battery JAGUAR XJ6 1994 2.G Workshop Manual

Terrn(s1 Abbreviation Definition Previously used (if applicable) term(s) (or Eng- lish Eauivalentl
5
Babbitt metal
backlight
back
-up lamp
balk ring
t
battery positive Voltage B+
Barometric Absolute Pressure BARO
Sensor
base Idle
base timing
battery
before bottom dead center BBDC
before top dead center BTDC
blower BLR
Body Processor Module BPM
British Standards BS
I British Standards Automotive BSAu
brake horsepower
brake mean effective pressure BMEP
brake
ontoff BOO
brake rotor
I bottom dead center BDC
bypass air BPA
bumper guard
I
bushing I
rotating component of manual transmission
which prevents premature engagement of
gears
The positive Voltage from
a battery or any
circuit connected directly to it.
sensor measuring the pressure of
surrounding air at any given temperature
and altitude
Idle
rpm determined by the throttle lever
being hard
-set on the throttle body with the
IAC solenoid disconnected
Spark advance in degrees before top dead
center of the base engine without any control
from the PCM
Electrical storage device producing DC
Voltage by means of electrochemical
reaction
event occurring before BDC
event (usually ignition) occurring before TDC
Device which supplies a current of air at
moderate pressure, e.g. heater or
AJC blower
Control module for body electrical systems,
e.g. interior lamps, windshield wash wipe
control etc..
standard specification issued by the British
Standards Institution
effective horsepower developed by an
engine or motor, as measured by a brake
applied to its output shaft
that part of the effective pressure developed
in a cylinder that would result in a cylinder
output equal to the bhp of the engine
indicates the position of the brake pedal
process of bedding
-in the internal working
surfaces of e.g. an engine by avoiding excess
build
-up of heat
lowest point of piston travel in a
reciprocating engine
mechanical control of throttle bypass air
cylindrical plain bearing white
metal
backlight,
rear screen reversing lamp
baulk ring
B+,
+ve, VSS
BARO, APS
CCM (Central
Control Module).
CPU
brake disc
running
-in
overrider bush
Issue 1 August 1994 8 X300 VSM

Term(s) Abbreviation Definition Previously used (if applicable) term(s) (or Eng- lish Eauivalent)
K
kilogrammes (mass) kg
kilogrammes (force) kgf
kilogrammes force per square kgf/cm2 centimeter
kilometers
km kilometres
kilometers per hour
km/h km/h, kph
kilopascals
kPa
kilovolt kV
knock
I
the sharp metallic produced sound when two
pressure fronts collide in a combustion
1 chamber (see also ping)
I sensor which detects the onset of detonation I knock sensor KS I and signals the ECM to retard the ignition I
L
lash
left
-hand LH
left
-hand drive vehicle LH D
left-hand thread LH Thd
levelina
I
license I
license plate
liquid crystal display LCD
Liter
I L
louver
lowered beam
lug nut free
play, end-float
optical digital display system, applied
voltage to which varies the way the crystals
reflect liaht,
thereby modifvina the display
primary circuit
of the ignition system, linking
the battery to the primary winding in the
ignition coil levelling
licence
registration
plate,
number
date
Litre
louvre
diooed beam
wheel nut
Issue 1 August 1994 18 X300 VSM

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.
e
0
0
X300 VSM Issue 1 August 1994 2

3.2.2 ENGINE - GEARBOX/ TRANSMISSION
ASSEMBLY, RENEW
SRO 12.37.01/90
The engine /transmission unit on the V12 6.0 liter model is mounted on three engine mounting / bracket assemblies
fitted to the front crossmember on either side of the engine bay. The engine/ transmission rear mount is a mounting
bracket and spring assembly fitted and secured to body underframe longitudinal members. For access to remove the
engine carry
out the following procedures:
WARNING: WHEN WORKING WITHIN 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 two air cleaner assemblies, see SRO’s 19.10.01 & 19.10.02.
. Remove the engine cover, see SRO 12.29.93 (V12 Engine Service Manual).
Depressurize the fuel system, see SRO 19.50.02, section 5.1.
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 air conditioning system, see section 14, Charge Recovery (System depressurization).
Disconnect
the battery.
mounting arrangements.
CAUTION: Do
not vent refrigerant directly to the atmosphere and always use Jaguar approved recovery/recycle/ra charge equipment.
Drain the engine oil, see 3.2.3 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 UNTIL THE EXCESS PRESSURE CAN ESCAPE. LEAVE THE 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 equallyspaced to the inlet manifold studs. The four engine lifting brackets
should be positioned towards the front and the rear of the assembly. Ensure the front of thevehicle is jacked
up secure- ly on stands when removing the assembly.
X300 VSM Issue 1 August 1994 2

Fuel, Emission Control & Engine Management (AJ16)
5.1.3
SRO 19.60.13 FUEL RAIL
SRO 19.45.11 REGULATOR VALVE
SRO 18.10.01 INJECTORS
SRO 18.10.02 INJECTORS (VEHICLE SET)
FUEL
RAIL /PRESSURE REGULATOR VALVE/ INJECTORS (SUPERCHARGED), RENEW
Fig. 1
Remove
. Reposition top edge of trunk front liner for access.
. Disconnect multi-plug from evaporative loss flange inset (Fig. 1 ).
. Switch ignition on.
. Switch ignition off.
. Disconnect earth lead eyelet (1 Fig.1) from inlet manifold stud.
. Disconnect engine harness to oxygen sensor leads multi-plug.
. Disconnect engine harness to starter motor solenoid link lead multi-plug.
. Undo fuel injector multi-plug cover fixings (2 Fig.1).
. Disconnect cover from injectors (3 Fig.1).
Crank engine to depressurize fuel system.
Disconnect
battery,see Section 15.
Undo fuel rail to feed pipe union nut
(4 Fig.1).
X300 VSM 5 Issue 1 August 1994

Fuel, Emission Control & Engine Management (AJ16)
5.1.4
SRO 19.60.13
FUEL RAIL /PRESSURE REGULATOR VALVE/ INJECTORS (NORMALLY ASPIRATED ENGINE),
SRO 19.45.11
SRO 18.10.01 INJECTORS
SRO 18.10.02 INIECTORS (VEHICLE SET)
IB
RENEW
Fig. 1
Remove
. Reposition top edge of trunk front liner for access.
. Disconnect multi-plug from evaporative loss flange inset (Fig.1).
. Switch ignition on.
. Crank engine to depressurize fuel system.
. Switch ignition off.
. Disconnect battery, see Section 15.
. Disconnect earth lead eyelet (1 Fig.1) from inlet manifold stud.
. Disconnect engine harness to oxygen sensor leads multi-plug.
. Disconnect engine harness to starter motor solenoid link lead multi-plug.
. Undo fuel injector multi-plug cover fixings (2 Fig.1).
. Disconnect cover from injectors (3 Fig.1).
. Undo fuel rail to feed pipe union nut (4 Fig.1).
Issue 1 August 1994 X300 VSM 7

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.
e
0
0
0
Issue 1 August 1994 10 X300 VSM

Fuel, Emission Control & Engine Management (AJ16)
5.1.8
SRO
SRO IDLE
SPEED CONTROL VALVE/ GASKETS (NORMALLY ASPIRATED), RENEW
18.30.74 IDLE SPEED CONTROL VALVE
18.30.77 IDLE SPEED CONTROL VALVE GASKET
Remove
. Disconnect battery.
9 Remove the intake elbow to throttle housing hose.
Disconnect idle speed control valve multi-plug.
. Disconnect throttle potentiometer multi-plug.
. Remove clevis pin circlip.
. Reposition link arm from quadrant.
. Disconnect kick down cable (where fitted) from quadrant.
Open throttle fully and disconnect inner cable from quad-
Carefully release throttle against stop.
rant.
Fit pipe clamps
to throttle body heater feed and return
hose.
Disconnect feed hose from throttle body stub pipe.
rn Remove throttle body assembly from inlet manifold.
Remove idle speed control valve from throttle body.
. Remove gasket.
. Retrieve distance piece from throttle body recess. Fig.
1
Refit in the
reverse order of the removal procedure.
0
0
0
0
Issue 1 August 1994 12 X300 VSM

Fuel, Emission Control & Engine Management (V12) ~~ ~
5.2.5
SRO
18.30.74 VEHICLE SET
IDLE SPEED CONTROL VALVE/ GASKETS, RENEW
SRO
18.30.73 VALVE- RIGHT HAND
SRO 18.30.76 GASKET
- RIGHT HAND
SRO
SRO 18.30.75 GASKET- LEFT HAND
18.30.72
VALVE
- LEFT HAND
Remove
. Disconnect battery.
. Drain coolant from radiator, see Section 4.2.
. Disconnect idle speed control valve multi-plug.
Disconnect all hoses linked to the idle speed control valve.
. Remove valve.
. Remove gasket.
Refit in the reverse order of the removal procedure.
5.2.6 FUEL CUT-OFF INERTIA SWITCH, RENEW
SRO
18.30.35
Remove
. Disconnect battery.
. Remove the 'A' post lower trim pad.
= Remove the EMS control module, see Section 15.
. Disconnect vehicle harness through-panel connector.
. Disconnect inertia switch multi-plug (Fig. 2).
9 Remove switch.
Refit in the reverse order
of the removal procedure. Fig.
1
Fig. 2
X300 VSM 9 Issue 1 August 1994

Manual Transmission & Clutch (AJ16)
7.1.2 MANUAL TRANSMISSION ASSEMBLY, RENEW
SRO 37.20.01
. Disconnect the battery.
. Remove inlet manifold rear securing nuts.
. Remove injector harness mounting bracket.
. Fit lifting bracket 18G 1465 and secure with the nuts.
. Fit Service Tool MS 536 (Fig. 1) across the wing channels
Fit and engage retaining hook.
. Tighten hook nut to take weight of engine.
. Disconnect lambda sensor block connectors.
. Remove the exhaust front pipe to the intermediate pipe
securing nut / bolt.
. Remove the front pipe to manifold securing nuts and
remove the front pipe assembly.
. Carefully ease exhaust system down for access.
Remove the drive (propeller) shaft assembly, see Section
. Fit blanking plug to rear of transmission.
. Remove clutch slave cylinder complete with push rod
Disconnect transmission switch multi-way connector and
. Place jack in position beneath the transmission.
. Take weight on the jack, and remove rear mounting to
. Lower jack and remove rear mounting assembly.
Remove jack and jacking channel.
. Remove mounting spring and spring mounting rubber.
. From above: undo retaining hook nut to lower rear of
transmission (do not allow engine to foul steering rack).
. From below: remove selector shaft yoke securing nut / bolt (3 Fig. 2).
. Disconnect selector shaft yoke from lower gearshift lever
and remove wavy washer.
. Remove gear selector remote control securing bolts (1 Fig. 2).
. Remove mounting rubbers and washers (2 Fig. 2).
. Reposition remote control assembly for access.
. Remove transmission-to-engine adaptor plate securing
and
align to rear lifting bracket.
9, SRO 47.15.01.
from bell housing and secure clear.
secure clear.
body securing bolts.
bolts
(1 Fig. 3).
N.&: Leave two opposing bolts in for safety.
Fig. 1
Fig.
2
Fig. 3 ~ ~ ~~ ~
Issue 1 August 1994 2 X300 VSM