fuel JAGUAR XJ6 1994 2.G Workshop Manual

Introduction
FOREWORD
This Vehicle Service Manual (VSM) is Dart
-
of a
set of service literature which covers -. diagnosis and rectification of problems associated with all areas of the X300 family of vehicles.
It is designed to be read in conjunction with other manuals, namely the various Unit Service Manuals (USM) (as
applicable to the particular vehicle under diagnosis/ repair) and the X300 Electrical Diagnostic Manual (EDM); see list
below.
It should be noted that its scope is limited to those areas that are unique to the family, e.g. Remove & Refit procedures
for Body Components, Engine, Transmission etcetera, Fuel, Emissions & Engine Management systems, and so on.
Fault Diagnosis and repair procedures (together
with Technical Data, Recommended Lubricants, Capacities etcetera) for major assemblies such as engines, automatic and manual transmissions, are covered in the separate Unit Service
Manuals.
The Unit Service Manuals are notvehicle
-specific, but are designed to be read in conjunction with this VSM, and, where so equipped, with other Jaguar Vehicle Service Manuals for new models launched subsequent to the X300 family.
The X300 Electrical Diagnostic Manual is the final part of the 'set' of service documentation. This manual
is
family-specific, and is designed to aid theTechnician to isolate electrical faults and to correct them. It covers all aspects
of electrical fault diagnosis, including:
OBD
II Codes and emission control system related fault diagnosis / rectification.
Circuit Diagrams
Component (Relays, fuse boxes, control modules etcetera) Location
/ Harness Diagrams I Ground Locations
Connector Locations.
Service Manuals Required
The Manuals required to service the X300 family of vehicles are as follows:
X300 Vehicle Service Manual
X300 Electrical Diagnostic Manual
Unit Service Manuals:
AJ16 Engine Service Manual
VI2 Engine Service Manual ZF AutomaticTransmissions Service Manual (ZF supplies transmissions for 3.2 liter and 4.0 liter normally aspirated
versions) Powertrain Automatic Transmissions Service Manual (The Powertrain name succeeds that of Hydra
-Matic.
Powertrain are suppliers of the 4L 80 E transmission as fitted to 4.0 litre supercharged and 6.0 litre versions)
Each
of the X3Okpecific manuals is divided into Sections which adopt the same title and number where relevant, i.e. Section 5.1 of both the VSM and the EDM cover Fuel, Emission Control & Engine Management System (AJ16). An
over
-all contents list showing each section title and number together with its page-edge locator is given in this section
and in the introduction to the EDM.
The VSM (not applicable to the EDM) also contains Appendices which cover specialized areas such as the current
vehicle specification, routine maintenance schedule etc. These are carried at the rear of this Manual, and have their
own contents page within this section.
INDEX
rapid location of information. The entries are set out as per the following example: @ This manual carries a comprehensive index at the rear, which is designed to save the Technician time by permitting
CLIMATE CONTROL SYSTEMS. Section 14.
See also Electrical Diagnostic Manual
Clutch
Description: Sect. 7.7 - 10
Fault diagnosis: Sect 7.1 - 11
In the example the heading in upper case lettering is to a section title, and it refers to the section number, 14, and also to the EDM as electrical diagnostic information will be found in that manual's section 14. The entry for clutch tells us that the relevant description will be found on page 10 of Section 7.1 of this manual, and
that fault diagnosis procedures start on page 11. In this case there is no reference to the EDM as electrical diagnosis does not apply to this area.
GLOSSARY OF TERMS
This Section contains a Glossary of general and emissions-related terminology (commencing on page 5).
X300 VSM 1 Issue 1 August 1994

e-
@
Contents
Fuel, Emission Control & Engine Management (AJI 6)
Manual Transmission & Clutch (AJl6)
Driveshafts & Final Drive
Suspension Systems
Body Components & Trim
Climate Control Systems
Issue 1 August 1994 3 x300
- - ~~

Introduction
.OSSARY OF TERMS
Term(s)
Crankshaft Position
Crankshaft Position Sensor
Crankshaft Position
liming Ring
Crankcase Ventilation System
cubic centimeters
curb weight
4 Control
CKP
CKPS
CKPTR
cv
cm3
Control Module
P
T Abbreviation (if applicable)
CM
cylinder sleeve, sleeve
I I
Definition
a means or device to direct and regulate a process or guide the operation of a machine,
apparatus or system
a self-contained group of
electrical/electronic components, designed
as a single replaceable unit, and controlling
one or more processes as above
flexible, usually fabric, roof of an open
(convertible) vehicle
shaft, carrying pinions, running parallel to
the mainshaft in
a transmission unit
split pin which is used as
a locking device for
a castellated nut, etc.
generates crankshaft position information in
conjunction with the CKPTR (also generates
speed information in certain applications)
toothed ring which triggers the CKPS
system which scavenges camshaft cover and
crankcase emissions and feeds them into the
inlet manifold.
weight of vehicle with fuel, lubricants and
coolant, but excluding driver, passengers or
payload
thin
-walled, hard metal cylinder inserted into
the cylinder block of an engine, and in which
the piston runs
Previously used
term(s) (or Eng.
lish Eauivalent)
hood,
convertible hood
layshaft
split pin,
cotter pin
cubic
centimetres kerb weight
cylinder liner ~ ~~
Issue 1 August 1994 10 X300 VSM

Introduction
Term(s) Abbreviation Definition
(if applicable) Previously
used term(s) (or Eng-
lish Equivalent)
downshift
draft _.
drivability
driveshaft
driveshaft tunnel
dry sleeve
Dual Overhead Cam
Data
Data Link Connector
Data Output Line
defogger, backlight defogger
degree (angle or temperature)
Department of Transportation
(US)
Department of Transport (UK)
Deutsche lnstitut fur
Normuna
diameter
Diagnostic Module
Diagnostic Test Mode
Diagnostic Trouble Code
differential housing
differentia
I pressure
Differential Pressure Feedback
EGR
dimmer switch DOHC
DLC
DOL
deg, O
DOT
DTP DIN dia
DM
DTM
DTC
DPFE longitudinal
shaft transmitting power from
transmission output to rear axle differential
tunnel
in floor above the driveshaft (propeller
shaft)
cylinder sleeve which is not in contact with
coolant
engine configuration with two camshafts
positioned above the valves
(US) Fact or group of facts.
connector providing access
andlor control of
the vehicle information, operating
conditions, and diagnostic information
circuit that sends certain information from
the PCM to the instrument cluster
German Standards regulation body
Supplemental Restraint System
(non-controlling) module for diagnostics
overview
a level of capability in an OBD system. May
include different functional states
to observe
signals, a base level to read
DTCs, a monitor
level which includes information on signal
levels,
bi-directional control with onloff board aids, and the ability to interface with
remote diagnosis
an
alphahumeric identifier for a fault
condition identified by the On
-Board
Diagnostic
(OBD) system
rotating housing
(in a bevel differential)
attached to the crownwheel, carrying the
final drive pinions
pressure difference between two regions e.g.
between intake manifold and atmospheric
pressures
an EGR system that monitors differential
EGR pressure across a remote orifice
to control EGR flow change
down
draught
driveability
propeller shaft
transmission
tunnel
dry liner
(English) Group
of facts (i.e. plural
of
datum)
HRW, rear screen
heater, demister
Self Test Mode
Self Test Code.
Fuel Fail code
differential cage
dip switch,
dipper switch
Issue 1 August 1994 11 X300 VSM

Introduction c
GLOSSARY OF TERMS
Term(s) Abbreviation Definition Previously used (if applicable) term(s) (or Eng- lish Equivalent)
0
EGRT Sensor
EGR Vacuum Regulator
1 Read-only memory
I Electronic Engine Control
kronic Secondary Air Injection
Engine Control Module
Engine Coolant Level
ECT Sensor
Engine Speed
Engine Speed Sensor
1 Evaporative Emission Control
Va Ive
Exhaust Gas Recirculation
Solenoid Vacuum Valve
Exhaust Gas Recirculation
Temperature Sensor
Exhaust Gas Recirculation Valve
Extreme Pressure EGR
EGRT EVR
EVP
EDM
EEPROM EPROM EEC
EAlR
ECM ECL
ECT
ECTS
RPM
EPA
EVAP
EVAPP EGRS
EGRT Sensor
EGRV EP System
which reduces
NOx emissions by
adding exhaust gases to the incoming
fuel/air charae
Sensing EGR function based on temperature
change.
controls EGR flow by changing vacuum to
the EGR valve
an EGR system that directly monitors EGR
valve position to control EGR flow
Manual which deals with the diagnosis of
electrical faults (see also Vehicle Service
Manual and Unit Service Manual)
a system that provides electronic control of
enaine electronics
a pump
-driven system for providing
secondarv air usina an electric air Dump
thermistor which provides engine coolant
temperature signal to the PCME to trigger
enrichment circuits which increase injector
'on' time for cold start and warm-up
sensor fitted on flywheel of
VI2 engine;
provides engine speed information
system designed to prevent fuel vapor from
escaping into the atmosphere. Typically
includes a charcoal filled canister to absorb
fuel
vaoor
additives to drive axle lubricants. Designed
to protect the spiral bevel gears from wear
induced by their
slidingholling action EGR
EEPROM,
EPPROM
EPROM ECU
engine coolant level indicator
Coolant temp.
sensor, ECT
revlmin. RPM
purge valve
EGR solenoid
valve
EGR temperature
sensor
X300 VSM issue 1 August 1994 13

Fan Control FC
Fascia
farad F
I Federal Motor Vehicle Safetv I FMVSS
Standard (US)
fender
fiber
Figure (illustration) Fig.
firewall
Flash Electrically Erasable Pro- FEEPROM grammable Read-only Memory
Flash Erasable Programmable
FEPROM Read-only Memory
Flywheel Sensor CKFS
fueling Fuel Injectors FI
Fuel Pressure Regulator Control FPRC
Fuel Pump FP
Fuel Pump Monitor FPM
Fuel Pump Relay FPR
fuel
rich/lean
engine cooling fan control
SI unit of electrostatic capacitance; more
usually subdivided to microfarad fascia,
facia
wing,
(also tonneau)
fibre
bulkhead,
dash panel
sensor mounted
so as to be triggered by each flywheel sensor
flywheel ring gear tooth to give an engine
speed signal
fuelling
iniectors
solenoid operated
devices that spray a fuel injectors,
metered auantitv of fuel into the inlet
~0rt.s
Drimarilv to aive extra fuel at cold start-uo used I
controls fuel pressure regulator;
I I
monitors oDeration of fuel DumD I I
qualitative evaluation of airbuel ratio based on a ratio known as stoichiometry, or 14.7:l
(Lambda)
Issue 1 August 1994 14 X300 VSM
0
0

a I
Introduction
Term(s) Abbreviation Definition (if applicable)
GLOSSARY OF TERMS
Previously used term(s) (or Eng-
lish Equivalent)
gauge (gage also used, but not
preferred)
gasoline
gas tank
gear cluster
gearshift (lever), shift lever
generator GEN rotating machine which converts mechanical
energy into electrical energy
Gramme centimeter
9cm
Grammes (force) 9f
Grammes (mass) g ground GND electrical conductor used as a common re-
turn for an electrical circuit or circuits, and
with a relative zero potential
-
I Issue 1 August 1994 15 X300 VSM
gauge
petrol,
petroleum spirit
petrol tank, fuel
tank
I a ys haft
gear lever
alternator
earth

Terrn(s) Abbreviation Definition Previously used (if applicable) terrn(s1 (or Eng-
lish Eauivalent)
Hall Effect process
where current is passed through a
small slice of semi-conductor material at the
same time as a magnetic field. Produces a
small voltage
in the semi-conductor
a fault currently present
in the system
hard fault
headlamp HL
Heated Oxygen Sensor
H02S electrically heated oxygen sensor which Lambda sensor, .- induces fueling corrections. HEGO, HOS
heavy
duty HD
Hertz (frequency)
HZ frequency, one cycle per second
High Mounted
Stoplamp HMSL
high tension (electrical) ht
hood bonnet
hose clamp hose clip
hour hour
h, hr
hydrocarbon HC
hydroplaning
I aquaplaning
X300 VSM Issue 1 August 1994 16

Introduction
Term(s) Abbreviation Definition Previously used (if applicable) term(s) (or Eng
lish Equivalent)
i
1 Idle Air Control
1 Idle Air Control Valve
ignition amplifier
ignition ground
Inertia Fuel Shut
-off
Inertia Fuel Shut
-off Switch
1 intake
Intake Air
Intake Air Temperature Sensor
Ignition
Intake Air Temperature Sensor
Injection
internal diameter
International Standards Organiz
-
ation
I interrupter IAC
IACV
IA
IGN GND
IFS
IFSS
I AT
IATS
IATSI
IATSF
i.dia
IS0
electrical control of throttle bypass air
stepper motor driven device which varies the
volume of air by
-passing the throttle to
maintain the programmed idle speed
device which amplifies the ignition system
OUtDUt
an inertia system that shuts off the fuel
supply when activated by pre
-determined
force limits brought about by (e.g.) collision
shuts down fuel and ignition systems in the
event of a vehicle impact
air drawn through a cleaner and distributed
to each cylinder for use in combustion
temperature of intake air
device used to measure IAT
thermistor which signals the ECM to retard
the ignition timing
in response to high inlet
air temperatures
thermistor which inputs air density
information to the ECM idle
speed con.
trol actuator, idle
air bypass con.
trol, idle speec
control valve
inertia switch
inlet
ACT,
airtempera. ture sensor, MAT:
ATSD, VAT, TBT
interruptor
Issue 1 August 1994 17 X300 VSM

- .. I lish Equivalent)
M
Malfunction Indicator Lamp MIL
Manifold Absolute Pressure MAP
Manifold Absolute Pressure Sen
- MAPS
sor
Manifold Surface Temperature MST
manual transmission,
M/T transmission
Mass Air Flow MAF
Mass Air Flow Sensor MAFS
maximum max.
metal inert gas MIG ~
meters (measurement) m
metric
(screw thread, e.g. M8) M
MFD I Microfarad
millimeters mm
millimeters
of mercury mmHg
minimum min.
minute minute
Model Year MY
Module
M
mold
Motorized In
-Car Aspirator MIA
muffler
multiport fuel injection MFI a required
on
-board indicator to alert the
driver of an emission related malfunction
absolute pressure of the intake manifold air
sensor located in the PCM and ported to the
intake manifold
transmission which is manually, externally
controlled
system which provides information on the
mass flow rate of the intake air to the engine
hot
-wire sensor which monitors air flow into
the intake manifold for fueling and ignition
control
electric welding system in which a stream of
inert gas
shielbs~the electrode, preventing
oxidation
unit of electrical capacitance, one millionth of
a farad
self contained group of electrical/electronic
components which is designed as a single
replaceable unit
device which constantly samples cabin
temperature by passing air over a sensor,
and communicates with the
NCCM to modify
NC system performance to suit
device which causes exhaust gas flow to
expand and thereby reduce its pressure and
hence its noise fuelling failure
gearbox
air flow meter
metres
min.
mould
motorized aspi
-
rator
silencer ~~
X300 VSM 19 Issue 1 August 1994