oil JAGUAR XJ6 1994 2.G Owner's Manual

Fuel, Emission Control & Engine Management (AJ16)
5.1.6 THROTTLE ASSEMBLY (SUPERCHARGED), RENEW
SRO 18.30.17 THROTTLE POTENTIOMETER
SRO 19.70.07 THROTTLE HOUSING GASKET
SRO 19.70.04 THROTTLE HOUSING
J 12-62 2
Fig. 1
Remove
. Disconnect battery.
. Remove the intercooler intake elbow.
. Raise vehicle on a four-post ramp.
. Remove the rear air duct to throttle body connecting hose.
Undo and remove bolts securing EGR supply pipe to manifold.
Remove EGR supply pipe gasket.
Reposition EGR sensor harness multi-plug from mounting bracket.
. Release throttle outer cable abutment from abutment bracket.
. Disconnect throttle inner cable from throttle linkage.
. Disconnect and remove return spring.
. Disconnect speed control actuator vacuum hose.
. Release cooling system pressure by slowly undoing the tank cap.
Tighten cap after pressure release.
. Remove abutment bracket assembly.
Disconnect idle speed actuator harness multi
-plug.
. Disconnect throttle potentiometer harness multi-plug.
. Fit pipe clamps to throttle housing cooling hoses and disconnect hoses from throttle housing.
Remove
the oil filter cartridge and gasket.
Remove speed control speed control bracket to throttle lever clevis pin and pin
circlip.
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Issue 1 August 1994 10 X300 VSM

Manual Transmission & Clutch (AJ16)
SECTlON CONTENTS
Sub-section Title SRO Page
i to iv ............ Preliminary Pages ................................................................ i to iii
7.1.1 ............. Manual Transmission. Description ...................................................... 1
7.1.2 ............. Manual Transmission Assembly, Renew ............................ 37.20.0 1 ............. 2
7.1.3
............. Front OilSeal. Renew .......................................... 37.23.06 ............. 5
7.1.4
............. Rear OilSeal. Renew ........................................... 37.23.01 ............. 6
7.1.5 ............. Gearshift Lever, Renew ......................................... 37.16.04 ............. 6
7.1.6 ............. Gearshift Lever Draught Excluder, Renew ......................... 37.16.05 ............. 6
7.1.7. ............ Gearshift Lever Knob. Renew .................................... 37.16.11 ............. 7
7.1.8. ............ Gearshifi Lever/ Remote Control Assembly, Renew .................. 37.16.20 ............. 7
7.1.9 ............. Gear Selector Shaft - Rear, Overhaul .............................. 37.16.4 1 ............. 9
7.1.10.
........... Reverse Lamp Switch. Renew .................................... 37.27.01 ............. 9
7.1.11 ............ Layshaft Front Seal. Renew ...................................... 37.23.07 ............. 9
7.1.12.
........... Clutch. Description .................................................................. 10
7.1.14.
........... Clutch Assembly, Renew ........................................ 33.10.01 ............ 14
7.1.15. ........... Clutch Master Cylinder, Renew .................................. 33.20.01 ............ 76
7.1.16. ........... Clutch Slave Cylinder, Renew ................................... 33.35.01 ............ 17
7.1.17.
........... Clutch Slave Cylinder, Overhaul ................................. 33.35.07 ............ 17
7.1.18. ........... Clutch Hydraulic System. Bleed .................................. 33.15.01 ............ 18
7 . 1 . 7 3 ............ Clutch. Fault Diagnosis .............................................................. 11
X300 VSM i Issue 1 August 1994

Manual Transmission & clutch (AJ16)
I Molykote FB 180 grease
Brake (clutch) fluid
- minimum
DOT 4
Dexron IID Transmission oil
Loctite
573
Tivoli Kay Adhesives No. 5696
Withdrawal arm pivots / Gearshift lever ball
Clutch hydraulic system
Front cover securing bolts
Exhaust sealer also used
in
ZF automatic
transmissions
Application
Material removal to clean up clutch face
IU SERVICE DATA
Specification
Up to lmm maximum
X300 VSM iii Issue 1 August 1994

Manual Transmission & Clutch (AJ16)
. Remove front clamp from unit lift.
. Raise / lower unit with jack, no stands.
. Traverse lift under ramp and take weight of transmission.
. Adjust jacking platform angles to suit transmission.
. Adjust side and rear clamps to suit transmission and tighten clamp wing nuts.
. Fit the safety chain assembly to left hand arm of lift, and secure with peg.
Pass safety chain over transmission and engage in front arm of lift. Tighten the safety chain adjuster.
. Remove remaining transmission to adaptor plate securing bolts and carefully lower transmission from engine.
. Remove transmission from ramp area.
. Remove clutch release bearing assembly from release lever.
. Remove clutch release lever retaining clip and remove lever.
. Remove release lever pivot pin.
Remove transmission switch.
. Remove rear mounting spring retainer securing nut.
. Reposition selector shaft pin cover.
0
Remove rear mounting spring retainer and remove rear mounting assembly.
Remove selector shaft yoke to selector shaft retaining pin and remove the yoke.
. Remove slave cylinder securing studs.
. Remove the transmission from the unit lift.
. Remove transmission drain plug and allow to drain, refit
the drain plug.
Fit new transmission to unit lift.
Fill transmission with oil and refit the level plug.
. Clean components and mating faces.
. Fit the slave cylinder mounting studs.
. Lubricate the selector output shaft.
. Fit selector shaft yoke (3 Fig. 1) to selector shaft and secure
with retaining pin (2 Fig. 1).
Reposition the retaining cover (1 Fig. 1) over the selector
shaft yoke retaining pin. -
. Fit the transmission rear mounting assembly and secure
with bolt.
. Fit reverse lamp switch.
. Lubricate the clutch release lever.
. Fit and align lever to transmission and engage onto pivot
pin.
Fit and fully seat lever to pivot retaining clip.
= Lubricate release bearing housing.
9 Fit and fully seat bearing assembly to lever.
. Select third gear.
. Move transmission to vehicle and raise into position.
Fia. 1
. Insert transmission input shaft into clutch and fully seat transmission against adaptor plate, ensuring that trans- mission is in line as it is fitted and seated to the plate.
X300 VSM 3 Issue 1 August 1994

Manual Transmission & Clutch (AJ16)
7.1.4 REAR OIL SEAL, RENEW
SRO 37.23.01
Remove the drive (propeller) shaft, see Section 9, SRO
47.15.01.
. Using a suitable oil seal remover, displace and removethe
rear oil seal (1 Fig. 1).
. Clean the seal mounting face.
. Lubricate the seal lip.
. Fit and seat the seal to the transmission.
. Refit the drive shaft, see 47.15.01.
7.1.5 GEARSHIFT LEVER, RENEW
SRO 37.16.04
. Remove and strip down the gear selector remote control
assembly as detailed in Sub-section 7.1.8.
. Rebuild and refit the gear selector remote control assem- bly (Sub-section 7.1.81, but fit a new replacement gear- shift lever and discard the original lever.
7.1.6 GEARSHIFTLEVER DRAUGHT EXCLUDER,
SRO 37.16.05 RENEW
. Remove
the gearshift lever knob (1 Fig. 2), see Sub-Sec-
. Open the centre console storage compartment.
tion 7.1.7.
= Remove the centre console securing screws, disconnect
Remove the foam sealing ring.
. Remove the draught excluder securing screws (2 Fig. 2)
and ring (3 Fig. 2) and remove the draught excluder (4 Fig.
2).
. Fit the new draught excluder over the gearshift lever and
secure with the ring (3 Fig. 2) and screws (2-Fig. 2).
. Refit the foam sealing ring.
Refit the centre console and reconnect the block
Close the centre console storage compartment.
. Fit the gearshift lever knob/ lock nut and align the knob to
Tighten the lock nut and reposition the gearshift lever
the
block connectors and remove the console.
connectors and secure with the screws.
its final position.
gaiter.
I --0-. I
J37.02~
Fin. 1
Fig. 2
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Issue 1 August 1994 6 X300 VSM

Manual Transmission & Clutch (AJ16)
GEAR SELECTOR SHAFT- REAR, OVERHAUL
iRY 37.16.41
. Remove the gear selector remote control assembly, see
Displace the selector shaft cover (1 Fig. 1).
. Remove the selector shaft to selector shaft yoke retaining
. Clean all components thoroughly and check for wear and
. Replace worn or damaged components as necessary.
Lubricate and fit the selector shaft yoke to the selector
. Reposition the selector shaft cover.
. Refit the gear selector remote control assembly, see
37.16.20.
pin
(2 Fig. I), and remove the yoke (3 Fig. 1).
damage.
shaft and secure with the retaining pin.
37.16.20.
7.1.10 REVERSE LAMP SWITCH, RENEW
SRO 37.27.01
. Raise the vehicle on a ramp.
. Note and disconnect reverse lamp switch multi-way
= Slacken off and remove the switch.
Clean the mating face.
Fit a new switch.
. Connect the multi-way connector.
. Lower the ramp.
connector.
7.1.11 LAYSHAFT FRONT SEAL, RENEW
SRO 37.23.07
a Remove the transmission assembly, see Sub-Section
. Removethefront oilseal assembly,seeSub-Section7.1.3.
. Using suitable oil seal remover tool, remove and discard
. Clean the transmission face and the front oil seal assem-
. Fit and fully seat the new seal to the casing.
= Refit the transmission front seal assembly.
. Refit the transmission.
7.1.2
layshaft plug
seal.
bly. Fig.
1
X300 VSM Issue 1 August 1994 9

Manual Transmission & Clutch (AJl6)
0
7.1.13 CLUTCH FAULT DIAGNOSIS
symptom
lifficult gear ?ngagement
3attling clutch
squeaking clutch
dibrating clutch or
:lutch judder (often pre- :eded by clutch grab)
stiff clutch operation
Possible Cause
Hydraulic system
defects
Operating mechan
- ism faults
Clutch unit faults
Primary pinion bear
-
ing fault
Clutch unit faults
Defects other than in
clutch unit
Operating linkage
fault
Check
Check fluid level in reservoir
Check for air in the system
Check for defective pedal
Check for damaged pressure plate
Check splines on clutch driven
plate and primary pinion shaft for
wear
Check clutch driven plate for loose
or broken springs and for warping
Check for wear in the clutch with
- drawal mechanism
Check for worn primary pinion
bearing
Check for seizing on primary shaft
or in flywheel
Check the clutch driven plate for
distortion and damage and for
loose or broken torque damper
springs
Check for oil and other foreign
matter on the clutch friction linings
Check for incorrectly fitted clutch
pressure
plate
Check that contact witness on fric-
tion linings is evenlv distributed -
Check for loose flvwheel fixings
and flywheel
run-out
Check for loose engine mountings
Check for worn drive (propeller)
shaft universal joints
Check for bent primary pinion
shaft
-
Check for damaged moving parts
in operating linkage
- -
Check for seized linkage, recheck
operation after remedv
Remedy
Replenish as necessary and
bleed system if necessary
Bleed the system
Renew return spring if
necessary
Renew pressure plate
Renew as necessary clutch
plate or primary pinion
Renew driven plate
Renew as necessary
Renew as necessary
Lubricate or renew as
necessary
Renew driven plate
Renew driven plate and clean
related parts
Dismantle from clutch and
refit where applicable
Renew driven plate as
necessary
Tighten to correct torque
loading
Lubricate linkage as
necess-
X300 VSM 11 Issue 1 August 1994

Manual Transmission & Clutch (AJ16)
'ossible Cause
:Iutch Fault
'rimary pinion bear-
ng
ncorrect fitting nethod
Clutch Fault Diagnosis
Check
Check for worn clutch driven plate
hub splines
Check for wear in bearing
Damage may be caused by
acci- dental loading during fitting
Symptom
:I utch knocks
herloading vehicle
hiving with
left foot
,esting on clutch )edal
:ractured clutch )late
Check mating components for
damage
Refer to owners handbook for per
-
missible load details
Check as described under 'slipping
clutch'
Excessive
lining wear
lperating mechan-
sm faulty
:Iutch unit faults
3rabbing clutch
harsh engagement
'rom standing start,
Iften followed by clutch
udder) Check
operating mechanism for
wear and binding which usually
indicates
a binding withdrawal
race thrust bearing
Check pedal for sticking parts in
-
cluding return spring
Check for oil on friction driven
plate
Checkclutch plate and flywheel for
wear. Check flywheel
runout. Check also for glazing on driven
plate linings
Check for driven plate hub splines
sticking on pinion shaft.
Check pinion shaft for wear.
Check for broken or weak pressure
springs.
Check torque damper springs in
clutch driven
plate
hgine mounting Check
for damaged or deteriorated
engine mountings.
Check fixings for tightness
Remedy
Renew driven plate
Renew as necessary
Always support trans
- mission weight during fitting
Renew driven plate
Fit replacement clutch as-
sembly
Fit replacement clutch as- sembly
Free
off bearing. Renew as
necessary
Free
off pedal and check for
damaged and distorted
parts.
Renew
if necessary
Clean
off cover.
Renew faces.
Rectify oil
leak
Reclaim or renew as appli-
cable
Free driven plate, and check
for wear and distortion
Renew
if necessary
Renew
if necessary
Issue 1 August 1994 12 X300 VSM

Clutch Fault Diagnosis
Symptom
Slipping clutch
[indicated by vehicle
speed not responding to
engine speed increase)
]ragging or spinning :lutch
Manual Transmission & Clutch (AJ16)
Possible Cause
Poor driving tech- nique
Operating mechan
-
ism faulty
Clutch unit faults
Operating mechan
-
ism faulty
Zlutch unit faults
2lutch unit faults
Check
Ensure that none of the remedy
conditions prevail
Checkfor binding withdrawal lever
Check for binding of clutch pedal
movement components
Check for oil on friction faces
Check for binding withdrawal lever
Check for binding of clutch pedal
movement components
Check for oil on friction faces
Check for broken or weak pressure
springs
.-
Check clutch plates and flywheel
for wear and distortion
Check clutch driven plate for frac
- tures and distortion.
Damage may be caused by acci
-
dental loading during assembly of
transmission to engine.
Always support transmission
weight during refitting
Check for primary pinion bearing
seized
Check clutch driven hub for bind
- ing on primary pinion splines.
Check for too thick friction linings.
Ensure linings
are good
Check for foreign matter in clutch
unit
Remedv
Do not increase engine speed
with clutch paGially' en-
gaged. Do not drive with left foot
resting on clutch pedal.
Free lever and check for wear
and distortion
Free
off seized or binding
components
Clean
off metal faces.
Renew driven plate.
Rectify oil leak.
Free lever and check for wear
and distortion
Free
off seized or binding
components
Clean
off metal faces.
Renew driven plate.
Rectify oil leaks.
Renew cover as necessary
Reclaim or renewclutch
plate
as applicable
Renew driven plate and
check mating components
for damage
Rectify or renew as necess
-
ary
Renew as necessary
Clean and renew compo
-
nents as necessary
X300 VSM 13 Issue 1 August 1994

1. SERVICE TOOLS & fQUlPMENT
Illustration
::(())(((((
Jaguar Number
JD 103
JD 161
Description Notes
Throttle valve alignment tool
Rotary switch setting tool
11. TORQUE TIGHTENING SPECIFICATIONS
Fixing Tightening Torque
(Nm)
Dipstick tube union nut 90
Drain plug 15
Fluid filter screws 8
Fluid pan securing bolts 8
Rotary switch to mounting bracket nuts
Transmission oil cooler pipes
20
10- 12
15- 18 Switch guard to sump pan bolts
111. SERVICE MA TERlA L S
Description USeS Notes
To be issued