transmission JAGUAR XJ6 1994 2.G User Guide

Term(s) Abbreviation Definition Previously used
(if applicable) term(s) (or Eng-
lish Equivalent)
T
tachometer
Thermal Vacuum Valve
Three
-way Catalytic Converter
Three
-way + Oxidation Catalytic
Converter TWC + OC
Throttle
------I
Throttle Body TB
Throttle Position TP
Throttle Position Sensor TPS
throw
-out bearing
throw
-out fork
tie
-rod (steering)
timing
tire
top dead center TDC
torque converter
Transmission
Transmission Control Module
Transmission Control Switch
Transmission Oil Temperature TOT
Transmission Range TR
I Transmission Speed Sensor TSS
tread
trunk
turn indicator, turn signal lamp
two cycle a
circuit that provides input for an electronic
tachometer display
controls vacuum levels or routing based on
temperature
catalytic converter that reduces the levels of
HC,
CO & NOx
catalyticconverter systemthat has both TWC
and OC. Usually secondary air is introduced
between the two catalvsts
procedure whereby the performance of a
product is measured under various
conditions - - . -. . . - . . -
a valve for regulating the supply of a fluid,
usually air or an aidfuel mixture, to an engine
device containing the throttle
interprets throttle position and movement to
identify idle, acceleration and full
-power
demands
relationship between spark plug firing and
piston position, usually expressed
in crankshaft degrees BTDC or ATDC of the
compression stroke
device which, by its design, multiplies the
torque in a fluid coupling between an engine
and transmission
device which selectively increases or
decreases the ratio of relative rotation
between its
inDut and outDut shafts
controls the shifting pattern of the
(automatic) transmission
Modifies the operation of electronically
controlled transmissions
indicates temperature
of transmission fluid
the range in which the transmission is
operating
indicates rotational speed of transmission
output shaft or turbine
shaft
track between tire contact centers; not to be
confused with tire contact tread pattern
principle of engine which fires every second
stroke of the piston cat
cat, dual bed
Throttle poten
-
tiometer, TPS, TP
clutch release
bearing
clutch release
lever
track rod
tvre
TCC, CCC, CCO,
LUS, MLUS,
MCCC
transmission
ECU
track boot, luggage
compartment
direction indica
- tor
two stroke
Issue 1 August 1994 26 X300 VSM

GLOSSARY Of
Term(s) Abbreviation Definition Previously used (if applicable) term(s) (or Eng- lish Eauivalent)
U
undercoating
unitized construction
Unit Service Manual
V
valve
valve lifter
vapor Vehicle Condition Monitor
Vehicle Emission Control
Information Label
Vehicle Service Manual
Vehicle Speed Sensor
Vehicle Identification Number
Viscositv Index
volatile
Voltage Regulator VCM
VECl Label
VSM
vss
VI N
VI
VR Service
Manual which pertains
to a major
'unit' (e.g. transmission, engine) fitted to a
Jaguar vehicle (see also Vehicle Service
Manual and Electrical Diagnostic Manual)
a device
by which the flow of liquid, gas,
vacuum or loose materials may be started,
stopped or regulated by a movable part
which opens, shuts or partially obstructs one
or more passageways or ports.
A 'Valve' is
also the movable part of such a device
in an OHC engine, the plunger fitted between
valve stem and cam lobe
instrument panel display which warns of
faults
Service Manual which pertains to a specific
family of Jaguar vehicles (see
also Unit
Service Manual and Electrical Diagnostic
Manual).
sensor which provides vehicle speed
information
number assigned to the vehicle
by the
manufacturer, primarily
for licensing and
identification purposes
(1) vaporizing at room temperature (liquid) (2) not permanent (memory)
device which regulates the variable output
voltaae of a aenerator underseal
unitary
construc
-
tion
tappet, bucket
vapour
road speed sen
- sor
Issue 1 August 1994 27 X300 VSM

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SECTION CONTENTS
Sub-section Title
i ................ Preliminary Page ............................................
2.1 .............. Jacking And Lifting ...........................................
2.1.1 ............. Jacking And Lifting. Safety Precautions ..........................
2.1.2 ............. Jacking And Lifting. Jacking Points ..............................
2.1.3 ............. Jacking And Lifting. Wheel Free Lift .............................
2.1.4 ............. Jacking And Lifting. Workshop Jacks ............................
2.1.4.1 ........... Jacking And Lifting. Workshop Jacks. Front - One Wheel ...........
2.1.4.2 ........... Jacking And Lifting. Workshop lacks. Front - Both Wheels ..........
2.1.4.3 ........... Jacking And Lifting. Workshop Jacks. Rear - Both Wheels ...........
2.2 .............. Vehicle Recovery ............................................
2.2.1. ............ Vehicle Recovery, General .....................................
2.2.2 .............
2.2.3 ............. Vehicle Recovery, Gear-shift Interlock - Manual Override .........
2.2.4 ............. Vehicle Recovery, Transporting .................................
2.2.5 ............. Vehicle Recovery, Towing Recovery .............................
2.2.6 ............. Vehicle Recovery, Vehicles With Defective Automatic Transmission ..
2.2.7. ............ Vehicle Recovery, Suspended Towing ...........................
2.2.8. ............ Vehicle Recovery, Rear Suspended Tow ..........................
Vehicle Recovery, Gear-shift Interlock ..........................
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August 1994

gg Jacking, lifting & Vehicle Recovery
2.2.4 Transporting
If thevehicle is being transported on a trailer or flatbed transporter (Fig. I), the handbrake must be applied, the wheels
chocked and if fitted with an automatic transmission, the gear selector lever moved to neutral, 'N' (see Gear-shift
Interlock).
e
JOS-031
Fig. 1
CAUTION: Do not select 'P' because the parking lock mechanism may be damaged by the continuous slight forward
and backward movement of the vehicle on the transporter.
There are four tie-down brackets on the vehicle underbody. Do not attach the tie down hooks of the transporter to the
towing eyes of the vehicle.
2.2.5 Towing Recovery
Adhereto local regulationsforthetowing ofvehicles. In certain countriesthe registration number ofthetowing vehicle
and an 'ON TOW sign or warning triangle must be displayed in a prominent position at the rear of the vehicle which
is being towed.
WARNING: WHEN THE ENGINE
IS NOT RUNNING, THE STEERING AND BRAKES WILL NO LONGER BE
ACCUMULATOR. THEREFORE, BE PREPARED FOR
HEAVY STEERING AND THE NEED FOR GREATLY
INCREASED BRAKE PEDAL PRESSURE.
POWER-ASSISTED.
APPLICATIONS
OF THE BRAKE PEDAL WILL GRADUALLY DEPRESSURIZE THE
*The vehicle may be towed by another for a SHORT DISTANCE ONLY (maximum
0,8km / O.Smile), with the gear lever
in neutral (N) provided that a speed of 48 km / h (30 mile / h) is not exceeded.
2.2.6
The vehicle must be towed with the rear wheels clear of the ground, see suspended towing.
Vehicles with Defective Automatic Transmission:
Issue 1 August 1994 4 X300 VSM

Jacking, lifting & Vehicle Recovery gg
2.2.7 Suspended Towing
CAUTION: Do not tow with sling-type equipment as damage to the bodywork may result. Do not front suspend tow vehides with automatic transmission.
2.2.8 Rear Suspended Tow
Remove the ignition key from the ignition /steering lock.
. Raise the vehicle using a lifting device with a cradle. This should be positioned under each rear wheel as indicated
in Fig. 1.
0
0
0
J08-026
Fig. 1
Issue 1 August 1994 5 X300 VSM

Engine (AJ16) I=
SECTION CONTENTS
Sub-section Tide
I to 111 . . . . . . . . . . . . Preliminary Pages . . . . . . . . . . . . . . . . . . . .
3.1.1 . . . . . . . . . . . . . Engine, General.. . . . . . . . . . . . . . . . . . . . .
3.1.2.. . . . . . . . . . . . Engine/ Transmission Unit, Renew.. . . . .
3.1.3 . . . . . . . . . . . . . Engine Oil, Renew . . . . . . . . . . . . . . . . . . .
3.1.4 . . . . . . . . . . . . Oil Filter Canister, Renew . . . . . . . . . . . . .
3.1.5 . . . . . . . . . . . . Front Engine Mounting Bracket Assembly,
3.1.6 . . . . . . . . . . . . Rear Engine Mounting Assembly, Renew .
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Renew .
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SRO
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. 12.41. 02/20 ......
. 12.60.00 .........
. 12.60.04 .........
. 12.45.01 LH
12.45.03 RH.. . . . .
.
12.45.04 .........
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August 1994

Engine (AJ16) 1-
Fixing lightening Torque
(Nm)
Cooling System
(continued)
Fan drive unit to pulley
Hose clamp, breather to thermostat
Hose clamp, breather to throttle body
Hose clamp, bypass hose
Hose clamp, water pump to pipe
Thermostat cover to housing
Thermostat to cylinder head
Water pipe bracket to inlet manifold 21,5 - 28.5
1,5
- 2,5
1,5
- 2,5
2,5
- 3,5
2,5
- 3,5
2 1,5
- 28,5
21.5 - 28,5
21,5 - 28,5
Water pump assembly
Water pump to timing cover 21,5 - 28,5
21,5 - 28,5
Water pump to water rail 2,5 - 3,5
Water rail to cylinder block
X300 VSM iii Issue 1 August 1994
21,5 - 28,5
@
Water temperature sensor to thermostat housing
Water temperature transmitter to thermostat housing 14,5 - 19,5
14,5 - 19,5
44,5 - 59,5
Engine Mounting
*Engine mounting bracket screw
' Exhaust Manifold
Exhaust manifold to cylinder head
Heatshield to exhaust manifold
Lifting eye setscrew (slave item only) 44,5 - 59,5
21,5 - 28,5
21,5 - 28,5
Miscellaneous Hoses
Hose clamp, heater return hose to throttle body
Hose clamp, hose to cam cover
Hose clamp, water pump
Oil Cooler (4,O liter supercharged)
Hose clamp, oil cooler hose to radiator cradle
Oil cooler clamp screw
5-7
Oil cooler pipe bracket screw
Oil cooler pipes to engine
Oil cooler to body
Tube nut,
all except those shown below
Tube nut, transmission pipes to transmission
1,5 - 2,5
2,5
- 3.5
2,5
- 3,5
7
- 10
1,5
- 2.5
14
- 18
17
-23
17
- 23
16
- 20
Oil Pump, Filter & Oil Pan
Drain plug 64,8 - 79,2
Filter head to cylinder block 21,5 - 28,5
Oil filter cartridge 12 - 15
Oil pan to cylinder block 21,5 - 28.5
Oil pan to timing cover 21,5 - 28,5
Oil pump and oil pump carrier to cylinder block 21,5 - 28.5
Rear cover to body 9,5 - 12,5
Relief valve plug 35,7 - 48,3
Supercharger
Adapter to timing cover
Air duct clamp to intercooler
Air duct hoses
Air duct lower to intercooler 22 - 28
2,5
- 3,5
2,5
- 3,5
2,5
- 3,5

3.1.1 ENGINE, GENERAL
The 3.2 /4,0 liter normallv aspirated
and the 4.0
Engine (AJ16)
liter supercharged engined vehicles are equipped with the AJ 16family of six cylinder in-line engines. The engines have a fully mapped engine management system with digital ignition and
individual on-plug ignition coils.
This section describes the service procedures to be carried out with the engine in situ.
It also covers the renewal of the engine / transmission unit.
For information relating to strip
-down, inspection, fault diagnosis, renovation and rebuild work, refer to the AJ16
Engine Service Manual.
X300 VSM 1 Issue 1 August 1994

Engine (AJ16)
3.1.2 ENGlNE/ TRANSMlSSlON UN/& RENEW
SRO 12.41.02/20
The engine/transmission unit on the AJ 16 normally aspirated and supercharged engined vehicles are fitted ontothree
engine mounting/bracket assemblies. The two front engine mountings for the 3.2/4.0 liter normally aspirated and the
4.0 liter supercharged engined vehicles are identical. They are fitted to the front crossmember on either side of the
engine bay. Rubber to metal
engine/transmission rear mounts used for both engine types, are secured to a support
bracket which traverses the two body underframe longitudinal members. For access to remove the engine carry out the following procedures:
WARNING: WHEN WORKING WlTHlN THE ENGINE COMPARTMENT, KEEP CLEAR OF THE RADIATOR COOLING
FANS AS THEY COULD START WITHOUT WARNING EVEN IF THE ENGINE IS NOT RUNNING.
. Remove the hood, see SRO 76.16.01, section 13
. Remove the air cleaner assembly.
. Depressurize the fuel system, see SRO 19.50.02, section 5.1.
Disconnect the battery.
. In line with the relevant SRO's and sections, remove all appropriate obstructing parts, including their fixing and
. Disconnect all mechanical and isolate all electrical linkages leading to and from the engine.
. De-gas the airconditioning system, see section 14, Charge Recovery (System depressurization).
mounting
arrangements.
CAUTION : Do not vent refrigerant directly to the atmosphere and always use Jaguar approved recovery/recycle/re- charge equipment.
. Drain the engine oil, see 3.1.3 this section.
. Drain the coolant, see SRO 26.10.01, section 4.1.
WARNING: DO NOT REMOVE THE HEADER TANK PRESSURE CAP WHILE THE ENGINE IS HOT. IF THE CAP MUST
BE REMOVED, PROTECT THE HANDS AGAINST ESCAPING STEAM AND SLOWLY TURN THE CAP ANTI- CLOCKWISE UNTILTHE EXCESS PRESSURE CAN ESCAPE. LEAVETHE CAP IN THIS POSITION UNTIL ALL
STEAM AND PRESSURE HAS ESCAPED AND THEN REMOVE THE CAP COMPLETELY.
Before lifting the complete engine/transmission unit with an engine hoist from the engine bay, ensure that two engine
lifting brackets (tool 18G. 1465) are secured equally spaced to the inlet manifold studs. The engine lifting brackets
should be positioned towards the front and the rear of the assembly. Ensure the front of the vehicle is jacked
up secure- ly on stands when removing the assembly.
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X300 VSM Issue 1 August 1994 2

Engine (AJ16)
3.1.5 FRONT ENGINEMOUNTING BRACKETASSEMBLY, RENEW
SRO 12.45.01 LH
SRO 12.45.03 RH
Each of the two engine mounting bracket assemblies com- prises a mounting rubber (1 Fig. 1) with an insulator (2 Fig.
1) clamped between two brackets ( 3&4 Fig. I).
The front of the engine complete with attached mounting
bracket assemblies is seated on support brackets welded to
the front crossmember and is secured to the brackets by
a single fixing arrangement comprising nuts, bolts and
washers.
. Jack up the vehicle and secure the engine hoist (Service
Tool MS53 C) to lifting eyes of the front engine lifting
brackets.
. Remove the front engine mounting bracket assembly to
front crossmember fixing screws. These can be accessed
via
two round openings positioned underneath the cross- member.
= Remove any obstructing parts preventing the front end of
the engine from being lifted from its seating.
Lift the front end of the engine / transmission unit slightly
and detach the front mounting bracket assemblies from
the lower engine housing.
3.1.6
SRO 12.45.04 REAR
ENGINE MOUNTING ASSEMBLY RENEW
The rear engine mounting assembly comprises a rubber to
metal engine/transmission rear mount (1 Fig. 2) secured to a support bracket (2 Fig. 2) by a single fixing arrangement.
. With the aid of the engine hoist (Service Tool MS53 C) se- cured to the lifting eyes of the rear engine lifting brackets,
and a jack positioned under the rear mounting bracket,
take the weight of the engine.
. Undo and remove the fixing arrangement securing the
rear engine mounting bracket assembly.
. Lower the jack and remove assembly.
. Dismantle the assembly, clean all components and exam- ine for any signs of wear or damage.
Renew components as necessary.
J12-8LL
Fig. 1
J 12- 8 LS
Fig. 2
8
Issue 1 August 1994 4 X300 VSM