JAGUAR XJ6 1994 2.G Workshop Manual
Page 1 of 521
XJ6 - XJI 2
Vehicle Service Manual
Published by Produd Development & Publications Jaguar Cars Limited
Publication Part Number - JJM 10 04 12 / 50
Page 2 of 521
This Vehicle Service Manual (VSM) is Dart
set of service literature which covers -. diagnosis and rectification of problems associated with all areas of the X300 family of vehicles.
It is designed to be read in conjunction with other manuals, namely the various Unit Service Manuals (USM) (as
applicable to the particular vehicle under diagnosis/ repair) and the X300 Electrical Diagnostic Manual (EDM); see list
It should be noted that its scope is limited to those areas that are unique to the family, e.g. Remove & Refit procedures
for Body Components, Engine, Transmission etcetera, Fuel, Emissions & Engine Management systems, and so on.
Fault Diagnosis and repair procedures (together
with Technical Data, Recommended Lubricants, Capacities etcetera) for major assemblies such as engines, automatic and manual transmissions, are covered in the separate Unit Service
The Unit Service Manuals are notvehicle
-specific, but are designed to be read in conjunction with this VSM, and, where so equipped, with other Jaguar Vehicle Service Manuals for new models launched subsequent to the X300 family.
The X300 Electrical Diagnostic Manual is the final part of the 'set' of service documentation. This manual
family-specific, and is designed to aid theTechnician to isolate electrical faults and to correct them. It covers all aspects
of electrical fault diagnosis, including:
II Codes and emission control system related fault diagnosis / rectification.
Component (Relays, fuse boxes, control modules etcetera) Location
/ Harness Diagrams I Ground Locations
Service Manuals Required
The Manuals required to service the X300 family of vehicles are as follows:
X300 Vehicle Service Manual
X300 Electrical Diagnostic Manual
Unit Service Manuals:
AJ16 Engine Service Manual
VI2 Engine Service Manual ZF AutomaticTransmissions Service Manual (ZF supplies transmissions for 3.2 liter and 4.0 liter normally aspirated
versions) Powertrain Automatic Transmissions Service Manual (The Powertrain name succeeds that of Hydra
Powertrain are suppliers of the 4L 80 E transmission as fitted to 4.0 litre supercharged and 6.0 litre versions)
of the X3Okpecific manuals is divided into Sections which adopt the same title and number where relevant, i.e. Section 5.1 of both the VSM and the EDM cover Fuel, Emission Control & Engine Management System (AJ16). An
-all contents list showing each section title and number together with its page-edge locator is given in this section
and in the introduction to the EDM.
The VSM (not applicable to the EDM) also contains Appendices which cover specialized areas such as the current
vehicle specification, routine maintenance schedule etc. These are carried at the rear of this Manual, and have their
own contents page within this section.
rapid location of information. The entries are set out as per the following example: @ This manual carries a comprehensive index at the rear, which is designed to save the Technician time by permitting
CLIMATE CONTROL SYSTEMS. Section 14.
See also Electrical Diagnostic Manual
Description: Sect. 7.7 - 10
Fault diagnosis: Sect 7.1 - 11
In the example the heading in upper case lettering is to a section title, and it refers to the section number, 14, and also to the EDM as electrical diagnostic information will be found in that manual's section 14. The entry for clutch tells us that the relevant description will be found on page 10 of Section 7.1 of this manual, and
that fault diagnosis procedures start on page 11. In this case there is no reference to the EDM as electrical diagnosis does not apply to this area.
GLOSSARY OF TERMS
This Section contains a Glossary of general and emissions-related terminology (commencing on page 5).
X300 VSM 1 Issue 1 August 1994
Page 3 of 521
A master index of numbered operations has bee? compiled for universal application to all vehicles manufactured by
Jaguar Cars Ltd.
Each operation described in this manual is allocated
a numberfromthe master indexand cross-refers with an identical
number in the Service Repair Operation Times Manual. The number consists of six digits arranged in three pairs.
Each operation is described in the sequence necessary to complete the operation in the minimum time, as specified
in the Manual of Repair Operation Times.
Where non-standard service tools (i.e. tools which are not generally available hand tools) are required to complete an
operation, the number and an illustration of that tool is given in the preliminary pages of the Section concerned.
TORQUE TIGHTENING SPEClFKATlONS
Torque tightening specifications are given in tabular form in the preliminary pages of the relevant Section.
REPAIRS AND REPLACEMENTS
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 fitting of replacement parts and accessories:
0 Safety features embodied in the vehicle may be impaired if other than genuine parts are fitted. In certain
territories, legislation prohibits the fitting of parts which are not produced to the vehicle manufacturer's
0 Torque wrench setting figures given in this Manual must be strictly adhered to.
0 Locking devices, where specified, must be fitted. If the efficiency of a locking device is impaired during removal it must be renewed.
0 Owners purchasing accessories while travelling abroad should ensure that the accessory and its fitted location
on the vehicle conforms to mandatory requirements existing in their country of origin.
0 The vehicle warranty may be invalidated by the fitting of other than genuine Jaguar / Daimler parts. All Jaguar
/Daimler replacements have the full backing of the factory warranty.
0 Jaguar / Daimler dealers are obliged to supply only genuine service parts.
References to the left or right-hand side of the vehicle are made as if viewing from the driver's seat.
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 Manufacturers reserve the right to vary their specifications, with or without notice, and
at such times and in such
manner as they thinkfit. Major as well as minorchanges may be involved in accordance with the Manufacturer's policy
of continuous improvement.
Whilst every effort is made to ensure the accuracy
ofthe particulars contained in this Manual, neither the Manufacturer
nor the Dealer, by whom this Manual is supplied, shall in any circumstances be held liable for any inaccuracy or the
[email protected] Jaguar Cars Lid. 1994
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any
form, electronic, mechanical, photocopying, recording or other means, without prior written permission of Jaguar
Cars Ltd., Service Department, Browns Lane, Coventry,
CV5 9DR, England.
X300 VSM Issue 1 August 1994 2
Page 4 of 521
Fuel, Emission Control & Engine Management (AJI 6)
Manual Transmission & Clutch (AJl6)
Driveshafts & Final Drive
Body Components & Trim
Climate Control Systems
Issue 1 August 1994 3 x300
- - ~~
Page 5 of 521
Page 6 of 521
Page 7 of 521
Page 8 of 521
GLOSSARY OF TERMS
This glossary of terms is intended to cover both general and emissions-related (to SAE J 1930) terminology. It is in- tended to enable the user to ascertain the meaning of standardized terms and acronyms used throughout the Manual.
The required term may be looked-up in the left-hand column, and subsequent columns give the standard abbreviation
or acronym, definitions and previously used terms, as applicable.
As this Manual is a world
-wide publication, and must comply with certain Society of Automotive Engineers Standards, it has been necessary to adopt the terminology etc. demanded by that Standard.
Term(s) Abbreviation Definition Previously used
(if applicable) term(s) (or Eng- lish Eauivalent)
accelerator Dedal AP
AI= measurement across the spanner flats of a
nut or bolt head
after bottom dead center
too dead center event
occurring after BDC
event occurring after TDC
Air Conditioning Signal air conditioning
operation is signalled to the PCM which
induces idle speed corrections to
compensate for engine load changes
module controlling air conditioning, heating
wing or similar, designed to obtain some
effect from the flow of air over
electrical current whose flow alternates in
direction, in a sinusoidal waveform
NCCM Air Conditioning Control Module
alternating current ac
Ambient temperature Temperature
of the air surrounding an object
SI unit of current AmDere A Amp Amp. hour -~ 1 Ampere flowing for one hour
system, usually ele&o&ally controlled (but ~- __. .. . Ampere hour
-Lock Braking System Ah
ABS can be mechanically) which prevents wheel
-up under braking by sensing lack of
rotation of a wheel(s) and diverting fluid
pressure away from
it (them). Originally Anti-Blockier System (Bosch).
ABS control module
/ traction control control
ABS I TC CM
antenna (plural, antennae or
Analoa Volt-Ohm meter analogue
AVOM unit of pressure
automatic transmission atm
axle shaft shaft
transmitting power to the rear wheel
Issue 1 August 1994 X300 VSM 7
Page 9 of 521
Terrn(s1 Abbreviation Definition Previously used (if applicable) term(s) (or Eng- lish Eauivalentl
battery positive Voltage B+
Barometric Absolute Pressure BARO
before bottom dead center BBDC
before top dead center BTDC
Body Processor Module BPM
British Standards BS
I British Standards Automotive BSAu
brake mean effective pressure BMEP
I bottom dead center BDC
bypass air BPA
rotating component of manual transmission
which prevents premature engagement of
The positive Voltage from
a battery or any
circuit connected directly to it.
sensor measuring the pressure of
surrounding air at any given temperature
rpm determined by the throttle lever
-set on the throttle body with the
IAC solenoid disconnected
Spark advance in degrees before top dead
center of the base engine without any control
from the PCM
Electrical storage device producing DC
Voltage by means of electrochemical
event occurring before BDC
event (usually ignition) occurring before TDC
Device which supplies a current of air at
moderate pressure, e.g. heater or
Control module for body electrical systems,
e.g. interior lamps, windshield wash wipe
standard specification issued by the British
effective horsepower developed by an
engine or motor, as measured by a brake
applied to its output shaft
that part of the effective pressure developed
in a cylinder that would result in a cylinder
output equal to the bhp of the engine
indicates the position of the brake pedal
process of bedding
-in the internal working
surfaces of e.g. an engine by avoiding excess
-up of heat
lowest point of piston travel in a
mechanical control of throttle bypass air
cylindrical plain bearing white
rear screen reversing lamp
Issue 1 August 1994 8 X300 VSM
Page 10 of 521
Term(s) Abbreviation Definition
GLOSSARY OF TERMS
Previously used term(s) (or Eng-
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
Camshaft Position Sensor CMPS
Canister Purge CANP
I Case Ground I CSEGND
Canadian Motor Vehicle Safety
trail built in to the geometry of a steered
roadwheel to give
it a caster - self-steering -
columnlmirror control module I C/M CM
Closed Loop System
clutch disc, clutch disk
connecting rod bearing
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
device which uses mechanical, magnetic or
friction type connections to facilitate
engaging or disengaging
two shafts or
rotating members charging
module casing ground
inclination of the plane of a wheel to the
ofthe vehicle. May be negative
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
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
friction disc of a clutch assembly clutch
diaphragm spring to release the clutch disc
Issue 1 August 1994 X300 VSM 9