Jaguar 5HP24 manual

T echnical Guide AJ-V8 Engine and 5HP24 T ransmission Introduction[...]

Published by Service Communications , Jaguar Cars Limited Publication Part No JJM 18 15 15/70, August 1996[...]

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Published by Service Communications , Jaguar Cars Limited Publication Part No JJM 18 15 15/70, August 1996 T echnical Guide AJ-V8 Engine and 5HP24 T ransmission Introduction[...]

Preface AJ-V8/5HP24 This T echnical 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 T echnical Guide must not be used as a reference sourc[...]

Contents AJ-V8/5HP24 1 Subject Page Glossary Abbreviations 2 Introduction 3 Engine Basic Engine 5 Engine Cooling 17 Engine Lubrication 20 V ariable V alve T iming 24 Air Intake System 27 Fuel System 33 Ignition System 35 Crankcase V entilation 35 EGR System 37 Engine Accessories 38 Accessory Drive 39 Engine Harness 41 Engine Covers 42 Engine Specif[...]

Glossary AJ-V8/5HP24 2 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 d[...]

Introduction AJ-V8/5HP24 3 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.[...]

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Engine AJ-V8/5HP24 5 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 conn[...]

Engine AJ-V8/5HP24 6 ENGINE STRUCTURE ENGINE DA T A LOCA TIONS 303-052 303-001 Cylinder Block 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 level[...]

Engine AJ-V8/5HP24 7 CYLINDER BLOCK, CRANKSHAFT AND BEDPLA TE 303-011[...]

Engine AJ-V8/5HP24 8 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. T wo hollow dowels align the bedpl[...]

Engine AJ-V8/5HP24 9 Connecting Rods and Pistons 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 seamles[...]

Engine AJ-V8/5HP24 10 Starter and Drive Plate 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 T echnical Guide, XK8 Introduction). The starter drive plate is attached to the rear of the crankshaft. A timing disc, for the engine spe[...]

Engine AJ-V8/5HP24 11 Cylinder Heads The cylinder heads are unique to each cylinder bank. Deep seated bolts, to reduce distortion, secure the cylinder heads to the cylinder block. T wo hollow dowels align each cylinder head with the cylinder block. The cylinder head gaskets consist of a silicon beaded composite gasket with metal eyelets for the cyl[...]

Engine AJ-V8/5HP24 12 T iming 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 exha[...]

Engine AJ-V8/5HP24 13 303-016 / 017 Primary Chain T ensioner Secondary Chain T ensioner Secondary Chain V ariable V alve T iming Unit Primary Chain TIMING GEAR[...]

Engine AJ-V8/5HP24 14 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 fri[...]

Engine AJ-V8/5HP24 15 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[...]

Engine AJ-V8/5HP24 16 Exhaust Manifold The thin-wall cast iron manifolds are unique for each cylinder bank. On engines with EGR, the A bank manifold has a connection for the transfer pipe. Spacers on the securing bolts allow the manifolds to expand and retract with changes of temperature while maintaining the clamping loads. Heat shields are integr[...]

Engine AJ-V8/5HP24 17 Engine Cooling The cooling system is a low volume, high velocity system with good warm-up and temperature profile characteristics. From the pump, the coolant flows into each bank of the cylinder block. In each bank, 50% of the coolant cools the cylinder bores and 50% is diverted through a bypass gallery . At the rear of the ba[...]

Engine AJ-V8/5HP24 18 Coolant Pump The coolant pump is installed between the two cylinder banks, on the front face of the cylinder block. The pumping element is a shrouded composite impeller . Coolant escapes from seal breather holes in the housing if the pump's bearing seal fails. An O-ring and an edge bonded rubber/aluminum alloy gasket seal[...]

Engine AJ-V8/5HP24 19 COOLANT HOSES A/C Heater Matrix 303-032 Electronic Throttle EGR V alve Electronic Throttle[...]

Engine AJ-V8/5HP24 20 Engine Lubrication Oil is drawn from the reservoir in the oil pan and pressurised by the oil pump. The output from the oil pump is then filtered and distributed through internal oil passages. All moving parts are lubricated by pressure or splash oil. Pressurised oil is also provided for operation of the variable valve timing u[...]

Engine AJ-V8/5HP24 21 LUBRICA TION SYSTEM 8 7 6 5 1. V alve Lifter Supply 2. Main Bearing Supply 3. Connecting Rod Bearing Supply 4. Bedplate/Cylinder Block Interface 5. Oil Pick-up 6. Pressure Relief V alve 7. Oil Pressure Switch 8. Oil Filter 9. Structural Sump/Bedplate Interface 10. Bedplate/Cylinder Block Interface 11. Oil Pump 12. Primary Chai[...]

Engine AJ-V8/5HP24 22 Oil Pump The oil pump is installed on the crankshaft at the front of the engine. The pump inlet and outlet ports align with oil passages in the bedplate. A rubber coated metal gasket seals the pump to bedplate interface. The pumping element is an eccentric rotor , which is directly driven by flats on the crankshaft. An integra[...]

Engine AJ-V8/5HP24 OIL SYSTEM COMPONENTS ON STRUCTURAL SUMP Pressure Switch Pick-up Filter 303-185[...]

Engine AJ-V8/5HP24 24 V ariable V alve T iming The variable valve timing system improves low and high speed engine performance, engine idle quality and exhaust emission. It is a two position system that operates on the intake camshafts only . There are 30° of crankshaft movement between the retarded and advanced positions. Engine oil pressure oper[...]

Engine AJ-V8/5HP24 25 Bush Carrier The bush carrier contains oil passages that link the engine oil supply to the valve timing unit. A lug on the bush carrier locates in the central bore of the valve timing unit. T wo hollow dowels at the bush carrier to cylinder block interface ensure the lug is accurately located. A scarf- jointed fibre ring seals[...]

Engine AJ-V8/5HP24 26 V alve T iming Solenoid The valve timing solenoid controls the position of the shuttle valve in the bush carrier . A plunger on the solenoid extends when the solenoid is energised and retracts when the solenoid is de- energised. Operation When the valve timing solenoids are de- energised, the coil springs in the bush carriers [...]

Engine AJ-V8/5HP24 27 This momentarily energises the valve timing solenoids to allow a spurt of oil into the valve timing units. The lubrication pulse occurs once every 5 minutes. Note: With the vehicle stationary and the hood open, operation of the valve timing solenoids may be audible when the lubrication pulse occurs at engine idle speed. Air In[...]

Engine AJ-V8/5HP24 28 Electronic Throttle The electronic throttle enables the ECM to control the flow of air into the engine. It includes: • an input shaft that receives driver inputs from the accelerator pedal via a conventional throttle cable • a mechanical guard, to prevent throttle valve position exceeding driver demand and to operate the t[...]

Engine AJ-V8/5HP24 29 Springs The input shaft spring and the mechanical guard spring oppose movement in the throttle open direction, and provide the "feel" of the accelerator pedal. The throttle valve spring and the drive gear spring oppose movement in the throttle closed direction. Operation The design of the input shaft and the mechanic[...]

Engine AJ-V8/5HP24 30 Operating Modes (Refer to the figure, page 31) Normal 1. Throttle cable inputs driver demand 2. Input shaft turns mechanical guard 3. Sensors supply ECM with inputs of driver demand 4. ECM operates dc motor 5. Sensor supplies ECM with inputs of throttle valve position 6. Gap maintained between throttle valve and mechanical gua[...]

Engine AJ-V8/5HP24 31 ELECTRONIC THROTTLE OPERA TING MODES Normal Mechanical Guard Cruise Crontrol Spring Force 303-080,/081/082 6 2 5 6 3 2 1 4 5 3 2 4 1 1 3 4[...]

Engine AJ-V8/5HP24 32 Induction Elbow The induction elbow provides the interface between the electronic throttle and the intake manifold. Connections on the induction elbow provide vacuum take-offs for various services. A boss on the rear of the elbow accommodates the EGR valve. Intake Manifold The intake manifold is manufactured in composite, with[...]

Engine AJ-V8/5HP24 33 Fuel System Fuel injectors, controlled by the ECM, are installed in the fuel rails on each side of the intake manifold. A cross-over pipe connects the two fuel rails together at the front of the manifold. A test valve in the cross-over pipe allows the fuel rail to be pressurised and depressurised during servicing and troublesh[...]

Engine AJ-V8/5HP24 34 Fuel Injectors Eight, side fed, dual straight jet, fuel injectors are installed in the fuel rails. The injectors are electromagnetic solenoid valves controlled by the ECM. T wo O-rings seal each injector to manifold interface. The fuel jets from the injectors are directed onto the back of the intake valves. Pressure Regulator [...]

Engine AJ-V8/5HP24 35 Ignition System The ignition system consists of two ECM controlled ignition amplifier modules, which each supply four spark plug mounted ignition coils. The 14 mm spark plugs, one per cylinder , locate in recesses down the center -line of each cylinder head. The on-plug ignition coils are secured to the camshaft covers. The en[...]

Engine AJ-V8/5HP24 36 CRANKCASE VENTILA TION SYSTEM Part Load Breather Hose Connector Full Load Breather Hose Connector 303-065/077/079[...]

Engine AJ-V8/5HP24 37 EGR System The EGR system is controlled by the ECM and consists of an EGR valve and a transfer pipe. The EGR valve is a 4 pole stepper motor installed on the rear of the induction elbow . The valve is cooled by the coolant return from the electronic throttle. The transfer pipe connects the right exhaust manifold to the EGR val[...]

Engine AJ-V8/5HP24 38 Engine Accessories All engine accessories are rigidly mounted to improve refinement, ie. there are no shock mounts. Accessory mounting brackets on the left and right sides of the engine support the A/C compressor/ P AS pump and the generator respectively . Dowels between the accessory mounting brackets and the engine ensure th[...]

Engine AJ-V8/5HP24 39 Replace Belt New Belt Maximum Length New Belt Minimum Length Belt Wear Indicator AUTOMA TIC TENSIONER Accessory Drive A single seven ribbed belt drives all the engine mounted accessories. The torsional vibration damper on the front of the crankshaft drives the belt. An automatic tensioner , located on the left accessory mounti[...]

Engine AJ-V8/5HP24 40 3 4 5 2 6 1 20 19 18 7 8 9 10 11 12 13 14 15 16 17 Connectors 1. PI032, B Bank VVT solenoid 2. PI027, B Bank Knock Sensor 3. PI004, Engine Coolant T emperature Sensor 4. PI026, A Bank Knock Sensor 5. PI031, A Bank V alve T iming Solenoid 6. PI035, MAFS (On vehicle) 7. PI050, Generator 8. PI040, Oil Pressure Switch 9. PI018-PI0[...]

Engine AJ-V8/5HP24 41 Engine Harness The engine harness links engine mounted electrical components to the vehicle's engine management harness. The connectors that interface with the engine management harness are attached to a bracket on the transmission housing. Integral nylon fasteners attach the harness to the engine. Connectors on component[...]

Engine AJ-V8/5HP24 42 Engine Covers Engine covers are installed over the fuel injectors. The covers are a push fit, held in position by mating studs and grommets on the covers and the engine. The rubber grommets isolate the covers from the engine to prevent noise. A sleeve connects the covers together at the rear . ENGINE COVERS MOUNTING POINTS ON [...]

Engine AJ-V8/5HP24 43 Engine Specifications Configuration 90° V8 Cylinder Head Dual overhead camshafts, 4 valves per cylinder V alve Clearances (Cold): Intake 0.18 to 0.22 mm (0.007 to 0.009 in) Exhaust 0.23 to 0.27 mm (0.009 to 0.011 in) Spark Plug T ype: NGK PFR5011E (platinum tipped center electrode) Spark Plug Gap: 1.0 mm (0.040 in) Firing Ord[...]

Engine Management AJ-V8/5HP24 44 ECM The engine management system is controlled by the ECM, which is installed in the control module enclosure in the engine compartment. The ECM provides optimum control of the engine under all operating conditions. It also incorporates a comprehensive monitoring and diagnostic capability . Software variations ensur[...]

Engine Management AJ-V8/5HP24 45 Inputs and Outputs Inputs and outputs are directed to and from the ECM through hard-wired connections and the CAN and ISO 9141/2 (Serial Communication) data buses contained in the engine management harness (for further information on the data buses, refer to the T echnical Guide, XK8 1997 Model Y ear Introduction). [...]

AJ-V8/5HP24 46 Engine Management 16 22 14 9 1 28 21 13 8 12 8 5 1 11 4 18 12 7 1 22 17 11 6 27 17 11 1 10 26 34 12 6 7 1 22 11 1 12 16 7 ECM PIN CONNECTIONS Connector/ Pin Circuit Pin Circuit Pin Circuit EM013 001 Fuel pump control 002 EMS programming 003 Cruise control switch LED 004 ) 005 ) 006 ) 007 ) Not used 008 ) 009 ) 010 ) 011 VSV 3 012 VSV[...]

AJ-V8/5HP24 47 Engine Management Engine Harness to Engine Management Harness Pin Connections Connector/ Pin Circuit Pin Circuit Pin Circuit PI001 001 Throttle position sensor 2 002 A/C compressor lock sensor ground 003 Throttle position sensor 1 004 Shield ground (throttle position sensor) 005 ECT sensor 006 Sensor ground (ECT , accelerator pedal p[...]

AJ-V8/5HP24 48 Engine Management Connector/ Pin Circuit Pin Circuit Pin Circuit PI002 001 ) 002 ) Not used 003 ) 004 ) 005 Injector supply 006 Throttle motor (-) 007 Throttle motor (+) 008 ) 009 ) Not used 010 ) 011 Not used 012 Generator regulator supply 013 Not used CAN Messages Messages on the CAN data bus used or output by the ECM are detailed [...]

AJ-V8/5HP24 49 Engine Management Sensors Engine management sensors that input to the ECM are detailed below: Barometric Pressure Sensor The barometric pressure sensor is installed in the ECM. It senses ambient pressure in the engine management enclosure of the engine compartment. HO2S A HO2S is installed in the intake end of each catalytic converte[...]

AJ-V8/5HP24 50 Engine Management Camshaft Position Sensor The camshaft position sensor is installed in B bank cylinder head at the rear of the intake camshaft. It is a variable reluctance sensor that provides an input of intake camshaft position. ECT Sensor The ECT sensor is installed in the coolant outlet duct. It provides an input of coolant temp[...]

AJ-V8/5HP24 51 Engine Management ENGINE SENSORS Knock Sensors ECT Sensor Camshaft Position Sensor Engine Speed Sensor 303-127[...]

AJ-V8/5HP24 52 Engine Management M ECM Inputs and Outputs 1. Intake Air T emperature Sensor 2. MAFS 3. Throttle Position Sensor 4. (Throttle) dc Motor 5. EGR V alve 6. Fuel Injector 7. Camshaft Position Sensor 8. On-plug Ignition Coil 9. H02S 10. 02S 11. Engine Speed Sensor 12. Accelerator Pedal Position Sensor 13. Mechanical Guard Position Sensor [...]

AJ-V8/5HP24 53 Engine Management Electronic Throttle The electronic throttle enables the ECM to perform the following functions: • engine air flow (ie. power) control • engine idle speed control • vehicle cruise control • stability/traction control (in response to ABS commands) • engine power limiting • vehicle speed limiting • revers[...]

AJ-V8/5HP24 54 Engine Management V ehicle Cruise Control The ECM operates the vehicle cruise control system, in all forward gears, in response to driver inputs through the master , SET+ , SET - , CANCEL and RES switches. When the master switch is pressed, two 12 V ignition supplies are connected to the ECM, one direct and one via the brake switch. [...]

AJ-V8/5HP24 55 Engine Management M CRUISE CONTROL SCHEMA TIC B+ Ignition Driver’ s Facia Fuse Box T o Dimmer Switch Master Switch Ignition Switched Ground Brake Switch Steering Wheel Switches Parking Brake Switch Engine Speed Sensor -VEHICLE SPEED -TRACTION ST A TUS -GEAR POSITION SELECTED CAN ECM VSV 2 VSV 3 VSV 1 Reservoirs Check V alve Throttl[...]

AJ-V8/5HP24 56 Engine Management Once cruise control is engaged, a further momentary press of the SET+ or SET - switch increments or decrements the set speed by 1.6 km/h (1.0 mph). The ECM then accelerates or decelerates the vehicle to the new set speed. The ECM stores a maximum of five incremental or decremental commands at any one time. Once the [...]

AJ-V8/5HP24 57 Engine Management CRUISE CONTROL V ACUUM SYSTEM Reservoirs Check V alve VSV 1 303-121 Stability/T raction Control If the CAN- TORQUE REDUCTION THROTTLE message from the brake control module requests torque reduction, the ECM reduces the throttle valve opening. It also changes the CAN- TRACTION ACKNOWLEDGE message to confirm that torq[...]

AJ-V8/5HP24 58 Engine Management Fuel Injection The ECM operates eight injectors to provide the engine with fuel. The amount of fuel required is determined from a base air:fuel ratio which is then adjusted for specific operating conditions. The ECM varies the number and duration of injector pulses per engine cycle to regulate the fuel flow . Inject[...]

AJ-V8/5HP24 59 Engine Management Starting The fueling start strategy operates independent of accelerator pedal position or movement, with the exception of a wide open throttle. The ECM produces steady state running at the target idle speed within 2 seconds of firing, after an overshoot of 200 to 300 RPM maximum. If the accelerator pedal demands a w[...]

AJ-V8/5HP24 60 Engine Management Base Ignition Map A base ignition map contains optimum timing for a nominal engine throughout the engine speed and load ranges. Corrections are then added to adjust for specific operating conditions. T emperature Corrections Corrections are added to the ignition timing to compensate for variations in intake air temp[...]

AJ-V8/5HP24 61 Engine Management V ariable V alve T iming The ECM energizes the valve timing solenoids to advance the intake valve timing and de-energizes them to retard it. The ECM uses engine load and speed maps to decide when to advance and retard the timing. The maps incorporate hysteresis for both engine load and speed to prevent "hunting[...]

AJ-V8/5HP24 62 Engine Management H02S Heaters The ECM energizes the heater elements of the HO2S during engine warm-up to shorten the time it takes for them to produce accurate outputs. Instrument Cluster The instrument cluster uses CAN messages from the ECM to operate the trip computer , tachometer , engine coolant temperature gauge and the BRAKE, [...]

AJ-V8/5HP24 63 Engine Management T o counteract the increase in engine coolant temperature that occurs after the engine stops, at ignition off: • if the fans are already on, the ECM keeps them on for 5 minutes, or until the ECT decreases to a pre-determined value, whichever occurs first • if the fans are off, the ECM determines, from ECT and in[...]

AJ-V8/5HP24 64 Engine Management Additional Input Checks Input Additional Strategy Action, Substitute or DefaultV alue Accelerator pedal Accelerator pedal position input 1 compared to If one input fails, the input of the other position (x 2) and accelerator pedal position input 2. two is used. mechanical guard Both accelerator pedal position inputs[...]

AJ-V8/5HP24 65 T ransmission Introduction The new ZF 5HP24 automatic transmission system features five forward gears and one reverse gear . It also features a filled-for -life oil system. Gearshift management is achieved using a T ransmission Control Module (TCM). TRANSMISSION Rotary Switch Connector Rotary Switch and Oil Inlet Pipe Oil Outlet Pipe[...]

AJ-V8/5HP24 66 T ransmission T ecnical Data T ransmission weight including fluid and torque converter 95.8 kg (211 lbs) Oil T ype A TF Esso L T71141 Oil Capacity 10 liters (2.645 US. gals) Gear Ratios 1st Gear 3.571:1 2nd Gear 2.202:1 3rd Gear 1.505:1 4th Gear 1.000:1 5th Gear 0.803:1 Reverse 4.095:1 Gearshifting Driver gear selection is transmitte[...]

AJ-V8/5HP24 67 T ransmission Electrical Description EM046 BLACK 16 9 14 6 5 2 3 1 10 13 mistaken for an oil leak. Electrical Connections Bayonet Connector A round, 16-pin, bayonet electrical connector is fitted at the rear left-hand side of the transmission which communicates with the 5 pressure regulators, 3 shift solenoids, oil temperature sensor[...]

AJ-V8/5HP24 68 T ransmission Management T ransmission Management The transmission management system uses both analogue and digital signals, to control the operation of the transmission. Digital signals are processed by the TCM to and from the vehicle multiplex network. Other input/output analogue signals are hardwired to the TCM. This information i[...]

AJ-V8/5HP24 69 T ransmission Management Gear Shift Interlock Gear shift interlock is controlled by the BPM, part of the SCP network. The gearshift release will only be activated when the ignition is in position II, transmission is in Park and the brake pedal is depressed. Once transmission is out of Park, the brake pedal has no effect on gearshifti[...]

AJ-V8/5HP24 70 T ransmission Management T ransmission Control Module Pin Connections Connector/ Pin Circuit Pin Circuit Pin Circuit EM007 001 Pressure Regulator 2 002 Mode Switch Illumination 003 Not used 004 Pressure Regulator 4 005 Pressure Regulator 1 006 Power Ground 007 Not used 008 Position Switch L2 009 Position Switch L4 010 Not used 011 No[...]

AJ-V8/5HP24 71 T ransmission Management TRACTION ST A TUS Brake Control Module TRANSMISSION INPUT SPEED ABS ST A TUS TRANSMISSION OUTPUT SPEED FRONT LEFT WHEEL SPEED TORQUE CONVERTER SLIP FRONT RIGHT WHEEL SPEED KICKDOWN SWITCH GEAR POSITION ACTUAL TORQUE CONVERTER ST A TUS TRANSMISSION SHIFT MAP TRANSMISSION MALFUNCTION TRANSMISSION F AUL T CODES [...]

AJ-V8/5HP24 72 Service T ools New T ools The table below lists the new service tools required for the AJ V8 engine. These are in addition to the tools already in use on 6 and 12 cylinder engines, some of which can also be used on the AJ V8. Details of new service tools for the 5HP24 transmission will be supplied at a later date. Part Number Descrip[...]