1. CAUTION: Use only a plastic scraper when removing old ......2009/07/26 · 35. Install the secondary timing chain tensioner. Tighten to 12 Nm. 36. Install the Variable Valve Timing

Assembly

1. CAUTION: Use only a plastic scraper when removing old gasket material. Clean all the mating faces and reusable parts thoroughly and check for damage. If gasket material remains on the cylinder head after cleaning, use a plastic tipped scraper to remove remaining material.

2. NOTE: Never remove pipe plugs or alignment dowels unless they are to be serviced.

Reseal oil passage blanking plugs, as necessary.

3. NOTE: The main bearings are precision selective fit. NOTE: Lubricate the upper crankshaft main bearings and thrust washers.

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Page 1 of 24ALLDATA Online - 2000 Jaguar S-Type V8-3996cc 4.0L DOHC (AJ28) SFI - Part 1 of 3

7/26/2009http://www.alldatapro.com/alldata/PRO~V129992417~C36042~R0~OD~N/0/77993956/7...

Install the upper crankshaft main bearings. Install the upper crankshaft thrust washers. Install the upper crankshaft main bearings.

4. CAUTION: Avoid damage to any crankshaft bearing surfaces.

Install the crankshaft.

5. NOTE: The main bearings are precision selective fit. NOTE: Install lower cylinder block and tighten bolts to specification within twenty minutes of applying sealer.





Apply a bead of sealant to the cylinder block housing. Use silicone gasket and sealant.

6. CAUTION: Make sure all dowels are fully seated into lower cylinder block prior to tightening the bolts. NOTE: Do not lubricate the lower cylinder block bolts. NOTE: Do not rotate crankshaft until all bolts are tightened to specification. NOTE: Bolts must be tightened within twenty minutes of applying sealer. NOTE: Tighten the bolt in the indicated sequence




Install the lower cylinder block to the upper cylinder block. Tighten bolts 21 through 32 to 15 Nm Tighten bolts 33 through 34 to 15 Nm Tighten bolts 1 through 10 to 25 Nm Tighten bolts 11 through 20 to 15 Nm Tighten bolts 1 through 10 to 35 Nm +135° Tighten bolts 11 through 20 to 20 Nm +150° Tighten bolts 21 through 32 to 20 Nm +90° Tighten bolts 33 through 34 to 20 Nm +150°

7. Remove excess sealant which may squeeze out at the front cover sealing surfaces.




8. Using the special tool, install the crankshaft rear oil seal. Make sure that the center bolt is unscrewed to below the face which is to fit to the crankshaft and position the tool to the crankshaft. Check that the nuts are fully unscrewed and install the two bolts to the crankshaft threads and lightly tighten.

9. Tighten the nuts, finger tight, to hold the tool assembly against the seal. Check that the seal and the tool are approximately parallel to the rear of the engine.





10. Press the seal into the housing. Hold each bolt stationary, in turn, and

tighten its nut a small amount (approximately two to three flats) in turn, to press the seal fully into the housing, until the tool is in contact with the cylinder block.

11. Remove the special tool from the crankshaft. Check that the seal is located correctly.

12. CAUTION: Use appropriate protection to prevent damage to the crankshaft bearing journals and cylinder bore surfaces. Install special tools to the connecting rods. Position the crankshaft journal at the bottom of the stroke. Make sure the piston rings are positioned at different positions opposite the thrust side of the piston before installation.

13. NOTE: Install pistons with arrow to front of engine.




Using the special tool compress the rings and install the piston and connecting rod. Lubricate all piston components. 14. CAUTION: When assembling the connecting rods and connecting rod caps it is

imperative that bearing slots and tangs be located on the same side of the connecting rods. CAUTION: Connecting rod bolts are torqued to yield and must be replaced. NOTE: Remove the special tools from the connecting rods. NOTE: Tighten the bolts in the indicated sequence.

Position the connecting rod cap on the appropriate connecting rod. Tighten to 10 Nm Tighten to 30 Nm Tighten to 90° 15. Rotate the crankshaft to check correct operation.





16. Install the oil pump. Install a new gasket. Tighten to 12 Nm .





17. Install the upper oil pan. Install a new gasket. Tighten to 21 Nm .

18. Install the oil separator. Install a new 'O' ring seal. Tighten to 12 Nm .

19. Install the lower oil pan. Install a new gasket. Tighten to 12 Nm .





20. Install the drive plate. Install the drive plate. Install the drive plate retaining bolts. Tighten to 15 Nm . Tighten to 110 Nm .

21. Position the crankshaft. Install the crankshaft setting peg 303-645 to the

crankshaft position sensor location.



Page 10 of 24ALLDATA Online - 2000 Jaguar S-Type V8-3996cc 4.0L DOHC (AJ28) SFI - Part 1 ...


22. Install a new left-hand cylinder head gasket. Make sure the cylinder head dowels are correctly located. Install a new left-hand cylinder head gasket.

23. NOTE: Tighten the bolts 1 through 10 the indicated sequence.

Install the left-hand cylinder head. Tighten bolts 1 through 10 to 20 Nm .





Tighten bolts 1 through 10 to 35 Nm . Tighten bolts 1 through 10 to 90° . Tighten bolts 1 through 10 to 90° . Tighten bolts 11 through 12 to 25 Nm .

24. Install a new right-hand cylinder head gasket. Make sure the cylinder head dowels are correctly located. Install a new left-hand cylinder head gasket.

25. NOTE: Tighten the bolts 1 through 10 the indicated sequence.




Install the right-hand cylinder head. Tighten bolts 1 through 10 to 20 Nm . Tighten bolts 1 through 10 to 35 Nm . Tighten bolts 1 through 10 to 90° . Tighten bolts 1 through 10 to 90° . Tighten bolts 11 through 12 to 25 Nm .

26. Install the left-hand inlet camshaft.





27. Install the camshaft bearing cap bolts evenly. Install the camshaft bearing caps.

Tighten to 10 Nm .

28. Install the left-hand exhaust camshaft.






Tighten to 10 Nm .

30. Install the right-hand inlet camshaft.






Tighten to 10 Nm .

32. Install the right-hand exhaust camshaft.





33. Install the camshaft bearing cap bolts evenly. Install the camshaft bearing caps. Tighten to 10 Nm .

34. Install the camshaft setting tool to the left-hand cylinder head.





35. Install the secondary timing chain tensioner. Tighten to 12 Nm .

36. Install the Variable Valve Timing (VVT) unit, exhaust camshaft sprocket and secondary timing chain assembly. Install the Variable Valve Timing (VVT) unit and exhaust camshaft sprocket retaining bolts but do not fully tighten.

37. Install the timing chain guide. Tighten to 12 Nm .





38. Install the crankshaft sprocket.

39. Install the chain tensioning tool 303-532 to the exhaust camshaft sprocket.

Reposition the sprocket (and the VVT unit) for the most advantageous position for use of the tool. Remove the tool.





40. Install the primary timing chain. Install the primary chain over the crankshaft

sprocket and the WT unit sprocket. There must be no slack on the drive side of the primary chain and the VVT unit must not be rotated on the camshaft.

41. Install the timing chain tensioner blade. Tighten to 14 Nm .





42. Install the primary chain tensioner assembly. Use a wedge 303-533 (or two if

required) between the primary chain tensioner and tensioner blade, to take up the slack in the chain. Tighten to 12 Nm .

43. Tighten the exhaust camshaft sprocket securing bolt. Install the chain

tensioner tool 303-532 to the sprocket holes.

� Apply force to the tool in an anti-clockwise direction to tension the chain on its drive side.

While applying the opposing force to sprocket and chain, tighten the sprocket bolt.





44. Tighten the VVT unit bolt. While still applying the opposing force to the

sprocket and chain (using 303-532), check that the wedges are still in place, tighten the VVT unit bolt. Remove the chain tensioning tool and the wedge(s).

45. Install the left-hand Variable Valve Timing (VVT) solenoid and bush carrier

assembly. Install new 'O' ring seals. Tighten to 21 Nm .





46. Remove the camshaft setting tool.

47. Install the camshaft setting tool to the right-hand cylinder head.





48. Install the secondary timing chain tensioner. Tighten to 12 Nm .

49. Install the Variable Valve Timing (VVT) unit, exhaust camshaft sprocket and

secondary timing chain assembly. Install the Variable Valve Timing (VVT) unit and exhaust camshaft sprocket retaining bolts but do not fully tighten





Documents

1. CAUTION: Use only a plastic scraper when removing old ......2009/07/26 · 35. Install the secondary timing chain tensioner. Tighten to 12 Nm. 36. Install the Variable Valve Timing