brake fluid JAGUAR XJ6 1994 2.G Workshop Manual

(if applicable) term(s) (or Eng-
lish Equivalent)
paragraph para
parking brake
Park Neutral Position PNP
Park Neutral Position Switch PNPS
Dart number I Dartno.
I pin boss
ping, pinging
piston pin
(also wrist pin)
power assisted steering
power steering pressure
. powertrain
program
Droaramable or Droarammable I
Droaramed or Droarammed I
Droaramer or Droarammer I
programing or programming
Programmable Electronic Control
I PECUS
Units System
I Programmable Read-only Mem- I PROM
on/ Prussian blue
Pump
purge cock I
indicates the selected non-drive modes of
the (automatic) transmission
boss in the piston wall (two per piston) which
is bored to
accept one end of the piston pin
metallic pinging sound caused by detonation
in the combustion chamber, usually caused
by incorrect grade of fuel (too low octane) or
over
-advanced ignition timing (see also knock)
pin which connects the connecting rod to the
piston, and permits articulation between the
two.
hvdraulic
DumD-assisted steerina svstem
the elements of
a vehicle by which motive
power is generated and transmitted to the
driven axle
sequence of events to be performed by
a
control module/comDuter
process whereby a common ECM is programmed on the production line to suit
the market requirements of
a particular vehicle
ROM with some provision for setting the
stored data after manufacture
device used to raise, transfer, or compress
fluids by suction, pressure or both handbrake
NDS, NGS, TSN,
gearbox sensor
piston pin boss
pinking
gudgeon pin
Dower steerina
drive line
programme, pro
-
gram
programmable
programmed
programmer
programming
enaineer's blue
drain plug, drain
tap
Issue 1 August 1994 X300 VSM 21

Manual Transmission & clutch (AJ16)
I Molykote FB 180 grease
Brake (clutch) fluid
- minimum
DOT 4
Dexron IID Transmission oil
Loctite
573
Tivoli Kay Adhesives No. 5696
Withdrawal arm pivots / Gearshift lever ball
Clutch hydraulic system
Front cover securing bolts
Exhaust sealer also used
in
ZF automatic
transmissions
Application
Material removal to clean up clutch face
IU SERVICE DATA
Specification
Up to lmm maximum
X300 VSM iii Issue 1 August 1994

Manual Transmission & Clutch (AJ16)
7.1.12 CLUTCH, DESCRIPTION
The single-plate, diaphragm-type clutch, is operated by the pushrod of the slave cylinder acting on the clutch lever.
The slave cylinder, mounted on the transmission bell housing, is operated hydraulically from the clutch master cylinder
through
a series of hydraulic pipes.
The piston in the master cylinder is operated
by a push rod from the clutch pedal, which is fitted to the bulkhead
mounted pedal box.
The clutch pedal is positioned to the left of the brake pedal.
The engines use
a twin-mass flywheel configuration with built-in springs to provide a smooth take-up of drive.
The flywheel is extremely heavy and great care must be taken when lifting
it from the vehicle.
Fig.
1 The Clutch Assembly
CAUTION: The hydraulic fluid used in the clutch hydraulic system is injurious to car paintwork. Utmost precautions
MUST at all times be taken to prevent spillage of fluid. Should fluid be accidentally spilled onto the
paintwork, wipe fluid off immediately with a cloth moistened with denatured alcohol (methylated
spirits).
Issue 1 August 1994 X300 VSM

Manual Transmission & clutch (AJ16)
7.1.15 CLUTCH MASTER CYLINDER, RENEW
SRO 33.20.01
. Remove the clutch master cylinder to clutch pedal clevis
pin securing clip (1 Fig. I), and remove the clevis pin (2
Fig. 1).
. Remove the master cylinder securing nuts (3 Fig. 1).
. Disconm.the hydraulic pipe (4 Fig. 1) from the master
cylinder, and fit blanking plugs to the pipe and master cy- linder.
. Remove the master cylinder assembly (5 Fig. 1) and the
gasket (6 Fig. 1).
. Fit the new master cylinder to the bench vice and fill the
reservoir.
. Refit the reservoir cap.
. Remove the blanking plug from the master cylinder.
. Prime the master cylinder by 'working' the push rod until
fluid appears at the hydraulic pipe outlet.
. Remove the master cylinder from the vice.
. Place a new gasket (6 Fig. 1) over the mounting studs.
. Fit and align the master cylinder assembly to the studs,
. Remove the blanking plug from the hydraulic pipe (4 Fig.
. Ensure that the union is clean and no foreign matter enters
and secure
with the nuts
(3 Fig. 1).
1 ).
the system.
WARNING: USE ONLY CLEAN BRAKE FLUID OR DENA- TURED ALCOHOL (METHYLATED SPIRITS) FOR
CLEANING. ALL TRACES OF CLEANING FLUID
ALL COMPONENTS MUST BE LUBRICATED
WITH CLEAN BRAKE FLUID AND ASSEMBLED
USING THE FINGERS ONLY.
MUST
BE REMOVED BEFORE RE
-ASSEMBLY.
. Reconnect the pipe (4 Fig. 1) to the master cylinder (5 Fig. I), and tighten the union nut.
. Align the push rod to the pedal.
. Clean and grease the clevis pin (2 Fig. 1).
Align andfit the clevis pin to the pedal and push rod.
. Fit the securing clip (1 Fig. 1).
. Bleed the clutch hydraulic system, see Sub-Section
7.1.18.
-4
1
J33 072 2
Fig. 3
issue 1 August 1994 16 X300 VSM

Manual Transmission & Clutch (AJ16)
e
7.1.16 CLUTCH SLAVE CYLINDER, RENEW
SRO 33.35.01
. Disconnect the pipe from the clutch slave cylinder, plug or
tape the pipe to prevent the ingress of any dirt.
. Remove the nuts (1 Fig. 1) and spring washers securing
the slave cylinder to the transmission.
. Remove the hose clip bracket (4 Fig. 1) complete with the
hydraulic hose/ pipe (5 Fig. I), and slide the slave cylinder (2 Fig. 1) off the mounting studs.
. Slide the rubber boot along the push rod (3 Fig. 1) and
withdraw the push rod from the cylinder.
. To refit the new clutch slave cylinder, reverse the removal
operations.
. Bleed the clutch hydraulic system, see Subsection
7.1.18.
Fig. 1
7.1.17 CLUTCH SLAVECYLINDER, OVERHAUL
SRO 33.35.07
. Remove the clutch slave cylinder, see Sub-Section 7.1.16.
. Dismantle the cylinder. The new parts in the kit will indicate which used parts should be discarded.
. Clean the remaining parts and the cylinder thoroughly with unused brake fluid of the recommended type and place
the cleaned parts on to a clean sheet of paper.
WARNING: USE ONLY CLEAN BRAKE FLUID OR DENATURED ALCOHOL (METHYLATED SPIRITS) FOR CLEANING.
ALL TRACES OF CLEANING FLUID MUST BE REMOVED BEFORE RE-ASSEMBLY. ALL COMPONENTS
MUST BE LUBRICATED WITH CLEAN BRAKE FLUID AND ASSEMBLED USING THE FINGERS ONLY.
. Examine the cylinder bore and the pistons for signs of cor- rosion, ridges or score marks. Provided the working sur- faces are in perfect condition, new seals from the kit can
be fitted, but if there is any doubt as to the condition of the
parts then a new cylinder must be fitted.
. Fit the new seal (1 Fig. 2) to the piston (2 Fig. 2) with the flat
back of the seal against the shoulder.
Lubricate theseal and thecylinder bore with unused brake
fluid of the recommended type and assemble thecylinder.
. Before fitting the dust cover (3 Fig. 21, smear the sealing
areas with rubber grease.
Squeeze the remainder of the grease from the sachet into
the cover to help protect the internal parts.
. Refit the clutch slave cylinder, see Sub-Section 33.15.01.
Bleed the clutch hydraulic system, see Sub-Section 7.1.18.
U 111 "I, II
Fig. 2
-3
X300 VSM 17 Issue 1 August 1994

Manual Transmission & Clutch (AJ16)
7.1.18 CLUTCH HYDRAULICSYSTEM, BLEED
SRO 33.15.01
CAUTION: Only use minimum DOT 4 brake fluid in the hy- draulic system.
. Remove the reservoir filler cap, and top up to the correct
level with hydraulic fluid.
. Attach one end of a bleed tube (1 Fig. 1) to the slave cylin- der bleed nipple (2 Fig. 1).
. Partiallyfill a clean container (3 Fig. 1) with hydraulicfluid.
. Immerse the other end of the bleed tube in the fluid.
. Slacken the slave cylinder bleed nipple.
. Pump the clutch pedal slowly up and down, pausing be-
. Top up the reservoir with fresh hydraulic fluid after every
tween
each stroke.
three pedal strokes.
CAUTION: Do not use fluid bled from the system for top- ping up purposes as this will contain air. If the fluid has been in use for some time it should be discarded. Fresh fluid bled from the system
may be used after it has stood for a few hours
allowing
all the air bubbles to disperse.
Pump the clutch pedal until the pedal becomes firm,
a Top up the reservoir, refit the filler cap.
tighten
the bleed nipple.
. Apply working pressure to the clutch pedal for two to three
minutes and examine the system for leaks.
X300 VSM Issue 1 August 1994 18
Fig. 1

bZF Automatic Transmission (AJ16) -
0
8.1.2 TRANSMISSION FLUID, RENEW
SRO 44.24.02
= Raise the hood and fit a fender cover.
. Raise the vehicle on a ramp.
. Place a drain tin in position beneath the transmission drain
Release and remove the transmission drain plug; allow
. Fit the drain plug with a new washer and torque tighten.
Reposition the drain tin beneath the dipstick tube union.
Remove the screw securing the dipstick tube bracket.
. Release the dipstick tube union nut and disconnect the
tube from the fluid pan.
. Drain the transmission fluid.
Clean the tube unions, reconnect the dipstick tube to the
. Lower the vehicle on the ramp.
. Remove the transmission dipstick.
. Renew the transmission fluid filter, see Subsection 8.1.6.
Fill the transmission with the correct fluid, see the ZF Auto-
Note: It will not be possible to get all the initial fill quantity
of fluid into the transmission.
. Refit the dipstick.
. Startthe engine, apply all brakes and run the transmission
With the engine still running, remove the dipstick.
Clean the dipstick and refit.
Remove the dipstick and check the transmission fluid
. Add fluid until the correct level is achieved.
. Stop the engine and refit the dipstick.
. Checkfluidleveltothe'HOT'marksaftera20mileroad run
(3,2L AND 4,OL)
Plug.
the fluid to drain.
fluid pan and torque tighten the union nut.
0
matic Transmissions Service Manual, General Data.
through
all gear positions and select 'Park'.
level. Remove the fender cover and lower the hood.
to ensure accurate results.
m
e
0
X300 VSM Issue 1 August 1994 6

Automatic Transmission (V12 & AJl6 Supercharged) Pomrtrain
8.2.1 GENERAL DESCRIPTION
This section provides information relating to the Powertrain 4L80-E transmissions fitted to the 4,O liter supercharged
engine (4,OL SC) and to the 6,O liter engine (6,OL).
The Powertrain 4L80-E is a four-speed, high torque capacity, electronically controlled automatic transmission, which
comprises a torque converter with lock-up direct drive clutch and three planetary gear sets. Five multiple diskclutches,
one intermediate sprag clutch assembly, two roller clutch assemblies and two band assemblies provide the drive el- ements necessary for correct sequential gear engagement and operation.
The torque converter containing
a pump, a turbine (rotor), a stator assembly, and a clutch pressure disksplined to the
turbine, acts as a fluid coupling for smooth torque transmission from the engine. The converter also supplies addi- tional torque multiplication when necessary, and the torque converter clutch (TCC) pressure disk provides a mechan- ical direct drive or 'lock-up' above a certain speed in top gear for greater fuel economy.
Gearshift operations are controlled from the Transmission Control Module (TCM), which governs the electronically
controlled valve body situated within the transmission.
Three planetary gear sets provide reverse and the four forward ratios, the changing of which is fully automatic in rela
- tion to load, vehicle speed and throttle opening. The Transmission Control Module receives and integrates various ve- hicle sensor input signals, and transmits operating signals to the solenoids located in the control valve assembly.
These solenoids govern the transmission operating pressures, up-shift and down-shift gear selection patterns and
also the torque converter clutch operation by pulse width modulated control.
8.2.1.1 Gear Ranges
Selectable gear positions are: P - Park, R - Reverse, N - Neutral, D - Drive, 3, 2.
P - Park position of the shift lever provides a mechanical locking of the output shaft of the transmission, and as such,
must only be engaged when the the vehicle is stationary. In addition, and for
extra safety, the handbrake should also
be applied. It is necessary to have the ignition ON and the footbrake applied to move the shift lever from the Park
position. For ignition key removal the shift lever must be in the Park position. The engine can be started in the Park
position.
R - Reverse enables the vehicle to be operated in a rearwards direction. The engine cannot be started in the Reverse
position.
N
-Neutral position enables the engine to be started and operated without driving the vehicle. It also allows the vehicle
to be moved manually for access, ie for removal of the propeller shaft.
D
-Drive position allows the automatic selection of all four forward gear ratios during normal driving conditions for
maximum efficiency and fuel economy. On acceleration, down-shifts are obtained by depressing the accelerator pedal
or by manual selection. The engine cannot be started in this position.
3
- Manual third position allows automatic operation of the three lower gear ratios but inhibits selection of the fourth
ratio. This position is used for towing a trailer or negotiating hilly terrain when greater engine braking control is re- quired. The engine cannot be started in this position.
2 - Manual second position allows automatic operation of the two lower gear ratios but inhibits selection of the third
and fourth ratios. This position is used for heavy traffic congestion or negotiating hilly terrain when even greater en
- gine braking control is required than is provided by manual third. This ratio may be selected at any vehicle speed - even if the transmission is in third or fourth ratio, the transmission will immediately down-shift to second gear pro- vided the vehicle speed is below 137 km / h (85 mile / h). The engine cannot be started in this position.
N.g!b: With the Performance Mode switch in the NORMAL position, the vehicle will pull away in second gear. How- ever, if more than 75 per cent of throttle is applied when the vehicle speed is between zero and 13 km/ h (8 mile / h), then first gear will be selected. From 13 to 61 km/ h (8 to 38 mile/ h) first gear is obtainable by 'kick-down'.
In 'sport' mode thevehicle pulls away in first gear and the transmission operatesfully in all four forward gears.
X300 VSM 1 Issue 1 August 1994

Automatic Transmission (V12 & AJ16 Supercharged) Powertrain
0
8.2.13 LUBRICATION SYSTEM, DRAIN AND REFILL
(4,OL SC AND 6,OL)
SRO 44.24.02
. Raise the vehicle on a ramp.
. Position a drain tin below the transmission unit.
. Release and remove the fluid pan drain plug.
. Allow the fluid to drain.
Clean the drain plug, including the magnet and the fluid
pan drain plug face.
. Fit and tighten the fluid pan drain plug.
. Remove the drain tin from below the transmission unit.
. Lower the vehicle on the ramp.
Open the hood and fit
a suitable fender cover.
Remove and wipe the dipstick.
. Fit a funnel to the dipstick tube.
. Initially fill the transmission with 4,5 liters of fluid.
. Remove the funnel.
. Open the front door.
. Check that the parking brake is applied.
. Start the engine.
Apply the footbrake.
Run the shift lever through all positions, finally returning
to the Park position.
. Release the footbrake.
. Insert the dipstick, then remove and inspect the level.
. Fit the funnel to the dipstick tube.
. Fill the transmission to the 'COLD' level mark on the dip-
stick with the correct fluid, see the Powertrain Automatic
Transmissions Service Manual, General Data.
CAUTION: On no account should the vehicle be driven un- less the fluid level is at the 'COLD' level and the
system primed.
0
Remove the funnel.
. Replace the dipstick.
. Switch the ignition OFF.
. Remove the fender cover and close the hood.
= Close the door.
J&&Q: 0 After road testing the vehicle, the fluid level on the
dipstick should be between the 'HOT' Min I Max
marks. Check the level with the transmission at nor-
mal operating temperature (90 to 100°C), with the
engine left running and the transmission in the Park
position.
m
0
Issue 1 August 1994 14 X300 VSM ~
__

Suspension Systems
11.4.3 Front End Inspection
Do not check and adjust front wheel alignment without carrying out the following inspection for front end damage and
wear:
. Check for specified air pressure in all four tires.
Raise front of vehicle off the floor; grasping upper and lower surface of the tire, shake each front wheel to check for
. Check front suspension lower arm ball joint and mounts for looseness, wear and damage.
Check steering gear mountings and all steering linkages for looseness.
. Renew parts if necessary.
. Grasp upper and lower surface of tire and shake each wheel to check wheel bearing end play.
. Check the action of the front dampers and the condition of their attachments, as sticking or binding front dampers
worn
bearings.
Check brake caliper mountings.
may not allow the vehicle to settle in to a normal level position, possibly affecting the front-wheel alignment.
m: Front wheel bearings are adjustable (0.001 to 0.003 in. endfloat).
11.4.4
. Check the wheel bearings.
. Inspect the front suspension upper joint and renew front suspension lower wishbone if needed.
Raise vehicle and position floor jacks beneath the front suspension lower wishbone.
Grasp the lower edge of the tire and move the wheel in and out.
While moving the wheel, observe the upper and lower wishbone.
. Movement between the vertical links and the wishbones indicates abnormal ball joint wear.
. Renew ball joints.
. Check the front wheel bearings.
. Check for excessive play and wear.
Upper / Lower Ball Joint Inspection
11.4.5 Damper Inspection
m: The gas-pressurized hydraulic front dampers are not serviceable, adjustable or refillable.
Verify that all attachments of the suspension components and the front dampers are tight. Renew any front damper
. Check front dampers for external damage.
. Check for oil leakage and vehicle sag.
that
has a damaged integral lower mounting bushing.
0 Oil Leak
Leakage is the condition in which the entire damper body is covered with oil and from where
it will drip on to
the pavement. Due to correct damper lubrication a light film of oil (weepage) can usually be seen on the upper
portion of the damper.
Should there be any leakage, ensure that the fluid does not originate from sources other than the front damper.
Renew worn or damaged dampers.
0 Vehicle Sag
Renewing front dampers will not correct the problem of vehicle sag, as basically this is controlled by the spring
units.
issue 1 August 1994 4 X300 VSM