ENGINE XJ 9-1 ENGINE TABLE OF CONTENTS page page DESCRIPTION AND OPERATION ENGINE IDENTIFICATION . . . . . . . . . . . . . . . . . . . 1 DIAGNOSIS AND TESTING SERVICE DIAGNOSIS—DIESEL— PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . 2 SERVICE DIAGNOSIS—DIESEL— MECHANICAL. . . . . . . . . . . . . . . . . . . . . . . . . . . 9 TAPPET NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SERVICE PROCEDURES VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . .
9-2 ENGINE XJ DIAGNOSIS AND TESTING (Continued) Displacement . . . . Bore . . . . . . . . . . . Stroke . . . . . . . . . . Compression Ratio . . . . . . . . . . . . . 2.5L (2499 cc) . 92.00 . 94.00 . 21:1 Vacuum at idle . . . . . . . 600 mm/Hg (23.6 In/Hg) Belt Tension . . . . . . . . . 400/500 N Automatic Tensioner Thermostat Opening . . . 80°C 6 2°C Generator Rating . . . . . Denso 12V—95A Cooling System Capacity. 9.5 Liter P/S Capacity . . . . . . . . . 0.75 Liter Engine Oil Capacity . . . 7.
ENGINE XJ 9-3 DIAGNOSIS AND TESTING (Continued) CONDITION ENGINE CRANKS, BUT WILL NOT START NO SMOKE ENGINE HARD TO START, OR WILL NOT START SMOKE FROM EXHAUST POSSIBLE CAUSES CORRECTION 6. No voltage to starter solenoid. 6. Check voltage to solenoid. If necessary, replace the solenoid. 7. Solenoid or starter motor inoperative. 7. Replace starter motor. 1. No fuel in supply tank. 1. Fill fuel supply. 2. Electrical fuel shutdown solenoid not operating. 2.
9-4 ENGINE XJ DIAGNOSIS AND TESTING (Continued) CONDITION ENGINE HARD TO START, OR WILL NOT START SMOKE FROM EXHAUST (CONT.) ENGINE STARTS, BUT WILL NOT KEEP RUNNING SURGING (SPEED CHANGE) POSSIBLE CAUSES CORRECTION 6. Air in fuel system or the fuel supply is inadequate. 6. Check the flow through the filter and bleed the system. Locate and eliminate the air source. 7. Contaminated fuel. 7. Verify by operating the engine with clean fuel from a temporary tank. Check for presence of gasoline.
ENGINE XJ 9-5 DIAGNOSIS AND TESTING (Continued) CONDITION ROUGH IDLE (IRREGULARLY FIRING OR ENGINE SHAKING) ENGINE RUNS ROUGH ENGINE RPM WILL NOT REACH RATED SPEED POSSIBLE CAUSES CORRECTION 1. If engine is cold, glow plug relay on glow plug(s) defective. 1. Refer to troubleshooting for cylinder head heater plugs (see Group 14, Fuel system). 2. Engine mounts damaged or loose. 2. Repair or replace mounts. 3. High pressure fuel leaks. 3.
9-6 ENGINE XJ DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION ENGINE RPM WILL NOT REACH RATED SPEED (CONT.) 6. Improperly operating injection pump. 6. Repair or replace injection pump. LOW POWER 1. Fuel control lever not moving to full throttle. 1. Check/correct for stop-to-stop travel. 2. High oil level. 2. Check/correct oil level. 3. Engine overloaded. 3. Check for added loading from accessories or driven units, brakes dragging and other changes in vehicle loading.
ENGINE XJ 9-7 DIAGNOSIS AND TESTING (Continued) CONDITION EXCESSIVE EXHAUST SMOKE ENGINE WILL NOT SHUT-OFF POSSIBLE CAUSES CORRECTION 1. Engine running too cold (white smoke). 1. Refer to troubleshooting for coolant temperature below normal (refer to Group 7, Cooling System). Inspect cylinder head heater plugs for proper operation. 2. Improper starting procedure (white smoke). 2. Use proper starting procedures. 3. Fuel supply inadequate. 3. Check fuel supply pressure and inlet restriction. 4.
9-8 ENGINE XJ DIAGNOSIS AND TESTING (Continued) CONDITION COOLANT TEMPERATURE ABOVE NORMAL POSSIBLE CAUSES CORRECTION 1. Low coolant level. 1. Check coolant level. Add coolant, if necessary. Locate and correct the source of the coolant loss, (refer to Group 7, Cooling). 2. Incorrect/improperly operating pressure cap. 2. Replace cap with the correct rating for the system. 3. Loose drive belt on water pump/fan. 3. Check/replace belt or belt tensioner. 4. Inadequate air flow to the radiator. 4.
ENGINE XJ 9-9 DIAGNOSIS AND TESTING (Continued) SERVICE DIAGNOSIS—DIESEL—MECHANICAL. CONDITION POSSIBLE CAUSES CORRECTION LUBRICATING OIL PRESSURE LOW 1. Low oil level. 1. (A) Check and fill with clean engine oil. (B) Check for a severe external oil leak that could reduce the pressure. LUBRICATING OIL PRESSURE TOO HIGH 2. Oil viscosity thin, diluted or wrong specification. 2. Verify the correct oil is being used. Check for oil dilution.
9 - 10 ENGINE XJ DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION LUBRICATING OIL LOSS 1. External leaks. 1. Visually inspect for oil leaks. Repair as required. 2. Crankcase being overfilled. 2. Verify that the correct dipstick is being used. 3. Incorrect oil specification or viscosity. 3. (A) Make sure the correct oil is being used. (B) Look for reduced viscosity from dilution with fuel. (C) Review/reduce the oil change intervals.
ENGINE XJ 9 - 11 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION EXCESSIVE ENGINE NOISES 1. Drive belt squeal, insufficient tension or abnormally high loading. 1. Check the automatic tensioner and inspect the drive belt. Make sure water pump, tensioner pulley, fan hub and generator turn freely. 2. Intake air or exhaust leaks. 2. Refer to Excessive Exhaust smoke (Engine Diagnosis Performance). 3. Turbocharger noise. 3.
9 - 12 ENGINE XJ SERVICE PROCEDURES (Continued) INSPECTION (1) Inspect for cracks in the combustion chambers and valve ports. (2) Inspect for cracks on the exhaust seat. (3) Inspect for cracks in the gasket surface at each coolant passage. (4) Inspect valves for burned, cracked or warped heads. (5) Inspect for scuffed or bent valve stems. (6) Replace valves displaying any damage. (7) Check valve spring height (Fig. 2). LOAD Kg HEIGHT mm STATE P1 0.00 H1 44.65 FREE LENGTH P2 32-36 H2 38.
ENGINE XJ 9 - 13 SERVICE PROCEDURES (Continued) with new valves and recut valve seat inserts to obtain correct stand down. REMOVAL AND INSTALLATION ENGINE MOUNTS — LHD DIESEL The engine mounts support the engine at each side. These supports are made of resilient rubber. REMOVAL—RIGHT SIDE (1) Disconnect the negative battery cable. (2) Remove the innercooler inlet hose from the turbocharger and position it out of the way (Fig. 6). Fig.
9 - 14 ENGINE XJ REMOVAL AND INSTALLATION (Continued) INSTALLATION—RIGHT SIDE (1) Position the engine mount and bracket and install the engine mount through bolt and nut, leaving them loose at this time. (2) Install, but do not torque the engine mount lower sill plate bolts. (3) Install the (4) engine mount bracket to engine block retaining bolts and torque to 61 N·m (45 ft. lbs.). (4) Torque the engine mount lower sill plate bolts to 41 N·m (30 ft. lbs.). (5) Remove the jack stand.
ENGINE XJ 9 - 15 REMOVAL AND INSTALLATION (Continued) (13) Position a jack stand and raise the weight off the left engine mount. (14) Remove the (4) engine mount bracket bolts from the engine block. (15) Remove the (4) trackbar support bracket bolts and remove the bracket (Fig. 9). Fig. 10 A/C Compressor Position & Orientation 1 2 3 4 5 – – – – – A/C COMPRESSOR MOUNTING BOLTS LEFT ENGINE MOUNT THROUGHBOLT NUT H BLOCK BOLTS COUPLER PINCH BOLT COMPRESSOR ELECTRICAL CONNECTOR Fig.
9 - 16 ENGINE XJ REMOVAL AND INSTALLATION (Continued) (6) Remove the engine mount throughbolt nut only. Leave the bolt installed at this time. (7) Position a jack stand and raise the weight off the right engine mount. (8) Remove the (4) trackbar support bracket retaining bolts and remove the bracket. (9) Remove the (4) engine mount bracket bolts from the engine block. (10) Remove the remaining engine mount lower sill plate bolt. (11) Remove the engine mount through bolt.
ENGINE XJ 9 - 17 REMOVAL AND INSTALLATION (Continued) (2) Install, but do not torque engine mount lower sill plate bolts. (3) Install the (4) engine mount bracket to engine block retaining bolts. Torque to 61 N·m (45 ft. lbs.). (4) Torque the (2) lower engine mount sill plate bolts to 41 N·m (30 ft. lbs.). (5) Install the (2) engine mount upper sill plate nuts. Torque to 41 N·m (30 ft. lbs.). (6) Remove the jack stand. Fig.
9 - 18 ENGINE XJ REMOVAL AND INSTALLATION (Continued) 2.5L DIESEL ENGINE REMOVAL (1) Disconnect both of the battery cables and remove the battery. (2) Mark the hinge locations on the hood for alignment reference during installation. CAUTION: Wrap the appropriate size drillbit with masking tape 1/4 inch from tip. This will prevent damaging the hood outer panel when drilling out the rivets retaining the hood latch cable control assembly.
ENGINE XJ 9 - 19 REMOVAL AND INSTALLATION (Continued) Fig. 18 Clutch Slave Cylinder Fig. 16 Engine Ground Wire Location 1 – RIGHT ENGINE MOUNT THROUGHBOLT NUT 2 – ENGINE GROUND WIRE 3 – OIL PAN 1 – CLUTCH SLAVE CYLINDER 2 – CLUTCH SLAVE CYLINDER RETAINING NUTS 3 – FRONT DRIVESHAFT (37) Remove the (3) nuts retaining the transfer case shift linkage and position the linkage aside (Fig. 19). Fig.
9 - 20 ENGINE XJ REMOVAL AND INSTALLATION (Continued) (38) Disconnect the electrical connectors and the vent hose and from the transfer case and transmission. (39) Support the rear of the transmission with a jack. (40) Remove the transmission support crossmember. (41) Lower the transmission to gain access to the transmission to engine retaining bolts. (42) Remove all the bolts securing the transmission to the engine assembly. Remove the transmission and the transfer case assembly from the vehicle.
ENGINE XJ 9 - 21 REMOVAL AND INSTALLATION (Continued) Fig. 21 Clutch Slave Cylinder 1 – CLUTCH SLAVE CYLINDER 2 – CLUTCH SLAVE CYLINDER RETAINING NUTS 3 – FRONT DRIVESHAFT Fig. 22 Exhaust System Inlet Pipe Connection 1 – OIL PAN 2 – EXHAUST INLET PIPE FLANGE RETAINING BOLTS 3 – EXHAUST SYSTEM SUPPORT CLAMP (23) Working inside the vehicle, install the shifter on the transmission (24) Install the shifter boot seal. (25) Install the center console. Refer to Group 23, Body for the procedure. Fig.
9 - 22 ENGINE XJ REMOVAL AND INSTALLATION (Continued) CYLINDER HEAD COVER REMOVAL (1) Disconnect the negative battery cable. WARNING: DO NOT REMOVE THE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR DRAIN COCK WITH THE SYSTEM HOT AND PRESSURIZED BECAUSE SERIOUS BURNS FROM THE COOLANT CAN OCCUR. Fig.
XJ ENGINE 9 - 23 REMOVAL AND INSTALLATION (Continued) HYDRAULIC TAPPETS Before disassembling any part of the engine to correct tappet noise, check the oil pressure. If vehicle has no oil pressure gauge, install a reliable gauge at the pressure sending unit. The pressure should be between 4 bars (50 psi) at 3000 RPM. Check the oil level after the engine reaches normal operating temperature. Allow 5 minutes to stabilize oil level, check dipstick.
9 - 24 ENGINE XJ REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Lubricate the tappets. (2) Install the tappets and retainers in their original positions. Ensure that the oil feed hole in the side of the tappet body faces up (away from the crankshaft). (3) Install the cylinder head, intake manifold, and exhaust manifold. Refer to cylinder head removal and installation in this section. (4) Install the push rods. (5) Install the rocker arms.
ENGINE XJ 9 - 25 REMOVAL AND INSTALLATION (Continued) (3) Remove the rocker arms assemblies and push rods. Refer to rocker arm and push rod removal and installation in this section. Retain the push rods, and rocker arms assemblies in the same order and position as removed. (4) Inspect the springs and retainer for cracks and possible signs of weakening. (5) Install an air hose adaptor in the fuel injector hole. (6) Connect an air hose to the adapter and apply air pressure slowly.
9 - 26 ENGINE XJ REMOVAL AND INSTALLATION (Continued) (17) Disconnect the oil drain line from turbocharger. (18) Remove the Exhaust manifold. Refer to Group 11, Exhaust System and Turbocharger. (19) Remove the Intake manifold. Refer to intake manifold removal and installation procedure in this section. (20) Remove the oil feed line retaining bracket at rear of #4 cylinder head. (21) Remove the oil feed line retaining bracket (Fig. 29). Fig.
ENGINE XJ 9 - 27 REMOVAL AND INSTALLATION (Continued) Fig. 32 Fuel Injector HOW TO IDENTIFY GASKET THICKNESS NO HOLES . . . . . . . . . . . . 1.41mm 2 HOLES . . . . . . . . . . . . . 1.51mm 1 HOLE . . . . . . . . . . . . . . 1.61mm Fig. 34 Steel Type Cylinder Head Gasket— identification MEASURING PISTON PROTRUSION (1) Use special tool VM.1010 with dial indicator special tool VM.1013 (Fig. 35). Fig.
9 - 28 ENGINE XJ REMOVAL AND INSTALLATION (Continued) from the edge of the piston and note the measurement (Fig. 36). (5) Repeat the procedure with the rest of the cylinders. (6) Establish the thickness of the steel gasket for all four cylinder heads on the basis of the greatest piston protrusion (Fig. 34). Measured dimension (mm) . . . . . . . . . 0.53 - 0.62 Cyl. head gasket thickness (mm) . . . . . 1.41 Piston clearance (mm). . . . . . . . . . . . . 0.80 - 0.89 Measured dimension (mm) . . . . .
XJ ENGINE 9 - 29 REMOVAL AND INSTALLATION (Continued) (9) Tighten the 12mm bolts in the following manner: (10) Side bolts (M1-M2): Tighten M1 bolts to 30 N·m, then rotate them 85° (65). Tighten M2 bolts to 30 N·m, then rotate them 85° (65). NOTE: If vehicle is equipped with A/C do not install A/C lines to compressor and charge A/C till Phase 2 is complete. (11) 2nd Phase: After 20 minutes of engine operation at operating temperature, allow engine to cool down completely.
9 - 30 ENGINE XJ REMOVAL AND INSTALLATION (Continued) VIBRATION DAMPER REMOVAL (1) Disconnect the negative battery cable. (2) Remove the fan and set fan inside fan shroud then remove fan shroud and fan as an assembly. (3) Remove the accessary drive belt. Refer to Group 7, Cooling System for procedure. (4) Remove the vibration damper nut. (5) Install special tool VM.1000-A to remove vibration damper. INSTALLATION (1) Install the vibration damper and align with key way.
ENGINE XJ 9 - 31 REMOVAL AND INSTALLATION (Continued) (4) Install the automatic belt tensioner. NOTE: The idler pulley has left hand thread. (5) Install the idler pulley. Torque nut to 40 N·m (29 ft. lbs.). (6) Install the fan pulley. Torque bolts to 56 N·m (41 ft. lbs.). (7) Install the vibration damper. torque nut to 196 N·m (147 ft. lbs.). (8) Install the accessary drive belt. Refer to Group 7, Cooling System for procedure). (9) Install the fan and fan shroud. (10) Connect the negative battery cable.
9 - 32 ENGINE XJ REMOVAL AND INSTALLATION (Continued) Fig. 44 Timing Marks Fig. 42 Camshaft Removal 1 2 3 4 – – – – CAMSHAFT GEAR CRANKSHAFT GEAR OIL PUMP VACUUM PUMP (11) If equipped, evacuate and charge the air conditioning system. Refer to Group 24, Heater and Air Conditioning for procedure. (12) Connect the negative battery cable. (13) Fill the cooling system. Check for leaks. WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN DIRECT LINE WITH THE FAN.
ENGINE XJ 9 - 33 REMOVAL AND INSTALLATION (Continued) sliding the new camshaft bearing shell over proper adapter. (2) Position the rear bearing in the tool. Install horseshoe lock and by reversing removal procedure, carefully drive bearing shell into place. (3) Install the remaining bearings in the same manner. The Bearings must be carefully aligned to bring oil holes into full register with oil passages from the main bearing.
9 - 34 ENGINE XJ REMOVAL AND INSTALLATION (Continued) (2) Remove the timing gear cover. Refer to timing gear cover removal in this section. (3) Align all the timing marks before removing the vacuum pump (Fig. 47). Fig. 48 Vacuum Pump 1 2 3 4 – – – – VACUUM PUMP CAMSHAFT OIL PUMP CRANKSHAFT Fig. 47 Timing Marks 1 2 3 4 5 6 – – – – – – VACUUM PUMP CAMSHAFT INJECTION PUMP TIMING MARKS OIL PUMP CRANKSHAFT (4) Remove the vacuum pump retaining bolts.. (5) Remove the internal vacuum pump.
ENGINE XJ 9 - 35 REMOVAL AND INSTALLATION (Continued) (5) Connect the negative battery cable. OIL FILTER ADAPTER AND ENGINE OIL COOLER REMOVAL (1) Disconnect the negative battery cable. (2) Remove the oil filter. (3) Remove the oil filter adapter/oil cooler retaining bolt (Fig. 52). (4) Remove the oil filter adapter. (5) Disconnect the engine oil cooler coolant hoses and remove the oil cooler. Fig. 50 Vacuum Pump Mounting Hole (6) Check the plunger for scoring, replace if necessary. Fig.
9 - 36 ENGINE XJ REMOVAL AND INSTALLATION (Continued) (2) Remove cylinder heads, refer to cylinder head removal in this section. (3) Raise vehicle on host. (4) Remove oil pan, refer to oil pan removal in this section. (5) Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Mark piston with matching cylinder number.
ENGINE XJ 9 - 37 REMOVAL AND INSTALLATION (Continued) Fig. 55 Ring Gap Measurement Fig. 57 Piston Rings—Removing and Installing 1 – FEELER GAUGE Fig. 58 Piston Ring Identification rod big end should also face in the same direction. To insert piston into cylinder use a ring compressor as shown in (Fig. 57). PISTON PIN INSTALLATION Fig.
9 - 38 ENGINE XJ REMOVAL AND INSTALLATION (Continued) CYLINDER WALL LINER ASSEMBLY REMOVAL (1) (2) (3) (4) Remove cylinder heads. Remove Oil pan. Remove pistons. Use tool VM-1001 to remove liners (Fig. 61). Fig. 59 Piston Ring Gap Location (2) Before installing the ring compressor, make sure the oil ring expander ends are butted and the rail gaps located as shown in (Fig. 59). Fig. 61 Liner Removal Tool Fig.
ENGINE XJ 9 - 39 REMOVAL AND INSTALLATION (Continued) (4) Remove liner and special tool. (5) Then select the correct shim thickness to give proper protrusion (0.01 - 0.06 mm). (6) Fit the shim and the O-rings onto the liner. (7) Lubricate the lower liner location in the block. Apply LOCTITE AVX to the corner of the liner seat. Apply LOCTITE AVX uniformly to the upper part of the liner at area. (8) Fit the liners in the crankcase making sure that the shim is positioned correctly in the seat.
9 - 40 ENGINE XJ REMOVAL AND INSTALLATION (Continued) Fig. 64 Liner Clamp Location CRANKSHAFT MAIN BEARINGS REMOVAL (1) Disconnect the negative battery cable. (2) Remove the engine from vehicle. Refer to engine removal and installation in this section. (3) Install the engine on an engine stand. (4) Remove the accessary drive system. (5) Remove the cylinder head cover. Refer to cylinder head cover removal and installation in this section. (6) Remove the rocker arm assemblies and push rods.
ENGINE XJ 9 - 41 REMOVAL AND INSTALLATION (Continued) Fig. 66 Crankshaft Special Tool VM.1004 1 – TOOL the carriers for assembly and remove the bolts, two for each carrier (Fig. 67). Fig. 68 Crankshaft and Carrier Bearing Assembly (4) Check the crankshaft main bearing journals to bearing clearances. Clearances of main bearings is.03 to.088mm (.0011 to.0035 in.). NOTE: Assemble engine according to sequence described, thus saving time and preventing damages to engine components.
9 - 42 ENGINE XJ REMOVAL AND INSTALLATION (Continued) (25) To verify correct end play, install 2 flywheel bolts 180° apart, and tighten bolts to 20 N·m plus 60° (15 ft. lbs. plus 60°). (26) Measure crankshaft end play with a dial gauge. Crankshaft end play should not exceed.153 to.304mm (.0060 to.0119 in.) (Fig. 70). Fig. 69 Main Bearing Support Alignment (11) Install the rear oil seal. (12) Install the new O-rings in adaptor plate. (13) Install the adaptor plate to block. Torque nuts to 26.
ENGINE XJ 9 - 43 REMOVAL AND INSTALLATION (Continued) ASSEMBLE (1) Clean all tappet parts in a solvent that will remove all varnish and carbon. (2) Replace tappets that are unfit for further service with new assemblies. (3) If plunger shows signs of scoring or wear, install a new tappet assembly. If valve is pitted, or valve seat on end of plunger is prevented from seating, install a new tappet assembly. (4) Assemble tappets. CLEANING AND INSPECTION CYLINDER HEAD CLEANING Fig.
9 - 44 ENGINE XJ CLEANING AND INSPECTION (Continued) PISTONS AND CONNECTING ROD ASSEMBLY INSPECTION—PISTONS (1) Piston Diameter: Size: 91.93-91.94mm (3.61913.6196 in.) Maximum wear limit.05mm (.0019 in.). (2) Check piston pin bores in piston for roundness. Make 3 checks at 120° intervals. Maximum out of roundness.05mm (.0019in.). (3) The piston diameter should be measured approximately 15 mm (.590 in.) up from the base. (4) Skirt wear should not exceed 0.1 mm (.00039 in.).
ENGINE XJ 9 - 45 CLEANING AND INSPECTION (Continued) BEARING-TO-JOURNAL CLEARANCE Compare internal diameters of connecting rod with crankshaft journal diameter. Maximum clearance between connecting rod and crankshaft journals.022 to.076mm (.0008 to.0029 in.). Fig. 74 Connecting Rod Identification 1 – CAMSHAFT SIDE 2 – 2–DIGIT NUMBER FOR WEIGHT CATEGORY 3 – 4–DIGIT REFERENCE NUMBERS FOR CORRECT ASSEMBLING Fig.
9 - 46 ENGINE XJ CLEANING AND INSPECTION (Continued) OIL PUMP (2) Check clearance between rotors (Fig. 80). CLEANING Wash all parts in a suitable solvent and inspect carefully for damage or wear. INSPECTION (1) Before installing oil pump check pump bore depth in block (A) and pump body height (B) (Fig. 78). Difference between A and B should be 0.020-0.082 mm. Fig. 80 Checking Rotor Clearance SPECIFICATIONS ENGINE SPECIFICATIONS Fig. 78 Oil Pump Bore Depth Fig.
XJ ENGINE 9 - 47 SPECIFICATIONS (Continued) DESCRIPTION SPECIFICATIONS Center bearing diameter Nominal . . . . . . . . . . . . . . . . . . . 63.050-63.093 mm −0.25 . . . . . . . . . . . . . . . . . . . . . 62.800-62.843 mm −0.125 . . . . . . . . . . . . . . . . . . . . 62.925-62.968 mm Clearance between journal and bearing: 0.030-0.088 mm Rear journal diameter Nominal . . . . . . . . . . . . . . . . . . . 79.980-80.000 mm −0.25 . . . . . . . . . . . . . . . . . . . . . 79.730-79.750 mm −0.125 . . . . . .
9 - 48 ENGINE XJ SPECIFICATIONS (Continued) DESCRIPTION SPECIFICATIONS Exhaust valve: Opens . . . . . . . . . . . . . . . . . . . . . . . 66° B. B. D. C. Closes . . . . . . . . . . . . . . . . . . . . . . . . 36° A. T. D. C. Face angle: Intake . . . . . . . . . . . . . . . . . . . . . . 55° 308 - 55° 408 Exhaust . . . . . . . . . . . . . . . . . . . . . 45° 258 - 45° 358 Head diameter: Intake . . . . . . . . . . . . . . . . . . . . . . 40.05-40.25 mm Exhaust . . . . . . . . . . . . . . . . . . . . . . .
ENGINE XJ 9 - 49 SPECIFICATIONS (Continued) DESCRIPTION TORQUE Injection pump gear Lock nut . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 N·m Injection pump Mounting nut . . . . . . . . . . . . . . . . . . . . . . 27.5 N·m Injector Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.5 N·m Intake manifold Mounting nut . . . . . . . . . . . . . . . . . . . . . . 32.5 N·m Main bearing oil delivery Union . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 - 50 ENGINE XJ SPECIAL TOOLS (Continued) Injection Pump Puller and Gear retainer VM. 1003 Cylinder Head Bolt Wrench VM. 1006A Crankshaft Remover/Replacer Sleeve VM. 1004 Cylinder Head Guide Studs VM. 1009 Torque Angle Gauge VM. 1005 Cylinder Liner Protrusion Tool VM.
ENGINE XJ 9 - 51 SPECIAL TOOLS (Continued) Flywheel Locking Tool VM. 1014 Bosch Pump Timing Adapter VM. 1011 Timing Cover Oil Seal Replacer VM. 1015A Injector Remover/Replacer Socket VM. 1012B Dial Indicator Gauge VM. 1013 Cylinder Retainer VM. 1016 1 – VM.
9 - 52 ENGINE XJ SPECIAL TOOLS (Continued) Crankshaft and Water Pump Pulley Holder VM. 1017 Cylinder Head Bolt Wrench M14 VM. 1019 Cylinder Head Bolt Wrench M12 VM. 1018 Cylinder Leakage Tester Adapter VM. 1021 Fig. 81 Top Dead Center Tool VM.
