roof 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

(if applicable) term(s) (or Eng- lish Equivalent)
I R
Radio Data System
Random Access Memory
I rear wheel drive
relay
relay module
reservoir
return
revolutions per minute
right
-hand
right
-hand drive vehicle
I rocker panel
I roof lining
RDS
RAM
ROM RWD
RM
RES
RTN
RPM
RH
RHD
local traffic information service which
automatically breaks
in to whichever station
is being received. Also programmable to
lock onto the strongest available frequency
for a given nationally available radio station,
regardless ofthe geographical location of the
receiver
fast access memory store which is accessible
for entry or extraction of data
fast access memory
in which data is fixed and
mav not be entered or extracted
an (usually) electro
-mechanical device in which connections in one circuit are opened
or closed by changes
in another circuit
a module containing two or more relays
container, usually for oils, coolants or
hydraulic fluids
a dedicated sensor ground circuit
shaft
-speed of a device, usually an engine or
motor
I
X300 VSM Issue 1 August 1994 22

i Introduction
GLOSSARY OF TERMS
0 [if applicable)
ss
Term(s) term(s) (or Eng-
lish Equivalent)
part of the shift mechanism of a manual selectorfork
transmission, mounted on the shift rail, and
relaying movement in the shift lever to the
sleeve coupling which moves gears in and
out of engagement
rail which carries the shift fork
controls shifting in an automatic
transmission
part engine, usually the cylinder block, short engine
crankshaft
I connecting rod I piston
assemblv. suDDlied as a reconditioned unit selector
rod
shift
fork
an undesirable connection between a
(usually electrical) circuit and any other point
in
-line engine which is mounted in the
vehicle at an angle from the perpendicular, as
AJ6
shift rail
shift
solenoid
inclined engine
short
block
SRCM
SIG RTN
short circuit
sun roof
sun roof control
module
slant engine
buffer block, usually of a rubber compound,
which fits between the axle and the body unit,
and absorbs any excess travel
device consisting of an electrical coil which,
when energized, produces a magnetic field
in
a plunger which is pulled to a central
position. A solenoid may be used as an
actuator
in a valve or switch
SAE
sliding roof
sliding roof control module
ci rcl
ip
bump stop
signal return
sc
snap ring
ing brake
brake lamp
sulphur,
-ic
an intake system which utilizes a
snubber
SCB
SRS
Society of Automotive Engineers
solenoid
supercharger (mechanically driven device
that pressurizes intake air, thereby increasing
density of charge air and the consequent
power output from a given displacement)
airbag restraint system for driver and front
splash
guard
speed
Speed Control Control Module
square centimeters
stabilizer bar
standard
station wagon
stop lamp
sulfur, sulfuric
supercharger
- - __. . . . ... - . Supercharger Bypass
Supplementary Restraint System Abbreviation
I Definition 1 Previously used
I mud flap
I the
magnitude of velocity (regardless of I I direction)
SCCM
I Module controlling Speed Control System I Cruise Control
cm2
std
1 seat passenger
SP I supply port of valve I
0
0
0
Issue 1 August 1994 24 X300 VSM

striker and the-fuel cap stowage magnet.
The fuel bowl, retained around the filler neck by a clip, containing a drain tube filter located over the mating drain tube,
is rubber moulded onto a steel armature and fitted to the BIW decking panel by five M5 nuts.
The fuel lid latching assembly fitted to the metal armature of the fuel bowl by an M5 nut, includes the locking pin and
the operating actuator.
The actuator operates from the central locking system driven by the security and locking control module
(SLCM).
The fuel tank, mounted across thevehicle behind the passenger compartment rear bulkhead, is held in position by two
retaining straps, tightened by two M5 fixing arrangements.
The fuel tank of AJ16 engined vehicles contains one fuel pump, supplying fuel to the normally aspirated engine and
two fuel pumps, supplyingfuel to the supercharged engine. They are regenerative turbine pumps supplied by
Nippon- Denso. Nominal operating pressure is 3 bar (3.7 bar for supercharged engine) above the manifold depression and
pump delivery is 90 litredhour minimum at 13.2 volts, 3 bar outlet pressure. The pump(s) draw a nominal current of 7 amperes at 13 volts, 3 bar outlet pressure, ambient temperatures. Built in to the pump assembly is a over-pressure
relief valve which blows at 4.5 - 8.5 bar.
Fuel is drawn by the pumps from the fuel tank and is then supplied to the fuel rail via a
70 micron filter and the fuel
feed line connected in series by fuel filter.
The amount of fuel being injected into the engine
is controlled by the fuel injectors combined with the engine control module (ECM). - Any excessive fuel flowing through the system, is returned to the fuel tankvia the fuel regulator valve mounted on the
fuel rail, the fuel return line and the check valve also located inside the tank.
The two filters prevent contaminants from entering the fuel rail and possible damage to the fuel injectors, the engine,
the pump and the underfloor filter.
The fuel pumps are switched on and off by relays controlled by the engine control module
(ECM).
The second fuel pump for the supercharged engine operates only in the higher speed range, switching on at 4000rpm and off at 3200rpm.
The fuel lines are made up of an assembly, combining steel under floor pipes and flexible conductive anti-permeation
tubing. In orderto perform speedy remove and refit operations, the underfloor steel lines are linked through the engine
bay bulkhead to the flexible tubing, leading to the fuel rail and the fuel regulator by using positive sealing, quick-fit
type connectors. The same type connectors, are used to connect the fuel feed and return line to the fuel tank.
Connectors used inside the engine bay are of different sizes tocorrespond with the difference in pipe diameter, whereas
the connectors for the feed and return lines at the fuel tank are the same size.
Except for the return line connector at the fuel tank, two release tools, one for each size of connector are required to
release all remaining connectors.
-~
Fuel, Emission Control & Engine Management (AJ16)
5.1.2 GENERAL DESCRIPTION
m: WORKING ON THE FUEL SYSTEM MAY RESULT IN FUEL AND FUEL VAPOUR BEING PRESENT IN THE
ATMOSPHERE. FUEL VAPOUR IS EXTREMELY FLAMMABLE, HENCE GREAT CARE MUST BE TAKEN WHllST WORKING ON THE FUEL SYSTEM. ADHERE STRICTLY TO THE FOLLOWING PRECAUTIONS:
DO NOT
SMOEIN THE WORK AREA.
DISPLAY 'NO SMOKING
' SIGNS AROUND THE AREA.
ENSURE THAT A
CO2 FIRE EXTINGUISHER IS CLOSE AT HAND.
ENSURE THAT DRY SAND
IS AVAILABLE TO SOAK UP ANY FUEL SPILLAGE.
EMPTY FUEL USING SUITABLE FIRE
PROOF EQUIPMENT INTO AN AUTHORIZED EXPLOSIOWROOF
CONTAINER.
DO NOT EMPTY FUEL
INTO A PIT.
ENSURE THAT WORKING AREA
IS WELL VENTILATED.
ENSURE THAT ANY WORK ON THE FUEL SYSTEM
IS ONLY CARRIED OUT BY EXPERIENCED AND WELL
QUALIFIED MAINTENANCE PERSONNEL.
The fuel filler assembly, supplied complete with serviceable lid, hinge and hinge spring, is fixed to the Body-in-White
(BIW) decking panel by two M5 nuts. Additional parts of the assembly comprise a adjustable rubber buffer, a snap-in
X300 VSM 3 Issue 1 August 1994

striker and the fuel cap stowage magnet.
The fuel bowl, retained around the filler neck by a clip, containing a drain tube filter located
overthe mating drain tube,
is rubber moulded onto a steel armature and fitted to the BIW decking panel. by five M5 nuts.
The fuel lid latching assembly fitted to the metal armature of the fuel bowl by an M5 nut, includes the locking pin and
the operating actuator.
The actuator operates from the central locking system driven by the Security and Locking Control Module (SLCM).
The fuel tank, mounted across the vehicle behind the passenger compartment rear bulkhead, is held in position by two
retaining straps, tightened by two M5 fixing arrangements.
VI2 engined vehicles are equipped with two fuel pumps located inside the tank. They are regenerative turbine pumps
supplied by Nippon Denso. Nominal operating pressure is 3 bar above the manifold depression and pump delivery
is 90 litres/hour minimum at 13.2 volts, 3 bar outlet pressure. The pump draws a nominal current of 7 amperes at 13 volts, 3 bar outlet pressure, ambient temperatures. Built in to the pump assembly is a over-pressure relief valve which
blows at 4.5 - 8.5 bar.
Fuel is drawn by the pumps from the fuel tank and is then supplied to the fuel rail via a
70 micron filter and the fuel
feed line connected in series by fuel filter.
The amount of fuel being injected into the engine is controlled by the fuel injectors combined with the engine control
module (ECM).
Any excessive fuel flowing through the system, is returned to thefuel tankvia the fuel regulator valve mounted on the
fuel rail, the fuel return line and the check valve also located inside the tank.
The two filters prevent contaminants from entering the fuel rail and possible damage to the fuel injectors, the engine,
the pump and underfloor filter.
The second fuel pump is controlled by the engine control module
(ECM) and works of a mapped fuel map. The pumps
'switch on' time depends on the fuel requirement which is depending on the engine load.
The fuel lines are made up of an assembly, combining steel underfloor pipes and flexible conductive anti
-permeation
tubing. In order to perform speedy remove and refit operations, the underfloor steel lines are linked through the engine
bay bulkhead to theflexibletubing, leading to the fuel rail and the fuel regulator by using positive sealing, quick
fit type
connectors. The same type connectors, are used to connect the fuel feed and return line to the fuel tank.
Connectors used inside the engine bay, are of different sizes to correspond with the difference in pipe diameter, where
- as the connectors for the feed and return lines at the fuel tank are the same size.
Except for the return line connector at the fuel tank, two release tools, one for each size of connector, are required to
release all remaining connectors.
Fuel, Emission Control & Engine Management (V12)
5.2.2 GENERAL DESCRIPTION
WARNING: WORKING ON THE FUEL SYSTEM RESULTS IN FUEL AND FUEL VAPOUR BEING PRESENT IN THE AT- MOSPHERE. FUEL VAPOUR IS EXTREMELY FLAMMABLE, HENCE GREAT CARE MUST BE TAKEN WHILST
WORKING ON THE FUEL SYSTEM. ADHERE STRICTLY TO THE FOLLOWING PRECAUTIONS:
PO NOT SMOKF, IN THE WORK AREA.
DISPLAY 'NO SMOKING
' SIGNS AROUND THE AREA.
ENSURE THAT A
CO2 FIRE EXTINGUISHER IS CLOSE AT HAND.
ENSURE THAT DRY SAND
IS AVAILABLE TO SOAK UP ANY FUEL SPILLAGE.
EMPTY FUEL USING SUITABLE FIRE PROOF EQUIPMENT INTO AN AUTHORIZED EXPLOSION PROOF
CONTAINER.
DO NOT EMPTY FUEL INTO A PIT.
ENSURE THAT WORKING AREA IS WELL VENTILATED.
ENSURE THAT ANY WORK ON THE FUEL SYSTEM
IS ONLY CARRIED OUT BY EXPERIENCED AND WELL
QUALIFIED MAINTENANCE PERSONNEL.
The fuel filler assembly, supplied complete with serviceable lid, hinge and hinge spring, is fixed to the Body-in-White (BIW) decking panel by two M5 nuts. Additional parts of the assembly comprise a adjustable rubber buffer, a snap-in
X300 VSM 3 Issue 1 August 1994

12.6 REAR WHEEL SPEED SENSOR - RENEW
SRO
70.60.04
. Drive the vehicle onto a ramp or raise the back and support
on two stands.
. Cut and remove the ratchet strap securing the speed sen- sor harness to the brake hose.
. Undo and remove the speed sensor to hub carrier secur- ing bolt (Fig. 1).
Remove the speed sensor from the hub carrier and allow
it to hang free, forward of the 'A' frame.
Open both rear doors and displace the rear seat cushion
from the seat pan brackets. Reposition the rear seat
cushion forwards.
9 Push the seat belts/ buckles through the seat cushion slots
and remove the rear seat cushion from the vehicle.
. Displace the RH side of the seat pan sound proofing (1 Fig. 2) to gain access to the speed sensor harness (2 Fig. 2).
9 Displace the speed sensor harness grommet (3 Fig. 2) from the seat pan aperture.
. Feed the speed sensor harness through the seat pan aper- ture and disconnect the multi-plug (4 Fig. 2).
9 Position the new speed sensor harness and connect the
multi-plug.
. Feed the speed sensor harness through the seat pan aper- ture to hang free below the vehicle.
. Refit and fully seat the speed sensor harness grommet to
the seat pan aperture.
Reposition theseat pan sound proofing to its original posi- tion.
Position the rear seat cushion and feed the seat belt / buckles through the slots.
Locate the rear seat cushion into the seat pan brackets (5 Fig. 2).
. Stow the seat belts / buckles.
. Position the speed sensor harness rearwards over the 'A'
Fit and tighten the speed sensor to hub carrier securing
Secure the speed sensor harness to the brake hose using
frame
and locate into the hub carrier.
bolt.
a ratchet strap. Trim the ratchet strap. Fig.
1
Fig. 2
Issue 1 August 1994 22 X300 VSM
0
0
0

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 -
Fixing
Seat belts
Front tear loop belt buckle to bracket fixing
Front belt buckle to bracket fixing
Tightening Torque (Nm)
30 - 40
30
- 40
Front belt reel bracket to body fixing
Front belt anchor fixing 30 - 40
30 - 40
7
-10
23
- 27
30
- 40
30 - 40
30
- 40
30 - 40
30
- 40
Front belt upper guide fixing
[Height adjuster to 'B' post screws
Height adjuster to seat belt anchor retaining
nut
Rear inertia belt anchor fixing
Rear inertia belt bracket to body fixing
Rear inertia belt reel securing bracket to body fixing
Rear inertia
/ static belt buckle bracket to body fixing ~
Rear
static belt / inertia buckle bracket to body fixing
: Sunroof ~
Sunroof frame
to roof
30 - 40
4
-5
111. SERVICE MATERIALS
Sunroof to frame 4-5
'Trunk
Compact disc autochanger bracket to body
I Battery clamp to tray
I Warning triangle lower bracket to trunk lid inner panel
9- 11
7
-10
1.5
X300 VSM V Issue 1 August 1994
I trunk lock barrel to lid
j Trunk latch actuator to bracket
Trunk latch actuator mounting to
lid
j Electrical carrier box to body
Load floor support block to body
Trunk seal retainer to body
trunk latch to lid and striker to body
4-5
7
-10
7
-10
7
-10
5
-7
9- 11
9- 11
Description Uses
'Fibrefresh' Carpet Shampoo
'1001' Foam Shampoo
'Novatreat' Cleaning
of water
-based stains from
carpets
Cleaning of water
-based stains from
carpets
Cleaning of water
-based stains from
carpets
Notes
'Genklene' (Trichloroethane)
'Spot Remover' Cleaning
of grease or oil based
stains from carpets
Cleaning of grease or oil based
stains from
caroets

Body Components & Trim
13.1 GENERAL DESCRIPTION
This section covers the following areas of the vehicle body:
0 Battery cover
0 Carpets - passenger compartment, trunk
0 Console - including radio, glovebox
0 Doors -frames, sealing, locks, trim, glazing
0 Fascia
0 Fuel filler flap assembly
0 Footrest
0 Hood - liners, gas strut, locking,
0 Illuminated sunvisor - inc mirror
0 Interior trim - trim pads, finishers, veneers
0 Mirrors - internal, external
0 Rear parcel tray
0 Roof console
0 Roof lining (headlining)
o Seats -front, rear -
0 Seat belts - front, rear
0 Sliding roof
0 Steering column cowl
0 Underscuttle pad
Refer to Appendix
A4 - Body Systems & Body Repair for information relating to crash-damage repairs and to the fol- lowing external components: exterior trim, bumpers, windscreen and rear screen, closures and sealing.
Refer to Section 15, Electrical for details of the following motors and solenoids: driver's and interior mirrors, window
lift, sunroof, seat / headrest and locking mechanisms (doors, trunk and filler cap).
Refer to Section 15, Electrical and Electrical Diagnostic Manual (EDM) for details of the passenger and driver airbags.
X300 VSM 1 Issue 1 August 1994

Body Components & Trim -
13.3.39 Roof lining (Headlining), Description
The roof lining is a one piece construction of 6mm thick polyurethane foam, covered with brush finish, suede effect,
knitted polyester.
13.3.40 Roof lining; Renew
. Position front seats fully rearwards and recline the passen-
. Disconnect vehicle battery ground lead.
. Remove:
ger
seat squab.
0 Sliding roof flange (where fitted).
0 Front passenger door.
0 Rear console (where fitted).
0 Center console.
0 Sunblind and bezel.
0 Combined grab handle and coat hook.
0 Rear quarter upper trim pad LH & RH.
0 Cantrail crash roll.
0 Illuminated sun visor.
0 Roof console.
9 Release multi-plug connectors from clips at roof console
Remove roof console retaining clip from headlining.
. Remove security sensors (where fitted) and disconnect
. Release roof lining to body tags and lower roof lining.
. Remove the roof lining:
Position the roof lining with the rear corner through the
passenger side rear door and the opposite cornerthrough
the driver side rear door.
. Position the roof lining across the car with the roof console
cut-out straddling 'B'-'C' post.
. Tip the roof lining forward against bottom of fascia with
rear edge of roof lining diagonally across door aperture.
. Carefully feed the roof lining out of the passenger side
front door, easing the edge cut-outs over the door aper- ture and any other obstruction.
aperture.
multi
-plugs.
. To
refit, carry out reversal of the above procedure.
X300 VSM 37 Issue 1 August 1994