Jaguar XJ-S. Service manual - part 37

 

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Jaguar XJ-S. Service manual - part 37

 

 

 
 

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retard a fraction of a degree more at idle than before (timing is set at 3000 RPM, well out of the influence of this 
thingy, so timing anywhere except idle will be unaffected).  There also might be some noise at idle with the weights 
hitting the metal shaft instead of the plastic stops, although how you would ever hear it above the general din of the 
engine idling is simply inconceivable. 

Plastic, brass or bronze will work nicely; steel might gall against the other steel parts, and aluminum or copper may 
be too soft and wear quickly.  Danilov doesn’t like the idea of plastic, since this is the type of application where 
choosing the wrong plastic will result in a part that gets hard and cracks with age; he found a porous bronze thrust 
washer at an Ace hardware store with the 1/2” OD and was able to drill out the ID to the correct size.  This sintered 
bronze bearing material is ideal, since the entire purpose of the material is for use as a bearing between steel parts.  
Another idea would be to buy a 5/16” ID - 1/2” OD bronze sleeve bushing and slice a suitable ring off one end of it 
(if you find a place that sells them, you might want to pick up a couple more such bushings; see the section on 
throttle linkage bushing replacement on page 267). 

 

CENTRIFUGAL ADVANCE REASSEMBLY:  Do not grease the sleeve bearing area between the rotor carrier shaft 
and the distributor shaft before reassembly; this bearing should be lubricated with full synthetic engine oil only.  Steve 
Holst shared his experience with the xj-s@jag-lovers.org discussion list:  “I can vouch for having no grease put in the 
rebuild.  I had my distributor rebuilt by my previous Jag mechanic before I knew of this list.  About two years later it 
was seized up again.  It didn't take long before that grease was gumming things up again.  I have a feeling that most Jag 
mechanics assume that slathering on the stuff is the way to do this job.  I cleaned it out myself that time and haven't had 
a problem since.” 

It is recommended that the pivots for the weights be lubricated with dry graphite only.  The ends of the springs and the 
contact surfaces all the way around the cam plate on the bottom of the rotor carrier shaft may be lubricated with a high 
temp light grease such as automotive contact grease, but make sure not to apply so much that there is any conceivable 
way you could cause a seizure if this grease hardens.  An unnamed source on the MG discussion list says, “Dupont 
makes a line of synthetic greases under the Krytox brand name which use a PFPE (perfluoropolyether) oil thickened 
with PTFE (Teflon).  It is rated for continuous use up to 260°C and down to forty below zero and is chemically inert, so 
it won't react with anything which may come into contact with it (gas, liquid or solid).  I think the GPL-225 would 
probably meet your needs, but something thicker (GPL-226) might be good, too.  You should be able to get a 'sample' 
tube of this stuff for about $10 or less.  Check out: 

 

 

http://www.lubricants.dupont.com/

 

Finding a replacement nylon clip apparently requires buying the entire service kit (see page 140), which you might 
want to consider anyway.  However, considering the clip’s failure tendencies, you may decide not to use it.  It has been 
found that an excellent method to retain the rotor carrier is to insert a couple of small metal washers that fit within the 
carrier but around the top of the shaft, followed by a tiny, chubby O-ring.  Snap the O-ring into the groove on the top of 
the shaft so that it retains the washers in place, which in turn retain the carrier.  David Johnson says, “I found a #61 O-
Ring at Home Depot was a perfect fit in the groove.  It has the following dimensions:  9/32” x 5/32” x 1/16”.  The O-
Ring has a slightly smaller diameter than the top of the shaft.  When you get it on it seems to stretch until it is a perfect 
fit for the groove.”  For owners in the UK, Carlos Artal says, “The O-ring can be found in the generic O-ring packet 
they sell at Halfords.  There are 2 boxes, one with large rings and one with small ones ; in the small O-rings one, there's 
a perfect sized O-ring.”  It might even be a good idea to try to find a Viton O-ring in this size, although since sealing 
isn’t the issue and you’d be willing to buy a new O-ring whenever you take the distributor apart perhaps you don’t care 
if it gets hard and brittle. 

Another suggestion:  Roger Bywater says, “Pulling the spindle apart invariably destroys the plastic retainer at the top 
but we find a small push on trim lock washer works just as well.” 

The washers need to have an OD less than 13/32” (10.3mm) but larger than 5/16” (7.9mm), and the ID needs to be at 
least 3/16” (4.8mm).  Brass washers would be ideal; you don’t need yet another source of rust in this assembly.  
Johnson says that Home Depot’s 5mm plain zinc washers fit perfectly.  “They are in the pull out boxes and not hanging 
on peg hooks.  4 per bag.” 

 
 

144

If these parts are installed properly the carrier should have a slight amount of up and down play, but if excessive there is 
the possibility the rotor carrier shaft might be able to slide up far enough to disengage the pins on the thingy down 
below.  If the thingy moves while thus disengaged, the rotor carrier shaft might come back down and crunch it.  This is 
unlikely to happen while running, but it might occur when somebody is trying to replace the rotor.  To avoid the 
problem, install at least two washers under the O-ring.  Better yet, do some trial fits while apart; first, try just the O-ring 
and washers on the distributor shaft to see how many will fit, then trial assemble the rotor carrier shaft, thingy, washers 
and O-ring without the centrifugal weights in the way and see if the pins on the thingy remain engaged when the rotor 
carrier shaft is lifted.  When through with the trial, it should be possible to simply pull the rotor carrier shaft off, 
popping the O-ring without damage, but just in case it’d probably be a good idea to have a couple of spare O-rings on 
hand for such trials. 

Once the rotor carrier shaft is in place and retained, you can connect up the centrifugal advance springs.  On the heavy 
one, it is recommended that the elongated end be positioned on the outward post that a weight pivots on rather than the 
inward post on the rotor carrier shaft baseplate.  It might not make any difference, but it’ll make sure the tip of the 
spring doesn’t touch the side of the rotor carrier itself.  It’ll probably be easier to assemble this way, too. 

If there is no felt plug in the top of the rotor carrier shaft, install one -- or just jam a cotton ball in there.  Something 
needs to hold some oil. 

 

DISTRIBUTOR OVERHAUL -- PAY SOMEONE ELSE VERSION:  Jeff Elmore points out that British Car Service 
(page 703) will overhaul your distributor for you.  “I called them and they said that they do the whole seals, bushings 
and new springs.  They said that they have an assortment of springs and they keep trying until they get the right 
advance curve.” 

 

DISTRIBUTOR INSTALLATION:  Since you read this book first and marked the parts correctly, installation is a snap. 
 If the crankshaft has not been disturbed, reinstall the distributor with the rotor pointing in the same direction it was 
before removal (Note:  Correcting a seized advance mechanism may make the rotor point slightly differently, but it’s 
real close.  You’ll know if you miss by one tooth on the drive gear).  If the crankshaft was turned, remove the oil filler 
cap, turn the engine until 10° BTDC and the mark you made on the sprocket is showing, and install the distributor with 
the rotor pointing towards the 1A contact on the cap. 

If you didn’t plan ahead and the engine has been turned, it is not so easy.  If you just take a blind shot at this you only 
have a 50/50 chance of getting it right.  There is a mark on the jackshaft, but the jackshaft turns at the same rate as the 
crankshaft, twice the rate of the distributor, so that mark is of no help. 

To ensure correct positioning, the 1A spark plug can be removed and the engine turned over with a thumb over the 
hole; the compression stroke can easily be determined.  However, getting the 1A plug out and a thumb over the hole is 
difficult on the H.E. (it’s much easier on the pre-H.E.).  You might try Bob Egerton’s bubble trick described in the 
section on timing starting on page 125.  There are also whistles sold that can screw into the plug hole to report when 
you’re on the compression stroke. 

Craig Sawyers says, “...look down the hole.  If it is on exhaust, you can just see the exhaust valve if you shine a light 
down the hole.  If it is on ignition, you won't see any valve (they'll both be shut).” 

Mike Morrin says, “There is an easier way.  Set the engine to TDC according to the mark on the crankshaft, get a short 
length of hose which will seal up against the spark plug hole, and blow into it.  On the compression stroke, you should 
go red in the face.” 

Alternatively you can check cylinder 6A (right rear cylinder), which may be easier for any of the methods described 
above.  This cylinder fires exactly one complete crankshaft rotation before and after 1A.  Therefore, you can find the 
top of the compression stroke on 6A and then turn the crankshaft through one complete turn.  Or, you can leave it there 
and install the distributor such that the rotor points to the 6A contact instead, exactly opposite the 1A contact. 

To place the distributor housing in the right place on the slotted holes so the vernier adjustment has a usable range, 
merely align it with the marks you made before you took it out.  You didn’t mark it?  Tsk, tsk.  Read on. 

 
 

145

Michael Neal claims, after working on these cars daily, that the optimum location of the distributor body on the three 
slotted holes is always the same.  The correct position “is with the distributor body set at 3.5 degrees retarded at the 
adjuster.  The centerline of the rotor will be 75% past the No. 1 line on the inner shield.  The slots for the holddown 
allen bolts will be 2/3 past the allen heads.  The tooth on the pickup will be roughly 5 degrees past the center of the 
pickup point.  Note that the distributor turns anti-clockwise.  This setting will give you near perfect timing almost every 
time with adjustments both ways.  Other settings tend to give too much retard or advance with no adjustment.”  

 

PREVENTING THE DAMN THING FROM SEIZING AGAIN:  After you’ve overhauled the distributor and fixed the 
seized advance, the rotor carrier/distributor shaft interface must be lubricated regularly; the Lubrication Chart in the 
ROM says two or three drops of clean engine oil in the felt under the rotor every 6,000 miles (every oil change - no, 
Quickie Lube is not likely to be doing this!).  This is not easy, as it requires removing the distributor cap, which in turn 
requires removing the cruise control unit and all the ignition wires.  This lubrication procedure is obviously very 
important; it is recommended that owners do it themselves, or make very sure their mechanic isn’t skipping this part of 
the maintenance.  Jan Wikström suggests installing a new felt pad, then taking it in for service.  If the pad is dry when 
checked afterward, cease doing business with that shop.  Perhaps good advice, but has a significant probability of 
eliminating every shop in the area from consideration! 

Note that many XJ-S distributors don’t seem to have any felt.  Considering the known problems here, it’d probably be a 
good idea to put some in.  Or, just a wad of cotton. 

Since the seizing appears to be caused by the lubricant getting baked, normal “clean engine oil” might not be the best 
idea.  I recommend that a synthetic engine oil be used, since it won’t tend to varnish or sludge and withstands higher 
temperatures without breaking down.  Soak the felt or cotton thoroughly every time you’re in there, and make sure 
you’re in there often enough.  It might not need to be as often as every 6,000 miles -- especially if you’re using 
synthetic motor oil -- but it’s better to be safe than sorry here, so make sure you do it often until you personally have 
confidence that you can go longer between oilings without the thing drying out or gumming up. 

It is suggested that spray lubricants of the flammable variety be avoided within the distributor.  When running, there are 
sparks between the rotor and the electrodes in the cap; vapors will be ignited upon starting, ruining your day. 

 

DISTRIBUTOR CAP REPLACEMENT:  Randy Wilson has a low opinion of the aftermarket products, and 
recommends buying only the genuine Lucas parts:  “The last time I checked, there was only one aftermarket cap 
available.  I ordered in a lot of them... and every single one was defective in one way or another.  Missing center 
buttons, missing vent tubes, pre-cracked, molded oval... Flimsy pieces.  They’re about 1/3 the price of the Lucas 
pieces... and not worth it.”  Note that the author has also purchased one of these aftermarket items, and in fact had 
trouble with the vent tubes simply falling off.  Rendering it usable required careful application of JB Weld. 

Jason Korke says, “I have found when I installed a replacement cap & rotor from "Standard" brand, they worked OK 
but the vent tubes broke off.  I reinstalled the Lucas cap, and found no spark!  Eventually I found the Standard cap & 
rotor will work and the Lucas cap & rotor will work, but do not mix the two brands.” 

 

DISTRIBUTOR CAP VENTING:  The 82-89 distributor cap has two fittings for a positive ventilation system.  Air is 
drawn through a small filter, through the distributor, and into the engine side of the air filter housing.  The filter is 
normally found laying against the left wing at the crossbrace attachment, and sometimes concerns owners because it 
appears to have been disconnected from somewhere. 

Reportedly this system was incorporated because the earlier distributor caps were cracking due to excessive heat, 
although some suspect removal of flammable vapors was the real reason -- see comments under DISTRIBUTOR 
SHAFT SEAL on page 141.  

The connection to the air filter housing is not actually to the housing directly, but rather to a hose between the housing 
and the auxiliary air valve (see page 263).  This is therefore a special molded hose with provision for a tiny fitting.  The 
fitting itself is a plastic elbow, and is often found to be broken.  It is not to difficult to find a suitable replacement, 

 
 

146

though, and you might even find a brass one.  Or, you can forget the whole thing and install a generic piece of hose 
between the air filter housing and the auxiliary air valve, and install a small fitting right onto the inner side of the air 
filter housing for connecting the vent line from the distributor. 

The filter itself is no more complicated than it looks.  Any generic fuel filter will serve as a replacement.  Unfortunately, 
some people actually have trouble finding one; David Littlefield says, “These used to be widely available as a generic 
fuel filter.  However, when I looked for one recently they were nowhere to be found.  I finally ran across one at my 
local auto parts store, but not with the automobile fuel filters -- it was in the lawnmower parts!”  Others suggest asking 
for a fuel filter for a VW.  Peter Havas got carried away and made a filter from a plastic film container stuffed with 
generic filter material (cotton, some types of vacuum cleaner filters, a coffee filter, or the crankcase ventilation filters 
sold in auto parts stores will serve).  He cut lots of little holes in one end, and cut a hole in the other end just a hair 
smaller than the OD of the hose and stuffed the hose into it.  This arrangement allows him to service the filter by 
opening it up and cleaning or replacing the “element”. 

Obviously, optimizing airflow and cooling would be a good idea, so replacing this filter before it gets significantly 
plugged up is recommended.  If you drive in dusty conditions, take note. 

If you would like to help this system out, reroute the intake filter to somewhere in front of the radiator.  This will draw 
cooler air, and will also draw more air since this is a high pressure area.  The cooler air should also help the electronic 
ignition pickup last longer. 

It’s possible that this ventilation scheme was retrofitted to earlier cars.  It may also be possible to drill the older cap and 
fashion suitable fittings, one in the side for an inlet and one out the top for an outlet.  A few pieces of hose, a fuel filter, 
and a connection to the engine side of an air filter housing and it’s done. 

 

Lucas OPUS Mark 2 (pre-1982) 

 

LUCAS “OPUS” MARK 2 IGNITION -- DESCRIPTION:  This is a brief description of how the pre-1982 ignition 
system works, based on the more detailed description in SAE paper 720163 on the development of the engine. 

The pickup within the distributor consists of an E-shaped transformer with one input coil and two output coils.  The 
input coil is on the center leg of the E and is fed a 600KHz input signal from the amplifier.  The two output coils are on 
the outer legs of the E and are wired in series so that their outputs cancel -- provided the two sides of the transformer 
are equal. 

When one of the ferrite inserts built into the plastic rotor in the distributor aligns itself with one side of this transformer, 
it magnetically completes the circle on one side of the E.  Since the output coil on this side is now more closely coupled 
with the input coil than the other output coil, its output is greater -- and the two no longer cancel each other.  A 
transistor in the amp is toggled by the resultant output signal, triggering a spark. 

 

TROUBLESHOOTING:  Jan Wikström sends this procedure for testing the OPUS ignition system: 

1. 

Pull the lead from coil to distributor out of the distributor and jam it under a fuel pipe so there’s a gap 
of about 1 mm (.04in) between the brass and the nearest engine part. 

2. 

Crank the engine.  Do you get fat, blue sparks in the gap?  Then the ignition is OK and you need to 
troubleshoot the injection system.  If not, continue: 

3. 

Pull the spade connector off the coil terminal marked (+).  Turn the ignition on, then test the power 
with a spare light bulb between the connector and engine bare metal (this is better than a voltmeter, 
because it will reveal a poor contact with insufficient current carrying capacity).  Is the lamp bright?  
Then continue; if there’s no voltage, check the ignition switch and all its wiring including the ballast 
resistor. 

 

 

 

 

 

 

 

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