V12 Engine Service Manual
Contents
1. Cil requires changing Worn crankshaft journals Excessive crankshaft end float Worn main bearing shells Worn oil pump Oil pressure reliefvalve stick ing open Oil pressure spring too weak Insufficient oil in oil pan Engine overheating relief valve Faulty gauge or sensor Incorrect grade oil viscosity too low Water in oil Check oil level and color Listen for rumble or knock Fit dial gauge and measure Listen for rumble Remove oil pump and check the clearances Remove valve and check for sticking Remove spring and check spring rates Check oil level Referto EDM Check oil viscosity Check oil level and check if oil is a milky white color Check for leaking head gasket Change oil and filter Renew crankshaft Renew thrust washers Check crankshaft journals for wear and renew shells Renew oil pump Renew valve Renew spring Top up as required Refer to Overheating fault finding in Section 42 VSM Rectify as required Renewoil and filter Renew oil and filter Renew head gasket Issue 1 August 1994 V12 Engine Service Manual Symptom Possible Cause Check nsufficient oil pres ure continued cracked oil pump housing 3locked oil strainer Jil pump pipe O rings pick up pipe Main oil gallery seals leaking r gallery blocked Remove oil pan and visually check Remove oil pan and visually check Removeoil pan and pipes and ch2. Cleanand lubricate the exposed surfaces ofthe crankshaft and the insidesurfacesofthetool body removal installs tion tool JD 163 with clean engine oil s Locatethetool bodyonthecrankshafttoabuttheseal rear face which is located flush with the rear of the crankcase Align both holes through the tool body with the threaded holes inthe crankshaft rear flange screw both bolt assem blies 2 Fig 1 into them to lock the tool body to the crank shaft Place the center punch 1 Fig 1 through one of the tool body s outer three holes and note the distance by which the shoulder of the punch stands proud a Using a hammer Fig 1 penetrate the seal up to 2 mm determine this from the distance noted in the previous operation CAUTION Do not exceed 2 mm depth a Removethe punch andinsertthe self tapping screw 1 Fig 2 turning it no morethan 11 9 turns a Repeatthe procedure for inserting the two other screws CAUTION Do notexceed2 turns or the screw may break s Removethe two bolt assemblies so that the center bolt 2 Fig 2 can be turned clockwise to extract the seal a Remove and discard the seal from the tool a Cleanthe surface ofthe crankshaft and ensure itis smooth and free of damage Lubricate the surface with clean en gine oil Fit the new seal squarely onto the crankshaft using the guide supplied with the seal CAUTION The seal guide must not be separated from the seal prior to fitment
3. BY APDOINTMENT TO BY APPOINTMENT TO BY APPOINTMENT TO HER MAJESTY GLFEN ELIZABETH HEH MAJESTY QUEEN ELIZABETH INS ROYAL HIGHNESS THE PRINCE OF WALES THE QUEEN MOHER T c MANUFACTURERS OF DAIMLER AND JAGUAR CARS MANUFACTURERS OF DAIMLER AND JAGUAR CARS MAKUFACTJRERS OF DAIMLER AND JAGUAF CARS JAGUAR CARS LIMITED COVENTRY JAGUAR CARS LIMITED COVENTRY JAGUAR CARS LIMITED COVENTRY JAGUAR V12 Engine Service Manual Published by Product Development amp Publications Jaguar Cars Limited Part of set JJM 10 04 12 50 V12 Engine Service Manual CONTENTS Section Title SRO Page FOTEWOIG Dea anonim enim Matah buta medan ee ii xa kata dr Siet Service Tools amp Equipment ENEE iii Il v Kumat edu Torque TighteningSpecifications ENEE vi Ill er Service Materials Rimini x Nee SEIVICE DANG u un ua ee xi Tian ag naga General Description oo cece eee nenn nenn nennen nn nennen nenn nenn 1 mam CONSTUCHON sasi nu aa aa anna aa ALA a STRE 1 Werner F ll How ll Syste nous ae a Rn ENNER anne en 1 TD ame Ie E GrankcaseiBreather ea einen 2 UE EEN Cooling Syst sis sen een 2 RECENT RUN Service e EE 2 PAN aaa ate strate sat EE EE latet NER DRE EIS I wie aie MNMEEEUNNNANEITE 2 Daviau aye ann Fault DIAGNOSIS PPP 3 IT aee Er eo ee Introduction ssa seccieierererrreemdar en neh 3 JD aca draw dete Diagnostic Procedures EE 3 D Kawanan wakai Service Operations winx Laman Uban Iban LAN DAA Raha Pkn nela rd 7 Al Sea maa Os Cartishalt Henew s iess aa
4. Issue 1 August 1994 V12 Engine Service Manual 4 7 Crankshaft Damper and Pulley Renew SRO 12 21 01 a Removethe drive belts Remove the pulley securing bolts 1 2 Fig 1 and with draw the crankturning plate 3Fig 1 spacers 4Fig 1 and the pulley 5 Fig 1 Fit a suitable wedge to the drive plate and remove the crankshaft damper bolt 6 Fig 1 Alternatively Service Tool 18G 1205 with longer screws and spacers may be used Fig 2 Use Service Tool 18G 1436A to remove the crankshaft damper assembly Fig 3 Remove the timing disc 7 Fig 1 from the damper 8 Fig 1 e Clean and examine all components for wear and damage and renew as necessary a Fitthe timing disc 7 Fig 1 tothe replacement damper 8 Fig 1 withthe roll pin 9Fig 1 andsecure with the screws 10 Fig 1 a Fitthe damper assembly to the crankshaft nose and se cure with the damper bolt 6 Fig 1 Fitthe pulley 5 Fig 1 and the crank turning plate 3 Fig 1 and secure with the securing bolts and spacers 1 2 4 Fig 1 a Refitthe drive belts 112 851 Fig 1 Fig 2 Ji2 89 Fig 3 Issue 1 August 1994 18 V12 Engine Service Manual 4 10 Engine Cover Renew SRO 12 29 93 a Rotate the four turn fasteners V i of aturn anti clockwise and removethe engine cover Fig 1 Removethe four fas tener sockets from the fuel rail a Fitfour new fastener sockets to the fuel
5. Worn camshaft drive chains tensioners Wipe clean run engine and visually check Wipe bell housing clean run engine and visually inspect for cleanliness Visual check Visual check Renew seal Renew seal Renew gasket Renew cylinder block Check valve clearances Remove valves and check springs Remove valves and check guides Remove valves and check in serts Check oil pressure gauge re ading Check valve timing Check valve clearances and for lackof lubrication Remove front timing cover and check for wear Adjust valve clearances Renew as necessary Renew as necessary Renew as necessary Referto Insufficient Oil Pres sure fault finding Adjust valve timing Adjust valve clearances Referto Insufficient Oil Pres sure fault finding Renew as necessary Issue 1 August 1994 Symptom Possible Cause Noisy chains Low oil pressure Tensioners not released Chainsworn Sprockets worn Tensioner s worn V12 Engine Service Manual Visually check remove and checkfor wear Visual check Visual check Renew as necessary Renew as necessary Renew as necessary Jetonation knock Ignition timing too far ad Referto EDM Rectify as required Ipinking vanced Head gasket s leaking Check engine oil level and Renew head gasketis check for contamination of oil Pressure test cooling system and check for contamination of coolant in headertank Fuel air mi
6. 22 28 Tappet blockto cylinder head stud 13 17 Dipstick Tube Dipstick tube to throttle body 4 5 Drive Chain System Camshaft position sensor 5 7 Chain tensioner setscrew 22 28 Damper assembly upper bracket bolt 22 28 Idler shaft retention 43 57 Sprocket to auxiliary shaft 10 5 13 5 Thrust plate to cylinder block 22 28 Upper chain tensioner bolt 22 28 Engine Mountings Heatshieldto hydraulic mount 4 5 Exhaust Manifold 3 8 in diameter stud 13 17 Front heatshield setscrew 17 23 Rear heatshield setscrew 34 46 Fuel railto manifold 85 11 5 vii Issue 1 August 1994 V12 Engine Service Manual Fixing Tightening Torque Nm Generator Mounting Adjuster sleeve nut 34 46 Adjuster sleeveto adjuster bracket 17 23 Adjuster to generator 17 23 Cylinder block to timing cover bracket 43 57 Generator mounting bracket pivot bolt 34 46 Intake Manifold Top cover mounting stud 85 11 5 Elbowto intake manifold 8 5 11 5 Intake manifold stud 85 11 5 Throttle housing to intake manifold 4 5 Throttle stop screw locknut 4 5 Manifold Ends Intake manifold connector bracket screw 7 10 Manifold end connector assembly 13 17 Vacuum take off screw 85 11 5 Oil Cooler Hose clamp oil cooler hose to radiator cradle 7 10 Oil cooler pipe clamp plate nut 15 5 20 5 Oil cooler pipe connector 25 35 Oil cooler pipesto engine 17 23 Oil cool
7. Exhaust 38 17 to 38 18 mm Interference fit in cylinder head Intake and exhaust 0 09 mm Tappet Outside diameter 34 87 to 34 90 mm Diametrical clearance 0 02 to 0 04 mm dalve spring Free length Outer 53 4 mm Inner 44 0 mm amshaft sprocket Number of teeth 42 crankshaft sprocket Number of teeth 21 dler sprocket Number of teeth 21 liming chain ype Endless duplex Number of pitches 180 Pitch 9 525 mm Roller diameter 6 35 mm Dil filter Type Full flow disposable canister Jil pressure engine at normal At idle speed 05 bar minimum perating temperature At 4000 RPM 4 0 bar minimum Jil pump Type Gilardini Motorfides xiii Issue 1 August 1994 V12 Engine Service Manual Drive Belt Tensions Application Specification Generator drive belt Burroughs method new belt 775N Inservice if tension falls below 230 N reset at 400 N Clavis method new belt 182to 188 Hz In service if tension falls below 119 Hz reset at 137 to 143 Hz Measuring point mid way between pulleys Water pump air injection pump drive belt Burroughs method new belt 650 N In service if tension falls below 320 N reset at 400 N Clavis method new belt 169to 175Hz Inservice if tension falls below 127 Hz reset at 132to 138 Hz Measuring point mid way between crankshaft and air injection pump pulleys Power assisted steering pump air conditioning Burroughs method new belt 790 N rotate engine 3 compressor drive belt times minimum and reset at 7
8. Tool MS 621 Examine the valve seat inserts for pitting or excess wear If renewal is necessary proceed as follows Removethe inserts by machining leaving approximately 0 25 mm 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 a Grind down the outside diameter of the new insert to a di mension 0 08 mm larger than the insert recess Heat the cylinder headfor 30 minutes from coldto atem perature of 150 C 300 F Fitthe insert ensuring that it beds evenly in the recess a When the cylinder head has cooled re cut the valve seat using Service Tool MS 621 13 V12 Engine Service Manual 112 262 Fig 1 Fia 2 Fig 3 Issue 1 August 1994 V12 Engine Service Manual ay Note If newvalve inserts have been fitted the clearance between valve stem andcam must bechecked See Service Data inthe Preliminary Pages 1 Thedimension must be taken betweenthe valve stem and the back of the cam a Should this dimension not be obtained metal must be ground from the valve seat of the insert Note Use only suitable grinding equipment Removeonly very small amounts of metal from the valve seat at one time before re checking the clearance a Examinethe cam followers for wear on the top face these should be perfectly flat Check for any sign of barreling on the side faces Fig 1 R
9. inthe suction pipe Oil isfed under pressurevia internal galleries inthe cylinder blockto the filter head where it is regulated by a relief valve Any relief oil is returned directly to the suction side of the oil pump The mainoil flow isthen directed to the oil filter is again regulated and in the event of a blockage in the system is by passed After filtration the main oil flow passes through a cooler via a regulator to guard against blockage After cooling the main oil isfed into the main oil gallery for distributionto various parts of the engine Filtered oil is directed under pressure from the main oil gallery to the seven main bearings and then by oil ways inthe crankshaft tothe connecting rod bearings An oil feed pipe connectedto the rear ofthe cylinder block drawing oil fromthe main gallery feeds the camshaft bearings The idler gear is lubricated with oilfromthe main gal lery by oil ways drilled at the front of block 1 Issue 1 August 1994 V12 Engine Service Manual 1 3 Crankcase Breather Blow by gases are recycledthrough the air intake system to maintain a crankcase depression thus preventing their escapeto the atmosphere Bothcylinder banks have identical full and part load breathers The breather pipes are con nected to the top cover plate between the two banks The other ends of the full load breather pipes are connected to stub pipes on the intake hoses The part load breather pipes consist of hosestaken from the full
10. or it will be rendered un suitable for use Refitthe tool body ontothe crankshaftto abut the seal rear face Align the holes through the tool body with the threaded holesinthe crankshaftflange insertboth bolt as Fia 2 semblies and screw them in until the bolts bottom Removethe seal guide Tighten the nuts washers alter nately againstthe tool face zturn at atime untilthe seal casing is driven into its location in the crankcase by the front rim of the tool Remove the bolt assemblies and remove the body of the tool from the crankshaft Refitthe drive plate see Section 4 6 i lt UOI AM 874 Issue 1 August 1994 20 V12 Engine Service Manual a Fit and tighten the cylinder head to front cover securing nuts a Remove the sprocket retaining tool Service Tool JD 40 1 Fig 1 a Refit the sprocket to the camshaft see Section 4 12 a Check and if necessary adjust the valve clearances see Section 4 3 a Refit the rubber grommet to the front cover Replacethe components removedfor access and reconnect the exhaust system with the vehicle supported on axle stands Fillthe system with coolant see Section 4 2 inthe appropriate Vehicle Service Manual 23 Issue 1 August 1994 V12 Engine Service Manual 4 12 Camshaft Sprocket Renew e Rotate the crankshaft until the required camshaft is 180 from TDC and remove two camshaft securing bolts en sure that neithe
11. 0 Drive plateto crankshaft 85 105 Pulley damper bolt 14 18 Timing disc setscrew 85 115 Turning plate to pulley 14 18 Issue 1 August 1994 vi V12 Engine Service Manual Fixing lightening Torque Nm Cylinder Block Air injection pump connector bracketto cvlinder block 5 7 3 8 in UNF nut 34 46 Bearing cap to cvlinder block 1 2 in diameter stud 23 31 i Bearing cap to cylinder block 3 8 in diameter short stud 13 17 Bearing cap to cylinder block 3 8 in diameter long stud 13 17 Bearing cap to cylinder block nut 76 5 93 5 Cylinder headto cylinder block 7 16 in diameter stud 23731 Cylinder head to cylinder block 3 8 in diameter stud 6 8 Oil filter face plug 5 7 Oil gallery rear plug 85 115 Undershield nut 76 5 93 5 Cylinder Head and Camshaft Cover Camshaft bearing cap stud 13 17 Camshaft bearing cap to tappet block 10 5 13 5 Camshaft cover bolt 17 23 Camshaft cover screw 8 5 11 5 l Camshaft position sensor 5 7 Coupling assembly to camshaft 22 28 Cylinder headto cylinder block domed nut 64 78 Cylinder head to cylinder block nut 34 42 Cylinder head to timing cover 22 28 Exhaust manifold stud 13 17 Exhaust manifoldto cylinder head 17 23 Intake manifold stud 13 17 Intake manifoldto cylinder head 17 23 Tappet blockto cylinder head nut 17 23 Tappet blockto cylinder head socket screw
12. 3933 Fig 2 e Remove the cylinder sleeve retainers Special Tool JD 41 Fig 1 e Fit and align the new cylinder head gasket a Fit and align the cylinder head ensuring that pipes or cables harnesses are not trapped assistance may be re quired s Fit andtighten the cylinder head securing nuts with refer ence to the sequence shown in Fig 3 See Service Data in the Preliminary Pages for the correct torque figures 312 776 2 4 13 11 9 8 10 12 ss Issue 1 August 1994 22 V12 Engine Service Manual 4 8 Crankshaft Front Oil Seal Renew SRO 1221 14 Remove the crankshaft damper assembly and pulley see Section 4 7 Remove the crank damper woodruff key Fig 1 Prize the seal from the timing cover using a screwdriver Fig 2 Discard the seal and withdraw the crankshaft spacer Fig 1 Examineallcomponentsforwear and damage and renew as necessary Ensure that the seal recess is absolutely clean Smear the new seal with clean engine oil Positionthe seal squarely inthe recess andseat usingSer vice Tool JD 129 and crank bolt Fig 3 Refit the crankshaft spacer and the woodruff key Refitthe crankshaft damper assembly and pulley see Sec tion 47 8 Leg A 12 787 Fig 2 J12 788 19 Issue 1 August 1994 V12 Engine Service Manual 4 9 Crankshaft Rear Oil Sea Renew SRO 12 21 20 a Remove the drive plate see Section 4 6
13. 90 N Inservice if tension falls below 270 N reset at 630 N Clavis method new belt 117 Hz rotate engine 3 times minimum and reset to 117 Hz Inservice if tension falls below 70 Hz reset at 90 Hz Measuring point mid way between crankshaft and air conditioning compressor pulleys Issue 1 August 1994 ziy V12 Engine Service Manual 1 GENERAL DESCRIPTION Set in a60 degree Vee formation the engine hastwelve cylinders six in each bank each with a bore of 90 mm and astroke of 78 5 mm giving an overall capacity of 5993 cubic centimeters On each cylinder bank a single overhead camshaft actuatestwo valves per cylinder Fuel is supplied to each cylinder via an injector fed from a regulated fuel rail Clean air is supplied via paper element air cleaners on each cylinder bank To comply with statutory regulations insome countries andto reduce emissions during the warm up period secondary air is deliveredtothe exhaust mani folds by an engine driven air injection pump This improves oxidation untilthe catalytic converters arefully effective All engine functions are controlled by an integrated engine management system which incorporates the on board diagnostic system OBDII 1 1 Construction The skirted design crankcase is manufactured in aluminum alloy and its open top deck houses slip fit wet cast iron cylinder sleeves Housedinthe crankcase is the cast iron crankshaft which is nitro carburize treate
14. Description Notes Piston ring compressor Illustration Jaguar Number 18G 55A 18G 1432 Valve guide remover replacer 18G 1436 A Crank pulley remover and timing damper oil pressure simulator 18G 1465 Engine lifting bracket Camshaft timing jig Damper setting jig Jackshaft setting jig Camshaft sprocket retainer Cylinder sleeve retainers iii Issue 1 August 1994 V12 Engine Service Manual illustration Jaguar Number Description Notes JD 50 JD 128 Timing chain tensioner retainer Crank front seal remover Crank front seal replacer JD 181 JD 183 JD 6118C Fuel injection pressure test kit Quick fit pipe disconnecting tool Valve spring compressor JD 6118C 2 Adapter for valve spring compressor MS 53C Engine support beam MS768 Basic handle set Issue 1 August 1994 V12 Engine Service Manual Illustration Jaguar Numbe Description Notes MS 150 8 Expandablepilot NAS 204 Valve seat adjustable cutter MS 621 Valve seat adjustable cutter MS 1519A Valve spring compressor MS 1520 Engine stand MS 1520 1 Engine stand add on for V12 engine TAS 1520 2 Adapter assembly for MS s 2 1520 E e AS 1520 3 Adapter assembly for MS 1520 1 not illustrat
15. asure the valve clearances 2 Fig 1 betweenthe heel ofthe cam 4 Fig 1 andthe cam followers 3Fig 1 m Make anote of each reading Shouldtheclearances be incorrect see Service Datainthe Preliminary Pages proceed as follows Remove the camshafts see Section 4 1 Remove the cam followers 3Fig 1 a Remove each shim 5 Fig 1 inturn check the size with a micrometer and note the reading a Calculate the size of shim requiredfollowing the examples shown below a When the correct shim sizes have been obtained refit shims and cam followers to the cam carrier Lubricate the camshaft journals with clean engine oil Refit the camshafts see Section 4 1 Recheck the valve clearances a Refit the camshaft covers see Section 4 2 VALVE CLEARANCES Excessive Clearance inches Size of existing shim 0 100 Plusthe actual clearance noted 0 019 0 119 Less the specified valve clearance 0 013 Requiredshim size 0 106 Insufficient Clearance inches Size of existing shim 0 107 Plusthe actual clearance noted 0 010 0 117 Less the specified valve clearance 0 013 Requiredshimsize 0 104 Note SeeService Datainthe Preliminary Pagesfor valve clearances and available valve shim sizes Issue 1 August 1994 10 4 4 Cylinder Head Overhaul SRO 12 29 21 Removethe cylinder head assemblies see Section 4 1 1 Note Always support the cylinder heads on blocks of wood This will prevent damage to the
16. d exhaust 0 30 to 0 35 mm Spark plug Type NGK BR7 EF Sap 0 65 mm Ignition coil Type Nippondenso DIS Uumber per vehicle 2 Primary winding resistance 0 45 to 0 55 ohm Secondary winding resistance 11 5 to 15 5 kohm at 20 C Secondary winding open circuit roltage atengine idle speed 34 kV minimum Plug lead resistance Zylinder bank A Zylinder bank B 1A 13 24 kohm 2A 11 64 kohm 3A 8 48 kohm 4A 7 40 kohm 5A 8 72 kohm 6 A 14 00 kohm 1B 8 72 kohm 2B 11 64 kohm 3B 7 92 kohm 4B 10 48 kohm No 1 cylinder at crankshaft pulley 5B 15 96 kohm 6B 22 32 kohm end BankA is right hand bank viewed from drive plate end Fuel injection equipment Type uel pressure Micro processor controlled engine management system 3 bar Exhaust Emission idle speed engine at normal operating temperature Ixhaust gas analyzer reading at engine idle speed and normal yperating temperature Automatic transmission 0 5 CO maximum with catalytic converter fitted 700 RPM gear selector in neutral xi Issue 1 August 1994 V12 Engine Service Manual Application Item Specification compression pressure Cylinder pressure 13 6 to 16 3 bar with all spark plugs removed throttle fully open engine at operating temperature anda minimum cranking speed of 300 RPM Differential pressure between c
17. d to give a very high quality finish on the bearing surfaces and help increasethe 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 crank shaft end float is controlled by halfthrust washersfitted on each side of the center main bearing The gears and pulleys which drive the timing chain and external drive belts are keyed onto the crankshaft nose and held captive by a single bolt fitted intothe end of the crankshaft The H section connecting rods are of forged steel and have small end bushesof lead bronze with steel backing which are machinedto size after being pressedinto the connecting rod Connecting rod bearings are madefrom lead bronze on split steel backed shells with lead indium overlay Pistons are manufactured from aluminum alloy and are fitted with three rings two upper compression rings and one lower oil control scraper ring The pistons run on hardened steel piston pins which are offset from the center line of the piston towards the thrust face A majorfeature of the engine isthe design of the aluminum alloy cylinder heads The heads utilize the May Fireball combustion chamber which by virtue of its design gives better fuel air mixing and controlled even burning These lean burn combustion qualities aid fuel economy and helpto meet increasingly stringent emission regulations The cylinder heads carr
18. damage to the valves which when open protrude below the cylinder head face Removethe valves see Section 4 4 Boreoutthe stripped threadto 19 05 mmdiameterandtap out to 16 UNF 2B Dimension A Fig 1 Counter boreto 24 13 mm Dimension B a Dimension C 22 23 mm Dimension D 14 22 mm 14 48 mm Dimension E 10 78 mm Dimension F 15 75 mm Dimension G 11 81 mm 11 94 mm Fitthe screwed insert ensuringthat itsits firmly atthe bot tom ofthe thread a Drilland reama3 17 mm diameter hole 2 83 mm deep be tween 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 10 16 mm Fig 2 a Refitthe valves see Section 4 4 Refitthe appropriate cylinder head see Section 4 11 J12 101 EEE Issue 1 August 1994 16 4 6 Drive plate Renew SUO 125313 a Removethe torque converter Fit a suitable wedge to prevent the drive plate rotating and remove the drive plate securing bolts 1 Fig 1 and discard them a Removethe drive plate and the reinforcing ring a Clean and examine all components renew as necessary a Thoroughly clean all mating faces Fit the replacement drive plate and the reinforcing ring and secure with the bolts a Refit the torque converter V12 Engine Service Manual 17 J12 840
19. e 1 August 1994 12 Should a mark be made on only one side ofthe face the face is not concentric with the valve stem a Clean the valve and again coat with Prussian blue and ro tate 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 to lapping of the valves Check valve guide wear by inserting a new valve into the guide to be checked lift it 6 mm from its seat and rock it sideways Movement ofthe valve across its seat must not exceed 05 mm A Fig 4 Should the movement exceed this tolerance the valve guide must be replaced Use Service Tool 18G 1432to drift out the old guide Fig 2 Ensurethat the relevant valve guide is selected prior to fitting a 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 Removethe old valve guide and reamthe cylinder headto the relevant dimension Immerse the cylinder head in boiling water for 30 minutes Coat the guide with graphite grease and using Service Tool 18G 1432 1 Fig 3 drift in the guide from the camshaft side until the snap ring is seated inthe groove Note The interference should not be sufficient to require the use of excessive force when fitting the guide After fitting a valve guide the valve seat must be recut using Service
20. eck Eliminate causes other possible Jil pressuretoo high 3urning oil Relief valve stuck shut Wrong pressure relief valve Incorrect grade engine oil viscositytoo high Gauge or sensor fault Enginetemperature too low Worn cylinder bores Worn valve guides Worn intake valve seals Worn piston rings Cylinder head gasket s leak ing Incorrect grade of engine oil Remove valve and check for sticking Remove spring and checkthe rate Check oil viscosity Referto EDM Check wear with a compara tor Insert valve in guide and check side movement Remove seals and check for splits or wear Measure rings in bore Check for blue smoke from exhaust Check oil viscosity Remedy Renewthe pump Remove oil pick up pipe and clean strainer Fit new O rings Fit new O rings or clear oil gallery Clean or renewthe valve Renew spring Renew oil and filter Rectify as required Referto Too Coldfault finding in Section 42 VSM Rebore cylinders as necess ary Renew valve guides as necessary Renew in sets Renew rings in sets and re bore as necessary Renew head gasket s Renew oil and filter osing oil leaking ixcessive noise romvalve gear Worn front oil seal Worn rear oil seal Leaking gaskets Cylinder block cracked Excessivevalve clearance Broken valve spring s Brokenvalve guide Broken valve seat insert Lack of lubrication Valve clash Worn camshaft s
21. ed A 992 Snap On Oil filter canister removal tool v Issue 1 August 1994 V12 Engine Service Manual li TORQUE TIGHTENINGSPECIFICATIONS Fixing Tightening Torque Nm Air Cleaner Hose clamp hoseto air cleaner and elbow 3 4 Air Conditioning Compressor Mounting Adjuster sleeve to mounting bracket 22 28 Belt tension bracketto tappet block 17 23 Bracketto camshaft cover 22 28 Compressorto mounting plate 22 28 Air Injection Pump Adjuster bolt to pump 30 40 Adjuster screwto pump 22 28 Air pipe assembly setscrew 34 46 Air pipeto intake manifold 10 5 13 5 Check valve 30 40 Hose clamp air pipeto check valve 25 35 Nyloc nut 22 28 Pump front mounting bracket bolt 17 23 Pump pivot bolt 22 28 Pump side mounting bracket bolt 34 46 Connecting Rod Connecting rod nut 50 60 Cooling System Fan drive unit pulley nut 13 17 Fan drive unit pulley stud 17 23 Fanto fan drive unit 17 23 Heater offtake adapter 32 38 Hose clamp bypass pipe to water pump 25 35 Hose clamp ISCV to tee piece on water housing 25 35 Inlet spout to water pump 17 23 Temperature switch to water rail 22 28 Water pump assembly screw 85 11 5 Water pump casing to timing cover 17 23 Water pump plate to timing cover 17 23 Water pumpto cylinder block 22 28 Water pumptotiming cover 17 23 Crankshaft Damper bolt 180 22
22. eplace all followers that are worn or suspect Wash the valves springs collets and cam followers and air dry After the valve springs have been thoroughly washed they must be examined for fatigue and distortion Renew as necessary Test the valve springs either by comparison with the fig ures given in DATA or by comparison with a new valve spring using a recommended valve spring testing ma chine To test against a new valve spring insert both valve springs end to end between the test equipment Apply a load to partly compress the springs and measure their comparative lengths Fig 2 Fig 1 Note isthe old spring fthedistanceat A issmallerthanthe distance at B then A must be replaced a 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 s All valve springs which have diminished in length and or 1 are not square must be renewed Fit the valves into the Fig 2 guides and place the cylinder head on wooden blocks a Fit the valve spring seats intake valve guide oil seals springs and collars Compress the springs using Service Tool JD6118C and in sert the split collets a Apply sealant tothe camshaft carrier s mating surface and refit the camshaft carrier See Service Materialsinthe Pre liminary Pages TTT TT J12 276 Issue 1 August 1994 14 V12 En
23. er block stud 13 17 Timing cover plateto cylinder block 22 28 Timing cover to cylinder block 22 28 Timing cover to cylinder head 13 17 Transmission Units Bottom cover to casing 10 5 13 5 Bottom cover to flywheel cover 9 11 Coupling flange setscrew 37 43 Drive plateto torque converter setscrew 58 5 71 5 Flywheel cover to cylinder block 10 5 13 5 Oil pan distance pieceto cylinder block 17 23 Pipe bracket Taptite screw 3 5 45 Selector lever nut 21 5 28 5 Transmission pipes to oil cooler 17 23 Transmission pipes to transmission unit 16 20 Transmission unitto cylinder block 41 49 Issue 1 August 1994 V12 Engine Service Manual Description Uses Notes Dow 111 silicone grease Plug lead to spark plug Or equivalent to Ford Motor Company Specification ESE M1C171 A Hylosil 102 sealant Half moon seal to camshaft carrier Filler cap O ring Loctite 518 sealant Camshaft carrier to cylinder head Tivoli Kay adhesive No 5696 sealant Exhaust system joints Vaseline or Silicon 5000 Top of oil filler tube Issue 1 August 1994 V12 Engine Service Manual IV SERVICE DATA Engine Data Application Item Specification General Uumber of cylinders 12 Zylinder bank arrangement 60 degree vee formation 3ore 90 0 mm Stroke 78 5 mm Subic capacity 5993 cm Zompression ratio 11 1 Ignition timing Valve clearance ntake an
24. er to body 17 23 Oil Pump Filter and Oil Pan Baffle plate to sandwich to cylinder block 22 28 Clamp bracket setscrew 13 17 Cover housing bolt 22 28 Oylinder block support bracket setscrew 50 70 Delivery elbow to oil pump 22 28 Oil filter canister 187 17 Cil filter headto cylinder block 22 28 Oil pan adapter setscrew 10 5 13 5 Oil pan drain plug 61 75 Oil pan sandwich blanking plate setscrew 10 5 13 5 Oil pan sandwich to cylinder block 22 28 Oil pan to oil pan sandwich 22 28 Oil pan to sandwich and cylinder block 22 28 Oil pipe bracket setscrew 22 28 Outlet elbow bolt 10 5 13 5 Pipe clamp to pillar nut 22 28 Pump assembly to cylinder block 22 28 Rear pipe bracket setscrew 22 28 Relief valve assembly 102 142 Suction elbow to oil pump 22 28 Taptite screw 5 7 Issue 1 August 1994 viii V12 Engine Service Manual Fixing lightening Torque Nm Power Steering Front and rear platesto mounting bracket 22 28 Pulleyto pump 22 28 Pumpto engine 22 28 Spark Plug and Ignition Coil Rear coil mounting bracketto camshaft cover 10 5 13 5 Spark plug 13 17 Starter Motor Bracket clamp Taptite screw 3 5 4 5 Rear support bracket to cylinder block 34 46 Starter motor to cylinder block 31 5 42 5 Timing Cover Air pump mounting and adjuster bolt 22 28 Bearing housing to cylinder block nut 22 28 Bearing housing to cylind
25. g 3Fig 1 a Fit but do notfully tighten one retaining bolt 5 Fig 1 and new tab washer 6 Fig 1 Fitthe second retaining boltto the tab washer and secure the two bolts Remove the timing gauge Service Tool C 3993 Fig 3 a Rotatethe engine andfit the remaining sprocket retaining bolts and new tab washer a Lock over all the tabs a Re checkthe camshaft timing using Service Tool C 3993 Fig 3 25 V12 Engine Service Manual JL Ax LC d eeh Ro Baer owe 577 Issue 1 August 1994 26 Fault diagnosis Diagnostic procedures 3 Introduction 3 Foreword ii G General description Construction 1 Cooling system 2 Crankcase breather 2 Full flow oil system 1 S Service materials x Service operations Check amp adjust Valve clearances 10 Fitting Spark plug insert 16 Overhaul Cylinder head 11 Renew Camshaft 7 Camshaft cover gasket 9 Camshaft sprocket 24 Crankshaft damper amp pulley 18 Crankshaft oil seal Front 19 Rear 20 Cylinder head gasket 22 Drive plate 17 Engine cover 21 Service procedures Sealants 2 Service tools amp equipment iii T Torque tightening specifications vi 27 Index Issue 1 August 1994 28
26. gine Service Manual s Refit the original shims in the valve collar recesses 1 Fig 1 s Ensurethat the shims are seatedcorrectly and fit the cam followers Note Ifthe cylinder head has been overhauled to the ex tent of having the valve seats recut each shim should be 0 010 in smaller than the original Lubricate the camshaft and fit to the camshaft carrier en suring that it is fitted with the slot to the top a Fitthe bearing caps washers and securing nuts 1 2 Fig 2 Progressively tighten the securing nuts to the correct torque working from the center outwards See Torque Tightening Specifications in the Preliminary Pages Check and adjust the valve clearances See Section 4 3 Note Afinal checkofthe valve clearances should be done Fia 1 when the cylinder headisfitted andtightened to the cylinder block Cleanthe cylinder headthoroughly and checkthe cylinder head and cylinder block for warping bowing or cracks s Ensure that the cylinder head and block mating faces are clean and all oil water galleries are not obstructed a Repeatthe overhaul procedure for the right handcylinder head Refitthecylinder head assemblies see Section 4 11 15 Issue 1 August 1994 V12 Engine Service Manual 4 5 Spark Plug Insert Fitting SRO 122978 a Removethe appropriate cylinder head see Section 4 1 1 Note Always support the cylinder heads on blocks of wood This will prevent
27. h should be consulted where necessary Faults relatedto the cooling system are dealt with in Section 42 and to the fuel system in Section 52 inthe appropriate Vehicle Service Manual VSM 3 2 Symptom Diagnostic Procedures Possible Cause Check Remedy ngine does notstart fails to rotate Battery leads loose or ter minals corroded Battery discharged Starter motor inoperative Check the condition of the leads and terminals Check condition of battery with hydrometer Ifthe lights dim when ignition switch is operated the starter may be jammed in starter ring Check for loose and dirty con nections to the starter motor Clean and tighten as necess ary Charge or renew battery as necessary Remove starter motor free off pinion and refit Clean and tighten connec tions ingine rotates but Starter motor speedtoo low Check battery leads and ter vill not fire minals Check state of battery charge Faulty ignition system Referto EDM Remove the spark plugs Fuel system defect herheating Clean and tighten terminals Charge or renew battery as necessary Rectify as required Clean and re gap the spark plugs renew if worn out Refer to Fuel System fault finding in Section 52 VSM Refer to Section 42 VSM Overheating at tick aver Referto Section 42 VSM Too cold Referto Section 42 VSM oss of coolant Referto Section 42 VSM nsufficient oil pres iure
28. linder head s and overhaul Rectify as required Adjust valve timing Adjust valve clearances Renew guides or decarbonize the cylinder heads Overhaul the cylinder heads Engine spits back into air boxes Engine fails to idle Issue 1 August 1994 Excessively weak mixture Air leaking into intake mani fold s Incorrect ignition timing Valve clearances insufficient Cylinder head gasket s leak ing Blockage in exhaust system Refer to EDM Run engine and check for leaks whistling Spray Easy Start around suspect area the engine speed will in crease if an air leak is present Rectify as reguired Renew intaketube or gasket Referto EDM Check clearances Check for restrictions Rectify as reguired Adjust clearances Refer to Detonation Knock fault finding Remove the restrictions or renew necessary components as 4 SERVICE OPERATIONS 4 1 Camshaft Renew SRO 12 13 02 LEFT HAND SRO 12 13 03 RIGHT HAND Remove the camshaft covers see Section 4 2 a Remove the idler tensioning pulley assembly from the right hand cylinder head Rotate the engine to the cam removal position TDC until Timing Gauge C 3993 can be inserted intothe recessin the camshaft Fig 1 Note the two uppermost camshaft sprocket retaining bolts Remove Timing Gauge C 3993 e Rotatethe engine untilthe two LOWER camshaft sprocket retaining bolts on the relevant camshaft become acces
29. load breather hoses and are connected to the centre of the intake manifolds Inthis way a suitable depression is maintained at all throttle settings 1 4 Cooling System The engine is cooled in a conventional manner by the circulation of a solution of good quality anti freeze and water The water pump is mounted directly abovethe crankshaft and is belt drivenfromthe crankshaft by athree point drive which also drives the air injection pump Thecoolant isfed intothe cylinder block by external pipes and is drawn from the engine via athermostat in each cylinder bank to the radiator or directly returned to the engine if the coolant tem perature is too low 2 SERVICE PROCEDURES 2 1 Sealants One of the specified sealantsfor use onthis engine is the Marston compound known asHylosil 102 a white amine cure system rubber Shouldthis not beavailable an equivalent amine cure sealant must be used Under no circumstances should an acidtoxycure system be used Loctite 518 sealant is also specified for certain applications See Service Ma terials inthe Preliminary Pagesfor the correct sealantfor each application Issue 1 August 1994 2 3 3 1 FAULT DIAGNOSIS Introduction V12 Engine Service Manual The following diagnostic procedures are provided to assist properly qualified personsto identify and rectify the faults relating to the engine which are most likely to encountered Reference is made to the Electrical Diagnostic Manual EDM whic
30. n inai win ond san aah kamal ana eR aan naa 12 13 02 LH 7 12 13 03 RH 7 E Camshaft Cover Gasket Renew nnnnnnnnnnnnn nun nenn nn nn un nn nnn 12 2943 LH 9 12 29 44 RH 9 T Eo PE aud aye aoe Valve Clearance Check and Adjust NN 12 29 48 10 AEA erna ER Cylinder Head Overhaul NN 122921 une 11 EEN Spark Plug Insert Fitting ENEE eene 12 29 78 eee 16 AO E Drive plate Hee EE 12 53 13 EE 17 ES ak Crankshaft Damperand Pulley Renew oom 12 2E0T Lotes 18 BB E an aa Bahan Crankshaft Front Oil Seal Renew oonna anna I2 2 EN E SEENEN 19 EI vau Ba akuntan ata Crankshaft Rear Oil Seal Renew nunnununnnnnenun nenn nn nun nn nn nn 122120 ami aa cece a s 20 2 10 ee Engine Cover Henew ema na en ein T229 97 baba 21 AN WE Cylinder Head Gasket Renew 12 29 02 LH 22 12 29 03 RH 22 d 12 vici anu Camshaft Sprocket Renew EE EEN 24 i Issue 1 August 1994 V12 Engine Service Manual FOREWORD This Service Manual has been designed to enable the skilled Jaguar technician to correctly service and repair the Jaguar 6 Oliter V12 engine It assumes that the engine has been removed from the vehicle in accordance with the Vehicle Service Manual and isinaclean condition and all service tools and materials are available An index can be found atthe rear ofthe manual Issue 1 August 1994 V12 Engine Service Manual 1 SERVICE TOOLS amp EQUIPMENT
31. n using scrapers or wire brushes for re moving carbon deposits avoid scratching the valve faces and seats A soft wire brushisthe most suitable implement for this purpose Fig 1 e Clean all carbon and other deposits from the valve guides using a Suitable valve guide brush Thoroughly wash thecylinder headto ensurethat all loose carbon is removed and dry the head with a high pressure air line After cleaning and polishing each valve examine the stems for straightness and wear using a suitable dial gauge and vee block see example at Fig 2 Examine the valve faces for burns pitting and distortion Renew any valves that are excessively worn bent or too badly pitted to 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 a Lightly lap the valves into the seats with a fine grinding compound The reseating operation should leavethe fin ished surfaces smooth Excessive lapping will groove the valve face resulting ina poor seat when the engine is hot Fig 3 shows A Correctly seated D Undesirable condition C Method of rectification Totestthevalvesforconcentricity with their seats coatthe face of the valve with Prussian blue or similar and rotate the valve against the seat a Ifthe valve face is concentric with the valve stem a mark will be made all around the face geed Issu
32. ns Refer to Detonation Knock fault finding Renew valve Re cut or renew valve seat Issue 1 August 1994 V12 Engine Service Manual zngine backfires Incorrect ignition timing Valve burned out Ignition fault Fuel injection fault Air leakageinto from the ex haust system Leakage past valves and guides Ignitiontiming retarded Incorrect valve timing Valves not closing properly Referto EDM Check cylinder compressions Referto EDM Check for leaksorblowsin the system Check for crankcase fumes and referto EDMfor analysis of exhaust gases Referto EDM Check valve timing Check valve clearances Check for wear or gum in valve guides Check for poor seating of valves Symptom Possible Cause Check Remedy Rough running at Ignition fault Referto EDM Rectify as required Yormal engine speed continued Fuel injectionfault Refer to Fuel System fault finding in Section 5 2 V8M Air leaking into intake mani Run engine and check for Renew gasket s or mani foid s leaks whistling Spray Easy fold s Start around suspect area the engine speed will in crease if an air leak is present Leaking exhaust Visual check Repair leak or renew exhaust Rough idle Valve timing incorrect Check valve timing Adjust valve timing Rectify as required Renewvalve Rectify as required Refer to Fuel System fault finding in Section 5 2 VSM Repair leaks or renew system if necessary Remove the cy
33. rail position the new engine cover and securethe four fasteners by thumb pressure into the sockets 21 Issue 1 August 1994 V12 Engine Service Manual 4 11 Cylinder Head Gasket Renew SRO 12 29 02 LEFT HAND SRO 12 29 03 RIGHT HAND Drain the cooling system see Section 4 2 and depressurize the fuel system see Section 5 2 these sections are inthe ap propriate Vehicle Service Manual Disconnectthe exhaust system with the vehicle supported on axle stands Remove components as requiredfor access to the cylinder head and proceed as follows Removethe sprocket from the camshaft see Section 4 12 a Removethe front cover securing nuts e Release the cylinder head retaining nuts 7 46 in domed and in and remove the cylinder head assistance may be required Note During the cylinder head removal reposition the camshaft oil feed pipe for access Note Always support the cylinder head on blocks of dee LOK geen wood This will prevent damage to the valves which when open protrude below the cylinder head face Fia 1 a Remove and discard the cylinder head gasket s Fit cylinder sleeve retainers Service Tool JD 41 Fig 1 Removethe breather housing to cylinder head gasket and water rail to cylinder head gaskets Note Clean alljointing faces Always fit new gaskets and seals on assembly Check that the other camshaft is still at TDC using Service Tool C
34. replacement camshaft to its carrier using Service Tool Timing Gauge C 3993 to positionthe camshaft cor rectly Fig 2 Fitthe bearing caps washers and securing nuts 1 2 Fig 1 Progressively tighten the securing nuts to the correct torque working from the center outwards See Torque Tightening Specifications inthe Preliminary Pages Check that Timing Gauge C 3993 is in position Engage the camshaft sprocketto the camshaft and fit but do notfully tighten one retaining bolt and tab washer a Remove Service Tool JD 40 a Fitthe second retaining bolttothe tab washer and secure the two bolts Remove Service Tool C 3993 a Rotatethe engine andfit the remaining sprocket retaining bolts and tab washer mn Repeat the procedure for the right hand camshaft if necessary Fit Service Tool JD 50 Chain Tension Retainer and raise the timing chain tensioner slightly a Check and adjust the valve clearances see Section 4 3 a Lock over all the tabs Insert Service Tool JD 50 Release Tool throughthetiming cover Release the locking catch and allow the tensioner to expand Remove both Service Tools Check the valve clearances see Section 4 3 a Refitthe rubber grommet to the front of the timing cover a Refit the camshaft covers see Section 4 2 J12 069A Issue 1 August 1994 8 4 2 CamshaftCover Gasket Renew SRO 12 29 43 LEFT HAND SRO 12 29 44 RIGHT HAND Remove
35. rthe bolts northetab washer drop into the timing case Rotatethecrankshaft untilthecamshaft isat TDC and align using Service Tool C3993 Timing Gauge Fig 1 Slacken but do NOT remove the two remaining bolts e Removethe rubber grommet fromthe right hand front of the timing cover insert Service Tool JD 50 1 Fig 2 and release the locking catch on the timing chain tensioner FitServiceTool JD 50 ChainTension Retainer 2 Fig 2 to the right hand camshaft and retract the timing chain ten sioner until the locking catch is engaged a Remove Service Tools JD 50 e Remove the remaining two left hand camshaft sprocket bolts and fit Service Tool JD 40 1 Fig 3 to secure the sprocket to the retainer plate CAUTION Do notrotatethe engine while the camshaft is disconnected SF 192 577 Issue 1 August 1994 24 Engage the camshaft sprocket 1 Fig 1 to the camshaft Release the chain tension by fitting Service Tool JD 50 chaintension retainer 2 Fig 2 raising the timing chain tensioner slightly and then insetting Service Tool JD 50 ReleaseTool 1 Fig 2 through the timing cover and re leasingthe lockingcatch which allows the tensioner to ex pand Remove both Service Tools Check that the camshaft is still at TDC using Service Tool C 3933 Fig 3 a Remove the snap ring 3 Fig 1 a Reposition the coupling 4 Fig 1 to align the retaining holes and refit the snap rin
36. s ible a Pushback the lock tabs and removethetwo retaining bolts ensurethat the tab washer or the bolts do not drop into the timing case a Rotate the engine to the camshaft removal position TDC and refit Timing Gauge C 3993 Slacken but do NOT remove the two remaining camshaft sprocket retaining bolts a Remove the rubber grommet from the front of the right hand timing cover and insert Service Tool JD 50 Release Tool 1 Fig 2 and releasethe locking catch onthe timing chain tensioner Fit Service Tool JD 50 Chain Tension Retainer 2 Fig 2 and retract the timing chain tensioner until the locking catch is engaged Remove Service Tool JD 50 Removethe remaining two camshaft sprocket bolts and fit Service ToolJD 40 1 Fig 3 to retain the sprocketto the re tainer plate CAUTION Do notrotate the engine while the camshaft is disconnected V12 Engine Service Manual Issue 1 August 1994 V12 Engine Service Manual Gradually slacken off each camshaft cap securing nut 1 Fig 1 twoturnsat atimeuntilthevalvespringsarefully relaxed Note the cap to carrier relationship Remove the nuts washers and lift off the bearing caps 2 Fig 1 and remove the left hand camshaft 3Fig 1 Clean and examine all components thoroughly Replace worn or damaged components as necessary Ensure that all oilways are clear Lubricate the camshaft journals with clean engine oil Fit the
37. s 0 38 to 1 14 mm iston pin Type Fully floating Length 79 25 to 79 38 mm Outside diameter Grade Aired 23 809 to 23 812 mm Grade B green 23 806 to 23 809 mm Issue 1 August 1994 V12 Engine Service Manual Application Item Specification Number of journals 7 Nominal lift 9 5 mm Permissible end float 0 13 mm Thrust load point Front end of camshaft dalve Head diameter at gauge point Intake 41 15 to 41 40 mm Exhaust 34 32 to 34 60 mm Valve face angle Valve stem diameter Intake and exhaust 45 25 degrees Intake and exhaust 7 854 to 7 866 mm Valve clearance Intake and exhaust 0 30 to 0 35 mm Adjustment of valve clearance Method Shims Shim sizes available Between 0 085 in and 0 108 in in increments of 0 005 in dalve guide Material Cast iron Length Intake 48 50 mm Exhaust 43 82 mm Outside diameter Standard no groove 12 72 to 12 75 mm First oversize twogrooves 12 85 ito 12 88 mm Second oversize three grooves 12 98 to 13 01 mm Valve guide bore concentricity with Within 0 025 mm i e total indicator guide outside diameter reading of 0 050 mm Clearance between valve stem and 8 13 mm plus the valve clearance cam heel dalve seat Seating angle 44 50 to 44 75 degrees Valve seat insert outside diameter Intake 42 93 to 42 94 mm
38. the engine cover see Section 4 10 Removethe left handor right hand intake manifold as re quired For right hand camshaft cover and engine set only Remove the idler tensioning pulley assembly from the right hand cylinder head Disconnectthe air conditioning compressor multi way connector Remove and reposition the compressor for access do NOT disconnect the manifold or pipework For right hand and left hand camshaft covers Removethe securing nuts and bolts 1 Fig 1 and remove the camshaft cover Remove and discard the gasket 2 Fig 1 and the half moon seal 3 Fig 1 Clean the mating faces and the half moon seal seat Apply sealant to the half moon seal 3 Fig 1 and seat in position See Service Materials inthe Preliminary Pages Fit and align the new camshaft cover gasket refitthe cam shaft cover and secure with nuts and bolts 1 Fig 1 For right hand camshaft cover and engine set only Refit the air conditioning compressor Reconnectthe compressor multi way connector and refit the idlertensioning pulley assembly to the right hand cyl inder head For right hand and left hand camshaft covers Refitthe intake manifold Refit the engine cover see Section 4 10 V12 Engine Service Manual J12 839 Issue 1 August 1994 v12 Engine Service Manual 4 3 Valve Clearance Checkand Adjust SRO 12 29 48 Removethe camshaft covers see Section 4 2 Rotate the engine as necessary and me
39. valves which when open protrude below the cylinder head face Removethe spark plugs and exhaust manifolds from the cylinder head Graduallyslacken off eachcamshaftcap securing nut two turns at atime untilthe valve springs are fully relaxed a Note the cap to carrier relationship a Removethe nuts washers 1 Fig 1 and liftoffthe bearing caps 2 Fig 1 a Removethe camshaft 3Fig 1 Using a magnet lift out the cam followers 1 Fig 2 a Removethecamshaft carrier and removealltraces of seal ant from carrier and head faces Remove the valve springs using Service Tool JD 6118C and adapter JD 6118C 2 Fig 3 11 V12 Engine Service Manual Fig 1 Issue 1 August 1994 V12 Engine Service Manual a Retrievethe collets 1 Fig 1 collars 2Fig 1 and spring retaining plates 4 Fig 1 s Remove the valves 5 Fig 1 noting the relationship be tween valve and guide to ensurecorrect pairing during re assembly 1 e Remove the seals from the intake valve guides 2 ay Clean all component parts Check for wear and burning of valves or seats a Check the cylinder head face for distortion Ifdistortionis evident amaximum of 0 025 mm may bere moved by skimming the cylinder head a Taking care notto damage the inside surface of the com bustion chambers remove all traces of carbonfrom the in take and exhaust ports J12 502 CAUTION Whe
40. xture too weak Referto EDM Rectify as required Engine running too hot Refer to Overheating fault finding in Section 42 VSM Valve timing incorrect Check valve timing Adjust valve timing Incorrect grade fuel Loss of power Burned valves renew valves Sticking valves Check cylinder compressions Remove cylinder head s and renew valves guides or springs Poor engine tune Referto EDM Rectify as required Insufficient valve clearance Check valve clearance Adjust as necessary Fuel injection fault Refer to Fuel System fault finding in Section 5 2 VSM Lowcompression incylinders Check compressions Rebore re ring as necessary Ignition fault Referto EDM Rectify as required Valve timing incorrect Check valve timing Adjust valve timing Partial seizure of engine Remove spark plugs and ro Overhaul engine as required tate crankshaft Worn camshaft s Remove camshaft s and Renewcamshaft s check for wear Incorrect grade fuel If all other checks OK this Drain fuel tank and refill with could be the cause correct grade fuel 2ough running at Sticking valves Check cylinder compressions Renew valve springs or 1ormal engine speed Broken valve springs Piston fault Leaking head gasket s Valve burned out Valve seat burned out Check cylinder compressions and for bent valve stems Check cylinder compressions Check cylinder compressions Check cylinder compressions guides Renew valve springs and valves as required Renew pisto
41. y the tappet block cam carrier in which the single camshaft per cylinder bank runs directly with two steel in line valves per cylinder which runincastiron guides Each valve hastwo valve springs and is operated by the camshaft via a chilled cast iron buckettappet and clearance adjustmentshim Manufacturedin cast iron with chilled cams the camshafts are retained by machined aluminum caps Thetappet block is manufactured in cast aluminum alloy and is topped by a cover of the same material Camshaft drive is by a single duplex chain which incorporates an idler sprocket in its drive line Drive for the chain is provided by the crankshaft and chain tension is controlled by atensioner blade and three damper blades Three external drive belts situated at the front of the engine are operated by pulleys mounted on the crankshaft nose The three belts drive the following Generator Air conditioning compressor and power steering pump Water pump cooling fan and air injection pump Two windage trays are fitted below the crankcase which prevent oil being sucked up andthrown into the crankcase thereby alleviating windage and power loss Boltedonto the bottomofthecrankcase isthe aluminum sandwich plate the front part of which forms the base of the engine with the rear part opening outto let oil reach the pressed steel oil pan The oil pan is bolted to the sandwich plate 1 2 Full flow Oil System Oil is drawn from the oil pan via a gauze filter fitted
42. ylinders 1 38 bar maximum ylinder block Material Main bearing line bore diameter Aluminum alloy 80 429 to 80 434 mm ylinder block nominal bore liameter after honing For piston grade A 89 990 to 90 002 mm For piston grade B 90 005 to 90 018 mrn ylinder sleeve Type Slip fit wet sleeve Material Cast iron Outside diameter piston grades A and B 97 99 to 98 01 mm ylinder head Material Aluminum alloy Combustion chamber May design two valves per cylinder rankshaft Material Cast iron Number of main bearings 7 Main bearing type Vandervell VP3 Journal diameter 76 215 to 76 246 mm Thrust washer thickness 2 57 to 2 62 mm Permissible end float 0 075 to 0 279 mm Crankpin diameter 58 40 to 58 44 mm sonnecting rod Length between centers 151 38 to 151 50 mrn Bore for connecting rod bearing 62 000 to 62 014 mm Connecting rod bearing diametrical clearance Connecting rod bearing side clearance 0 027 to 0 062 mm 0 17 to 0 33 mm Bore for small end bushing 26 98 to 27 005 mm iston Type Solid skirt Skirt clearance 0 03 to 0 04 mm iston diameter Grade A 89 960 to 89 972 mm Grade B 89 975 to 89 987 mm iston ring Number of compression rings 2 Number of oil control rings 1 Gap when fitted in bore Top compression ring 0 30 to 0 55 mm Second compression ring 0 30 to 0 50 mm Oil control ring rail
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