v12 Engine Manual x300 - v12 - Service PDF
v12 Engine Manual x300 - v12 - Service PDF
v12 Engine Manual x300 - v12 - Service PDF
CON TENTS
Section Title SRO Page
Foreword ........................................................................... ii
I ................ Service Tools& Equipment ........................................................... iii
II ................ Torque Tightening Specifications ....................................................... vi
111............... ServiceMaterials ..................................................................... x
IV ............... Service Data ....................................................................... xi
1 ................ General Description .................................................................. 1
1.1 .............. Construction ........................................................................ 1
7.2 .............. Full-flow Oilsystem ................................................................. 1
1.3 .............. Crankcase Breather ................................................................... 2
1.4 .............. CoolingSystem ...................................................................... 2
2 ................ Service Procedures ................................................................... 2
2.1 .............. Sealants ............................................................................ 2
3 ................ Fault Diagnosis ...................................................................... 3
3.7 .............. Introduction ......................................................................... 3
3.2 .............. Diagnostic Procedures ................................................................ 3
4 ................ Service Operations ................................................................... 7
4.1 .............. Camshaft. Renew .............................................. 12.13.02-LH ......... 7
12.13.03-RH ......... 7
4.2 .............. Camshaft Cover Gasket, Renew .................................. 12.29.43-LH ......... 9
12.29.44-RH ......... 9
4.3 .............. ...............................
Valve Clearance, Check and Adjust 12.29.48 ............ I O
4.4 .............. Cylinder Head, Overhaul ........................................ 12.29.21 ............ 11
4.5 .............. Spark Plug Insert Fitting ......................................... 12.29.78 ............ 16
4.6 .............. Drive-plate, Renew ............................................ 12.53.13 ............ 17
4.7 .............. Crankshaft Damperand Pulley, Renew ............................ 12.27.01 ............ 18
4.8 .............. Crankshaft Front Oil Seal, Renew ................................. 12.21.74 ............ 19
4.9 .............. Crankshaft Rear Oil Seal, Renew ................................. 12.21.20 ............20
4.10 ............. Engine Cover, Renew ........................................... ............ 21
72.29.93
4.11 ............. Cylinder Head Gasket, Renew ................................... 12.29.02-LH ........ 22
12.29.03-RH ........ 22
4.12 ............. Camshaft Sprocket. Renew ........................................................... 24
FOREWORD
This Service Manual has been designed t o enable the skilled Jaguar technician to correctly service and repair the
Jaguar 6.0liter V I 2 engine.
It assumes that the engine has been removed from the vehicle, in accordance with the Vehicle Service Manual, and
is in a clean condition and all service tools and materials are available.
A n index can be found at the rear of the manual.
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JD 40 Camshaft sprocket retainer
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V12 Engine Service Manual
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AS 1520-2 Adapter assembly for MS
1520
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V12 Engine Service Manual
SERVICE DATA
Engine Data
Ignition timing
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xi Issue 1 August 1994
V12 Engine Service Manual
I Number of journals 17 I
I Nominal lift 19,s mm
Permissible end float 10,13 mm 1
Thrust load point Front end of camshaft
dalve Head diameter (at gauge point) Intake: 41,15 t o 41,40 mm
1
I
Exhaust: 34,32 to 34.60 mm
Valve face angle 1 Intake and exhaust: 45,25 degrees
Valve stem diameter 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 1 Shims
'
dalve guide Material
Length Intake: 48,50 mm
Exhaust: 43,82 mm
Outside diameter Standard - no groove: 12,72 to 12,75
~ mm
' First oversize - t w o grooves: 12,85
1 to 12,88 mm
Second oversize - three grooves:
12.98 to 13,Ol mm
Valve guide bore concentricity with Within 0,025 mm (i.e.tota1 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
Exhaust: 38,17 to 38,18 mm
Interference fit in cylinder head Intake and exhaust: 0,09 mm
rappet 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
zamshaft sprocket Number of teeth 42
zrankshaft sprocket Number of teeth 21
dler sprocket Number of teeth 21
liming chain Type Endless duplex
Number of pitches 180
Pitch 9,525 mm
Roller diameter 6,35 mm
3 1 filter Type Full flow disposable canister
31 pressure (engine at normal At idle speed 0.5 bar (minimum)
)perating temperature)
At 4000 RPM 4,O bar (minimum)
31 pump Type Gilardini Motorfides
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V12 Engine Service Manual
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GENERAL DESCRIPTION
Set in a 60 degree Vee' formation, the engine has twelve cylinders - six in each bank- each with a bore of 90 mm and
a stroke of 78,5 mm, giving an overall capacity of 5993 cubic centimeters. On each cylinder bank, a single overhead
camshaft actuates two valves per cylinder. Fuel is supplied to each cylinder via a n 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
in some countries and to reduce emissions during the warm-up period, secondary air is delivered t o the exhaust mani-
folds by an engine-driven air injection pump. This improves oxidation until the catalytic converters are fully 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.
Housed in the crankcase is the cast iron crankshaft, which is nitro-carburize treated to give a very high quality finish
on the bearing surfaces and help increase the life of the bearing journals. The crankshaft is supported by seven main
bearing caps, which have bearings of lead bronze on split steel backed shells with a lead indium overlay. Any crank-
shaft end-float is controlled by halfthrust washers fitted on each side ofthe center main bearing. The gears and pulleys
which drive the timing chain and external drive belts are keyed on t o the crankshaft nose and held captive by a single
bolt fitted into the end of the crankshaft.
The 'H' section connecting rods are of forged steel and have small end bushes of lead bronze with steel backing, which
are machined to size after being pressed intothe connecting rod. Connecting rod bearings are made from 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 major feature of the engine is the 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 help to meet increasingly stringent emission regulations. The
cylinder heads carry the tappet block (cam carrier) in which the single camshaft per cylinder bank runs directly, with
two steel. in-line valves per cylinder which run i n cast iron guides. Each valve has two valve springs and is operated
by the camshaft via a chilled cast iron bucket tappet and clearance-adjustment shim.
Manufactured in cast iron with chilled cams, the camshafts are retained by machined aluminum caps. The tappet 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 a tensioner 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 and thrown into the crankcase,
thereby alleviating windage and power loss. Bolted ontothe bottomofthecrankcase is the aluminum sandwich plate,
the front part of which forms the base of the engine, with the rear part opening out t o let oil reach the pressed steel
oil pan. The oil pan is bolted to the sandwich plate.
1.2 Fu//-f/ow Oil System
Oil is drawn from the oil pan via a gauze filter fitted in the suction pipe. Oil is fed under pressure via internal galleries
in the cylinder block to 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 main oil flow is then 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, t o
guard against blockage. After cooling, the main oil is fed into the main oil gallery for distribution to 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 in the crankshaft, t o the connecting rod bearings. An oil feed pipe connected to the rear of the cylinder block
drawing oil from the main gallery, feeds the camshaft bearings. The idler gear is lubricated with oil from the main gal-
lery by oil-ways drilled at the front of block.
2. SERVICE PROCEDURES
2.1 Sealants
One of the specified sealants for use on this engine is the Marston compound known as Hylosil 102, a white amine cure
system rubber. Should this not be available, an equivalent amine cure sealant must be used. Under no circumstances
should an acidtoxycure system be used. Loctite 518sealant is also specified for certain applications. See Service Ma-
terials in the Preliminary Pages for the correct sealant for each application.
FAU LT DIAGNOSIS
3.1 Introduction
The following diagnostic procedures are provided to assist properly qualified persons to identify and rectify the faults
relating to the engine which are most likely to encountered. Reference is made to the Electrical Diagnostic Manual
(EDM), which should be consulted where necessary. Faults related to the cooling system are dealt with in Section 4.2
and t o the fuel system in Section 5.2 in the appropriate Vehicle Service Manual (VSM).
3.2 Diagnostic Procedures
Symptom Possible Cause Check Remedy
Engine does not start Battery leads loose or ter- Check the condition of the Clean and tighten as necess-
fails t o rotate) minals corroded leads and terminals ary
Battery discharged Check condition of battery Charge or renew battery as
with hydrometer necessary
Starter motor inoperative If the lights dim when ignition Remove starter motor, free
switch is operated, the starter off pinion and refit
may be jammed i n starter
ring.
Check for loose and dirty con- Clean and tighten connec-
nections to the starter motor tions
ingine rotates but Starter motor speed too low Check battery leads and ter- Clean and tighten terminals
Nil1 not fire minals
Check state of battery charge Charge or renew battery as
necessary
Faulty ignition system Refer to EDM Rectify as required
Remove the spark plugs Clean and re-gap the spark
plugs, renew if worn out
Fuel system defect Refer t o Fuel System fault
finding in Section 5.2, VSM
herheating Refer to Section 4.2, VSM
herheating at tick- Refer to Section 4.2, VSM
iver
Refer t o Section 4.2, VSM
-oss of coolant Refer t o Section 4.2, VSM
nsufficient oil pres- Oil requires changing Check oil level and color Change oil and filter
iure
Worn crankshaft journals Listen for rumble or knock Renew crankshaft
Excessive crankshaft end- Fit dial gauge and measure Renew thrust washers
float
Worn main bearing shells Listen for rumble Check crankshaft journals for
wear and renew shells
Worn oil pump Remove oil pump and check Renew oil pump
the clearances
Oil pressure relief valve stick- Remove valve and check for Renew valve
ing open sticking
Oil pressure relief valve Remove spring and check Renew spring
spring too weak spring rates
Insufficient oil i n oil pan Check oil level T o p u p as required
Engine overheating Refer to Overheating fault
finding in Section 4.2, VSM
Faulty gauge or sensor Refer to EDM Rectify as required
Incorrect grade oil (viscosity Check oil viscosity Renew oil and filter
too low)
Water in oil Check oil level and check if oil Renew oil and filter
is a milky white color
Check for leaking head gasket Renew head gasket
SERVICE OPERATIONS
4.1 Camshaft, Renew
SRO 12.13.02 - LEFT-HAND
SRO 12.13.03 - RIGHT-HAND
1 Remove the camshaft covers, see Section 4.2.
1 Remove the idler tensioning pulley assembly from the
right-hand cylinder head.
1 Rotate the engine to the cam removal position (TDC)until
Timing GaugeC3993can be inserted into the recess inthe
camshaft (Fig. 1).
1 Note the two uppermost camshaft sprocket retaining
bolts. Remove Timing Gauge C 3993.
1 Rotate the engine until the two LOWER camshaft sprocket
retaining bolts on the relevant camshaft become access-
. ible.
Push backthe locktabs and remove the two retaining bolts
(ensure that the t a b washer or the bolts do not drop into
the timing case).
1 Rotate the engine t o the camshaft removal position (TDC)
and refit Timing Gauge C 3993.
0 1 Slacken, but do NOT remove the two remaining camshaft Fia. 1
Fia. 3
.
9 Remove Service Tool JD 40.
Fit the second retaining bolt to the tab washer, and secure
the t w o bolts.
..
= Check the valve clearances, see Section 4.3.
Refit the rubber grommet to the front of the timing cover.
Refit the camshaft covers, see Section 4.2.
. shown below.
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.
.
= Using a magnet, lift out the cam followers (1 Fig. 2).
Remove thecamshaft carrier and removeall traces of seal-
Fin. 3
. ‘C-Method of rectification.
To testthevalvesforconcentricity withtheirseats,coatthe
face of the valve with Prussian blue or similar and rotate A
Fig. 3
Fig. 3
m: between
If new valve inserts have been fitted, the clearance
valve stem and cam must be checked. See
Service Data in the Preliminary Pages.
9 The dimension must be taken between the valve stem and
J 12 276
Fig. 3
Fia. 2
.
SRO 12.29.78
Remove the appropriate cylinder head, see Section 4.1 1.
Note: Always support the cylinder heads on blocks of
wood. This will prevent damage to the valves
which, when open, protrude below the cylinder
head face.
Remove the valves, see Section 4.4.
Bore out the stripped thread to 19.05 mmdiameterand tap
out to 16 UNF - 28 (Dimension 'A' Fig. 1).
.
9 Dimension 'H' = 10,16 mm (Fig. 2).
Refit the valves, see Section 4.4.
Refit the appropriate cylinder head, see Section 4.11.
Fig. 2
Drive-plate, Renew
..
SUO 12.53.13
Remove the 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.
Remove the drive-plate and the reinforcing ring.
.
Clean and examine all components, renew as necessary.
Thoroughly clean all mating faces.
Fit the replacement drive-plate and the reinforcing ring,
Fig. 1
m Fit the pulley (5 Fig. 1) and the crank turning plate (3 Fig.
1) and secure with the securing bolts and spacers (1,2,4
0
. Fig. 1).
Refit the drive belts.
Fig. 2
112.789
Fig. 3
.
SRO 12.29.93
Rotate the four turn-fasteners ‘/4 of a turn anti-clockwise
and remove the engine cover (Fig.1). Removethe four fas-
Fia. 1
..
proceed as follows.
Remove the sprocket from the camshaft, see Section 4.12.
Remove the front cover securing nuts.
Release the cylinder head retaining nuts, in. domed
and 3/8 in., and remove the cylinder head-assistance may
be required.
m: During the cylinder head removal, reposition the
camshaft oil feed pipe for access.
14
Fig. 3
Fig. 2
Fig. 3
SRO 12.21.20
1 Remove the drive-plate, see Section 4.6.
1 Clean and lubricate the exposed surfaces ofthe crankshaft
andthe insidesurfacesofthetool body,(removal /installs-
tion tool - JD 163) with clean engine oil.
1 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 in the crankshaft rear flange, screw both bolt assem-
blies (2 Fig.1) into them to lock the tool body t o 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.
1 Using a hammer (Fig.l), penetrate the seal (up to 2 mm);
determine this from the distance noted in the previous
operation. ? I 2 b73
1
2); turning it no more than 1'/2 turns.
Repeat the procedure for inserting the two other screws.
0
CAUTION: Do not exceed 2 turns or the screw may break.
m Remove the two bolt assemblies, so that the center bolt (2
Fig. 2) can be turned clockwise t o extract the seal.
1 Remove and discard the seal from the tool.
1 Clean the surface ofthe crankshaft and ensure it issmooth
and free of damage. Lubricate the surface with clean en-
gine oil.
1 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 t o fitment or it will be rendered un-
suitable for use.
Refit the tool body onto the crankshaft to abut the seal rear
face. Align the holes through the tool body with the
threaded holes in the crankshaft flange, insert both bolt as- Fia. 2
semblies and screw them in until the bolts 'bottom'.
1 Remove the seal guide. Tighten the nuts / washers alter-
nately against the tool face, '/2 turn at a time, until the 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.
1 Refit the drive-plate, see Section 4.6.
. nuts.
Remove the sprocket retaining tool - Service Tool JD 40
.. (1 Fig. 1).
Refit the sprocket to the camshaft, see Section 4.12.
Check, and if necessary adjust, the valve clearances, see
. Section 4.3.
Refit the rubber grommet t o the front cover.
Replace the components removed for access and reconnect
the exhaust system with the vehicle supported on axle
stands. Fill the system with coolant, see Section 4.2 in the
appropriate Vehicle Service Manual.
Fig. 1
Fig. 3
e 1
Engage the camshaft sprocket (1 Fig. 1) t o the camshaft.
Release the chain tension by fitting Service Tool JD 50
(chain tension 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-
leasing the locking catch which allows the tensioner t o ex-
pand.
1 Remove both Service Tools.
1 Check that the camshaft is still at TDC using Service Tool
C 3933 (Fig. 3).
.
1 Remove the snap-ring (3 Fig. 1).
Reposition the coupling (4 Fig. 1) to align the retaining
1
. bolts and new tab washer.
Lock over all the tabs.
Re-check the camshaft timing, using Service Tool C 3993
n
(Fig. 3).
Fig. 3
F
Fault diamosis
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 & 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 & 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 & equipment, iii
T
Torque tightening specifications, vi