brake JAGUAR XJ6 1994 2.G Repair Manual

Brakes
12.8
SRO 70.60.21
PRESSURE CONSCIOUS REDUCING VALVES - RENEW
Refer to Section 12.4, Brake System Bleeding before carrying out this procedure. Pay particular attention to the warn- ings and cautions relating to brake fluid, cleanliness and cleaning materials.
Note: The illustration shows the hydraulic control module of a 6 cyl. vehicle with traction control. Hydraulic control
modules on non-traction control vehicles have only three outlet ports. Apart from this, the removal procedure
is the same for all vehicles.
. Raise the vehicle.
Displace the bleeder screw dust cap of the front LH caliper.
The dust cap will remain captive on the bleed screw.
rn Connect a bleeder tube and bottle to the bleeder screw (1 Fig. 1) and open the bleeder screw.
Fit a brake pedal hold-down tool (JDS-9013) between the
brake pedal and the steering wheel. Adjust the tool to op- erate the brake pedal 60mm down. This operation is
necessary to prevent fluid
loss from the reservoir through
disconnected brake pipes.
. Re-tighten the front LH caliper bleeder screw. Disconnect
the bleeder tube from the bleeder screw and remove the
tube and bottle. Refit the bleeder screw dust cap.
rn Place absorbent material underneath the hydraulic con- trol module to absorb any spillages.
. Undo the rear brake pipe gland nuts (1 Fig. 2) at the pres- sure conscious reducing valves (PCRVs) (2 Fig. 2). Remove
the rear brake pipes.
m: Take necessary steps to prevent rotation of the
PCRVs when removing the rear brake pipes.
Fit plugs immediately to the brake pipes and the PCRVs to
Undo and remove the PCRVs. Fit plugs immediately to the
. Clean the surrounding area.
. Fit new PCRVs to the hydraulic control module, removing
plugs immediately priorto connection. Tighten the PCRVs.
. Connect the rear hydraulic brake pipes to the PCRVs, re- moving the plugs immediately prior to connection.
Tighten the gland nuts.
prevent
fluid loss.
PCRVs
and the hydraulic control module.
0
Note: Take necessary steps to prevent rotation of the
PCRVs when fitting the rear brake pipes.
. Removethe absorbent material and clean the surrounding
. Ensure that all fixings are torque tightened to specified tol-
Release the brake pedal hold-down tool and remove.
. Bleed the brake system (refer to sub-section 12.4.4).
. Examine the hydraulic control module for leaks.
area.
erances. Fia.
1
Fia. 2
X300 VSM 25 Issue 1 August 1994

12.9 ABS/ TC CM - RENEW
SRO 70.60.02
70.60.20
Refer to Section 12.4, Brake System Bleeding before carry-
ing out this procedure. Pay particular attention to the warn- ings and cautions relating to brake fluid, cleanliness and
cleaning materials.
Remove the hydraulic control module. Refer to sub-sec- tion 12.7, SROs 70.60.18 & 19.
Disconnect the pump electric motor to ABS/TC CM multi- plug (1 Fig 1).
Undo and remove two securing screws and remove the
ABS 1 TC CM.
Clean the mating faces of the hydraulic control module
and the new ABS /TC CM. Fit and tighten two securing
screws.
Re-connect the pump electric motor to ABS/TC CM multi-
Plug.
. Refit the hydraulic control module. Refer to sub-section 12.7, SROs 70.60.18 & 19.
Fig. 1
Issue 1 August 1994 26 X300 VSM
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SECTION CONTENTS
Sub-Section Title SRO Page
13.3.19 .......... Underscuttle Pad. Drivers Side. Remove for Access and Refit .......... 76.46.1 1/90 ......... 26
13.3.20
.......... Underscuttle Pad. Passenger Side. Remove for Access and Refit ....... 76.46.15/90 ......... 26
13.3.21
.......... Fascia Closing Panel - Passenger Side. Renew ...................... 76.46.27 ............ 27
13.3.22
.......... Fascia Closing Panel -Drivers Side. Renew ......................... 76.46.28 ............ 27
13.3.23
.......... Fascia Center Veneer Panel. Renew ............................... 76.47.06 ............ 28
13.3.24
.......... Console Finisher Veneer Panel. Renew ............................ 76.47.26 ............ 29
13.3.25 .......... Console Ashtray Lid Veneer Panel. Renew ......................... 76.47.27 ............ 30
13.3.26 .......... Console Ashtray Surround Veneer Panel. Renew .................... 76.47.28 ............ 30
13.3.27
.......... Console Rear Extension Veneer Panel. Renew ...................... 76.47.30 ............ 30
13.3.28 .......... Console Ashtray, Renew ......................................... 76.67.18 ............ 31
13.3.29
.......... Steering Column Upper cowl. Renew ............................. 76.46.02 ............ 32
13.3.30
.......... Steering Column Lower cowl. Renew ............................. 76.46.03 ............ 32
13.3.3
1 .......... Steering Column Switchgear Mounting Bracket. Renew .............. 76.46.33 ............ 33
13.3.32
.......... 'A' Post Lower Trim Pad. Renew .................................. 76.13.30 ............ 35
13.3.33
.......... Rear Quarter Upper Trim Pad. Renew .................................................. 35
13.3.34
.......... 'B' Post Upper Trim Pad. Renew ....................................................... 35
13.3.35 .......... 'B' Post Lower Trim Pad. Renew ....................................................... 35
13.3.36 .......... Handbrake Lever Trim. Renew ........................................................ 35
13.3.37
.......... Combined Grab Handle and Coat Hanger Hook. Renew .................................. 35
13.3.38
.......... Sun Visor Assembly RH or LH. Renew .................................................. 36
13.3.39
.......... Roof Lining (Headlining). Description .................................................. 37
13.3.40
.......... Roof Lining. Renew ................................................................. 37
13.4 ............. Trunk ........................................................................\
..... 38
13.4.1
............ Trunk. Description .................................................................. 38
13.4.2.
........... Trunk Side Liner - Left Hand. Renew .............................. 76.19.22 ............ 39
13.4.3
............ Trunk Side Liner - Right Hand. Renew ............................. 76.19.23 ............ 39
13.4.4
............ Trunk Floor Carpet. Renew ...................................... 76.19.30 ............ 39
13.4.5.
........... Trunk Front Liner, Renew ........................................ 76.19.3 1 ............ 39
13.4.6.
........... Trunk Seal Retainer, Renew ...................................... 76.19.44 ............ 40
13.4.7.
........... Trunk Lid Striker, Adjust .............................................................. 40
13.4.8
............ Trunk Lid Liner, Renew ............................................................... 40
13.4.9
............ Trunk Seal Retainer, Renew ........................................................... 40
13.4.10
.......... Trunk Lid Lock Striker, Renew ......................................................... 40
13.4.11
........... Trunk Lid Lock Barrel. Renew ......................................................... 40
13.4.12
.......... TrunkLidLockMechanism. Renew .................................................... 41
13.3.13
.......... Trunk Lid Gas Strut. Adjust. Renew .................................................... 41
13.4.14
.......... Trunk LidHinge. Renew .............................................................. 41
13.4.15 .......... Trunk Rear Liner, Renew ............................................................. 41
13.5
............. Hood ........................................................................\
..... 42
13.5.1
............ Hood Description ................................................................... 42
13.5.2
............ Plenum Chamber Finisher, Renew ................................ 76.10.01 ............ 42
13.5.3 ............ Hinge. Renew ...................................................................... 42
13.5.4
............ Gasstrut. Renew .................................................................... 43
13.5.5
............ HoodLockRHorLH. Renew ......................................................... 43
issue 1 August 1994 X300 VSM

Body Components & Trim -
13.3.24 Console Finisher Veneer Panel, Renew
SRO 76.47.26
Apply the handbrake.
. Turn the ignition ON.
. Press the brake pedal and position the gear selector in 'N'.
Turn the ignition OFF.
. Remove the console ashtray, see sub-section 13.3.28.
9 Carefully displace the mode switch from the gear sur-
. Disconnect the mode switch from the harness multi-plug.
. Displace and remove the switch surround finisher.
. Displace and remove the gear lever surround finisher.
. Displace and remove the veneer panel rear finisher.
. Undo and remove the veneer panel wing nuts. See Fig. 2.
. Displace and remove the console finisher veneer panel.
. Remove the stud plates.
. Place the veneer panel aside.
. Place the new panel to the front.
Fit and align the stud plates.
. Fit and fully seat the veneer panel to the console.
. Fully seat the rear of the veneer panel.
. Fit and tighten the wing nuts.
. Fit and align the veneer panel rear finisher.
. Fit and fully seat the gear lever surround.
. Fit and fully seat the mode switch surround.
. Connect the mode switch to harness multi-plug.
. Fully seat the mode switch.
. Refit the ashtray.
. Place the gear selector in 'I".
round finisher. See Fig. 1.
See Fig. 1.
See Fig. 3.
Fig. 1
J76.801
Fig. 2
Fig. 3
X300 VSM 29 Issue 1 August 1994

31
30
29
28 27
26
4 26 24 21 23 22 7 20 19 18 18 17 8
a
10
11
12
13
14
1s
1M-137
1. Tachometer 2. Speedometer
3. Battery Condition 4. FuelGauge 5. Oil Pressure 6. Coolant Temperature 7. Odometer /Trip Computer Display 8. Primary Warning Indicators (RED) 9. Exhaust Temperature 10. Low Oil Pressure 11. Seat Belt Not Fastened 12. Boot Open 13. DoorOpen 14. Coolant Level 15. Air Bag Fault 16. Status / Warning Lamps
17. Hand Brake On (RED) 18. Brake System Fault (RED)
19. Main Beam On (BLUE) 20. Direction Indicator Right (GREEN) 21. Status / Warning Lamps 22. Direction Indicator Left (GREEN) 23. Traction Control Off (GREEN) 24. Transmission Sport Mode (GREEN) 25. Charging Fault (RED) 26. Check Engine (AMBER)
27. Low Fuel Level (AMBER) 28. Anti - Lock Fault (AMBER) 29. Traction Control Fail (AMBER) 30. Bulb Fail (AMBER) 31. Washer Fluid Level (AMBER) 32. Transmission Fault (AMBER)
Fig.
1 Instrument Panel, Front Mew
w: The 'Premium Unleaded Fuel Only' caution is added to the Federal Market vehicles, also 'PARK BRAKE and
'BRAKE' replace international symbols used in all other markets.
m: Six cylinder vehicle version shown; the tachometer red-line on 12 cylinder vehicles starts at 6000 RPM.
The front of the
PECUSprogrammable instrument panel features 6 analog gauges, 22 warning lamps /tell tales and
a Liquid Crystal Display (LCD), the rear of the panel accommodates two PCB mounted connectors, one 24-way
connector, one 48-way connector, one instrument panel identification label and 14 light bulbs arranged in groups of
seven on either side. Three power inputs and two ground inputs are provided for 'POWER UP' and 'POWER DOWN'
sequence, the three power inputs comprising battery, ignition and auxiliary. The instruments are protected by a
housing
/ lens assembly.
15.2.7 Gauges
The two major gauges are tachometer and speedometer, and the four minor gauges indicate battery condition, fuel
level, oil pressure and coolant temperature.
Each gauge is contained
in a sealed non-serviceable can and must be renewed as a complete unit in case of any
damage.
CAUTION: Extreme care should be exercised when renewing instrument pand components to avoid damago to the delicate indicator needles.
X300 VSM 9 Issue 1 August 1994

IT Electrical
15.2.8 Odometer
With the ignition 'OFF' the odometer is permanently dis-
played but not illuminated. With the ignition 'ON' the odo- meter is displayed and also illuminated.
Trip information or driver information messages may be dis
-
played instead of the 'ODO'. By pressing the 'ODO' button
once or twice the trip and driver information messages can
be deleted and the
'ODO rdisplayed.
W. The odometer value is not stored within the LCD
module.
15.2.9 Trip Computev
This provides information on the vehicle's speed, fuel usage
and distance traveled
all of which are calculated by a micro
processor.
The controls, part of the fascia switch assembly, are located
on the right
-hand side pod positioned to the right-hand side
of the steering column.
I
/
J86-192L
Fig. 1
15.2.10 Driver Information Messages
Two fault messages, FLUID - AIRBAG are displayed via the LCD in conjunction with relevant warning lamps.
If an
airbag fault exists or the brake fluid is low, a message will automatically be displayed on the LCD and the relevant
warning lights illuminated. Should both faults exist at the same time, each message is displayed alternatively for ap
- proximately 2 seconds.
Messages may becancelled
by pressing the 'ODO button which allowsthe LCD to return to its last displayed message.
The warning lamps will not be extinguished. If the fault is not repaired the message(s) and the warning lamp(s) will
be redisplayed when the ignition is switched on.
15.2.11 /llumination
Warning indicator lamp illumination is controlled by a microprocessor located inside the instrument panel.
The seven right
-hand warning indicators are primary warning lamps illuminating 'RED and the seven left-hand warn-
ing indicators are secondary warning lamps illuminating 'AMBER'
The eight lower lamps are
a mixture of status and warning lamps.
With the ignition
'OFF' the LCD is not illuminated.
With ignition
'ON' and side lights 'OFF' the LCD is illuminated at maximum brightness.
With the ignition on and side lights
'OFF' the LCD is dimmed as are the gauges.
The long
life type bulbs are enclosed by orange and brown coloured bulb holders which must never be interchanged.
Replacement bulbs must always be of the same colour.
CAUTIQN: Always dwonnect the battery ground lead before commencing with any instrument rsimwal procedure.
15.2.12 General Repair Notes
0 After lens removal do not rest instrument panel face down as this causes damage to the delicate gauge needles.
Avoid scratching the gauge faces and ensure cleanliness when handling the panel.
0 To minimize the risk of damage and contamination to the instrument panel, all repairs must be carried out in a non - static and dust -free environment. Avoid touching connector pins and pcb components to minimize
risk of static damage.
0 The instrument panel has two different types of bulb holders each of which must be located correctly when
changing the bulbs.
Issue 1 August 1994 10 X300 VSM

e LmmJ
Power assisted, ventilated discs,
sliding calipers: FN60 single piston
60mm Power assisted, ventilated discs,
FN48 single piston sliding calipers
48mm Mechanical, operating
on rear
drums within bell of the rear brake
discs.
291mm
305mm
28mm. wear limit 27mm
20mm, wear limit 18,5mm
Vacuum power, hydraulic operation
Bore diameter:
25,4mm
Jurid 518
Jurid 101
Ferodo 3612
6,51 vacuum
Electrical inductive sensors at the
wheels which detect rotational
speed.
Hydraulic: vehicles
with traction
control - contains four solenoid
valves, one for each wheel; vehicles
without traction control
- contains
three solenoid valves, one for each front wheel and one for both rear
wheels.
Solid state digital
unit (integral with hydraulic module).
Specification
Braking System
Front brakes: all vehicles.. ........ .................... ........... ...
Caliper piston diameter: ..........
Rear brakes: all vehicles ..........
...
...
....................
....................
...........
...........
Caliper piston diameter ...........
Parking brake ....................
...
...
....................
....................
...........
...........
Disc diameter:
Front
.........................
Rear .........................
Front .........................
Rear .........................
Brake operation .................
Master cylinder ..................
Main brake friction pad material:
Front
........................
Rear ........................
Parking brake friction shoe material
Brake
servo booster assembly
Boost ratio
......................
Disc thickness:
...
... ....................
....................
...........
...........
...
...
...
...
....................
....................
....................
....................
...........
...........
...........
...........
...
...
.. ....................
....................
....................
...........
...........
...........
... .................... ...........
Anti-lock braking system (ABSI
Wheel sensors ................... ... .................... ...........
ABS modulator .................. ... .................... ...........
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Control module type ............. ... .................... .........
Issue 1 August 1994 X300 VSM AI-95MY 3

Braking System and Clutch System
Fluid Specification .........
Make & Type. ..............
Grease Points
Grease Specification .......
Grease Type ...............
Fuel Tank
Capacity:
total refill
...............
indicated refill capacity . .
Issue 1 August 1994
Specificat ion
..............
..............
..............
..............
..............
..............
...........
...........
...........
...........
...........
........... ...............
...............
...............
...............
...............
...............
Dot 4
Jaguar
Brake Fluid
N.L.G.I. Consistency
No.2
Multipurpose Lithium Grease
81 liters
75 liters
('E' to 'F' on fuel gauge)
A1-95MY '8 X300 VSM

Description Capacity Type
Door guard lamp. 12V 5W Capless long life
Flasher side repeater 12V 5W Capless long life
Fog lamp - Front. 12v 55w Halogen H3
Fog lamp
- Rear guard 12v 21w Bayonet long life
Front turn indicator
I 12v21w I Bayonet long life
Pilot lamp
I 12V 5W I Capless long life
Headlamp
I 12v55w I Halogen HI
High mounted stop lamp (where fitted). 12v Capless long life
Roof console central courtesy lamp
12V 5W Capless long life.
Roof console reading lamp
12V 6W Capless
Luggage compartment lamp
12V 5W Capless long life
License plate lamp 12V 5W Festoon
Rear turn indicator
12v 21w Bayonet yellow long
Rear quarter courtesy lamp (lower section)
12V 5W Capless long life
Rear quarter reading lamp (upper section) 12V 6W Capless
Back
-up lamp 12v 21w Bayonet long life
Stop /Tail lamp
Sun visor vanity mirror lamp
12v 1,2w Capless 286
Tail lamp 12V 5W Bayonet long life
5X5W
12V 21V 5W Twin filament bayonet long life
Indicator bulbs
Bulb Designation Holder Colour Rating
Exhaust temperature warning indicator bulb Orange 12,5V 1,2W
Low oil pressure indicator bulb
Orange 12,5V 1,2W
Seat belt warning indicator bulb
Orange 12,5V 1,2W
Boot open warning indicator bulb
Orange 12,5V 1,2W
Door open warning indicator bulb
Orange 12,5V 1,2W
Coolant level warning indicator bulb
Orange 12,5V 1,2W
Air bag fault indicator bulb Orange 12,5V 1,2W
Parking brake 'on' indicator bulb Orange 12,5V 1,2W
Brake system warning indicator bulb Orange 12,5V 1,2W
Main beam 'on' indicator bulb
Orange 12,5V 1,2W
Right turn indicator bulb Orange 12,5V 1,2W
LCD illumination bulb (right)
Orange 12,5V 1,2W
LCD illumination bulb (left) Orange 12,5V 1,2W
Left turn indicator bulb
Orange 12,5V 1,2W
Traction control 'off indicator bulb
Orange 12,5V 1,2W
Transmission sport mode indicator bulb
Orange 12,5V 1,2W
Charging fault warning bulb
Orange 12,5V 1,2W
Check engine warning indicator bulb Orange 12,5V 1,2W
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X300 VSM Issue 1 August 1994 AI-95MY 12

Routine
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1. Engine oil - refill 2. Engine oil - drain
3. Transmission fluid - refill 4. Transmission fluid -drain 5. Brake fluid - refill 6. Engine coolant - refill 7. Clutch fluid - refill
J 10-054
8. 9.
10. PAS fluid
- refill
11. Windshield wash reservoir - refill
12. Axle shaft UJs - grease
13. Door check-arm - grease
Final
drive oil
- refill
Final drive oil - drain
Fig. 1 Fluids and Lubricants Service Points
- 6 Cylinder Vehicles
Issue 1 August 1994 A2-95MY 1 X300 VSM