ECU JAGUAR XJ6 1994 2.G Owner's Guide

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

bZF Automatic Transmission (AJ16) -
0
8.1.2 TRANSMISSION FLUID, RENEW
SRO 44.24.02
= Raise the hood and fit a fender cover.
. Raise the vehicle on a ramp.
. Place a drain tin in position beneath the transmission drain
Release and remove the transmission drain plug; allow
. Fit the drain plug with a new washer and torque tighten.
Reposition the drain tin beneath the dipstick tube union.
Remove the screw securing the dipstick tube bracket.
. Release the dipstick tube union nut and disconnect the
tube from the fluid pan.
. Drain the transmission fluid.
Clean the tube unions, reconnect the dipstick tube to the
. Lower the vehicle on the ramp.
. Remove the transmission dipstick.
. Renew the transmission fluid filter, see Subsection 8.1.6.
Fill the transmission with the correct fluid, see the ZF Auto-
Note: It will not be possible to get all the initial fill quantity
of fluid into the transmission.
. Refit the dipstick.
. Startthe engine, apply all brakes and run the transmission
With the engine still running, remove the dipstick.
Clean the dipstick and refit.
Remove the dipstick and check the transmission fluid
. Add fluid until the correct level is achieved.
. Stop the engine and refit the dipstick.
. Checkfluidleveltothe'HOT'marksaftera20mileroad run
(3,2L AND 4,OL)
Plug.
the fluid to drain.
fluid pan and torque tighten the union nut.
0
matic Transmissions Service Manual, General Data.
through
all gear positions and select 'Park'.
level. Remove the fender cover and lower the hood.
to ensure accurate results.
m
e
0
X300 VSM Issue 1 August 1994 6

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)
8.1.4 TRANSMISSION ROTARY SWITCH, ADjUST
SRO 44.15.37
. Raise the vehicle on a ramp.
. Position the shift lever to 'N' ensuring that the stalk enters
the gate
'N' notch centrally.
9 Release and remove the transmission unit rotary switch
protection cover
(1 Fig.1) to fluid pan bolts.
. Remove the rotary switch protection cover from the fluid
pan bosses.
. Slacken the rotary switch to mounting bracket securing
nuts.
Displace the rubber blanking plug from the rotary switch
center boss
(2 Fig.1).
. Fit Service Tool JD161 (Fig.2) to the rotary switch to align
the switch rotor with the switch body.
CAUTION: Service Tool JD161 is a precision tool and
. Evenly torque tighten the rotary switch to mounting
. Disengage and remove ServiceTool JD161 from the rotary
. Fully seat the rubber blanking plug into the rotary switch
. Fit the rotary switch protection cover and align with the
. Fit and torque tighten the rotary switch protection cover to
Lower the vehicle on the ramp.
. Check for correct operation of start inhibit and gear selec-
(4,011
should be treated as such.
bracket securing nuts.
switch.
center boss.
fluid pan bosses.
fluid pan securing bolts.
tion.
12 JL 4 - 689
Fig. 1
Fin. 2
X300 VSM Issue 1 August 1994 8

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 (AJl6)
8.1.6 TRANSMISSION FLUID FILTER, RENEW
SRO 44.24.07
9 Raise the hood and fit a fender cover.
. Raise the vehicle on a ramp.
. Drain the transmission lubrication system, see Sub-sec-
. Removethefluid pan,seeSub-section8.1.7 (4,OL)orSub-
. Release and remove the fluid filter securing screws; dis-
. Remove and discard the filter '0' ring.
. Clean the new filter and mating faces.
. Fit the '0' ring to the new filter; fit and seat the filter assem-
. Fit and torque tighten the filter securing screws.
. Refitthefluidpan,seeSub-section8.1.7 (4,OL)orSub-sec-
. Lower the vehicle on the ramp.
. Refill the transmission unit with fluid, see Subsection
8.1.2.
Remove the fender cover and lower the hood.
(3,2L AND 4,011
tion 8.1.2.
section
8.1.8 (3,2L).
place and remove the fluid filter.
bly to the valve body.
tion 8.1.8
(3,2L).
8.1.7 FLUID PAN, RENEW (4,OL)
SRO 44.24.04
. Raise the hood and fit a fender cover.
. Raise the vehicle on a ramp.
. Drain the transmission lubrication system, see Sub-sec-
tion 8.1.2.
Release and remove the rotary switch protection cover to
fluid pan securing screws; remove the rotary switch
protect ion cover.
Release and remove the fluid pan securing bolts and
clamps
(1 Fig. 1). Displace and remove the fluid pan
(2 Fig. 1).
. Drain the fluid pan. Remove and discard the fluid pan
gasket if the gasket is damaged.
Remove the magnets from the fluid pan and place the fluid
pan aside.
. Clean the gasket faces and magnets.
Fit a serviceable gasket to the new fluid pan.
. Fit the magnets in position in the fluid pan.
Fit and align the fluid pan to the transmission unit; fit and
torque tighten the fluid pan clamps and securing bolts.
. Fit the rotary switch protection cover to the fluid pan
bosses and fit and torque tighten the rotary switch protec-
tion cover securing bolts.
. 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 11 Issue 1 August 1994

Automatic Transmission (AJ16)
8.1.8 FLUID PAN, RENEW (3,2L)
SRO 44.24.04
. Raise the vehicle on a ramp.
. Drain the transmission lubrication system, see Sub-sec-
tion 8.1.2.
Release and remove the fluid pan securing bolts and
clamps
(1 Fig. 1).
. Displace and remove the fluid pan (2 Fig. 1).
= Drain the fluid pan. Remove and discard the fluid pan
. Remove the magnetsfrom the fluid pan and place the fluid
. Clean the gasket faces and magnets.
. Fit a serviceable gasket to the new fluid pan.
. Fit the magnets in position in the fluid pan.
9 Fit and align the fluid pan to the transmission unit.
Fit the fluid pan clamps; fit and torque tighten the fluid pan
. Lower the vehicle on the ramp,
. Raise the hood and fit a fender cover.
. Refill the transmission unit with fluid, see Sub-section
. Remove the fender cover and lower the hood.
gasket
if the
gasket is damaged.
pan aside.
securing bolts.
8.1.2.
8.1.9
SRO 44.24.05
. Raise the hood and fit a fender cover.
. Raise the vehicle on a ramp.
. Drain the transmission lubrication system, see Sub-sec-
FLUID PAN GASKET, RENEW (3,2L)
tion 8.1.2.
. Release and remove the fluid pan securing bolts clamps
. Displace and remove the fluid pan (2 Fig. 1).
(1 Fig. 1).
Remove and discard the fluid pan gasket.
pan aside.
. Removethe magnetsfrom the fluid pan and place thefluid
. Clean the fluid pan, gasket faces and the magnets.
. Fit a new fluid pan gasket.
. Fit the magnets in position in the fluid pan.
9 Fit and align the fluid pan to the transmission unit, fit the
fluid pan clamps,fit and torquetighten the fluid pan secur-
ing bolts.
. Lower the vehicle on the ramp.
. Refill the transmission unit with fluid, see Sub-section
. Remove the fender cover and lower the hood.
8.1.2.
/>U492
Fig. 1
Fig. 1
j
X300 VSM Issue 1 August 1994 12

Automatic Transmission (AJ16)
8.1.10 TRANSMISSION SPEED SENSOR, RENEW (4,OL)
SRO 44.15.34
9 Raise the hood and fit a fender cover.
. Raise the vehicle on a ramp.
. Drain the transmission lubrication system, see Sub-sec-
Remove the fluid pan, see Sub-section 8.1.7.
. Displace the transmission speed sensor harness from the
valve body rear securing clip.
Release and remove the speed sensor and connector re-
taining clip from the valve body.
. Displace the speed sensor and connector from the trans-
mission main casing.
9 Disconnect and remove the speed sensor from the har-
ness connector.
. Clean the speed sensor, retaining clip and mating surface.
Connect the new speed sensor to the harness connector.
Fully seat the speed sensor into the transmission unit
tion
8.1.2.
main
casing.
. Fit the speed sensor and connector retaining clip to the
valve body, engaging the tangs onto the connector.
clip securing screws.
the valve body rear; secure the clip.
. Fit and tighten the speed sensor and connector retaining
. Reposition and fully seat the speed sensor harness into
. Refit the fluid pan, see Sub-section 8.1.7.
. Lower the vehicle on the ramp.
. Refill the transmission unit with fluid, see Sub-section
8.1.2.
Remove the fender cover and lower the hood.
X300 VSM 13 Issue 1 August 1994

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