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Technical Guide
AJ-V8 Engine
and
5HP24 Transmission
Introduction
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Published by Service Communications, Jaguar Cars Limited Publication Part No JJM 18 15 15/70, August 1996
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Technical Guide AJ-V8 Engine and 5HP24 Transmission Introduction Published by Service Communications, Jaguar Cars Limited Publication Part No JJM 18 15 15/70, August 1996
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AJ-V8/5HP24 Preface This Technical Guide introduces the new AJ V8 engine and 5HP24 transmission installed in the XK8 Sports car. It is intended to give Jaguar Dealer workshop personnel an overview of their construction and operation, and is for information purposes only. The contents of this Technical Guide must not be used as a reference source for servicing procedures; all servicing procedures must be in accordance with the appropriate Service Manual. This Technical Guide will not be updated.
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Contents AJ-V8/5HP24 Subject Page Glossary Abbreviations 2 Introduction 3 Engine Basic Engine 5 Engine Cooling 17 Engine Lubrication 20 Variable Valve Timing 24 Air Intake System 27 Fuel System 33 Ignition System 35 Crankcase Ventilation 35 EGR System 37 Engine Accessories 38 Accessory Drive 39 Engine Harness 41 Engine Covers 42 Engine Specifications 43 Engine Management ECM 45 Electronic Throttle 53 Fuel Pump 58 Fuel Injection 58 Ignition 59 EVAP System 60 Variable Valve Timing 61 EGR System 61
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AJ-V8/5HP24 Glossary The following abbreviations are used in this document: Abbreviation Description ABS anti-lock braking system A/C air conditioning A/CCM air conditioning control module BPM body processor module BHP brake horse power ˚C degree Celsius CAN controller area network CDI cubic inch displacement DIN Deutsche Institut für Normung dc direct current DTC diagnostic trouble code ECM engine control module ECT engine coolant temperature EGR exhaust gas recirculation EMS engine management
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Introduction AJ-V8/5HP24 The AJ-V8 4.0 litre, engine is the first of a new family of Jaguar engines. Designed to give excellent performance, refinement, economy and low vibration levels it also conforms to the strictest emission legislation. Weighing only 200 kilograms (441 lb), the engine is shorter by 12 inches (300 mm) than the current AJ16 4.0 litre engine. Compression ratio is 10.75:1, with four valves per cylinder. The cylinder heads, block and bedplate are all cast aluminum. Cylinders hav
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Engine AJ-V8/5HP24 303-056 Basic Engine The AJ-V8 is an all new 90° V8 liquid cooled engine that gives refined and effortless performance. Constructed in aluminum alloy, the AJ-V8 introduces several innovative design features new to Jaguar engines, the most notable of these being: • a bedplate • nikasil coated cylinder bores • fracture split connecting rods • variable valve timing • aluminum alloy valve lifters • electronic throttle control. 5
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AJ-V8/5HP24 Engine Cylinder Block ENGINE STRUCTURE 1 The cylinder block is an "enclosed V" design, which provides an inherently rigid structure with good vibration levels. Nikasil (a composition of nickel and silicon) coated cylinder bores provide good friction, heat transfer and piston noise levels. A low volume coolant jacket improves warm-up times and piston noise levels; the longitudinal flow design of the jacket, with a single cylinder head coolant transfer port in each bank, improves rigid
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Engine AJ-V8/5HP24 CYLINDER BLOCK, CRANKSHAFT AND BEDPLATE 303-011 7
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AJ-V8/5HP24 Engine Bedplate SEALANT TRACK ON BEDPLATE The bedplate is a structural casting bolted to the bottom of the cylinder block to retain the crankshaft. The use of a bedplate further improves rigidity. Iron inserts, cast into the main bearing supports of the bedplate, minimise main bearing clearance changes due to heat expansion. Two hollow dowels align the bedplate with the cylinder block. Beads of sealant seal the joint between the bedplate and the cylinder block. 303-012 Crankshaft CRA
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Engine AJ-V8/5HP24 Connecting Rods and Pistons CONNECTING ROD AND PISTON The connecting rods are manufactured in sinter forged steel. The bearing caps are produced by fracturing the opposing sides of the connecting rod at the bearing horizontal center-line. As well as being easier to manufacture, when re-assembled the fractured surfaces interlock to form a strong seamless joint. The cylinder position is etched on adjoining sides of the joint to identify matching connecting rods and bearing caps.
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AJ-V8/5HP24 Engine STRUCTURAL SUMP AND OIL PAN Torque Converter Access 303-010 Starter and Drive Plate STARTER MOTOR The engine starter motor is installed at the rear right side of the engine, at the cylinder block to bedplate split line (for further details of the starter motor see Technical Guide, XK8 Introduction). The starter drive plate is attached to the rear of the crankshaft. A timing disc, for the engine speed sensor, is spot welded to the front face of the drive plate. 303-062 10
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Engine AJ-V8/5HP24 TIMING DISC STARTER DRIVE PLATE 303-035 303-034 The 14 mm spark plugs, one per cylinder, locate Cylinder Heads in recesses down the center-line of each cylinder The cylinder heads are unique to each cylinder head. bank. Deep seated bolts, to reduce distortion, An engine lifting eye is cast into the front of each secure the cylinder heads to the cylinder block. cylinder head (the rear lifting eyes, one on each Two hollow dowels align each cylinder head with cylinder head, are b
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AJ-V8/5HP24 Engine A BANK CYLINDER HEAD Exhaust Camshaft Intake Camshaft Lifting Eye 303-047 Timing Gear Single row primary and secondary chains drive the camshafts of each cylinder bank. The primary chains transmit the drive from two sprockets on the crankshaft to variable valve timing units on the intake camshafts. The secondary chains transmit the drive from the variable valve timing units to sprockets on the exhaust camshafts. (Continued on Page 14) 12
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Engine AJ-V8/5HP24 TIMING GEAR Secondary Chain Tensioner Primary Chain Secondary Chain Variable Valve Timing Unit Primary Chain Tensioner 303-016 / 017 13
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AJ-V8/5HP24 Engine Timing Gear (Continued) A key locates the two drive sprockets on the crankshaft. The crankshaft's torsional vibration damper retains the sprockets in position. The variable valve timing units and the exhaust camshaft sprockets are non-interference, non- keyed fits on their respective camshafts; the drive being transmitted by the face to face friction load produced by the valve timing unit/sprocket securing bolt. Each chain has an hydraulic tensioner operated by engine oil. A j
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Engine AJ-V8/5HP24 Camshaft Covers The camshaft covers are manufactured from vinyl ester composite. The A bank camshaft cover incorporates an outlet for the full load engine breather. The B bank camshaft cover incorporates the engine oil filler cap and an outlet for the part load engine breather. Identical oil separators are incorporated below the breather outlet in each cover (see Crankcase Ventilation, page 35). Silicon rubber in-groove gaskets seal the joints between the camshaft covers and t
