You might try some of the other model sections. The X308 section is a likely candidate.

 

Is this it? http://www.mediafire.com/download.php?6ems6a1yrf5oovc

 

That's it!

My office firewall was blocking that page, but I was able to download it through my Android phone and transfer to PC. Thanks, WXKR.

And thank YOU, Motorcarman, for taking the trouble to convert and upload this document. Fantastic.

 

+1 That's it!

I remembered it looked like a scan from a photocopy and not an original but couldn't remember the title.

Thanks,
Graham

 

It was scanned at a copy center from the engine course offered by Jaguar at one of the training centers. A student guide in the form of a 3 ring binder is provided when the class is attended.
I had mine copied and uploaded it for info to the forum members.

The engine course 180 is for the V8 only and the 168 is for BOTH V8 and V6.

bob gauff

 

ok both heads are off now and thanks for the manual it will be a great help when rebuilding, ordered the parts from British parts in the end the jaguar parts where just too expensive more than double the price

They did say though that I didnt need new head bolts as they are not stretch bolts? they look like stretch bolts to me and they were very tight for a 10mm bolt, could the jag agents get it wrong?

lots of cleaning up to do now and wait for the heads to be pressure tested if I get the bits I plan to start rebuilding on Saturday

 

I was expecting either new bolts to be specified or, similar to the AJ6 in the XJ40, that they could be used twice and should be pop marked to indicate prior removal/replacement.

Neither JTIS nor the Engine Repair Course that Bob uploaded suggest the bolts should be renewed. You can download the JTIS Cylinder Head section from my MediaFile account if you don't have it:

http://www.mediafire.com/download.php?ccrrdd2ycvzhaz8

The Cylinder Head Removal & Replacement procedure details the three stage head bolt torque procedure to 20Nm then 35Nm followed by 90 degrees. This certainly is more normal practice with stretch bolts!

You've said they were very tight. Do you thing it's possible they may have been tightened well beyond the recommended torque in a doomed attempt to fix the gasket problem?

Graham

 

They got it wrong. On warranty they may be re-used once? There is a TSB out on this requiring marking the head bolt on re-use. Same as mentioned by GGG.

 

If there is any doubt about the one-use bolts for the cylinder head, just replace them and be sure to discard the previously used bolts. While the TSB may indicate the bolts may be reused, that is false economy in my opinion due to the labour involved should the gasket fail or cylinder head warp.

NBCat

 

Do you have this TSB available or a link to it?

I've searched through the TSB's Gus has on his site but can't find anything related to cylinder head on the XK8/XKR.

AJ6 manual details the head bolt re-use. AJ16 manual states they must be replaced on the later straight six. AJ-V8 manual makes no specific mention of either re-use or replacement.

I'm with NBCat and would replace them regardless but would like to see the official Jaguar policy.

Graham

 

Am not aware of a TSB describing the re-use of headbolts, but I find it in several documents that the headbolts can be used a second time of the AJV8s, and you need to mark them if you have re-used them. One of them is the Vehicle Specifications guide, and another is the online Topix repair guide.

 

Avos,

Thanks - found it in the 2002 Vehicle Specification in the section with the torque sequence:



It's also in the later version.

The bolts (part number AJ89986) for years 1997-2005 are listed at £7.43 ($11.69) each by BritishParts which may well influence Diamonddave's decision on re-use.

Graham

 

And here comes some good advice -

USE RANGE ROVER BOLTS.

GGG is right, they're £9 from Jaguar, £1.50 from Range Rover, I have both items on my desk and they're exactly the same, you won't see a farmer paying near ten quid for a flaming bolt!

They are stretch, and I don't re-use them, drilling out cylinder blocks isn't a nice job. By the way, the RR and Jag ones are now TORX head, obviously so they don't round off as I've seen this and read about it being a common problem.

@ Dave, replace the hoses under the S/C whilst in there. And it's a matter of course to use all new gaskets.

 

Sorry, no. That's stuff that accumulates like lint in the gray matter

But as you can see from the followups, its documented all over the place.

 

Buy 2 sets of FELPRO Lincoln LS 3.9 bolts.

bob gauff

 

Bob, he's UK based. RR are a better bet.

 

I think you mean RIBE bolts. The difference is the Torx has a pointed apex and the Ribe is squared.

Here is a TSB for the bolts. They are used in several places. VW/AUDI has also used this fastener for a long time now.

bob gauff

 

There are varying lengths of this type tool; I have the VW/Audi tool motorcarman mentioned, but it's a very common tool and can be sourced from various places such as Nissan, not just from Jaguar.

NBCat

 

How much?

 

Length or price?