oil JAGUAR XFR 2010 1.G Workshop Manual

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

Throttle Body303-05D: Accessory Drive - V8 S/C 5.0L PetrolSpecificationDescription and OperationComponent Location
OverviewRemoval and InstallationAccessory Drive Belt
Accessory Drive Belt Idler Pulley
Accessory Drive Belt Tensioner
Supercharger Belt Idler Pulley
Supercharger Belt Tensioner303-06C: Starting System - V8 5.0L Petrol/V8 S/C 5.0L PetrolSpecificationDescription and OperationComponent Location
Overview
System Operation and Component DescriptionDiagnosis and TestingStarting System
Starting System - Vehicles With: Smart KeyRemoval and InstallationStarter Motor303-07B: Engine Ignition - V8 5.0L Petrol/V8 S/C 5.0L PetrolSpecificationDescription and OperationComponent Location
Overview
System Operation and Component DescriptionDiagnosis and TestingEngine IgnitionRemoval and InstallationIgnition Coil-On-Plug - V8 S/C 5.0L Petrol303-08C: Engine Emission Control - V8 5.0L Petrol/V8 S/C 5.0L Petrol
Description and OperationComponent Location
Overview
System Operation and Component DescriptionDiagnosis and TestingEngine Emission Control303-12D: Intake Air Distribution and Filtering - V8 S/C 5.0L PetrolSpecification

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

Speed Control Module
Speed Control Sensor
Speed Control Switch4: Electrical
412: Climate Control System
412-00: Climate Control System - General InformationSpecificationDiagnosis and TestingClimate Control SystemGeneral ProceduresAir Conditioning (A/C) System Recovery, Evacuation and Charging (82.30.30)
Air Conditioning (A/C) System Flushing
Contaminated Refrigerant Handling
Electronic Leak Detection
Fluorescent Dye Leak Detection
Inspection and Assembly Requirements
Manifold Gauge Set Connection
Refrigerant Oil Adding - TDV6 3.0L Diesel /V8 5.0L Petrol/V8 S/C 5.0L Petrol
Refrigerant System Tests
Air Conditioning (A/C) Compressor Commissioning412-01: Climate ControlSpecificationDescription and Operation
Air Distribution and FilteringComponent Location
Overview
System Operation and Component DescriptionHeating and VentilationComponent Location
Overview
System Operation and Component DescriptionAir ConditioningComponent Location
Overview
System Operation and Component DescriptionControl ComponentsComponent Location
Overview
System Operation and Component DescriptionRemoval and InstallationAmbient Air Temperature Sensor
Blower Motor

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

Hydrofluorocarbon HFC High tension HT Hydrocarbon HC Idle Air Control IAC
Stepper motor driven device which varies the volume of air by-passing the
throttle to maintain the programmed idle speed Intake Air Temperature IAT Temperature of intake air Inertia Fuel Shut-off IFS
An inertia system that shuts off the fuel supply when activated by pre-determined force limits brought about by (e.g.) collision Input Shaft Speed ISS Indicates input shaft speed Key On, Engine Off KOEO Key On, Engine Running KOER Kilogram (mass) kg Kilogram (force) kgf Kilogram force per square
centimeter kgf/cm²
Kilometer km Kilometer per hour km/h Kilopascal kPa Kilovolt kV Knock Sensor KS
Sensor which detects the onset of detonation, and signals the ECM to
retard the ignition Liquid Crystal Display LCD
Optical digital display system, to which applied voltage varies the way the crystals reflect light, thereby modifying the display Lighting Control Module LCM Light Emitting Diode LED Low Tension LT
Primary circuit of the ignition system, linking the battery to the primary winding in the ignition coil Left-Hand LH Left-Hand Drive LHD Mass Air Flow MAF
System which provides information on the mass flow rate of the intake air
to the engine Manifold Absolute Pressure MAP Absolute pressure of the intake manifold air Manifold Absolute Pressure and Temperature MAPT
Malfunction Indicator Lamp MIL
A required on-board indicator to alert the driver of an emission related
malfunction Meter (measurement) m Metric (screw thread, e.g. M8) M Farad F Unit of electrical capacitance Millimeter mm Millimeter of mercury mmHg Millisecond ms Model year MY Newton N SI unit of force. 1 N = 0.2248 pounds force Newton Meter Nm SI unit of torque. Must not be confused with nm (nanometer) Negative Temperature
Coefficient NTC
Naturally aspirated N/A
Fuelling system using intake air at atmospheric pressure; not supercharged or turbocharged Noise, Vibration and Harshness NVH North American Specification NAS Vehicles for sale in the USA and Canadian markets On-Board Diagnostic OBD
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 system or a related system Oxides of Nitrogen Nox Oxygen Sensor O2S A sensor which detects oxygen content in the exhaust gases On-board Refuelling Vapour Recovery ORVR
Output State Control OSC Output Shaft Speed OSS Passenger Air Bag Deactivation PAD Pulsed Secondary Air Injection PAIR Passive Anti-Theft System PATS Positive Crankcase Ventilation PCV Parameter Identification PID
An index number referring to a parameter within a module without knowledge of its storage location Park/Neutral Position PNP Pulse Width Modulation PWM Programmable Electronic
Control Units System PECUS
Process whereby a common ECM is programmed on the production line to
suit the market requirements of a particular vehicle

Have a suitable fire extinguisher available when using welding or heating equipment.

First Aid

Apart from meeting any legal requirements it is desirable for someone in the workshop to be trained in First Aid procedures.
Splashes in the eye should be flushed carefully with clean water for at least ten minutes.
Soiled skin should be washed with soap and water.

Individuals affected by inhalation of gases, fumes etc. should be removed to fresh air immediately. If effects persist, consult a
doctor.

If liquids are swallowed inadvertently, consult a doctor giving the information on the container or label. Do not induce vomiting
unless this action is indicated on the label.

Fluoroelastomer

See Viton.

Foams - Polyurethane

See also Fire.
Used in sound and noise insulation. Cured foams used in seat and trim cushioning.
Follow manufacturer's instructions.
Unreacted components are irritating and may be harmful to the skin and eyes. Wear gloves and goggles.

Individuals with chronic respiratory diseases, asthma, bronchial medical problems, or histories of allergic diseases should not
work in or near uncured materials.
The components, vapors or spray mists can cause direct irritation, sensitivity reactions and may be toxic or harmful.

Vapors and spray mists must not be inhaled. These materials must be applied with adequate ventilation and respiratory
protection. Do not remove the respirator immediately after spraying, wait until the vapor/mists have cleared.

Burning of the uncured components and the cured foams can generate toxic and harmful fumes. Smoking, naked flames or the
use of electrical equipment during foaming operations and until vapors/mists have cleared should not be allowed. Any heat
cutting of cured foams or partially cured foams should be conducted with extraction ventilation.

Freon

See Air Conditioning Refrigerant.

Fuels

See also, Fire, Legal Aspects, Chemicals and Solvents.
Avoid skin contact with fuel where possible. Should contact occur, wash the affected skin with soap and water.

Gasoline (Petrol)

Highly flammable - observe No Smoking policy.

Swallowing can result in mouth and throat irritation and absorption from the stomach can result in drowsiness and
unconsciousness. Small amounts can be fatal to children. Aspiration of liquid into the lungs e.g. through vomiting, is a very
serious hazard.

Gasoline dries the skin and can cause irritation and dermatitis on prolonged or repeated contact. Liquid in the eye causes
severe pain.

Motor gasoline may contain appreciable quantities of benzene, which is toxic upon inhalation, and the concentration of
gasoline vapors must be kept very low. High concentrations will cause eye, nose and throat irritation, nausea, headache,
depression and symptoms of drunkenness. Very high concentrations will result in rapid loss of consciousness.

Ensure there is adequate ventilation when handling and using gasoline. Great care must be taken to avoid the serious
consequences of inhalation in the event of vapor build up arising from spillages in confined spaces.
Special precautions apply to cleaning and maintenance operations on gasoline storage tanks.
Gasoline should not be used as a cleaning agent. It must not be siphoned by mouth. See First Aid.
Gas - oil (Diesel Fuel)
See warnings and cautions in relevant manual sections.
Combustible.
www.JagDocs.com

Highly flammable, flammable - observe No Smoking policy

Pressurized Equipment

See High Pressure Air, Lubrication and Oil Test Equipment.

Solder

Solders are a mixture of metals such that the melting point of the mixture is below that of the constituent metals (normally
lead and tin). Solder application does not normally give rise to toxic lead fumes, provided a gas/air flame is used.
Oxy-acetylene flames should not be used, as they are much hotter and will cause lead fumes to be produced.

Some fumes may be produced by the application of any flame to surfaces coated with grease etc. and inhalation of these
should be avoided.

Removal of excess solder should be undertaken with care, to make sure that fine lead dust is not produced, which can give
toxic effects if inhaled. Respiratory protection may be necessary.
Solder spillage and filings should be collected and removed promptly to prevent general air contamination by lead.
High standards of personal hygiene are necessary in order to avoid ingestion of lead or inhalation of solder dust from clothing.

Solvents

See also Chemical Materials, Fuels (Kerosene), Fire.
e.g. acetone, white spirit, toluene, xylene, trichloroethane.

Used in cleaning and de-waxing materials, paints, plastics, resins, thinners etc.
Some may be highly flammable or flammable.
Skin contact will degrease the skin and may result in irritation and dermatitis following repeated or prolonged contact. Some
can be absorbed through the skin in toxic or harmful quantities.
Splashes in the eye may cause severe irritation and could lead to loss of vision.

Brief exposure to high concentrations of vapors or mists will cause eye and throat irritation, drowsiness, dizziness, headaches
and, in the worst circumstances, unconsciousness.

Repeated or prolonged exposure to excessive but lower concentrations of vapors or mists, for which there might not be
adequate warning indications, can cause more serious toxic or harmful effects.
Aspiration into the lungs (e.g. through vomiting) is the most serious consequence of swallowing.

Avoid splashes to the skin, eyes and clothing. Wear protective gloves, goggles and clothing if necessary.

Ensure good ventilation when in use, avoid breathing fumes, vapors and spray mists and keep containers tightly sealed. Do not
use in confined spaces.

When spraying materials containing solvents, e.g. paints, adhesive, coatings, use extraction ventilation or personal respiratory
protection in the absence of adequate general ventilation.
Do not apply heat or flame except under specific and detailed manufacturer's instructions.

Sound Insulation

See Fibre Insulation, Foams.

Suspended Loads


CAUTION: Never improvise lifting tackle.

There is always a danger when loads are lifted or suspended. Never work under an unsupported, suspended or raised load e.g.
suspended engine, etc.

Always make sure that lifting equipment such as jacks, hoists, axle stands, slings, etc., are adequate and suitable for the job,
in good condition and regularly maintained.

Transmission Brake Bands

See Asbestos.

Underseal

See Corrosion Protection.

Viton

In common with many other manufacturers' vehicles, some components installed to the Jaguar range have 'O' rings, seals or
gaskets which contain a material known as 'Viton'.

Viton is a fluoroelastomer, that is a synthetic rubber type which contains Fluorine. It is commonly used for 'O' rings, gaskets
and seals of all types. Although Viton is the most well known fluoroelastomer, there are others, including Fluorel and
Tecmoflon.

When used under design conditions fluoroelastomers are perfectly safe. If, however, they are exposed to temperatures in
excess of 400º C, the material will not burn, but will decompose, and one of the products formed is hydrofluoric acid.
This acid is extremely corrosive and may be absorbed directly, through contact, into the body.

'O' rings, seals or gaskets which have been exposed to very high temperatures will appear charred or as a black sticky
substance.
DO NOT, under any circumstances touch them or the attached components.

Enquiries should be made to determine whether Viton or any other fluoroelastomer has been used in the affected 'O' ring, seal
or gasket. If they are of natural rubber or nitrile there is no hazard. If in doubt, be cautious and assume that the material may
be Viton or any fluoroelastomer.

If Viton or any other fluoroelastomers have been used, the affected area should be decontaminated before the commencement
of work.

Disposable heavy duty plastic gloves should be worn at all times, and the affected area washed down using wire wool and a
limewater (calcium hydroxide) solution to neutralize the acid before disposing of the decomposed Viton residue and final
cleaning of the area. After use, the plastic gloves should be discarded carefully and safely.

Welding

See also Fire, Electric Shock, Gas Cylinders.

Welding processes include Resistance Welding (Spot Welding), Arc Welding and Gas Welding (and cutting).
Resistance Welding (Spot Welding)
This process may cause particles of molten metal to be emitted at a high velocity, and the eyes and skin must be protected.
Arc Welding
This process emits a high level of ultraviolet radiation which may cause arc-eye and skin burns to the operator and to other
persons nearby. Gas-shielded welding processes are particularly hazardous in this respect. Personal protection must be worn,
and screens used to shield other people.
CONTACT LENS WEARERS ARE ADVISED TO REVERT TO ORDINARY SPECTACLES WHEN ARC WELDING as the arc spectrum is
believed to emit microwaves which dry out the fluid between the lens and the eye. This may result in blindness when the lens
is removed from the eye.
Metal spatter will also occur, and appropriate eye and skin protection is necessary.

The heat of the welding arc will produce fumes and gases from the metals being welded, the rods and from any applied
coatings or contamination on the surfaces being worked on. These gases and fumes may be toxic and inhalation of these
should be avoided. The use of extraction ventilation to remove the fumes from the working area may be necessary particularly
in cases where the general ventilation is poor, or where considerable welding work is anticipated. In extreme cases or confined
spaces where adequate ventilation cannot be provided, air-fed respirators may be necessary.
Gas Welding (and Cutting)

Oxy-acetylene torches may be used for welding and cutting, and special care must be taken to prevent leakage of these gases,
with consequent risk of fire and explosion.
The process will produce metal spatter and eye and skin protection is necessary.

The flame is bright, and eye protection should be used, but the ultraviolet emission is much less than that from arc welding,
and lighter filters may be used.

The process itself produces few toxic fumes, but such fumes and gases may be produced from coatings on the work,
particularly during cutting away of damaged body parts, and inhalation of the fumes should be avoided.

In brazing, toxic fumes may be produced from the metals in the brazing rod, and a severe hazard may arise if brazing rods
containing cadmium are used. In this event particular care must be taken to avoid inhalation of fumes and expert advice may
be required.

SPECIAL PRECAUTIONS MUST BE TAKEN BEFORE ANY WELDING OR CUTTING TAKES PLACE ON VESSELS WHICH HAVE
CONTAINED COMBUSTIBLE MATERIALS, E.G. BOILING OR STEAMING OUT OF FUEL TANKS.

Warning Symbols on Vehicles

Decals showing warning symbols will be found on various vehicle components.