open hood JAGUAR XJ6 1994 2.G Workshop Manual

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

Automatic Transmission (V12 & AJ16 Supercharged) Pomrtrain
8.2.2 TRANSMISSION INTERNAL HARNESS, RENEW
SRO 44.15.35
. 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
U: Note the internal harness cable runs for assembly
purposes and remove the transmission internal har- ness multi-pin socket (1 Fig. I), discarding the '0' ring seal (2 Fig. 1); see Sub-section 8.2.19.
. Disconnect the internal harness plug from the 'A' Shift
. Disconnect the internal harness plug from the 'B' Shift
. Disconnect the internal harness plug from the pressure
. Disconnect the internal harness plug from the pulse width
. Disconnect the internal harness plug from the variable
force motor.
. Displace the internal harness from the retaining clips.
Remove the internal harness from the transmission unit.
. Place the harness aside.
. Clean all relevant parts.
. Fit the new internal harness to the transmission unit.
. Secure the internal harness to its retaining clips.
. Connect the internal harness plug to the variable force
. Connect the internal harness plug to the pulse width
. Connect the internal harness plug to the pressure switch
. Connect the internal harness plug to the 'B' Shift solenoid.
. Connect the internal harness plug to the 'A' Shift solenoid.
Fit a new internal harness multi-pin socket '0 ring, refit
the multi-pin socket to the main case and connect the ex- ternal harness, see Subsection 8.2.19.
. Refit the fluid pan, see Subsection 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 Subsection 8.2.13.
Remove the fender cover and close the hood.
(4, OL SC AND 6,OL) e
tion 8.2.13.
Sub-section 8.2.15 (6,OL).
solenoid.
solenoid.
switch manifold.
modulator (TCC solenoid).
motor.
modulator.
manifold.
@
2
Fig 1
Issue 1 August 1994 X300 VSM 5

Automatic Transmission (V12 & AJ16 Supercharged) Powertrain
8.2.3
SRO 44.15.39
. Open the hood and fit a suitable fender cover.
9 Raise the vehicle on a ramp.
. Drain the transmission lubrication system, see Subsec-
. Remove the fluid pan, see Sub-section 8.2.14 (4,OL SC) or
. Remove the fluid filter, see Sub-section 8.2.18.
Disconnect the internal harness plug from the pressure
Release and remove the pressure switch manifold to valve
. Remove the manifold from the valve body.
. Retrieve the manifold to valve body '0' ring seals (Fig.1)
Clean the valve body manifold seating area.
. Fit new '0' ring seals to the grooves in a new pressure
Fit the manifold to the valve body.
. Fit and tighten the manifold to valve body securing bolts.
Connect the internal harness plug to the pressure switch
Refit the fluid filter, see Sub-section 8.2.18.
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
. Remove the fender cover and close the hood.
PRESSURE SWITCH MANIFOL D, RENEW
(4,OL SC AND 6,OL)
tion 8.2.13.
Sub
-section 8.2.15 (6,OL).
switch manifold.
body securing bolts.
and discard.
switch manifold.
manifold.
Sub
-section 8.2.15 (6,OL).
8.2.13. Fig.
1
Issue 1 August 1994 6 X300 VSM

Automatic Transmission (V12 & AJ16 Supercharged) Powertrain
8.2.6
SRO 44.15.40
. 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.
INPUT SPEED SENSOR, RENEW (6,OL)
curing bolts.
Slacken the underfloor catalyst
to intermediate silencer
clamps securing bolts.
9 Displace the underfloor catalyst assembly rearwards to
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
. Reposition the edge of the transmission tunnel insulation
. Release and remove the input speed sensor securing bolt.
. Reposition the speed sensor protection cover for access,
noting that the cover remains captive on the harness.
Disconnect the speed sensor harness multi
-pin plug.
- Displace and remove the speed sensor from the trans- mission case.
Clean the transmission case area.
. Fit a new ‘0 ring seal to a new input speed sensor.
. Lubricate the ‘0 ring seal.
. Fit and fully seat the speed sensor to the transmission
. Reconnect the harness multi-pin plug.
Reposition and align the protection cover.
. Fit and tighten the speed sensor securing bolt.
Reposition the insulation foam to its original position.
Remove the block of wood from between the underfloor
. Apply sealant to the downpipe joints and olives. See Ser-
Fit and seat the olives 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.
Remove the fender cover and close the hood.
catalyst
and the body for access.
foam for access.
0
case.
catalyst and the floor.
vice Materials
in the preliminary pages, this Section.
Reconnect the underfloor catalyst to the downpipes.
0
ing bolts.
assembly.
lppl
0
X300 VSM issue 1 August 1994 8

Powertwin Automatic Transmission (V12 & AJ16 Supercharged)
8.2.7
SRO 44.15.41
OUTPUT SPEED SENSOR, RENEW (6,OL)
. 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.
Place a suitable piece of wood between the underfloor
catalyst and the body for access.
. Reposition the edge of the transmission tunnel insulation
foam for access.
. Release and remove the output speed sensor securing
bolt.
Reposition the speed sensor protection cover for access,
noting that the cover remains captive on the harness.
. Disconnect the speed sensor harness multi-pin plug.
. Displace and remove the speed sensor from the trans-
. Clean the transmission case sensor area.
. Fit a new '0' ring seal to a new output speed sensor.
. Lubricate the '0' ring seal.
Fit and fully seat the speed sensor to the transmission
. Reconnect the harness multi-pin plug.
Reposition and align the protection cover.
. Fit and tighten the speed sensor securing bolt.
Reposition the insulation foam to its original position.
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.
. Remove the fender cover and close the hood.
curing
bolts.
cl amps securing bolts.
disconnect from the downpipes.
mission case.
case.
0
ing bolts.
assembly.
Issue 1 August 1994 X300 VSM 9

Automatic Transmission (V12 & AJ16 Supercharged) Powertrain
8.2.8 TEMPERATURE SENSOR, RENEW
(4,OL SC AND 6,011
The temperature sensor forms part of the internal wiring
harness. Should the sensor require replacement, a new wir- ing harness must be fitted. See Subsection 8.2.2.
8.2.9 VARIABLE FORCE MOTOR, RENEW
SRO 44.15.43
. 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
Remove the fluid filter, see Subsection 8.2.18.
Disconnect the internal harness plug from the variable
Release and remove the motor retaining clamp to valve
. Remove the retaining clamp (2 Fig.1) and remove the
Fit a new variable force motor to the valve body.
CAUTIOI\I: Do not adjust the motor screw and ensure that
the motor filter is not damaged.
. Align the motor.
. Fit the motor to the valve body retaining clamp.
. Fit and tighten the motor retaining clamp securing screw.
Connect the internal harness
plug to the motor.
. Refit the fluid filter, see Sub-section 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
(4,OL SC AND 6,011
tion 8.2.13.
Sub
-section 8.2.15 (6,OL).
force motor.
body securing screw (1
Fig.1).
motor (3 Fig.1) from the valve body and place aside.
Sub
-section 8.2.15 (6,OL).
8.2.13.
m Remove the fender cover and close the hood.
JU 596
Fig. 1
X300 VSM Issue 1 August 1994 10

Powortrain Automatic Transmission (V12 & AJl6 Supercharged)
8.2.10 PULSE WIDTH MODULATOR (TCC
SRO 44.15.44
. Open the hood and fit a suitable fender cover.
. Raise the vehicle on a ramp.
Drain the transmission lubrication system, see Sub-se
. Remove the fluid pan, see Subsection 8.2.14 (4,OL SC) or
. Remove the fluid filter, see Subsection 8.2.18.
. Disconnect the internal harness plug from the pulse width
. Remove the modulator to valve body retaining clip.
. Displace and remove the modulator from the valve body,
. Remove and discard the '0' ring seals from the modulator.
Place the modulator aside.
Fit new '0' ring seals to a new pulse width modulator.
. Lubricate the '0' ring seals.
. Fit and seat the modulator, in the correct orientation, to the
. Fit the pulse width modulator to valve body retaining clip.
. Connect the internal harness plug to the modulator.
. 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.
SOLENOID), RENEW (4,OL SC AND 6,OL) a
tion 8.2.13.
Subsection 8.2.15
(6,OL).
modulator.
noting the orientation.
valve body using a twisting motion.
Sub
-section 8.2.15 (6,OL).
X300 VSM 11 Issue 1 August 1994

Automatic Transmission (V12 & AJ16 Supercharged)
8.2.11 'A' SHIFT SOLENOID, RENEW
(4,Ol SC AND 6,OL)
SRO 44.15.45
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 internal harness plug from the 'A' Shift
. Release and remove the 'A' Shift solenoid to valve body
. Remove the solenoid from the valve body (Fig. 1).
= Remove and discard the '0' ring seal from the valve body.
. Place the solenoid aside.
. Fit a new '0 ring seal to a new 'A' Shift solenoid.
. Lubricate the '0' ring seal.
Fit the solenoid to the valve body using a twisting motion.
. Fit and tighten the solenoid to the valve body using a new
. Connect the internal harness plug to the solenoid.
. 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
Remove the fender cover and close the hood.
tion
8.2.13.
Sub
-section 8.2.15 (6,OL).
solenoid.
securing screw.
securing screw.
Sub
-section 8.2.15 (6,OL).
8.2.13.
Fin. 1
Issue 1 August 1994 12 X300 VSM

Pomrtrain Automatic Transmission (V12 & AJ16 Supercharged)
8.2.12 '6' SHIFT SOLENOID, RENEW
(4,OL SC AND 6,OL)
SRO 44.15.46
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
. Disconnect the internal harness plug from the 'B' Shift
. Release and remove the 'B' Shift solenoid to valve body
. Remove the solenoid from the valve body (Fig. 1).
. Remove and discard the '0' ring seal from the solenoid.
= Place the solenoid aside.
. Fit a new '0' ring seal to a new 'B' Shift solenoid.
. Lubricate the '0' ring seal.
. Fit the solenoid to thevalve body using a twisting motion.
. Fit and tighten the solenoid to the valve body using a new
. Connect the internal harness plug to the solenoid.
. 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.
tion
8.2.13.
Subsection 8.2.15
(6,OL).
solenoid.
securing screw.
securing screw.
Sub
-section 8.2.15 (6,OL).
Fig. 1
X300 VSM 13 Issue 1 August 1994

Automatic Transmission (V12 & AJ16 Supercharged) Powertrain
0
8.2.13 LUBRICATION SYSTEM, DRAIN AND REFILL
(4,OL SC AND 6,OL)
SRO 44.24.02
. Raise the vehicle on a ramp.
. Position a drain tin below the transmission unit.
. Release and remove the fluid pan drain plug.
. Allow the fluid to drain.
Clean the drain plug, including the magnet and the fluid
pan drain plug face.
. Fit and tighten the fluid pan drain plug.
. Remove the drain tin from below the transmission unit.
. Lower the vehicle on the ramp.
Open the hood and fit
a suitable fender cover.
Remove and wipe the dipstick.
. Fit a funnel to the dipstick tube.
. Initially fill the transmission with 4,5 liters of fluid.
. Remove the funnel.
. Open the front door.
. Check that the parking brake is applied.
. Start the engine.
Apply the footbrake.
Run the shift lever through all positions, finally returning
to the Park position.
. Release the footbrake.
. Insert the dipstick, then remove and inspect the level.
. Fit the funnel to the dipstick tube.
. Fill the transmission to the 'COLD' level mark on the dip-
stick with the correct fluid, see the Powertrain Automatic
Transmissions Service Manual, General Data.
CAUTION: On no account should the vehicle be driven un- less the fluid level is at the 'COLD' level and the
system primed.
0
Remove the funnel.
. Replace the dipstick.
. Switch the ignition OFF.
. Remove the fender cover and close the hood.
= Close the door.
J&&Q: 0 After road testing the vehicle, the fluid level on the
dipstick should be between the 'HOT' Min I Max
marks. Check the level with the transmission at nor-
mal operating temperature (90 to 100°C), with the
engine left running and the transmission in the Park
position.
m
0
Issue 1 August 1994 14 X300 VSM ~
__