (screw)9.5-12Nm
Camshaftsprocket tocamshaft23-27Nm
Clip-hosetobreatherpipe2.4Nm
Crankshaftpulley to crankshaft203.5Nm
Crankshaftpulley to crankshaftdamper 23-27Nm
Crankshaft speed sensor housing to timing cover
23-27Nm
Cylinderblock drainplug to cylinderblock 68-75Nm
Cylinderhead to cylinderblock (bolts)23-27Nm
Cylinderhead to cylinderblock (nuts)82-86Nm
Distributorclampplate to timingcover9.5-12Nm
Driveplatecentrecoupling9.5-12Nm
Exhaust manifoldto cylinderhead23-27Nm
Fan/torquatrolunit to waterpump 23-27Nm
Heatshield to exhaustmanifold23-27Nm
Heaterpipe to cylinder head23-27Nm
Heaterpipe to inlet manifold9.5-12Nm
Hose-bottomhoseto waterpump3.8-4.3Nm
Hose-expansiontank to waterpump 2.5-3.5Nm
Hose-heater returnpipe to waterpump 2.5-3.5Nm
Hose-water pump to thermostathousing2.5-3.5Nm
Hydraulicpump to timingcover23-27Nm
Inletmanifoldto cylinderhead23-27Nm
Intakeelbow to throttlehousing2.4Nm
Lower chaintensioner to cylinderblock 23-27Nm
Oilsump to timing cover23-27Nm
Power steeringpump tomounting23-27Nm
Reactionshoe to cylinderhead23-27Nm
Timingcover to cylinderblock 23-27Nm
Tophose to thermostat housing3.8-4.3Nm
Upperstatic damper to cylinderblock 23-27Nm
Upper timing chain tensioner to cylinder block
23-27Nm
Waterpumpto timingcover23-27Nm
0
a
8
12-6

8. ... ... . -
ENGINE2.9
w' SPANNER SIZES
6mm
8mm
1Omm
13mm
19mm(SERVICE TOOL-18G 1436)
30mm
1/2in AF(SERVICE TOOL-BOLTS 18G 1437/1)
9/16in AF
5/8in AF
13/16in AF
1Ornm (ALEN KEY)
3/4 WHITWORTH
OILS/GREASES/SEAIANTS
Half moonseals tocamcarrier 'HYLOSIL 102'
Hydraulicpump driveplate securing bolt 'LOCTITE'
'0'Rings 'PETROLEUMJELLY'
Sump totimingcover 'HYLOSlL 102'.
Timingcover tocylinderhead 'HYLOSIL 102'.
Thermostat housing to extension piece 'HYLOSIL
102'.
0474b/10
AUXILLIARY SHAFT REAR SEAL
RENEW 12.10.32
Remove the power steering pump drive coupling and
removethe distributor drive shaft oil seal usingService
Tool JD 118 (18G 1468).Cleanand lubricatethe new
sealand matingfaces.
UsingService Tool 18G 1469fit andfully seat the drive
shaft seal (2Fig 1).
NOTE: Under no circumstances must the plastic seal
insert beremovedpriortofitting of the seal.
Refitthe power steeringpumpdrivecoupling.
TORQUE FIGURES
Steeringpump toadaptor49-54Nm
SERVICETOOLS
JD 11 8(186 1468)Auxilliaryshaft oilsealremover
18G 1469Auxilliary shaft oilsealreplacer
Fig 1
12-7

9. .. . .
ENGINE 2.9
SPANNER SIZES
13mm
19mm(SERVICE TOOL)
0439b
CAMSHAFT
RENEW 12.13.02
Openthe bonnet.
Releasethe plug leadretainingclipsfrom the camcover
brackets.
Unclipthe distributercap.
Disconnectthe HT lead from the coil and position the
plugleadsover the inletmanifold.
Remove the nuts (1 Fig 1)and bolts (2 Fig 1) securing
the camcoverto the cam carrier.
Removethe camcover(3Fig 1).
Removeand discardthe cam cover gasket andthe half
moonsealfrom the rear of the cylinderhead.
Clean the camcover andcylinderhead.
Jack upthe vehicleandplaceontwo stands.
Rotatethe engineandset at T.D.C. number 1cylinder.
Remove the bolts (5 Fig 2) securing the reaction shoe
(6 Fig 2) to the cylinder head, remove the shoe and
discardthe gasket.
Usingservicetool JD 101 (1Fig2)de-tensionthe upper
timing chaintensioner.
Knock down the lock tab ears securing the camshaft
sprocket bolts, remove the bolts (2 Fig 2) and tab
washers.
Gradually remove the nuts (1 Fig 3) securing the cam-
shaft caps.
NOTE: Slacken each nut two turns at a time to release
the loadonthe camshaftuntilthe valve springsarefully
relaxed.
Note the position of the caps (2 Fig 3) relative to the
cylinderheadand remove.
Removethe camshaft (3Fig3).
Cleanall component partsand inspectfor wear and/or
damage.
Oilthe camshaftjournals.
Placethe replacementcamshaft(3Fig3)inthe cylinder
headwith the slot for thetiming gaugefacing upwards,
re-oil the camshaft journals and fit the bearing caps
(2Fig3)back intheir respectivepositions.
Fit the nuts (1 Fig 3)and gradually tighten each nut of
each camshaftcap two turns at atime untilallthe caps
arefully securedandtorquedtightened.
Using Service Tool C3993 camshaft timing tool, set
the camshaftto T.D.C.
Positionthe chain (3Fig2) over the sprocket and align
the sprocketto the camshaft.
Fit the reaction shoe (6 Fig 2) and release the upper
tensioner.
Removethe clip securing the inner wheel and align the
securingbolt holes,fit the bolts.
1
I
5 2 4
J12 PPI
Fig 1
Fig2
3
I
512 45.
Fig3
12-8

10. ENGINE2.9
Rotate the engine as necessary to measure the valve
clearances (Fig 1) between the heel of the camshaft
and the cam followers, the correct clearance is 0.012
to0.014in.
DATA
Valveclearances
Inlet 0.012-0.014in
Exhaust 0.012-0.014in
EXCESSIVECLEARANCE Inches
Size of existingshim 0.100
Plusthe actualclearance noted 0.019
0.1 19
0.013
=requiredshimsize 0.106
INSUFFICIENTCLEARANCE Inches
Lessthe specifiedvalveclearance
Sizeof existingshim 0.107
Plusthe actualclearance noted 0.010
0.1 17
Lessthe specifiedvalve clearance 0.013
= requiredshimsize 0.104
Availableshimsizes
Letter Thickness
A
B
C
D
F
G
H
I
J
K
L
M
N
0
P
0
R
S
T
U
V
w
X
0.085 in
0.086 in
0.087 in
0.088 in
0.089in
0.089 in
0.090 in
0.091 in
0.094 in
0.095 in
0.096in
0.097 in
0.098 in
0.099 in
0.100 in
0.101 in
0.102 in
0.103 in
0.104 in
0.105 in
0.106 in
0.107 in
0.108 in
Fig 1
12-9

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12. ENGINE 2.9
Should the clearances by incorrect, Remove the bolts
(5 Fig 2 page 12-8) securing the reaction shoe to the
cylinder head, removethe shoe.
Using Service Tool JD 101 (1 Fig 2 page 12-8)
de-tensionthe uppertimingchaintensioner.
Remove the bolts (2 Fig 2 page 12-8) securing the
camshaftsprocket.
Graduallyremovethe nuts (1Fig3 page 12-8)securing
the camshaftcaps.
NOTE: Slacken each nut two turns at a time to release
the loadonthe camshaftuntilthe valve springsarefully
relaxed.
Note the position of the caps relative to the cylinder
headandremove.
Removethe camshaft(3 Fig3 page 12-8).
Using a suitable magnet remove the cam followers (1
Fig 1).
adjustment, check the size of the existing shimswith a
micrometer and note the reading. Calculate the size of
the shim requiredfollowing the examplesinDATA.
Refitthe camfollowers.
Oilthe camshaftjournals.
Placethe replacement camshaft (3 Fig3 page 12-8)in
the cylinder head with the slot for the timing gauge
facing upwards re-oil the camshaftjournals and fit the
bearingcaps back inthier respectivepositions.
Fit the nuts (1 Fig 3 page 12-8) and gradually tighten
each nut of eachcamshaftcap two turns at atime until
all the caps arefully securedandtorquedup.
Using Service Tool C3993 camshaft timing tool, set
the camshaftto T.D.C. Positionthe chain (3Fig2 page
12-8) over the sprocket and align the sprocket to the
camshaft.
Usinga new gasket fit the reaction shoe (6 Fig 2 page
12-8)and releasethe uppertensioner.
Removethe clip securingthe inner wheel and align the
securing bolt holes, fit new tab washers and bolts (2
Fig2 page 12-8).
Tightenthe bolts and knockupthe locktabs.
Rotate the engine as necessary to measure the valve
clearances between the heel of the camshaft and the
camfollowers, the correct clearance is0.012to 0.014
in.
Cleanthe camcover andcylinder head.
Apply 'Hylosil 102' to the half moon seal andfit to the
apertureinthe rearof the cam carrier.
Fit a new gasket to the cam carrier, fit and align the
carncover (3 Fig 1 page 12-8). fit the plug lead
brackets and secure the assembly to the cam carrier
with the nuts (1 Fig 1 page 12-8) and bolts (2 Fig 1
page 12-8).
Refit the distributor cap and plug lead clips to the
brackets.
Reconnectthe HTleadto the coil.
Closethe bonnet.
. G2 ,lr. 4 J12 155
Remove all the shims or only those requiring - ~ - - - _ - _-
Fig 1
12-10

13. ENGINE2.9
DATA
SERVICE TOOLS
C3993Camshafttiming tool
JD 101Timingchain tensionreleasehook
DATA
Valveclearances
Inlet 0.012-0.014in
Exhaust0.012-0.014in
EXCESSIVECLEARANCE
Size of existingshim
Plusthe actualclearancenoted
Lessthe specifiedvalveclearance
= requiredshimsize
INSUFFICIENTCLEARANCE
Size of existingshim
Plusthe actualclearance noted
Lessthe specifiedvalve clearance
= requiredshimsize
Availableshimsizes
Letter Thickness
A
B
C
D
F
G
H
. I
J
K
L
M
N
0
P
Q
R
S
T
U
V
w
X
0.085 in
0.086 in
0.087 in
0.088 in
0.089 in
0.089 in
0.090in
0.091 in
0.094 in
0.095 in
0.096in
0.097 in
0.098 in
0.099in
0.100in
0.101in
0.102 in
0.103 in
0.104 in
0.105 in
0.106 in
0.107 in
0.108in
Inches
0.100
0.019
0.119
0.013
0.106
Inches
0.107
0.010
0.1 17
0.013
0.104
12-11

14. TORQUE FIGURES
ENGINE2.9
Searingcaps to camshaftcarrier 11-13.5Nm
Camshaftcover tocam carrier (nut)23-27Nm
Camshaftcover to cam carrier (screw)9.5-12Nm
Camshaftsprocket tocamshaft23-27Nm
Reactionshoe tocylinder head23-27Nm
SPANNER SIZES
1Omm
13mm
9/16in AF
OILS/GREASES/SEAUNTS
Half moon sealsto cam carrier 'HYLOSIL102'.
CAMSHAFT COVER GASKET
RENEW 12.29.39
Openthe bonnet.
Releasethe plugleadretainingclipsfromthe camcover
brackets.
Unclipthe distributercap.
Disconnectthe HT lead from the coil and position the
plugleadsover the inletmanifold.
Remove the nuts (1 Fig 1)and bolts (2 Fig 1) securing
the camcoverto the cam carrier.
Removethe camcover(3Fig 1).
Removeand discardthe cam cover gasket and the half
moonsealfrom the rear of the cylinder head.
Cleanthe camcover andcylinder head.
Apply 'Hylosil 102' to the half moon seal and fit to the
aperture inthe rear of the cam carrier.
Fit a new gasket to the cam carrier, fit and align the
camcover, fit the plug lead brackets and secure the
assembly to the cam carrierwith the nutsand bolts.
Refit the distributor cap and plug lead clips to the
brackets.
Reconnectthe HTleadto the coil.
Closethe bonnet.
1
I
,
5 2 4
J17411
Fig 1
12-12

15. ENGINE2.9
DATA
TORQUEFIGURES
Camshaftcover tocamcarrier (nut)23-27Nm
Camshaftcover tocamcarrier (screw)9.5-12Nm
SPANNERSIZES
8mm
13mm
01LS/GREASES/SEAlANTS
Half moonseals tocamcarrier 'HYLOSIL102'.
0452b
CONNECTING ROD BEARING-
ENGINESET
RENEW 12.17.16
Openthe bonnet.
Drain the engine oil and remove the front cross-
member.
Remove the bolt securing the dipstick to the inlet
manifoldand removethe dipstick.
Removethe air cleanerelement.
Slackenthe alternator adjustingnut and pivot nut, pivot
the alternator towards the engine and disconnect the
drive belt.
Removethe alternator link armtrunnion bolt.
From below disconnect the alternator feed wires and
remove the alternator pivot bolt and nut, remove the
alternator.
Remove the rear spacers and move the power
assisted steering pipes for access. Slackenthe union
securing the oil drain back tube to the sump and pull
tube clear of the sump.
Positionthe steering rack to allow access to the sump
securing bolts slacken the bolts with the exception of
two bolts, removesump securing bolts (1Fig 1).
Removethe bell housingto sumpsecuring bolts.
Finally removethe remainingsump bolts and lower the
sump (2Fig 1).
Placea suitable drain tin below the oil transfer housing
area and remove the housing securing bolts (1 Fig 2),
remove the housing assembly (2 Fig 2) and pull the
pipes (3Fig2)from the housing.
Fig 1
Fig2
12-13

16. ENGINE2.9
Remove and discard the '0'rings, clean the housing
andoil pipes.
Remove the bolts (1 Fig 1) securing the crankshaft
windage trays (2 Fig 1) to the cylinder block and
removethetrays.
Turn the engine over for access to the first connecting
rod.
Removethe nuts (1Fig 2) securingthe cap (2Fig 2) to
the connecting rod and remove the cap and bearing
assembly.
Note the position of the cap relativeto the connecting
rod and also that they are numbered to each other (1
Fig3).
Discardthe bearing shell (2Fig3),movethe connecting
rod and piston up the bore and remove the bearing
shellfrom the connectingrod (3Fig3).
Removethe 'paired' bearingcap ie 1-6,2-5,3-4. as in
the previousdescription.
Clean and polish the crankshaft journals, oil the new
bearingsandfit two halvesto the connectingrods.
NOTE: Ensurethat the 'tag' (4Fig3)onthe shell isfully
seated inthe connectingrod.
Oilthe crankshaftjournals.
Pull one piston and rod down the bore and guide onto
itsrelativecrankshaftjournal.
Fitabearingshellto the 'matched' connectingrodcap.
NOTE: Ensurethat the 'tag' (4Fig3)on the shell isfully
seated inthe connecting rod, oil the shell and fit to the
crankshaft/connecting rodassembly.
Ensurethat the 'numbers' (1Fig3)arefitted together.
Fitthe securingnuts(1Fig 2)andtighten.
Repeat the procedure for the second piston and
connectingrodassembly.
Rotatethe crankshaftfor the second matched pairand
repeatthe procedure.
Repeatthe procedurefor thethird pair.
Clean the windage trays (2 Fig 1) fit and secure to the
cylinderblock with the bolts (1Fig 1).
Carefully fit new '0' rings to the oil pipes (1 Fig 4),
lubricatethe '0' ringswithpetroleumjelly. Removethe
draintin andfit the pipesto the oil pump.
Apply 'Hylosil 102'to the tranfer housinggasket face,
fit the housing (2 Fig 2 page 12-13) to the engine and
secure with the bolts (1Fig2 page 12-13).
Fig 1
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Fig4
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