battery JAGUAR XJ6 1994 2.G User Guide

Manual Transmission & Clutch (AJ16)
GEARSHIFT LEVER KNOB, RENEW
:RY 37.16.11
. Displace the gearshift lever gaiter for access and slacken
the gearshift lever knob lock nut (1 Fig. 1) and remove the
gearshift lever knob
(2 Fig. 1).
- Fit the new gearshift lever knob and align to its final posi- tion.
. Tighten the lock nut and reposition the gearshift lever
gaiter.
7.1.8 GEARSHIFT LEVER/ REMOTE CONTROL
ASSEMBLY, RENEW
SRO 37.16.20
. Disconnect the battery.
. Remove inlet manifold rear securing nuts.
. Fit lifting bracket 18G 1465 and secure with the nuts.
. Fit Service Tool MS 538 (Fig. 2) across the wing channels
and align to rear lifting bracket.
Fit and engage retaining hook.
. Tighten hook nut to take weight of engine.
Select third gear and remove the gearshift lever knob.
. Disconnect lambda sensor block connectors.
Remove the exhaust front pipe to the intermediate pipe
securing nut / bolt.
. Remove the sealing olive.
. Take the weight of the rear engine mounting using a jack,
. Remove the rear mounting securing bolts.
. Lower and remove the rear mounting assembly.
Carefully ease exhaust system down for access.
jack channel
and a suitable block.
. Remove the drive (propeller) shaft assembly, see Section 9, SRO 47.15.01.
. From above: undo retaining hook nut to lower rear of
transmission (do not allow engine to foul steering rack).
From below: slacken but do not remove the selector shaft
bolt
(3 Fig. 3).
. Remove the gear selector remote control securing bolts (1 Fig. 1) and reposition for access.
Finally remove the selector shaft bolt (3 Fig. 3).
. Remove the gear selector remote control assembly from
the selector shaft.
b: To aid removal, invert the gear selector remote con- trol assembly, i.e. gearshift lever pointing down- wards.
2
Fig. 1
Fig. 2
Fig. 3
X300 VSM 7 Issue 1 August 1994

Automatic Transmission (AJI 6)
8.1.3 TRANSMISSION CONTROL MODULE, RENEW
0 (4, OL)
SRO 44.15.32
. Raise the trunk lid and disconnect the battery.
. Remove the passenger side dash liner for access.
Displace and remove the air conditioning footwell outlet
duct.
. Release and remove the footwell carpet securing fastener:
displace and reposition the carpet for access.
Release the Transmission Control Module
(TCM) bracket
to body bracket securing nut
(1 Fig. 1).
. DisplacetheTCM mounting brackettang (2 Fig. 1)fromthe
body bracket and mounting stud.
= Reposition the TCM, release the TCM multi-pin plug lever
lock and disconnect the multi
-pin plug (3 Fig. 1).
. Release and remove the TCM mounting bracket securing
bolts and remove the TCM.
= Fit and align the new TCM to the mounting bracket.
. Fit and tighten the TCM securing bolts.
. Connect the TCM harness multi-pin plug and secure the
Position the TCM to body mounting bracket, ensuring that
Fit and tighten the TCM securing nut.
. Position the footwell carpet and fit the carpet fastener.
. Fit and align the footwell outlet duct to air conditioning
. Position and fit the duct fastener to the blower motor slot.
. Refit the dash liner.
. Reconnect the battery.
multi-pin plug lever lock.
the tang locates
in the bracket slot and stud.
unit.
1
i
J44-703 U
Fig. 1
Issue 1 August 1994 X300 VSM 7

Automatic Transmission (AJ16)
8.1.5 TRANSMISSION ROTARY SWITCH, RENEW
0 (4,OL)
SRO 44.15.36
. Check the shift cable adjustment.
. Switch the ignition ON, apply the footbrake and move the
Switch the ignition OFF and disconnect the battery.
. Open the armrest lid.
. Release and remove the ashtray securing screws.
. Displace the ashtray assembly for access.
. Disconnect the cigar lighter / illumination harness con-
. Place the ashtray assembly aside.
. Displace and remove the console veneer panel rear fin-
isher.
Carefully displace the Performance Mode switch from the
gear surround finisher.
. Disconnect the Performance Mode switch from the har-
ness multi-pin plug.
Displace and remove the Performance Mode switch sur-
round finisher.
Displace and remove the shift lever surround finisher.
. Release and remove the veneer panel wing nuts.
= Displace and remove the console finisher veneer panel.
Cut and remove the rotary switch harness securing straps.
= Disconnect the rotary switch harness multi-pin plugs.
. Reposition the tunnel carpet for access to the harness
Displace and reposition the grommet down through the
. Feed the harness through the tunnel to the underside of
. Raise the vehicle on a ramp.
. From beneath the vehicle, release and remove the rotary
switch harness to transmission
'F" clip securing nut; dis-
place and reposition the 'P' clip from the stud.
Release and remove the rotary switch harness to trans-
mission 'P' clip securing screw.
Release and remove the rotary switch protection cover
(1 Fig.1) securing bolts; displace and remove the switch
cover.
shift
lever to
'N'.
n ect o rs .
@
grommet.
tunnel.
the vehicle.
Disconnect the transmission multi-pin socket (2 Fig.1).
. Reposition the harness clear of the transmission unit.
. Release and remove the rotary switch securing nuts.
. Displace and remove the switch assembly.
. Displace and remove the 'P' clips from the harness.
. Fit and align the 'P' clips to the new harness / switch as-
. Displace the rubber sealing plug (3 Fig.1) from the rotary
sembly.
switch.
i3 2 JLL-690
Fig.
1
X300 VSM 9 Issue 1 August 1994

Automatic Transmission (AJl6)
. Ensure the shift lever is in 'N'.
. Fit and fully seat a new rotary switch to the transmission
unit.
Fit but do not fully tighten the rotary switch securing nuts.
. Fitand align ServiceTool JD161 (Fig.l)tothe rotaryswitch
. Finallytorque tighten the rotary switch securing nuts.
Displace and remove Service Tool JD161.
. Reposition and fit the rubber sealing plug to the switch.
. Reconnect the transmission unit multi-pin plug.
. Reposition the harness and feed the multi-pin plugs and
. From below the vehicle, reposition the harness 'P' clip to
. Fit and tighten the 'F" clip securing nut.
. Align the harness 'P' clip to transmission shift abutment
Fit and tighten the 'P' clip securing screw.
. Fit and align the rotary switch protection cover; fit and
torque tighten the securing bolts.
. From inside the vehicle, fit the grommet in the correct
orientation and reposition the harness in the correct posi
-
tion.
to
align the switch rotor to the switch body.
grommet through the tunnel aperture.
its mounting stud.
bracket.
. Reconnect the rotary switch harness multi-pin plugs.
. From below the vehicle, ensure that there is no excess
slack
in the switch harness that could foul the propshaft.
. Lower the vehicle on the ramp.
Reposition and fit the tunnel carpet.
Using suitabletiestraps,securethe harnesstotheconsole
= Fit and fully seat the veneer panel to the console; fit and
harness.
tighten the wing nuts.
Fit and fully seat the shift lever surround.
multi-pin plug and fully seat the switch.
Connect the Performance Mode switch to the harness
Fit and align the console veneer panel rear finisher.
9 Place the ashtray assembly in position.
= Reconnect the cigar lighter / illumination harness con-
nectors.
Reposition and
fit the ashtray assemb1y;fit and tighten the
securing screws.
. Close the armrest lid.
Reconnect the battery
Fia. 1
Issue 1 August 1994 10 X300 VSM

Automatic Transmission (AJ16)
8.1.11 TRANSMISSION INTERNAL HARNESSMULTI-
PIN SOCKET '0' RING, RENEW (4,OL)
SRO 44.24.20
. Disconnect the battery.
. Raise the vehicle on a ramp.
. Drain the transmission lubrication system, see Sub-sec-
. Remove the fluid pan, see Sub-section 8.1.7.
. Remove the fluid filter, see Sub-section 8.1.6.
. Remove the transmission speed sensor, see Sub-section
8.1.10.
. Disconnect the rotary switch harness multi-pin plug
(1 Fig. 1) from the transmission multi-pin socket.
. Release and remove the multi-pin socket to main trans-
mission casing securing nut.
. Release and remove the valve body assembly, ensuring
that the
multi-pin socket is freed from the main case aper-
ture.
. Remove the valve body harness multi-pin socket '0' ring
and discard.
. Clean the valve body and mating faces.
. Fit a new '0' ring to the multi-pin socket
. Fit thevalve body assembly to the transmission unit. Dur-
ing valve body fitment, engage the shift lever quadrant
peg into the manual valve and seat the
multi-pin socket
through the main case orifice.
m. Theflat onthesideofthe multi-pinsocket should be
located on the vertical (left-hand) side of the case.
. Fit but do not tighten the valve body assembly securing
screws.
. Gently push the valve body assembly forward to assume
this position
during the final tightening operation.
. Carry out final tightening of the valve body assembly to
main casing securing screws.
Fit and tighten the harness
multi-pin socket to main casing
securingnut.
. Connect the rotary switch harness multi-pin plug to the
transmission
multi-pin socket.
. Refit the speed sensor, see Sub-section 8.1.10.
Renew the fluid filter, see Sub-section 8.1.6.
. Refit the fluid pan, see Sub-section 8.1.7.
. Lower the vehicle on the ramp.
. Reconnect the battery.
. Refill the transmission unit with fluid, see Sub-section
8.1.2.
. Remove the fender cover and lower the hood.
Raise
the hood and
fit a fender cover.
tion
8.1.2.
Fig. 1
Issue 1 August 1994 14 X300 VSM

Automatic Transmission (AJ16)
8.1.12 VALVE BODY ASSEMBLY, RENEW (4,Ol)
SRO 44.40.01
Raise the hood and fit a fender cover.
. Disconnect the battery.
. Raise the vehicle on a ramp.
. Drain the transmission lubrication system, see Sub-sec-
. Remove the fluid pan, see Subsection 8.1.7.
. Remove the fluid filter, see Sub-section 8.1.6.
. Remove the transmission speed sensor, see Subsection
8.1.10.
. Disconnect the rotary switch harness multi-pin plug from
the transmission multi
-pin socket.
. Release and remove the multi-pin socket to main trans-
mission casing securing nut.
Release and remove the valve body assembly to main cas-
ing securing screws.
. DisDlace and remove the valve body assemblv, ensurina
tion
8.1.2.
that
the multi-pin socket is freed from the main case apery
ture. - . Remove the valve body harness multi-pin socket '0' ring
. Clean the valve body and main case mating faces. Check
. Fit a new '0' ring to the multi-pin socket.
. Fit the valve body assembly to the transmission unit. Dur-
ing valve body fitment, engage the shift lever quadrant
peg into the manual valve and seat the multi
-pin socket
through the main case orifice.
m: Theflat on the side of the multi-pin socket should be
located on the vertical (left-hand) side of the case.
. Fit but do not tighten the valve body assembly securing
screws.
Gently push the valve body assembly forward to assume
this position during the final tightening operation.
Carry out final tightening of the valve body assembly to
main casing securing screws.
. Fit and tighten the harness multi-pin socket to main casing
. Connect the rotary switch harness multi-pin plug to the
. Refit the speed sensor, see Subsection 8.1.10.
. Renew the fluid filter, see Subsection 8.1.6.
Refit the fluid pan, see Sub-section 8.1.7.
* Lower the vehicle on the ramp.
. Reconnect the battery.
. Refill the transmission unit with fluid, see Sub-section
8.1.2.
. Remove the fender cover and lower the hood.
and discard.
for any signs of damage.
securing nut.
transmission multi
-pin socket.
Issue 1 August 1994 X300 VSM 15

Automatic Transmission (AJ16)
8.1.13
SRO 44.40.01
. Raise the hood and fit a fender cover.
Disconnect the battery.
. Raise the vehicle on a ramp.
Drain the transmission lubrication system, see Su
. Remove the fluid pan, see Sub-section 8.1.8.
. Remove the fluid filter, see Subsection 8.1.6.
VALVE BODY ASSEMBLY, RENEW (3’21)
tion 8.1.2.
-sec-
. Release and remove the valve body securing screws
Displace and remove the valve body assembly.
Clean the valve body and mating faces.
Fit the new valve body to the transmission unit, locating
the throttle valve behind the throttle valve cam and en
-
gage the selector.
(1 Fig. 1).
. Fit but do not tighten the valve body securing screws.
. Fit and engage Service Tool JD 103 between the valve
body and the throttle valve pin.
Align the valve body assembly.
. Fully tighten the valve body securing screws.
. Remove Service Tool JD 103.
= Fit a new fluid filter, see Sub-section 8.1.6.
. Refit the fluid pan, see Subsection 8.1.8.
. Lower the vehicle on the ramp.
. Refill the transmission unit with fluid, see Subsection
. Remove the fender cover and lower the hood.
8.1.2.
Fig. 1
X300 VSM Issue 1 August 1994 16

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

Driveshafts & Final Drive
9.8 FINAL DRWE UNIT RENEW
SRO 51.25.13
. Disconnect vehicle battery ground lead.
. Support the vehicle at the rear and remove the rear road
wheels.
Disconnect brake pad wear sensor multi-plug at RH hub
carrier and remove tie straps from wishbone. Release
ABS speed sensors at
RH and LH hub carriers and remove
tie straps from wishbones.
. Remove rear brake calipers, see Section 12, and support
at bump stop. Disconnect main handbrake cable at com- pensator, short cables at joining piece and remove com- pensator.
. Remove fixings, FLEXIBLE coupling to differential DRIVE FLANGE.
CAUTIW: Under no circumstances must the flexible
coupling (or itsfixings) be loosened or removed
from the drive shaft flange.
. Remove fixings center bearing to crossmember (1 Fig. 1) and push drive shaft rear section forward to disengage
from pinion spigot. Fig. 1
w: Take account of any shims located between the center bearing and the crossmember.
. Release fixings and remove, over axle exhaust pipe mounting from wide mounting bracket.
. Support the rear suspension assembly from below and remove fixings from RH and LH sides in the following order:
1. Shock absorber to body upper fixings.
2. Differential strut to body (1 Fig. 2).
3. 'A' frame bush (2 Fig. 2).
4. Lower mounting bracket assembly to body (3 Fig. 2).
. Carefully lower the unit clear of the vehicle and place in a safe working location.
. Release handbrake cable to wide mounting bracket clips.
. Disconnect RH and LH axle shafts from differential couplings, note camber shim and discard fixings.
. Remove wishbone pivot bolt, washers and remove wisbone / hub / axle shaft assembly RH and LH.
issue 1 August 1994 6 X300 VSM