fuel JAGUAR XFR 2010 1.G Workshop Manual

Table of ContentsContents1: General Information
100: Service Information
100-00: General Information
Description and OperationAbout This Manual
Application and Use of Specifications
Battery and Battery Charging Health and Safety Precautions
Brake System Health and Safety Precautions
Diesel Fuel System Health and Safety Precautions
General Service Information
Health and Safety Precautions
How To Use This Manual
Important Safety Instructions
Petrol and Petrol-Ethanol Fuel Systems Health and Safety Precautions
Solvents, Sealants and Adhesives
Standard Workshop Practices
Symbols Glossary
Supplemental Restraint System (SRS) Health and Safety Precautions
Road/Roller Testing
Window Glass Health and Safety Precautions
Diagnostic Trouble Code (DTC) IndexDTC: Adaptive Damping Module (SUMB)
Diagnostic Trouble Code (DTC) IndexDTC: Anti-Lock Braking System (ABS)
Diagnostic Trouble Code (DTC) IndexDTC: Audio Amplifier Module (AAM)
Diagnostic Trouble Code (DTC) IndexDTC: Blind Spot Monitoring System Module (SODL/SODR)
Diagnostic Trouble Code (DTC) IndexDTC: Central Junction Box (CJB)
Diagnostic Trouble Code (DTC) IndexDTC: Climate Control Module (HVAC)
Diagnostic Trouble Code (DTC) IndexDTC: Digital Audio Broadcast Module (DABM)
Diagnostic Trouble Code (DTC) IndexDTC: Driver Door Module/Passenger Door Module (DDM/PDM)
Diagnostic Trouble Code (DTC) IndexDTC: Driver/Passenger Seat Module (DSM/PSM)
Diagnostic Trouble Code (DTC) IndexDTC: Electric Parking Brake (PBM)
Diagnostic Trouble Code (DTC) Index V8 S/C 5.0L Petrol, DTC: Engine Control Module (ECM)
Diagnostic Trouble Code (DTC) IndexDTC: Front Seat Climate Control Module (DCSM)
Diagnostic Trouble Code (DTC) IndexDTC: Headlamp Control Module (HCM)
Diagnostic Trouble Code (DTC) IndexDTC: Instrument Cluster (IPC)
Diagnostic Trouble Code (DTC) IndexDTC: Integrated Audio Module (IAM)
Diagnostic Trouble Code (DTC) IndexDTC: Integrated Control Panel (FCIMB)

Overview
System Operation and Component DescriptionDiagnosis and TestingEngineGeneral ProceduresEngine Oil Draining and Filling
Engine Oil Vacuum Draining and Filling
Fuel Pump Camshaft Timing Check
Fuel Pump Camshaft Timing Adjustment
Valve Clearance Check
Valve Clearance AdjustmentRemoval and InstallationCamshaft LH
Camshaft RH
Crankshaft Front Seal
Crankshaft Pulley
Crankshaft Rear Seal
Cylinder Head LH
Cylinder Head RH
Engine Mount LH
Engine Mount RH
Exhaust Manifold LH
Exhaust Manifold RH
Flexplate
Oil Cooler
Oil Filter Element
Oil Pan
Oil Pan Extension
Oil Pump
Timing Cover
Timing Drive Components
Valve Cover LH
Valve Cover RH
Cylinder Block Oil Gallery Plug
Fuel Pump Camshaft - Assembly Part Number: INA Timing Drive
Fuel Pump Camshaft - Assembly Part Number: Tsubaki Timing Drive
Lower Timing Cover
ValvesRemovalEngineInstallationEngine

SpecificationDescription and OperationComponent Location
Overview
System Operation and Component DescriptionDiagnosis and TestingEngine Cooling - V8 5.0L Petrol/V8 S/C 5.0L PetrolGeneral ProceduresCooling System Draining and Vacuum Filling
Cooling System Partial Draining, Filling and Bleeding - V8 S/C 5.0L Petrol
Cooling System Draining, Filling and Bleeding - V8 S/C 5.0L PetrolRemoval and InstallationAuxiliary Radiator
Coolant Expansion Tank
Cooling Fan Motor and Shroud - Vehicles With: Supercharger
Cooling Module - Vehicles With: Supercharger
Coolant Pump - Vehicles With: Supercharger
Radiator (26.40.01) - Vehicles With: Supercharger
Thermostat Housing - Vehicles With: Supercharger303-03D: Supercharger Cooling - V8 S/C 5.0L Petrol
Description and OperationComponent Location
Overview
System Operation and Component DescriptionRemoval and InstallationRadiator303-04E: Fuel Charging and Controls - V8 S/C 5.0L PetrolSpecificationDescription and OperationComponent Location
Overview
System Operation and Component DescriptionDiagnosis and TestingFuel Charging and ControlsGeneral ProceduresFuel Injection Component CleaningRemoval and InstallationFuel Injectors
Fuel Rail LH
Fuel Rail RH
Left-Hand Fuel Rail High-Pressure Fuel Pump
Right-Hand Fuel Rail High-Pressure Fuel Pump303-03C: Engine Cooling - V8 5.0L Petrol/V8 S/C 5.0L Petrol

Catalyst Monitor Sensor RH
Crankshaft Position (CKP) Sensor
Engine Control Module (ECM)
Engine Coolant Temperature (ECT) Sensor
Engine Oil Level Sensor
Front Knock Sensor (KS) LH
Front Knock Sensor (KS) RH
Fuel Rail Pressure (FRP) Sensor
Heated Oxygen Sensor (HO2S) LH
Heated Oxygen Sensor (HO2S) RH
Manifold Absolute Pressure (MAP) Sensor
Mass Air Flow (MAF) Sensor
Rear Knock Sensor (KS) LH
Rear Knock Sensor (KS) RH
Variable Valve Timing (VVT) Oil Control Solenoid LH
Variable Valve Timing (VVT) Oil Control Solenoid RH307: Automatic Transmission/Transaxle
307-01B: Automatic Transmission/Transaxle - TDV6 3.0L Diesel /V8 5.0L Petrol/V8 S/C 5.0L
PetrolSpecificationDescription and OperationComponent Location
Overview
System Operation and Component DescriptionDiagnosis and TestingDiagnosticsGeneral ProceduresTransmission Fluid Level Check
Transmission Fluid Drain and RefillRemoval and InstallationInput Shaft Seal
Extension Housing Seal
Transmission Control Module (TCM) and Main Control Valve Body
Transmission Fluid Pan, Gasket and Filter
Transmission Support Insulator - V8 5.0L Petrol/V8 S/C 5.0L Petrol
Transmission, Transmission Fluid Cooler and Transmission Fluid Cooler Tubes - V8 5.0L Petrol/V8
S/C 5.0L Petrol
Transmission and Transmission Fluid Cooler - V8 5.0L Petrol/V8 S/C 5.0L PetrolRemovalTransmission - V8 5.0L Petrol/V8 S/C 5.0L PetrolInstallationTransmission - V8 5.0L Petrol/V8 S/C 5.0L Petrol

310: Fuel System - General Information
310-00: Fuel System - General InformationSpecificationGeneral ProceduresFuel System Pressure Release - V8 5.0L Petrol/V8 S/C 5.0L Petrol
Fuel Tank Draining
Spring Lock Couplings
Quick Release Coupling
Quick Release Coupling - Push Connect310-01C: Fuel Tank and Lines - V8 5.0L Petrol/V8 S/C 5.0L PetrolSpecificationDescription and OperationComponent Location
Overview
System Operation and Component DescriptionDiagnosis and TestingFuel Tank and LinesRemoval and InstallationFuel Level Sender
Fuel Pump and Sender Unit
Fuel Tank
Fuel Tank Filler Pipe
Fuel Rail High-Pressure Fuel Pump Supply Line310-02: Acceleration ControlSpecificationDiagnosis and TestingAcceleration ControlRemoval and InstallationAccelerator Pedal310-03C: Speed Control - V8 5.0L Petrol/V8 S/C 5.0L PetrolSpecificationDescription and OperationComponent Location
Overview
System Operation and Component DescriptionDiagnosis and TestingSpeed ControlGeneral ProceduresSpeed Control Sensor AdjustmentRemoval and InstallationSpeed Control Deactivator Switch

SpecificationRemoval and InstallationAir Deflector
Cowl Vent Screen (76.10.01)
Engine Rear Undershield
Fender Splash Shield
Hood
Radiator Splash Shield
Secondary Bulkhead Center Panel
Secondary Bulkhead Panel LH - TDV6 3.0L Diesel /V8 5.0L Petrol/V8 S/C 5.0L Petrol
Secondary Bulkhead Panel RH - TDV6 3.0L Diesel /V8 5.0L Petrol/V8 S/C 5.0L Petrol501-03: Body Closures
Removal and InstallationFront Door
Fuel Filler Door
Fuel Filler Door Assembly
Luggage Compartment Lid (76.19.01)
Rear Door501-05: Interior Trim and OrnamentationSpecificationRemoval and InstallationA-Pillar Trim Panel
B-Pillar Lower Trim Panel
B-Pillar Upper Trim Panel
C-Pillar Lower Trim Panel
C-Pillar Trim Panel
Cowl Side Trim Panel
Engine Cover - V8 5.0L Petrol/V8 S/C 5.0L Petrol
Front Door Trim Panel (76.34.01)
Front Scuff Plate Trim Panel
Instrument Panel Speaker Grille
Headliner
Loadspace Scuff Plate Trim Panel
Loadspace Trim Panel
Loadspace Trim Panel LH
Loadspace Trim Panel RH
Luggage Compartment Lid Trim Panel
Parcel Shelf
Rear Door Trim Panel
Rear Scuff Plate Trim Panel
Sun Visor (76.10.48)
Sun Visor Vanity Mirror

Published: 11-May-2011
General Information - Diesel Fuel System Health and Safety Precautions
Description and Operation
WARNINGS:

Fuel may not give adequate warning before toxic or harmful effects arise.
Exposure to fuel can be harmful and can cause severe health damage or death.
Provide adequate ventilation when working on fuel systems.
Extreme care must be exercised when handling hot fluids. Always wash off spilled fluids from affected areas of skin
immediately.


Fuel must not be used as a cleaning agent.


Keep fuel containers tightly closed, out of direct sunlight and in a cool area. Keep away from heat sources, ignition
sources and oxidizing agents.


SKIN CONTACT: Fuel is mildly irritating to the skin and may cause dermatitis due to defatting effect. Remove
contaminated clothing. Wash affected areas of skin with soap and water. Seek medical attention for any persistent skin
irritation or abnormality. Wash contaminated clothing before reuse.


SKIN CONTACT: Excessive or prolonged skin contact with diesel fuel may cause serious skin disorders including skin
cancer.


EYE CONTACT: Fuel is mildly irritating to the eyes. Flush with plenty of running water, blinking as often as possible. Do
not force the eyelid open. Seek medical attention for any persistent eye irritation or abnormality.


SWALLOWED: Fuel is moderately toxic and tends to foam on vomiting. If drawn into the lungs, inflammation may
develop. Do not induce vomiting. If spontaneous vomiting occurs place the victim in a forward position to reduce the risk of
fuel being drawn into the lungs. Give nothing by mouth. If breathing but unconscious, place in the recovery position. If
breathing has stopped, apply artificial respiration. Seek immediate medical attention.


INHALED: Fuel is toxic to the respiratory and other body systems. Exposure may result in various symptoms including
drowsiness, unconsciousness or severe health damage. Move a victim to fresh air. Keep a victim warm and at rest. If
unconscious, place in the recovery position. If not breathing, apply artificial respiration. Give cardiac massage if necessary.
Seek immediate medical attention.
CAUTIONS:


Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is essential that absolute
cleanliness is observed when working with these components.


Make sure that the workshop area in which the vehicle is being worked on is as clean and as dust free as possible.
Make sure that non-plated tools are used.
Tools must be cleaned using a new brush and fresh suitable evaporative cleaning agent.


Make sure to use a steel topped workbench covered with clean, lint-free, non-flocking material.
Make sure that all parts removed from the vehicle are placed on the lint-free, non-flocking material.
Make sure that any protective clothing worn is clean and made from lint-free, non-flocking material.

General Information - General Service Information
Description and Operation

Repairs and Replacements Published: 28-Dec-2012

When service parts are required, it is essential that only genuine Jaguar/Daimler replacements are used.

Attention is drawn to the following points concerning repairs and the installation of replacement parts and accessories:

Safety features embodied in the vehicle may be impaired if other than genuine parts are installed. In certain territories,
legislation prohibits the installation of parts which are not produced to the vehicle manufacturer's specification.
Torque wrench setting figures given in this manual must be strictly adhered to. Locking devices, where specified, must
be installed. If the efficiency of a locking device is impaired during removal it must be renewed.
Owners purchasing accessories while travelling abroad should make sure that the accessory and its installed location on
the vehicle conform to mandatory requirements existing in their country of origin.
The vehicle warranty may be invalidated by the installation of other than genuine Jaguar/Daimler parts. All
Jaguar/Daimler replacements have the full backing of the factory warranty.
Jaguar/Daimler dealers are obliged to supply only genuine service parts.

Vehicle Specifications

Purchasers are advised that the specification details set out in this manual apply to a range of vehicles and not to any specific
one. For the specification of a particular vehicle, purchasers should consult their dealer.

The Manufacturer reserves the right to vary the specifications, with or without notice, and at such times and in such manner as
the Manufacturer thinks fit. Major as well as minor changes may be involved, in accordance with the Manufacturer's policy of
continuous improvement.

Whilst every effort is made to make sure the accuracy of the particulars contained in this manual, neither the Manufacturer nor
the Dealer, by whom the manual is supplied, shall in any circumstances be held liable for any inaccuracy or the consequences
thereof.

Service Repair Operation Numbering

A master index of numbered operations has been compiled for universal application to all vehicles manufactured by Jaguar
Land Rover Limited.

Each operation is allocated a number from the master index and cross-refers with an identical number in the Repair Operation
Times schedule. The number consists of six digits arranged in three pairs.

Each maintenance procedure in this manual is described in the sequence necessary to complete the operation in the minimum
time, as specified in the Repair Operation Times schedule.

References to Bank-1 and Bank-2

References to Bank-1 and Bank-2 are made with regard to the engine. When viewed from the flywheel the right-hand bank will
be Bank-1 and the left-hand bank will be Bank-2.

Special Tools

Any special tools and equipment required to perform a maintenance procedure, are shown at the beginning of each procedure.
When possible, illustrations are given to assist in identifying the tool needed.

Disconnecting/Connecting the Battery

Always stop the engine before disconnecting the battery negative lead and make sure the battery positive lead is isolated i.e.
wrapped in a suitable cloth.


WARNING: Radio code saving devices must not be used when conducting work on Air Bag or Fuel systems. It must be
noted that, when using these devices, the vehicle electrical system is still live albeit with a reduced current flow.


NOTE: Before disconnecting the battery make sure that the radio receiver/cassette player/mini disc player and compact
disc player keycodes are known and, that no data is required from the Engine Control Module (ECM) as battery disconnection
will erase any fault codes and idle/drive values held in the Keep Alive Memory (KAM).
Always disconnect the battery before commencing repair operations which require:
The vehicle to be jacked up
Work on the engine
Work underneath the vehicle
Arc welding
Alternatively a Radio Code Saver may be used, when not working on the Air Bag or Fuel systems. With the battery

Always reduce the engine speed to idle before disconnecting the jump leads.

Before removing the jump leads, switch on the heater blower (high) or the heated rear screen, to reduce the voltage peak
when the leads are removed.

Always disconnect the jump leads in the reverse order to the connecting sequence and take great care not to short the ends of
the leads.

Do not rely on the generator to restore a discharged battery. For a generator to recharge a battery, it would take in excess of 8
hours continuous driving with no additional loads placed on the battery.

Component Cleaning

To prevent ingress of dirt, accumulations of loose dirt and greasy deposits should be removed before disconnecting or
dismantling components or assemblies.
Components should be thoroughly cleaned before inspection prior to reassembly.
Cleaning Methods:
Dry Cleaning
Removal of loose dirt with soft or wire brushes
Scraping dirt off with a piece of metal or wood
Wiping off with a rag

CAUTION: Compressed air is sometimes wet so use with caution, especially on hydraulic systems.
Blowing dirt off with compressed air (Eye protection should be worn when using this method)
Removal of dry dust using vacuum equipment. This method should always be used to remove friction lining material
dust (asbestos particles)
Steam Cleaning

Calibration of Essential Measuring Equipment


WARNING: Failure to comply may result in personal injury or damage to components.

It is of fundamental importance that certain essential equipment e.g. torque wrenches, multimeters, exhaust gas analysers,
rolling roads etc., are regularly calibrated in accordance with the manufacturers instructions.

Use of Control Modules

Control modules may only be used on the vehicle to which they were originally installed. Do not attempt to use or test a
control module on any other vehicle.

Functional Test

On completion of a maintenance procedure, a thorough test should be carried out, to ensure the relevant vehicle systems are
working correctly.

Preparation

Before disassembly, clean the surrounding area as thoroughly as possible. When components have been removed, blank off
any exposed openings using grease-proof paper and masking tape. Immediately seal fuel, oil and hydraulic lines when
separated, using plastic caps or plugs, to prevent loss of fluid and the entry of dirt. Close the open ends of oil ways, exposed
by component removal, with tapered hardwood plugs or readily visible plastic plugs. Immediately a component is removed,
place it in a suitable container; use a separate container for each component and its associated parts. Before dismantling a
component, clean it thoroughly with a recommended cleaning agent; check that the agent will not damage any of the materials
within the component. Clean the bench and obtain marking materials, labels, containers and locking wire before dismantling a
component.

Dismantling

Observe scrupulous cleanliness when dismantling components, particularly when parts of the brake, fuel or hydraulic systems
are being worked on. A particle of dirt or a fragment of cloth could cause a dangerous malfunction if trapped in these systems.
Clean all tapped holes, crevices, oil ways and fluid passages with compressed air.


WARNING: Do not permit compressed air to enter an open wound. Always use eye protection when using compressed air.

Make sure that any O-rings used for sealing are correctly reinstalled or renewed if disturbed. Mark mating parts to make sure
that they are replaced as dismantled. Whenever possible use marking materials which avoid the possibilities of causing
distortion or the initiation of cracks, which could occur if a center punch or scriber were used. Wire together mating parts where
necessary to prevent accidental interchange (e.g roller bearing components). Tie labels on to all parts to be renewed and to
parts requiring further inspection before being passed for reassembly. Place labelled parts and other parts for rebuild in
separate containers. Do not discard a part which is due for renewal until it has been compared with the new part, to make sure

Bus Topology of a
communication
network Coast Clutch Solenoid CCS Camshaft Position CMP Indicates camshaft position Carbon dioxide CO² Colorless gas with a density of approximately 1.5 times that of air Carbon monoxide CO Poisonous gas produced as the result of incomplete combustion Chlorofluorocarbon CFC Catalytic converter
In-line exhaust system device used to reduce the level of engine exhaust
emissions Celsius C
SI term for the Centigrade scale, with freezing point at zero and boiling point at 100 degrees Compact Disc CD Cylinder Head Temperature
Sensor CHT Sensor A sensor for measuring the temperature of the cylinder head Central Junction Box CJB Crankshaft Position CKP Indicates crankshaft position Clutch Pedal Position CPP Indicates clutch pedal position Controller Area Network CAN
A communication system which allows control modules to be linked together Constant Velocity CV Cubic centimeter cm³ Central Security Module CSM Electronic module to support security system functionality Data Link Connector DLC
Connector providing access and/or control of the vehicle information, operating conditions, and diagnostic information Driver Door Module DDM Electronic module to support driver door functionality Driver Seat Module DSM Electronic module to support driver seat functionality Daytime Running Lamps DRL Deutsche Institut fur Normung DIN German standards regulation body Diagnostic Trouble Code DTC
An alpha/numeric identifier for a fault condition identified by the On-Board Diagnostic (OBD) system Direct current dc
Current which flows in one direction only, though it may have appreciable pulsations in its magnitude Domestic Data Bus D2B Digital Versatile Disc DVD Electronic Automatic Temperature Control EATC
Exhaust Gas Recirculation EGR Exhaust Gas Recirculation Temperature Sensor EGRT Sensing EGR function based on temperature change Electronic Brake Force
Distribution EBD
Engine Control Module ECM Electronic module to support engine functionality Electronic Crash Sensor ECS Sensor to measure severity of impact Engine Coolant Temperature ECT Engine Oil Pressure EOP European On-Board Diagnostic EOBD Electronic Pressure Control EPC Electrically Erasable
Programmable Read-Only Memory EEPROM
Erasable Programmable
Read-Only Memory EPROM
Evaporative Emission EVAP
System designed to prevent fuel vapor from escaping into the atmosphere. Typically includes a charcoal filled canister to absorb fuel vapor Flash Electrically Erasable
Programmable Read-Only Memory FEEPROM
Front Electronic Module FEM Flash Erasable Programmable
Read-Only Memory FEPROM
Frequency Modulation FM Fuel Pump Driver Module FPDM Fuel Rail Pressure FRP Generic Electronic Module GEM Ground GND
Electrical conductor used as a common return for an electrical circuit or
circuits, and with a relative zero potential Global Positioning System GPS Global System for Mobile
Communication GSM
Gross Vehicle Weight GVW Heated Oxygen Sensor HO2S Electrically heated oxygen sensor which induces fuelling corrections