oil level JAGUAR XJ6 1994 2.G Workshop Manual

Introduction i
Term(s) Abbreviation Definition
(if applicable)
GLOSSARY OF TERMS
Previously used term(s) (or Eng-
lish Equivalent)
indicates camshaft position
device designed to hold dry material, e.g.
evaporative emission canister
controls purging of the EVAP canister
colorless gas with a density of approximately
1.5 times that of air
poisonous gas produced as the result of
incomplete combustion
camshaft
I
CID
sensor,
Hall sensor
Camshaft
Position
Camshaft Position Sensor CMPS
canister
Canister Purge CANP
Carbon Dioxide
CO2
I Case Ground I CSEGND
Carbon
Monoxide
camber
CO
Canadian Motor Vehicle Safety
Standard
caster
Catalytic Converter
Celsius
center
I
CMVSS
C
centimeters
I cm
trail built in to the geometry of a steered
roadwheel to give
it a caster - self-steering -
effect
caster,castor
color
columnlmirror control module I C/M CM
charge current
Closed Loop
Closed Loop System
Clutch
clutch disc, clutch disk
clutch
throwout bearing
connecting rod bearing
CL
CLS
a shaft on which phased cams are mounted.
Usually used to regulate opening and closing
of engine cylinder head valves
current developed by the generator
control system with one or more feedback
loops
device which uses mechanical, magnetic or
friction type connections to facilitate
engaging or disengaging
two shafts or
rotating members charging
current
Control
module casing ground
inclination of the plane of a wheel to the
vertical plane
ofthe vehicle. May be negative
or positive.
Also convex curvature across road surface
bearing (usually split, plain) at the lower end
of the connecting rod where
it connects with
the crankshaft big
end bearing
in
-line exhaust
system device used to reduce
the level of engine exhaust emissions
SI term forthe Centigradescale, with freezing Doint at zero and boilina Doint at looo
I centre
I centimetres
friction disc of a clutch assembly clutch
plate,
centre plate,
diaphragm spring to release the clutch disc
I colour
Issue 1 August 1994 X300 VSM 9

Term(s) Abbreviation Definition Previously used (if applicable) term(s) (or Eng- lish Eauivalent)
K
kilogrammes (mass) kg
kilogrammes (force) kgf
kilogrammes force per square kgf/cm2 centimeter
kilometers
km kilometres
kilometers per hour
km/h km/h, kph
kilopascals
kPa
kilovolt kV
knock
I
the sharp metallic produced sound when two
pressure fronts collide in a combustion
1 chamber (see also ping)
I sensor which detects the onset of detonation I knock sensor KS I and signals the ECM to retard the ignition I
L
lash
left
-hand LH
left
-hand drive vehicle LH D
left-hand thread LH Thd
levelina
I
license I
license plate
liquid crystal display LCD
Liter
I L
louver
lowered beam
lug nut free
play, end-float
optical digital display system, applied
voltage to which varies the way the crystals
reflect liaht,
thereby modifvina the display
primary circuit
of the ignition system, linking
the battery to the primary winding in the
ignition coil levelling
licence
registration
plate,
number
date
Litre
louvre
diooed beam
wheel nut
Issue 1 August 1994 18 X300 VSM

(if applicable) term(s) (or Eng- lish Equivalent)
N
National Institute of Occupational NIOSH Safety & Health (US)
Newton N SI unit of force. 1 N = 0.2248 pounds force
Newton meters Nm
SI unit of torque. Must not be confused with nm (nanometer)
compounds of nitrogen and oxygen formed
at high temperatures. Major source of
exhaust
-gas air-pollution
RAM which retains memory even if power
N
Ox
NVRAM
Memory supply is interrupted
normally aspirated fueling system using intake air at
atmospheric pressure; not supercharged or
turbocharged
Normally Closed NC
Normally Open NO
North American Specification NAS vehicles for sale
in the USA and Canadian
markets
0
I number I No.
octane number
I
I open circuit
I oriainal eauiDment manufacturer
I outside diameter OSHA
OBD
OEM
0. dia
OHC
oc
N Ox
02s
measure ofthe anti-knockproperties ofafuel
instrument which records the total mileage
covered by a vehicle
a system that monitors some or all computer
input and output control signals.
Signal(s) outside the pre-determined limits imply a
fault in the svstem or a related svstem
a circuit which does not provide a complete
path for flow of current
engine configuration with single camshaft
positioned above the valves
catalytic converter system that reduces
levels
of HC and CO
a sensor which detects oxygen content in the
exhaust gases mileometer
oilwav
EGO,
02 EOS,
EGS, OS, EGOS,
Lambda Sensor
Issue 1 August 1994 20 X300 VSM

Term(s) Abbreviation Definition Previously used
(if applicable) term(s) (or Eng-
lish Equivalent)
T
tachometer
Thermal Vacuum Valve
Three
-way Catalytic Converter
Three
-way + Oxidation Catalytic
Converter TWC + OC
Throttle
------I
Throttle Body TB
Throttle Position TP
Throttle Position Sensor TPS
throw
-out bearing
throw
-out fork
tie
-rod (steering)
timing
tire
top dead center TDC
torque converter
Transmission
Transmission Control Module
Transmission Control Switch
Transmission Oil Temperature TOT
Transmission Range TR
I Transmission Speed Sensor TSS
tread
trunk
turn indicator, turn signal lamp
two cycle a
circuit that provides input for an electronic
tachometer display
controls vacuum levels or routing based on
temperature
catalytic converter that reduces the levels of
HC,
CO & NOx
catalyticconverter systemthat has both TWC
and OC. Usually secondary air is introduced
between the two catalvsts
procedure whereby the performance of a
product is measured under various
conditions - - . -. . . - . . -
a valve for regulating the supply of a fluid,
usually air or an aidfuel mixture, to an engine
device containing the throttle
interprets throttle position and movement to
identify idle, acceleration and full
-power
demands
relationship between spark plug firing and
piston position, usually expressed
in crankshaft degrees BTDC or ATDC of the
compression stroke
device which, by its design, multiplies the
torque in a fluid coupling between an engine
and transmission
device which selectively increases or
decreases the ratio of relative rotation
between its
inDut and outDut shafts
controls the shifting pattern of the
(automatic) transmission
Modifies the operation of electronically
controlled transmissions
indicates temperature
of transmission fluid
the range in which the transmission is
operating
indicates rotational speed of transmission
output shaft or turbine
shaft
track between tire contact centers; not to be
confused with tire contact tread pattern
principle of engine which fires every second
stroke of the piston cat
cat, dual bed
Throttle poten
-
tiometer, TPS, TP
clutch release
bearing
clutch release
lever
track rod
tvre
TCC, CCC, CCO,
LUS, MLUS,
MCCC
transmission
ECU
track boot, luggage
compartment
direction indica
- tor
two stroke
Issue 1 August 1994 26 X300 VSM

Engine
3.1.3 ENGINE OIL, RENEW
SRO 12.60.00
. Undo and remove the sump plug positioned at the rear of
the sump, drain the engine oil into a suitable receptacle
and dispose of
it in a safe and environmentally friendly
manner.
Replenish the engine oil, to the correct level on the dip-
stick (see Fig. 1).
When the oil is renewed, start the engine, wait for the oil
light to extinguish and switch off the engine for 30 sec- onds.
. Finally remove and wipe clean the dip stick,
check the oil level - replenish if necessary.
. For recommended engine oil refer to Appendix AI.
3.1.4 OIL FILTER CARTRIDGE, RENEW
SRO 12.60.04
The white oil filter cartridge displaying the Jaguar logo, is lo- cated on the left-hand side of the engine below the throttle
assembly (Fig. 2).
When refitting, tighten the oil filter cartridge using hand
pressure only.
On no account use an oil filter strap designed
forthe removal
of cartridges.
m: The normal tightening torque of the oil filter is a 3/8 to 1/2 turn after initial contact.
1 JLX-076
Fig. 1
-~ ~ ~~~~~ Issue 1 August 1994 X300 VSM 3

Engine (V12)
3.2.3 ENGINE OIL, RENEW
SRO 12.60.00
. Undo and remove the sump plug positioned at the rear of
the sump, drain the engine oil into a suitable receptacle
and dispose of
it in a safe and environmentally friendly
manner.
. Replenishtheengineoiltothecorrect level (1 Fig. 1) onthe
dipstick.
1ynfa: If the '0' ring on the on the filler cap is damaged, re- move the '0' ring and clean the groove. Secure a
new '0' ring in position using silicon sealant. Treat
the screw threads with copper grease, and grease
the top face of the oil filler with Hylosil lubricant.
When the oil is renewed, start the engine, wait for the oil
light to extinguish and switch off the engine for 30 sec- onds.
. Finally remove and wipe clean the dip stick
(Fig. l), check the oil level - replenish as necessary.
For recommended engine oil refer to Appendix AI. Fig.
1
3.2.4
OIL FILTER CARTRIDGE, RENEW
SRO 12.60.04
The white oil filter cartridge displaying the Jaguar logo, is lo- cated on the lower left-hand side of the engine, near side of
the sump. Access for removing the cartridge is from under- neath the vehicle (Fig. 2).
Remove the catalyst heat shield (where fitted) and use a coil
spring type filter wrench to remove the cartridge.
Start and run the engine for a few seconds to charge the
filter, then stop the engine and
checkthe oil level. Replenish
as necessary.
I Fig. 2
Issue 1 August 1994 X300 VSM 3
r

Manual Transmission & Clutch (AJ16)
. Remove front clamp from unit lift.
. Raise / lower unit with jack, no stands.
. Traverse lift under ramp and take weight of transmission.
. Adjust jacking platform angles to suit transmission.
. Adjust side and rear clamps to suit transmission and tighten clamp wing nuts.
. Fit the safety chain assembly to left hand arm of lift, and secure with peg.
Pass safety chain over transmission and engage in front arm of lift. Tighten the safety chain adjuster.
. Remove remaining transmission to adaptor plate securing bolts and carefully lower transmission from engine.
. Remove transmission from ramp area.
. Remove clutch release bearing assembly from release lever.
. Remove clutch release lever retaining clip and remove lever.
. Remove release lever pivot pin.
Remove transmission switch.
. Remove rear mounting spring retainer securing nut.
. Reposition selector shaft pin cover.
0
Remove rear mounting spring retainer and remove rear mounting assembly.
Remove selector shaft yoke to selector shaft retaining pin and remove the yoke.
. Remove slave cylinder securing studs.
. Remove the transmission from the unit lift.
. Remove transmission drain plug and allow to drain, refit
the drain plug.
Fit new transmission to unit lift.
Fill transmission with oil and refit the level plug.
. Clean components and mating faces.
. Fit the slave cylinder mounting studs.
. Lubricate the selector output shaft.
. Fit selector shaft yoke (3 Fig. 1) to selector shaft and secure
with retaining pin (2 Fig. 1).
Reposition the retaining cover (1 Fig. 1) over the selector
shaft yoke retaining pin. -
. Fit the transmission rear mounting assembly and secure
with bolt.
. Fit reverse lamp switch.
. Lubricate the clutch release lever.
. Fit and align lever to transmission and engage onto pivot
pin.
Fit and fully seat lever to pivot retaining clip.
= Lubricate release bearing housing.
9 Fit and fully seat bearing assembly to lever.
. Select third gear.
. Move transmission to vehicle and raise into position.
Fia. 1
. Insert transmission input shaft into clutch and fully seat transmission against adaptor plate, ensuring that trans- mission is in line as it is fitted and seated to the plate.
X300 VSM 3 Issue 1 August 1994

Manual Transmission & Clutch (AJl6)
0
7.1.13 CLUTCH FAULT DIAGNOSIS
symptom
lifficult gear ?ngagement
3attling clutch
squeaking clutch
dibrating clutch or
:lutch judder (often pre- :eded by clutch grab)
stiff clutch operation
Possible Cause
Hydraulic system
defects
Operating mechan
- ism faults
Clutch unit faults
Primary pinion bear
-
ing fault
Clutch unit faults
Defects other than in
clutch unit
Operating linkage
fault
Check
Check fluid level in reservoir
Check for air in the system
Check for defective pedal
Check for damaged pressure plate
Check splines on clutch driven
plate and primary pinion shaft for
wear
Check clutch driven plate for loose
or broken springs and for warping
Check for wear in the clutch with
- drawal mechanism
Check for worn primary pinion
bearing
Check for seizing on primary shaft
or in flywheel
Check the clutch driven plate for
distortion and damage and for
loose or broken torque damper
springs
Check for oil and other foreign
matter on the clutch friction linings
Check for incorrectly fitted clutch
pressure
plate
Check that contact witness on fric-
tion linings is evenlv distributed -
Check for loose flvwheel fixings
and flywheel
run-out
Check for loose engine mountings
Check for worn drive (propeller)
shaft universal joints
Check for bent primary pinion
shaft
-
Check for damaged moving parts
in operating linkage
- -
Check for seized linkage, recheck
operation after remedv
Remedy
Replenish as necessary and
bleed system if necessary
Bleed the system
Renew return spring if
necessary
Renew pressure plate
Renew as necessary clutch
plate or primary pinion
Renew driven plate
Renew as necessary
Renew as necessary
Lubricate or renew as
necessary
Renew driven plate
Renew driven plate and clean
related parts
Dismantle from clutch and
refit where applicable
Renew driven plate as
necessary
Tighten to correct torque
loading
Lubricate linkage as
necess-
X300 VSM 11 Issue 1 August 1994

Driveshafts & Final Drive
9.3
SRO 51.10.24
Disconnect vehicle battery ground lead.
. Support the vehicle at the rear.
OUTPUT SHAFT END FLOAT, CHECK
Mount a dial test indicator (DTI) to the differential housing with the probe resting on the output shaft flange (DTI probe must be parallel to the output shaft center line and NOT at an angle).
. Push the wheel 1 shaft assembly inwards and zero the DTI; pull outwards and note the reading.
. If the end float exceeds 0,15 mm; firstly verify the shim preload and if this is found to be correct, renew the output
shaft bearing. See 51.10.22. this section, for shim check and renew operations.
9.4
SRO 51.20.19
rn Disconnect vehicle battery ground lead.
See operation 51.10.22. this section, for process detail, less bearing 1 oil seal renew.
OUTPUT SHAFT HOUSING ‘0’ RING, RENEW
Prior to removal of shaft assembly check output shaft end float in accordance with operation 51.10.24.
9.5 OIL SEAL - PINION FLANGE, RENEW
SRO 51.20.01
. Disconnect vehicle battery ground lead.
. Support the vehicle at the rear.
. Disconnect main handbrake cable at compensator.
’Match mark‘ the FLEXIBLE COUPLING to the differential DRIVE FLANGE and remove fixings.
Remove fixings center bearing to crossmember and push drive shaft rear section forward to disengage from pinion
spigot.
CAUTION: Under no circumstances must the flexible coupling (or its fixings) be loosened or removed from the drive
shaft flange.
Support the drive shaft, do not allow it to hang.
9 ‘Match mark‘ the drive flange retaining nut to both the pinion and the drive flange (Fig. 1).
. Slacken the flange retaining nut approximately half a turn and retighten to the ‘match mark‘ noting the required force.
. Remove the retaining nut, washer and drive flange.
CAUTION: Use only special tools; 18G 1205 to restrict rotation and JD 156 to remove drive flange.
. Inspect the drive flange oil seal surface for damage corrosion or grooving and replace as necessary.
. Remove oil seal from differential case taking care not to damage the machined counterbore.
rn Clean seal counterbore.
. Using special tool JD 198 fit replacement oil seal to differential case ensuring that, seal is square, fully seated and
If the force does NOT exceed 135 Nm, the final drive unit MUST be replaced.
Do not use abrasive cloth, or paper, to remove imperfections from the seal surface.
the
lip spring is not dislodged.
Apply grease to drive flange seal diameter and refit the flange to the pinion in the original position.
U: Do not hammer the drive flange onto the pinion; pull down with the drive flange nut.
Tighten the drive flange nut to the original noted torque PLUS 10%.
* Check that the pinion spigot radial run-out is to specifica- tion.
Fitting and reassembly is the reversal of this procedure en
- suring that drive shaft fixings are renewed and that the
shaft is aligned in accordance with Sub-Section 9.2.
Correct the final drive oil level if required.
. Tighten all fixings to specification.
Fig. 1
0
Issue 1 August 1994 4 X300 VSM

Driveshafts & Final Drive
9.6 OUTPUT SHAFT BEARING, RENEW
@ SRO 51.10.22
9.7
SRO 51.20.04
. Disconnect vehicle battery ground lead.
. Support the vehicle at the rear and remove the rear road wheel (or wheels).
9 'Match mark' the axle shaft flange to the output shaft flange and remove fixings, note camber shim.
. Thoroughly clean the area around the output shaft housing and differential case.
. Release fixings and remove output shaft assembly, discard '0' ring.
. Mark bearing retaining collar axially and drill 3 off holes 4,O mm diameter equally spaced, to a MAXIMUM depth of
. With a suitable chisel (2 Fig. 1) strike the collar across the three drilled holes to relieve tension within the steel.
CAUTION: Do not drill into the output shaft, it is not necessary to break the inside diameter of the collar. There is
no need to to split the collar when chiselling.
Using a suitable press, remove bearing and collar, remove the oil seal and discard it along with bearing.
CAUTION: The original bearing must NOT be cleaned and reused; always renew it.
Inspect the output shaft oil seal surface for damage corrosion or grooving and replace as necessary.
W:
OUTPUT SHAFT OIL SEAL, RENEW
5,O mm (1 Fig. 1).
Do not use abrasive cloth or paper to remove imperfections from the seal surface
. Using special tools JD 550-1 and 18G 134, assemble new oil seal to housing, ensuring that the seal top face is 1,8 mm below the housing top face and NOT down on the counterbore face.
Lubricate the output shaft seal diameter and oil seal lip and position the housing assembly to the shaft.
Using special tool SL 7 and a suitable press, assemble bearing to output shaft.
. Using special tool SL 7 and a suitable press, assemble retaining collar to output shaft.
= Fit the original shims and using hand pressure only to seat the assembly, check that theclearance between the output
. Using a new '0' ring and sealant on the mating faces, assemble the output shaft assembly to the differential case.
. Fitting and reassembly is the reversal of this procedure ensuring that all fixings are tightened to specification and
shaft
housing and differential case is in the range
0,05 to 0,13 mm. Shim to suit if not in this range.
See Sub
-Section 9.3 Output Shaft End Float Check.
new locking nuts are used.
Correct the final drive oil level
if required.
Issue 1 August 1994 X300 VSM