ECU JAGUAR XJ6 1994 2.G Repair Manual

Pomrtrain Automatic Transmission (V12 & AJ16 Supercharged)
8.2.14 FLUID PAN, RENEW (4,OL SC)
SRO 44.24.04
. Open the hood and fit a suitable fender cover.
. Raise the vehicle on a ramp.
. Drain the transmission lubrication system, see Sukec-
. Slacken the downpipe catalyst to intermediate catalyst
Slacken the intermediate catalyst to intermediate si-
9 Disconnect the intermediate catalyst pipe from the down-
. Clean the downpipe and intermediate pipe joint.
. Release and remove the fluid pan securing bolts.
Remove the fluid pan (1 Fig. 1)) and gasket (2 Fig. 1).
. Drain the residual fluid from the fluid pan.
Remove the fluid pan gasket.
. Clean the fluid pan gasket, which can be re-used if in good
Place the fluid pan gasket aside.
= Remove the magnet (3 Fig. 1) from the fluid pan.
= Clean the magnet and place on a clean surface.
. Clean the transmission fluid pan joint face.
. Clean the fluid pan.
Place the fluid pan aside.
. Attach the magnet to the recess in a new fluid pan.
. Fit and align a serviceable gasket to the fluid pan.
. Fit the fluid pan and gasket to the transmission unit.
. Fit and tighten the fluid pan securing bolts.
. Apply sealant to the intermediate pipe joint. See Service
Materials in the preliminary pages, this Section.
Reconnect the intermediate pipe to the downpipe.
Align the intermediate catalyst assembly.
. Tighten the intermediate pipe to the downpipe securing
. Align the intermediate silencers to the intermediate cata-
. Tighten the intermediate silencer securing clamps.
. Lower the vehicle on the ramp.
Refill the transmission unit with fluid, see Subsection
8.2.13.
. Remove the fender cover and close the hood.
tion 8.2.13.
clamp securing bolts.
lencers clamp securing bolts.
pipe.
condition.
clamp. lyst assembly.
.. rli
i
1
JLL-713
Fig. 1
X300 VSM 15 Issue 1 August 1994

Automatic Transmission (V12 & AJ16 Supercharged) Powertrain
8.2.15 FlUlD PAN, RENEW (6,Ol)
SRO 44.24.04
Open the hood and fit a suitable fender cover.
. Raise the vehicle on a ramp.
. Slacken the underfloor catalyst to downpipe clamps se-
. Displace and reposition the olive clamps on the pipes.
. Slacken the underfloor catalyst to intermediate silencer
Displace the underfloor catalyst assembly rearwards to
. Displace and remove the olives from the downpipes.
. Using a wire brush, clean the olives and downpipe joints.
m Place a suitable piece of wood between the underfloor
Drain the transmission lubrication system, see Sub-sec-
Release and remove the fluid pan securing bolts.
Drain the residual fluid from the fluid pan.
. Remove the fluid pan (1 Fig. 1) and gasket (2 Fig. 1).
. Clean the fluid pan gasket, which can be re-used if in good
. Place the fluid pan gasket aside.
. Remove the magnet (3 Fig. 1) from the fluid pan.
. Clean the magnet and place on a clean surface.
. Clean the transmission fluid pan joint face.
. Clean the fluid pan.
. Place the fluid pan aside.
. Attach the magnet to the recess in a new fluid pan.
. Fit and align a serviceable gasket to the fluid pan.
. Fit the fluid pan and gasket to the transmission unit.
. Fit and tighten the fluid pan securing bolts.
. Remove the block of wood from between the underfloor
catalyst and the floor.
. Apply sealant to the downpipe joints and olives. See Ser- vice Materials in the preliminary pages, this Section.
Fit and seat the olives to the downpipes.
Reconnect the underfloor catalyst to the downpipes.
. Reposition the olive clamps.
. Tighten the underfloor catalyst to downpipe clamps secur-
. Align the intermediate silencers to the underfloor catalyst
. Tighten the clamp securing bolts.
Lower the vehicle on the ramp.
. Refill the transmission unit with fluid, see Sub-section
curing
bolts.
clamps securing bolts.
disconnect from the downpipes.
catalyst and the body for access.
tion 8.2.13.
condition.
ing bolts.
assembly.
8.2.13. Remove the fender cover and close the hood.
JLL-719
Fin. 1 ~
Issue 1 August 1994 X300 VSM 16

Powertrain Automatic Transmission (V12 & AJ16 Supercharged)
8.2.16 FLUID PAN GASKET, RENEW (4,OL SC)
SRO 44.24.05
Open the hood and fit a suitable fender cover.
. Raise the vehicle on a ramp.
Drain the transmission lubrication system, see Sub-sec-
. Slacken the downpipe catalyst to intermediate catalyst
. Slacken the intermediate catalyst to intermediate si-
. Disconnect the intermediate catalyst pipe from the down-
Clean the downpipe and intermediate pipe joint.
. Release and remove the fluid pan securing bolts.
. Remove the fluid pan (1 Fig. 1) and gasket (2 Fig. 1).
. Drain the residual fluid from the fluid pan.
. Remove and discard the fluid pan gasket.
Remove the magnet (3 Fig. 1) from the fluid pan; clean the
. Place the magnet on a clean surface.
. Clean the transmission fluid pan joint face.
. Clean the fluid pan.
. Place the fluid pan aside.
. Attach the magnet to the recess in a new fluid pan.
. Fit and align a new gasket to the fluid pan.
. Fit the fluid pan and gasket to the transmission unit.
. Fit and tighten the fluid pan securing bolts.
. Apply sealant to the intermediate pipe joint. See Service
Materials in the preliminary pages, this Section.
. Reconnect the intermediate pipe to the downpipe.
. Align the intermediate catalyst assembly.
. Tighten the intermediate pipe to downpipe securing
. Align the intermediate silencers to the intermediate cata-
. lighten the intermediate silencer securing clamps.
. Lower the vehicle on the ramp.
tion 8.2.13.
clamp securing bolts.
lencers clamp securing bolts.
pipe.
magnet.
clamp. lyst assembly.
. Refill the transmission unit with fluid, see Subsection
8.2.13.
. Remove the fender cover and close the hood.
1
JLL-713
Fia. 1
X300 VSM 17 Issue 1 August 1994

Automatic Transmission (V12 & AJ16 Supercharged) Powertrain
8.2.17 FLUID PAN GASKET RENEW (6,OL)
SRO 44.24.05
Open the hood and fit a suitable fender cover.
. Raise the vehicle on a ramp.
. Slacken the underfloor catalyst to downpipe clamp secur-
. Displace and reposition the olive clamps on the pipes.
. Slacken the underfloor catalyst to intermediate silencer
. Displace the underfloor catalyst assembly rearwards to
ing
bolts.
clamps securing bolts.
disconnect from the downpipes.
Displace and remove the olives from the downpipes.
Using a wire brush, clean the olives and downpipe joints.
. Place a suitable piece of wood between the underfloor
Drain the transmission lubrication system, see Sub-sec-
Release and remove the fluid pan securing bolts.
. Remove the fluid pan (1 Fig. 1) and gasket (2 Fig. 1).
Drain the residual fluid from the fluid pan.
Remove and discard the fluid pan gasket.
Remove the magnet (3 Fig. 1) from the fluid pan; clean the
magnet.
Place the magnet on a clean surface.
Clean the fluid pan joint face.
Clean the fluid pan.
. Place the fluid pan aside.
. Attach the magnet to the recess in the fluid pan.
. Fit and align a new gasket to the fluid pan.
. Fit the fluid pan and gasket to the transmission unit.
. Fit and tighten the fluid pan securing bolts.
. Remove the block of wood from between the under floor
catalyst and the floor.
9 Apply sealant to the downpipe joints and olives. See Ser- vice Materials in the preliminary pages, this Section.
= Fit and seat the olives to the downpipes.
. Reconnect the underfloor catalyst to the downpipes.
. Reposition the olive clamps.
. lighten the underfloor catalystto downpipe clamps secur-
Align the intermediate silencers to the underfloor catalyst
. Tighten the clamp securing bolts.
. Lower the vehicle on the ramp.
. Refill the transmission unit with fluid, see Sub-section 8.2.13.
Remove the fender cover and close the hood.
catalyst
and the body for access.
tion
8.2.13.
ing bolts.
assembly.
2
1
JLL.7K
Fig. 1
0
0
0
0
Issue 1 August 1994 18 X300 VSM

Automatic Transmission (V12 & AJ16 Supercharged) Powertrain
8.2.19 TRANSMISSION INTERNAL HARNESS MULTI-
PIN SOCKET '0' RING, RENEW
(4,OL SC AND 6,011
SRO 44.24.20
9 Open the hood and fit a suitable fender cover.
. Raise the vehicle on a ramp.
. Drain the transmission lubrication system, see Sub-sec-
. Remove the fluid pan, see Sub-section 8.2.14 (4,OL SC) or
. Disconnect the external harness multi-pin plug from the
Note: The plug is secured to the socket by its captive lock- ing ring.
= Release and remove the internal harness multi-pin socket
. Displace the internal harness multi-pin socket from the
Remove and discard the '0 ring seal (Fig.1) from the
. Fit and seat a new '0' ring seal to the multi-pin socket.
. Reposition and seat the internal harness multi-pin socket
to the transmission casing.
. Fit and tighten the internal harness multi-pin socket to the
transmission casing securing nut.
Connect the external harness multi-pin plug to the inter- nal harness multi-pin socket; the plug is secured by its
captive locking ring.
Refit the fluid pan, see Sub-section 8.2.14 (4,OL SC) or Sub-section 8.2.15 (6,OL).
. Lower the vehicle on the ramp.
. Refill the transmission unit with fluid, see Sub-section
8.2.13.
. Remove the fender cover and close the hood.
tion
8.2.13.
Sub
-section 8.2.15 (6,OL).
internal harness multi-pin socket.
to transmission casing securing nut.
transmission casing.
multi
-pin socket.
0
0
0
0
X300 VSM Issue 1 August 1994 20

Pamrtrain Automatic Transmission (V12 & AJl6 Supercharged)
8.2.20
SRO 44.24.21 INTERNAL
L UBRICATION PIPE, RENEW
(4,OL SC AND 6,011
. Open
the hood and fit a suitable fender cover.
. Raise the vehicle on a ramp.
Drain the transmission lubrication system, see
Sub-sec- tion 8.2.13.
. Remove the fluid pan, see Subsection 8.2.14 (4,OL SC) or Sub-section 8.2.15 (6,OL).
Release and remove the internal lubrication pipe retainer to valve body securing bolt.
. Remove the lubrication pipe retainer.
. Release and remove the lubrication pipe clamp to valve
. Remove the lubrication pipe clamp.
. Displace and remove the lubrication pipe from the trans-
. Drain any residualfluidfromthe lubrication pipe and place
. Clean the relevant parts.
0 Fitandfullyseata newlubricationpipetothetransmission
body securing nut.
mission unit.
the pipe aside.
unit.
. Fit the lubrication pipe clamp.
. Fit and tighten the lubrication pipeclamptovalve bodyse-
. Fit the lubrication pipe retainer.
. Refit the fluid pan, see Sub-section 8.2.14 (4,OL SC) or
. Lower the vehicle on the ramp.
Refill the transmission unit with fluid, see Sub-section
8.2.13.
9 Remove the fender cover and close the hood.
curing
bolt.
Subsection
8.2.15 (6,OL).
X300 VSM Issue 1 August 1994

Pomrtrain Automatic Transmission (V12 & AJ16 Supercharged)
8.2.22 MANUAL DETENT SPRING, RENEW
SRO 44.26.10
9 Open the hood and fit a suitable fender cover.
. Raise the vehicle on a ramp.
. Drain the transmission lubrication system, see Sub-sec-
. Remove the fluid pan, see Subsection 8.2.14 (4,OL SC) or
. Remove the fluid filter, see Subsection 8.2.18.
. Select 'P (Park) and ensure that the pawl is engaged.
Release and remove the manual valve detent spring and
Remove the detent spring assembly and place aside.
. Clean the relevant parts.
Fit a new detent spring assembly to the valve body.
Fit but do not fully tighten the detent spring assembly to
the valve body securing bolts.
. Align the detent spring tocentralize the roller with the det- ent lever in the 'P' (Park) position.
. Check that in 'N' (Neutral), the shift lever is properly in
position. It is essential that the detent spring within the
transmission unit dictates to the shift lever and not the
other way around.
Finally tighten the detent spring assembly to valve body
securing bo
I ts .
(4,OL SC AND 6,011
tion 8.2.13.
Sub
-section 8.2.15 (6,OL).
roller assembly to valve body securing bolts.
. Refit the fluid filter, see Subsection 8.2.18.
Refit the fluid pan, see Subsection 8.2.14 (4,OL SC) or
. Lower the vehicle on the ramp.
. Refill the transmission unit with fluid, see Subsection 8.2.13.
. Remove the fender cover and close the hood.
Sub
-section
8.2.15 (6,OL).
X300 VSM 23 Issue 1 August 1994

Driveshafts & Final Drive
9.2 DRIVE SHAm, ALIGN
SRO 47.15.51
CAUTION: To preserve 'drive line' refinement, individual parts, other than fixings, MUST NOT be renewed. In the
event of any balance or drive shaft component related problem, the complete assembly must be renewed.
Under no circumstances must the flexible coupling (or its fixings) be loosened or removed from the drive
shaft flange.
Preliminary Checks
Before this procedure is actioned it is advisable to ensure that:
The gearbox mounting center stud is positioned centrally in relation to the crossmember inspection hole.
The crossmember is central on the body fixings and not 'hard over' to one side.
The differential spigot radial
run-out is within specification, see preliminary pages.
If the vehicle has been standing for
a period the tires may be 'flat-spotted'. If so, this will clear in approximate.;
400 km (250 miles). After this distance the source of vibration should be reassessed.
12 Cylinder
8 Remove exhaust center section.
All
8 Locate suitable 'plumb lines' over drive shaft outside diameter, but NOT over any balance weight or weld:
1.
2.
3.
l\lnfe:
Front section -behind gearbox output coupling, 12,7 mm (0.5 in) diameter weight (1 Fig. 1).
Rear section - immediately behind center bearing (2 Fig. 1).
Rear section - in front of differential flange (3 Fig. 1)
It is essential that the front weight should be as specified so that the different diameters of the two shafts may
be taken into account.
Method 1
8 Viewed from the rear with the rear 'plumb line' coincidental with the outside diameter of the front weight, the center
8 To re-align the center bearing, slacken bearing fixings and position to suit.
8 Tighten all fixings to specification ensuring that the 'anti-twist' plate is allowed to freely align before the center bear-
'plumb line' should align with the rear 'plumb line' (4 Fig. 1).
ing fixings are secured.
Fig. 1
1
JL7 OL3
0
0
0
0 ~~~~
Issue 1 August 1994 2 X300 VSM

0
0
Driveshafts & Final Drive ~ ~~~
Method 2
A refinement
to Method 1 may be made by stretching a line horizontally along the center line of the vehicle to touch
the outside diameter of the front weight and the rear ‘plumb line’. Take care not to bias the vertical lines with the hori- zontal line.
. Set the center ‘plumb line‘ to touch the horizontal line by movement of the center bearing (Fig. 1).
9 To realign the center bearing, slacken bearing fixings and position to suit.
. Tighten all fixings to specification ensuring that the ‘anti-twist’ plate is allowed to freely align before the center bear- ing fixings are secured.
I
6
101
H
-=I- ---
Fig. 1
Recommended /oca//y made tools
Plumb line Locally made Weight Locally made 12.7 mm (0,5 in) diameter mild steel
X300 VSM Issue 1 August 1994 3

@ Steering
Cause
Fluid level low?
Drive belt slack
(V12)
Pump drive loose (6cyl)
center pressures low
Air in system due to loose connection
Pump shaft seal faulty (fluid loss)
Delivery pressure or flow too low
Return flow restricted by blocked reser
-
voir filter
Both check valves blocked
Rack damper too
tight
Lower column incorrectly set
Excessive upper column friction
Faulty rotary valve or seal
Drive belt slack
(VI217
Engine idle speed too low
Pump drive loose
(6cyl)
Air in system due to loose connection
Pump shaft seal faulty (fluid
loss)
Delivery pressure or flow too low
Fluid level low?
tire pressures
high
Air in system due to loose connection
Stiff or seized steering joint
Rack damper too tight
Castor or tracking error
Lower column over extended
Fluid level low?
Air
in system due to loose connection
Pump shaft seal faulty (fluid
loss)
Rack damper loose
Pinion bearing faulty
Rack or column fixings loose
Rack mounting bracket loose
Rack mounting bush loose
Free play in column assembly
10.4 DIAGNOSTIC PROCEDURE
10.4.1 Introduction
The following diagnostic procedures are provided to rapidly pin-point mechanical faults which are not interrogated
by electrical means. Diagnostic procedures which require dedicated electrically operated equipment are dealt with in the 'Electrical Diagnostic Manual' (EDM) but may be mentioned here for reference.
10.4.2 Preliminary Action
Before any problem solving is undertaken it is essential that the fluid level and where applicable, belt tension, is
checked and if required corrected.
CAUTION: It is imperative that the power steering system does not become contaminated in any way. Always de cant fluid from a fresh sealed container and clean the area around the reservoir neck both before and after
topping-up. Never return drained fluid to the system.
10.4.2 Diagnostic Chart 1
Remedy
Rectify fluid loss and or top up
Re
-tension belt
Renew pump
Set to specification
Secure connection and bleed air out
Renew pump
Renew pump
Renew reservoir
Renew rack
Renew rack
Set to specification
Renew upper column
Renew rack
Retension belt
Reset idle speed
Renew
pump
Secure connection and bleed air out
Renew
pump
Renew pump
Rectify
fluid loss and or top up
Set to specification
Secure connection and bleed air out
Test and renew faulty joint
Renew rack
Check geometry and rectify
if required
Set to specification
Rectify fluid
loss and or top up
Secure connection and bleed air out
Renew pump
Renew rack
Renew rack
Tighten to specification
Renew rack
Renew rack
Check and rectify as required
Trouble
Heavy on both sides
Heavy on one side
Heavy when steering
rapidly
Vague feel about center
Knocking
1 vibration felt
at steering wheel
0
0
0
0
Issue 1 August 1994 6 X300 VSM