manual transmission JAGUAR X308 1998 2.G Workshop Manual

                Diagnosi
s
 and  Testing  
                     External Controls  
                 General Procedures  
                     Brake Shift  Interlock  Actuator Adjustment  (44.15.49)  
                     Brake Shift  Interlock  Actuator Manual  Override  
                     Kickdown Switch  Adjustment  (44.15.38)  
                     Selector Lever  Cable  Adjustment  (44.15.07)  
                 Removal and  Installation  
                     Brake Shift  Interlock  Actuator (44.15.48)  
                     Kickdown Switch  (44.15.23)  
                     Selector Lever  Cable  and  Bracket  (44.15.08)  
                     Selector Lev
er Gate  Finish  Panel  (76.25.24)  
                     Selector Lever  Indicator  Assembly  (44.15.14)  
                     Selector Lever  Indicator  Disc  (44.15.15)  
                     Selector Lever  Switch  (44.15.52)  
                     Selector Lever  Knob  (44.15.06)  
                 Disassembly  and  Assembly  
                     Selector Lever  Assembly  (44.15.05)  
 
             307‐05B : Automatic  Transmission/Transaxle  External  Controls  ‐ 4.0L  SC  V8 ‐ AJ26  
                 Description  and  Operation  
                     External Controls  
                 Diagnos
is and  Testing  
                     External Controls  
                 General Procedures  
                     Brake Shift  Interlock  Actuator Manual  Override  
                     Kickdown Switch  Adjustment  (44.15.38)  
                     Selector Lever  Cable  Adjustment  (44.15.07)  
                 Removal and  Installation  
                     Brake Shift  Interlock  Actuator (44.15.48)  
                     Kickdown Switch  (44.15.23)  
                     Selector Lever  Cable  and  Bracket  (44.15.08)  
                     Selector Lever  Gate  Finish  Panel  (76.25.24)  
                     Selector Lev
er Indicator  Disc  (44.15.15)  
                     Transmission  Control Switch  (TCS)  (44.15.12)  
                     Selector Lever  Knob  (44.15.06)  
 

irri
tation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin
cancer. Washing facilities and adequate means of skin protection should be provided.
Observe these recommendations:
Wear pro t
ective clothing and impe
rvious gloves when necessary.
Do not put oily
rags in pockets. Avoid contaminat
ing clothes, particularly underwear, with oil.
Overal
ls must be cleaned re
gularly; discard oil impregna ted clothing and footwear wh ich cannot be washed or
cleaned.
Fi rst
Aid treatment should be obtained
immediately for open cuts or wounds.
Use barrier
creams, applying before each work period, to en
able easier removal of dirty oil and grease from the skin.
Wa
sh with soap and water to ensure th
at all oil is removed (skin cleaner and a nail brush will help). The use of
preparations containing lanolin will help to replace the natural skin oils which have been removed.
Do
not use petrol, kerosene, gas oil, th
inners or solvents for washing skin.
If
skin disorders develop, obtain medical advice immediately.
Wh
ere prac
ticable, degrease components prior to handling.
W
h
ere there is a risk of fluids coming into contact with th
e eyes, suitable eye protection should be worn - goggles or
face shield. An eye wash facility should be provided.
Ensure that a
dequate ventilation is provided when volatile degreasing agents are being used.
E
n
vironmental Protection
In so
m
e countries it is illegal to pour used oil onto the ground
, down sewers or drains, or into water courses. The burning of
used engine oil in small space heaters or boilers is not reco mmended unless emission control equipment is fitted. Dispose of
used oil through authorized waste disposal contractors, to licensed waste disposal sites or to the waste oil reclamation
trade. If in doubt, contact the Local Authority for advice on disposal facilities.
On-Board Diagnostics (OBD)
Ve
hicles use programmed electronic control systems to prov
ide engine management and emission regulation, automatic
transmission operation and anti -lock braking control. These control systems ha ve an integral On-Board Diagnostics (OBD)
facility for use in conjunction with either Jaguar diagnostic equipment or a scan t ool which is capable of retrieving DTCs,
PIDs and performing active commands.
The OBD information in this manual provid es diagnostic and rectification procedures for emission related electrical and
mechanical systems. The informat ion is intended to facilitate fault diagnosis and the subsequent rectification of vehicles
without recourse to the portab le diagnostic unit (PDU).
OBD related information can be fo und in the following sections:
General Information

Engine M

anagement System
Auto

matic Transmission
Anti-lock Br

aking System
Where appropriate a section comprises the following sub-sections:
Description and Operation
A ge
neral illustration and parts list to help the identi
fication of the particular system or component.
A b
rief description of the system operating characteristics and monitoring procedure
accompanied by a component
illustration.
Addi ti
onal information, where appropriat
e, is provided in the form of component calibrations, characteristics and
cross sectional views.
A localized circui
t diagram is included to provide circuit iden
tification and details of connectors, splices, fuses, wire
gauge and colors. See Circuit Diagrams.
Diagnosis and Testing (dedicated to fault analysis and rectification)
Recommended special tools. Symptom chart; a ch
art contai
ning all relevant Diagnostic Trouble Code s (DTC), their possible causes and an
indication of the appropriate test.
Sp
ecific pinpoint test(s), de
signed so that fault diagnosis can be carr ied out in a logical and efficient manner.

diverter val
ve (if fitted) and oil filter.
Main
bearings
which are grooved in the upper positions and plain in
the lower positions. They are manufactured from
aluminium / tin material.
A c
rankshaft with under
cuts and rolled fillets for extra strength.
Fracture
-split connecting rods in sintered-forged steel.
Brackets
bolted to the front of
the cylinder
block are used to mo unt all accessories.
A sin
gle, seven ribbed vee belt
drives the accessories.
An au
tomatic belt tensioner for the front accessory drive,
incorporating a wear indicator.
An advanced en
gine management system inco
rporating electronic throttle control.
The un
it meets the requirements of the CARB OBDII USA legislation.
Ancillary Systems
The an
ci
llary systems, driven by the engine, each have a
detailed Description and Operation along with Diagnostic
Procedures, and Removal and Installation instructions ; refer to the following sections of this manual:
Power Steeri
ng Pump - Section 211-02
Ai
r Conditioning Compressor - Sectio
n 412-03
Engine
C
ooling Pump - Section 303-03
Generator
- Sectio
n 414-02
The drive belt, idler pulley and automatic tensioner are described in Section 303-05.
The engine starting system is described in Section 303-06.
En
gine Management and Emission Control System
Engine Control Modu
le (ECM)
Engine
management and exhaust emissions are controlled by the ECM, which has the
following main functions:
Fu
el injection
Idle
s
peed
Ignition Ev

aporative loss system
Engine
cooling fans Clim
ate control compressor clutch demand
The microprocessor within the ECM receiv es signals from various sensors and other modules and uses a pre-determined
program to compute engine management functions.
Adaptive functions are incorporated in the ECM to cater for co ntinuous adjustments to its computations to suit prevailing
conditions. Because the system also controls emissions to suit all modes, neither CO levels nor idle speed require service
attention or adjustment, except if an error should occur.
On Board Diagnostics are controlled by the ECM with the continuous monitoring of incoming signals and the subsequent
verification against what the module expects to 'see'. Should a si gnal be incorrect or missing, the ECM will substitute a fixed
value to provide the 'limp home mode' and alert the driver of the problem. Fixed values may be adopted for:
Transmission oil
temperature
Mechanica
l
guar
d position
Throttle blade angle Camshaft position

Inta
k
e air temperature
Diagnostic trouble codes (DTC), including OBD II codes, are stored in the ECM memo ry and can be read by an appropriate
retrieval tool.
Should either the ECM or TCM fa il, ensure that the control housing cooling fan is operating correctly. Failure of the cooling
fan MUST be rectified before renewing a control module and details of a fa n failure should accompany a returned control
module.

Starting System - Starting System
Diagn
osis and Testing
I
n
spection and Verification
W
A
RNING: Make sure
the vehicle is in NEUTRAL or PARK for vehicles with au tomatic transmission, NEUTRAL for
vehicles with manual transmissi on, and apply the parking brake. Failure to foll ow this instruction may result in personal
injury.
1. 1. Verify the customer concern.
2. 2. Visually inspect for obvious signs of mechanical or electrical damage, correct fitment, etc.
Vi
sual Inspection Chart
3.
3. If an obvi
ous cause for an observed or
reported concern is found, correct th e cause (if possible) before proceeding
to the next step.
4. 4. If the concern is not visually evident, refer to the Diagnostic trouble code (DTC) index.
CAUTION: When probing connectors to take measurements in the course of the pinpoint tests, use the adaptor kit,
part number 3548-1358-00. Failure to follow this in struction may result in damage to the vehicle.
• NOTE: When performing electrical voltag e or resistance tests, always use a digital multimeter (DMM) accurate to 3
decimal places, and with an up-t o-date calibration certificate. When testing resistance, always take the resistance of the
DMM leads into account.
• NOTE: Check and rectify basic faults before beginning diagnostic ro utines involving pinpoint tests.
Sym
ptom Chart
MechanicalElectrical
Starte
r motor
Flywheel

ring gear
Engine
s
eized
Batter
y condition, state of charge
Starte

r motor
F
u
se 3 of the EMS fuse box
High
power protec ti
on module
Starter relay Ignition switc
h

W
i
ring harness(es)
Damaged, loose or corroded connector
s

Body processor module (B
PM)

Engine
C
ontrol Module (ECM)
Sy
m
ptom
(
gene r
al)
Sy
m
ptom
(specific)
Possib l
e source
Acti
o
n
No
n
-Start
Engine does
not
crankEngine s
iezed
Batt
ery and
/or
cables
Inhibitor circuit St arte
r motor
Starter relay Ignition switc
h


ECM relay Body processor
modu le
Check that
the engine turns. Check the battery condition and state

of charge. For starter motor and ca ble tests,GO to Pinpoint Test A.
. For ECM relay
tests,
REFER to Section 303
-14
Electronic Engine Controls
.
Engine
c
ranks
too fast/slow
Batt ery and
/or
cables
St arte
r motor
Cy
linder
com
pression
Check the battery con
dition
and st
ate of charge. For starter motor
and cable tests,GO to Pinpoint Test A.
. Chec
k compressions.

Contains th
e hydraulic system pump.
Contains
th
e fluid temperature sensor.
The epicyclic geartrain:
Provi des fi
ve forward gears and Reverse.
Has
h
ydraulically actuated, multi-disk clutches, to select the required gear ratios.
Feature

s clutch-to-clutch operation to permit
gear shifts for uninterrupted power flow.
The electro-hydraulic control unit:
Is lo c
ated in the lower part of
the unit, within the fluid pan.
Is controlled
by the TCM (transmissio
n control module), and the manual selector valve which is cable operated.
Re
gulates the flow of fluid to the ge
artrain clutches via three solenoid-operated valv es and the manual selector
valve.
Has fi ve pressure
regulators for controll
ing fluid pressures within the system.
Is con
nected to the TCM via a 16-way connector mounted on
the left-hand side of the transmission casing. Refer to
Connector Pins Identification, Section 307-01A.
The hydraulic system pump:
Is l o
cated at the front of the transmission casing.
Is dri
v
en from the impeller hub,
pressurising the fluid whenever the engine is running.
Supplie
s fluid under pressure to the torq
ue converter, geartrain, electro-hydr aulic control unit and the lubrication
circuit.
D r
aws fluid from the fluid pa
n below the transmission casing, through a filter.
The rear extension housing:
Is bolt
ed to the rear of the transmission casing.
Provides the rear engine / transmi

ssion mo
unting point; refer to section 303-01.
Carrie
s the transmission output shaft oil seal.
Filled-for-l
i
fe Fluid System
The
transm
ission is 'filled for life' and
does not require fluid changes, except where extreme driving conditions prevail.
Routine level checking is not required and a dipstick is not pr ovided. A level / filler plug is fitted for level checking and
replenishment, following service actions; see 303-01 General Procedures.
Transmission Torque Converter

2.2. Check on non-volatile diagnostic memory by wr iting a test pattern and then reading it back.
3. 3. Internal 'watchdog' hardware to check whether the TCM has crashed.
Transmission Control Module Supply Voltage
The TCM monitors battery and igni tion switched supply voltages.
A permanent supply is used to maintain a battery backed 'memor y'. Should this supply be cut, due to battery disconnection
perhaps, the 'adaptive shift' valu es will be lost. This will result in a small reduction in shift quality for a period until th e
adaptions are 're-learned'
The TCM will adopt 'limp home' mode as a result of the supply voltage being >16V or <7V with an engine speed >1600
rpm.
Should the ignition supply be >7V but <9V the TCM will hold the gear that it has currently selected. If after 2.5 seconds,
with the engine speed >1600 rpm, the voltage remains at this level, 'limp home' mode will be adopted. The 2.5 second
delay is built in to prevent reaction to a momentary voltage fluctuation.
Operation
CAUTION: Disconnection of the TCM and / or the vehicle batt ery will cause system adaptions to be lost; this may be
apparent by shift quality degradation. Fo llowing reconnection, a period of 'varied' driving will reinstate adaptions and thus
normal operation. Please ensure that the customer is made aware that the adaption period is variable and may occur after
handover, as the transmission re-learns the prevailing driving style.
• NOTE: Should the TCM fail, please ensure that the control housing cooling fan is operating correctly. Failure of the cooling
fan MUST be rectified before renewing the TCM and details of a fan fa ilure should accompany the returned TCM.
The TCM processes information received in both analogue and digital form, such as:
Transmission input speed Transmission output speed Throttle position Pedal demand Gear selector position Engine torque Engine speed Transmission oil temperature Mode switch
This information is then used by the TC M to control shift energy management and decide which shift program to implement
and which gear to select.
The TCM uses the various sensors and inpu ts to monitor the correct operation of the system an d is programmed to take
default action and inform the operator when a fault occurs.
Safety Functions
The safety functions are designed to safeguard against inappr opriate actions by the operator as well as against system
malfunctions. The system prevents reve rse gear from being engaged at high forward speeds and prevents manual
downshifting at excessive engine speeds; these functions are not operational in mechanical limp-home mode.
The TCM constantly monitors the transmissi on for faults. In the event of a problem the TCM will adopt a 'limp home' mode
in which only P R N D - (selector in D but only fourth gear is enabled) are available. The operator will be made aware of
certain faults by an in strument panel warning.
The electrical and diagnostic system has been designed such that system integrity is protected at all times, the safety
concept being based on th e following three points:

Controller Area Network (CAN)
The TCM is an integral part of the CAN system which facilitates the interchange of real-time data between control modules
and sensors. Please see section 303- 14 for a full description of CAN.
OBDII Interface
Data concerning OBDII related transmission failures is stored in the ECM for access via the J1962 socket.
System Functions
Range Selection
The selector lever is connected to the transmission via a bowden cable, which operates the transmission selector shaft
between all positions except Drive to 4 .
The TCM detects the gear selected by means of a rotary position switch fitted to the transmission selector shaft. A separate
Drive to 4 switch is located within the 'J' gate' assembly.
Movement of the selector lever between Park, Reverse, Neutral and Drive manually directs th e flow of transmission oil; the
TCM having control of the forward gears selected while the lever is in the Drive position.
Shift Point Selection
The gearshift points are selected, by the TCM, as a function of the output speed, engine load, selector position and shift
program selected. The operator has control over the shift points via the selector lever, throttle pedal movement, kickdown
function and mode switch.
'J' Gate Layout

Mode Switch
This switch allows the driver to select one of two base shift maps; Normal and Sport modes, the switch being illuminated
when Sport is selected.
Special Shift Programs
These specific condition shift maps are available to enhance the operation of the vehicle under specific driving conditions.
and are listed below in order of priority / title and operating condition.
1. 1. Traction: When traction intervention is active
2. 2. Hot mode: Extreme engine / transmission temperatures

CAN Input Signals
Traction status ABS malfunction ABS status Engine torque status Throttle position Accelerator pedal position Engine torque reduction confirmation Engine speed Engine coolant temperature Cruise status OBDII fault code clear request Throttle malfunction warning RED or AMBER All road wheel speeds Token for network status ECM Token for network status INST Token for network status ABS Diagnostic data in from external device (PDU)
Output Signals
Solenoid valve 1 <-> 2 and 4 <-> 5 shift Solenoid valve 2 <-> 3 shift Solenoid valve 3 <-> 4 shift Solenoid valve converter lock-up clutch Control valve - modulating pressure Control valve - shift pressure
CAN Output Signals
Engine torque reduction request MIL status (whether present DTC should operate MIL) Transmission input speed Transmission output speed Converter slip Kickdown status Gear position (actual) Gear position (selected) Gear selection fault Converter lock-up status Current selected shift map Transmission oil temperature Transmission malfunction Pecus flag (state of current TCM program) Target for next gear position Gear shift torque transfer progress at shift MIL status (response to activate the MIL relevant to a DTC) OBDII fault code clear acknowledgement Transmission DTCs (P codes) Token for network status TCM Diagnostic data out to external device (PDU)
Emergency Running (elect ronic limp-home mode)
The TCM constantly monitors the transmissi on for faults. In the event of a problem the TCM will adopt the limp-home mode, in which the gear currently held remains engaged, until P is selected. The modulati ng and shift pressures will increase to
maximum and converter lock-up will be inhibited.
Following the selection of P , the only ratios available will be 2 (irrespective of forward ratio manual selection) and R .
With the vehicle at rest, the procedure to manually select is as follows:
1. 1. Select P .

Range Selection
The 'J' gate selector lever is connected to the transmission via a cable which operates the transmission selector shaft
between positions P R N D only. The shift lever disconnects from the cable when the lever is moved across the gate from D
to 4 .
Movement of the lever between P R N D manu ally controls the flow of transmission fluid, the TCM having control of the
forward gear selected in D .
Movement of the lever to 4 , 3 and 2 positions does not manu ally modify the fluid flow, the TCM detects these positions
using the DLS and controls the ratios electronically by energizing solenoids.
Shift Point Control
The gearshift points are controlled by the TCM, as a function of the output speed, engine load, engine speed, selector
position and shift program selected. The operator has control over the shift points via the shift lever, throttle pedal
movement, kickdown function and mode switch.
Mode Switch
This switch allows operator selection of two base shift modes; Normal and Sport; th e switch being illuminated when Sport is
selected. This function alters the values in the TCM shift point calculations.
Shift Programs
Upon encountering the following conditions, the TCM will auto matically modify the Normal or Sports shift map to enhance
the operation of the vehicle:
1. 1. Traction: When traction intervention is active.
2. 2. Hot mode: Extreme engine/transmission temperatures.
3. 3. Gradient: Under specific speeds and loads.
4. 4. Manual: Driver initiated override of the normal shif t map when the LH side of the 'J gate' is used.
Traction
When traction or stability control (engine or brake system de rived) is operational the TCM will implement the traction map
to maximize control of wheel slip.
Gradient
The gradient function is intended to enhance vehicle drivea bility when climbing a gradient or towing. The TCM will
implement the function when increased driving resistance is de tected, and provides enhanced driveability, additional cooling

Is hard-wired to the transmission control module.
Kickdown Switch (where fitted)

The kickdown switch:
Is floor mounted under the accelerator pedal. Is operated by pressing the pedal to the full throttle position. Provides maximum acceleration on driver demand, by signal ling the transmission control module to select the lowest gear to give maximum wheel torque.
Transmission Unit Gear Selector

The gear selector at the transmission unit:
Is connected to the driver's selector module by a Bowden cable. Operates the manual selector valve, which is part of the electro-hydraulic control unit. Operates the rotary switch, which is connected to the transmission control module.
Transmission Switches
Location, Rotary Switch