air condition JAGUAR XJ6 1997 2.G Workshop Manual

3261 Jaguar XJ6
LIVING WITH YOUR JAGUAR XJ6
IntroductionPage 0•4
Notes for UK readersPage 0•4
Safety first!Page 0•5
Roadside repairs
IntroductionPage 0•6
If your car won’t startPage 0•6
Jump startingPage 0•7
Wheel changingPage 0•8
Identifying leaksPage 0•9
TowingPage 0•9
Weekly checks
IntroductionPage 0•10
Underbonnet check points Page 0•10
Engine oil levelPage 0•11
Coolant levelPage 0•11
Brake fluid levelPage 0•12
Screen washer fluid level Page 0•12
Power steering fluid level Page 0•13
Wiper bladesPage 0•13
Tyre condition and pressure Page 0•14
BatteryPage 0•15
Bulbs and fusesPage 0•15
Lubricants, fluids and tyre pressuresPage 0•16
MAINTENANCE
Routine maintenance and servicingPage 1•1
Servicing specificationsPage 1•2
Maintenance schedulePage 1•3
Maintenance procedures Page 1•6
Contents

3261 Jaguar XJ6
REPAIRS & OVERHAUL
Engine and associated systems
Engine in-car repair procedures Page 2A•1
Engine removal and overhaul procedures Page 2B•1
Cooling, heating and air conditioning systems Page 3•1
Fuel and exhaust systems Page 4•1
Engine electrical systems Page 5•1
Emissions and engine cone control systems Page 6•1
Transmission
Automatic transmissionPage 7•1
DrivetrainPage 8•1
Brakes and suspension
Braking systemPage 9•1
Suspension and steering systems Page 10•1
Body equipment
Bodywork and fittingsPage 11•1
Body electrical systems Page 12•1
Wiring diagramsPage 12•16
REFERENCE
Dimensions and weights Page REF•1
Jacking and vehicle support Page REF•1
Radio/cassette unit anti-theft system - precaution Page REF•1
Conversion factorsPage REF•2
Use of EnglishPage REF•3
Buying spare parts and vehicle identification Page REF•4
General repair procedures Page REF•5
Tools and working facilities Page REF•6
MOT test checksPage REF•8
Fault findingPage REF•12
Glossary of technical terms Page REF•18
IndexPage REF•22
Contents

3261 Jaguar XJ6
Safety first!0•5
Working on your car can be dangerous.
This page shows just some of the potential
risks and hazards, with the aim of creating a
safety-conscious attitude.
General hazards
Scalding
• Don’t remove the radiator or expansion
tank cap while the engine is hot.
• Engine oil, automatic transmission fluid or
power steering fluid may also be dangerously
hot if the engine has recently been running.
Burning
• Beware of burns from the exhaust system
and from any part of the engine. Brake discs
and drums can also be extremely hot
immediately after use.
Crushing
• When working under or near
a raised vehicle,
always
supplement the
jack with axle
stands, or use
drive-on
ramps.
Never
venture
under a car which
is only supported by a jack.
• Take care if loosening or tightening high-
torque nuts when the vehicle is on stands.
Initial loosening and final tightening should
be done with the wheels on the ground.
Fire
• Fuel is highly flammable; fuel vapour is
explosive.
• Don’t let fuel spill onto a hot engine.
• Do not smoke or allow naked lights
(including pilot lights) anywhere near a
vehicle being worked on. Also beware of
creating sparks
(electrically or by use of tools).
• Fuel vapour is heavier than air, so don’t
work on the fuel system with the vehicle over
an inspection pit.
• Another cause of fire is an electrical
overload or short-circuit. Take care when
repairing or modifying the vehicle wiring.
• Keep a fire extinguisher handy, of a type
suitable for use on fuel and electrical fires.
Electric shock
• Ignition HT
voltage can be
dangerous,
especially to
people with heart
problems or a
pacemaker. Don’t
work on or near the
ignition system with
the engine running or
the ignition switched on.• Mains voltage is also dangerous. Make
sure that any mains-operated equipment is
correctly earthed. Mains power points should
be protected by a residual current device
(RCD) circuit breaker.
Fume or gas intoxication
• Exhaust fumes are
poisonous; they often
contain carbon
monoxide, which is
rapidly fatal if inhaled.
Never run the
engine in a
confined space
such as a garage
with the doors shut.
• Fuel vapour is also
poisonous, as are the vapours from some
cleaning solvents and paint thinners.
Poisonous or irritant substances
• Avoid skin contact with battery acid and
with any fuel, fluid or lubricant, especially
antifreeze, brake hydraulic fluid and Diesel
fuel. Don’t syphon them by mouth. If such a
substance is swallowed or gets into the eyes,
seek medical advice.
• Prolonged contact with used engine oil can
cause skin cancer. Wear gloves or use a
barrier cream if necessary. Change out of oil-
soaked clothes and do not keep oily rags in
your pocket.
• Air conditioning refrigerant forms a
poisonous gas if exposed to a naked flame
(including a cigarette). It can also cause skin
burns on contact.
Asbestos
• Asbestos dust can cause cancer if inhaled
or swallowed. Asbestos may be found in
gaskets and in brake and clutch linings.
When dealing with such components it is
safest to assume that they contain asbestos.
Special hazards
Hydrofluoric acid
• This extremely corrosive acid is formed
when certain types of synthetic rubber, found
in some O-rings, oil seals, fuel hoses etc, are
exposed to temperatures above 400
0C. The
rubber changes into a charred or sticky
substance containing the acid. Once formed,
the acid remains dangerous for years. If it
gets onto the skin, it may be necessary to
amputate the limb concerned.
• When dealing with a vehicle which has
suffered a fire, or with components salvaged
from such a vehicle, wear protective gloves
and discard them after use.
The battery
• Batteries contain sulphuric acid, which
attacks clothing, eyes and skin. Take care
when topping-up or carrying the battery.
• The hydrogen gas given off by the battery
is highly explosive. Never cause a spark or
allow a naked light nearby. Be careful when
connecting and disconnecting battery
chargers or jump leads.
Air bags
• Air bags can cause injury if they go off
accidentally. Take care when removing the
steering wheel and/or facia. Special storage
instructions may apply.
Diesel injection equipment
• Diesel injection pumps supply fuel at very
high pressure. Take care when working on
the fuel injectors and fuel pipes.
Warning: Never expose the hands,
face or any other part of the body
to injector spray; the fuel can
penetrate the skin with potentially fatal
results.
Remember...
DO
• Do use eye protection when using power
tools, and when working under the vehicle.
• Do wear gloves or use barrier cream to
protect your hands when necessary.
• Do get someone to check periodically
that all is well when working alone on the
vehicle.
• Do keep loose clothing and long hair well
out of the way of moving mechanical parts.
• Do remove rings, wristwatch etc, before
working on the vehicle – especially the
electrical system.
• Do ensure that any lifting or jacking
equipment has a safe working load rating
adequate for the job.
A few tips
DON’T
• Don’t attempt to lift a heavy component
which may be beyond your capability – get
assistance.
• Don’t rush to finish a job, or take
unverified short cuts.
• Don’t use ill-fitting tools which may slip
and cause injury.
• Don’t leave tools or parts lying around
where someone can trip over them. Mop
up oil and fuel spills at once.
• Don’t allow children or pets to play in or
near a vehicle being worked on.

3261 Jaguar XJ6
0•6Roadside repairs
The following pages are intended to help in dealing with
common roadside emergencies and breakdowns. You will find
more detailed fault finding information at the back of the
manual, and repair information in the main chapters.
If your car won’t start
and the starter motor
doesn’t turn
MIf it’s a model with automatic transmission, make sure the
selector is in ‘P’ or ‘N’.
MOpen the bonnet and make sure that the battery terminals
are clean and tight.
MSwitch on the headlights and try to start the engine. If the
headlights go very dim when you’re trying to start, the
battery is probably flat. Get out of trouble by jump starting
(see next page) using a friend’s car.
If your car won’t start
even though the starter
motor turns as normal
MIs there fuel in the tank?
MIs there moisture on electrical components under the
bonnet? Switch off the ignition, then wipe off any obvious
dampness with a dry cloth. Spray a water-repellent aerosol
product (WD-40 or equivalent) on ignition and fuel system
electrical connectors like those shown in the photos.
Pay special attention to the ignition coil wiring connector
and HT leads.
Check the condition and security of the
battery connections.ACheck that the spark plug HT leads are
securely connected by pushing them onto
the plugs and distributorery connections.BCheck that the HT leads and wiring
connectors are securely connected to
the ignition coil.C
Check that the wiring connectors are
securely connected to the injectors and
various fuel system sensors and switches.D
Check that electrical connections are secure (with the ignition switched off) and spray them
with a water dispersant spray like WD40 if you suspect a problem due to damp

3261 Jaguar XJ6
0•10Weekly checks
There are some very simple checks which
need only take a few minutes to carry out, but
which could save you a lot of inconvenience
and expense.
These "Weekly checks" require no great skill
or special tools, and the small amount of time
they take to perform could prove to be very
well spent, for example;MKeeping an eye on tyre condition and
pressures, will not only help to stop them
wearing out prematurely, but could also save
your life.
M
Many breakdowns are caused by electrical
problems. Battery-related faults are particularly
common, and a quick check on a regular basis
will often prevent the majority of
these.MIf your car develops a brake fluid leak, the
first time you might know about it is when
your brakes don't work properly. Checking
the level regularly will give advance warning of
this kind of problem.
MIf the oil or coolant levels run low, the cost
of repairing any engine damage will be far
greater than fixing the leak, for example.
Introduction
§3.6 litre engine
(others similar)
Viewed from right-hand side
AEngine oil level dipstick
BEngine oil filler cap
CCoolant expansion tank
DBrake fluid reservoir
EScreen washer fluid reservoir
FBattery
GPower steering fluid reservoir
Underbonnet check points

3261 Jaguar XJ6
0•14Weekly checks
Tyre condition and pressure
It is very important that tyres are in good
condition, and at the correct pressure - having
a tyre failure at any speed is highly dangerous.
Tyre wear is influenced by driving style - harsh
braking and acceleration, or fast cornering,
will all produce more rapid tyre wear. As a
general rule, the front tyres wear out faster
than the rears. Interchanging the tyres from
front to rear ("rotating" the tyres) may result in
more even wear. However, if this is
completely effective, you may have the
expense of replacing all four tyres at once!
Remove any nails or stones embedded in the
tread before they penetrate the tyre to cause
deflation. If removal of a nail does reveal thatthe tyre has been punctured, refit the nail so
that its point of penetration is marked. Then
immediately change the wheel, and have the
tyre repaired by a tyre dealer.
Regularly check the tyres for damage in the
form of cuts or bulges, especially in the
sidewalls. Periodically remove the wheels,
and clean any dirt or mud from the inside and
outside surfaces. Examine the wheel rims for
signs of rusting, corrosion or other damage.
Light alloy wheels are easily damaged by
"kerbing" whilst parking; steel wheels may
also become dented or buckled. A new wheel
is very often the only way to overcome severe
damage.New tyres should be balanced when they are
fitted, but it may become necessary to re-
balance them as they wear, or if the balance
weights fitted to the wheel rim should fall off.
Unbalanced tyres will wear more quickly, as
will the steering and suspension components.
Wheel imbalance is normally signified by
vibration, particularly at a certain speed
(typically around 50 mph). If this vibration is
felt only through the steering, then it is likely
that just the front wheels need balancing. If,
however, the vibration is felt through the
whole car, the rear wheels could be out of
balance. Wheel balancing should be carried
out by a tyre dealer or garage.
Tread Depth - visual check
The original tyres have tread wear safety
bands (B), which will appear when the tread
depth reaches approximately 1.6 mm. The
band positions are indicated by a triangular
mark on the tyre sidewall (A).1Tread Depth - manual check
Alternatively, tread wear can be
monitored with a simple, inexpensive device
known as a tread depth indicator gauge.2Tyre Pressure Check
Check the tyre pressures regularly with
the tyres cold. Do not adjust the tyre
pressures immediately after the vehicle has
been used, or an inaccurate setting will result.3
Tyre tread wear patterns
Shoulder Wear
Underinflation (wear on both sides)
Under-inflation will cause overheating of the
tyre, because the tyre will flex too much, and
the tread will not sit correctly on the road
surface. This will cause a loss of grip and
excessive wear, not to mention the danger of
sudden tyre failure due to heat build-up.
Check and adjust pressures
Incorrect wheel camber (wear on one side)
Repair or renew suspension parts
Hard cornering
Reduce speed!
Centre Wear
Overinflation
Over-inflation will cause rapid wear of the
centre part of the tyre tread, coupled with
reduced grip, harsher ride, and the danger of
shock damage occurring in the tyre casing.
Check and adjust pressures
If you sometimes have to inflate your car’s
tyres to the higher pressures specified for
maximum load or sustained high speed, don’t
forget to reduce the pressures to normal
afterwards.
Uneven Wear
Front tyres may wear unevenly as a result of
wheel misalignment. Most tyre dealers and
garages can check and adjust the wheel
alignment (or "tracking") for a modest charge.
Incorrect camber or castor
Repair or renew suspension parts
Malfunctioning suspension
Repair or renew suspension parts
Unbalanced wheel
Balance tyres
Incorrect toe setting
Adjust front wheel alignment
Note: The feathered edge of the tread which
typifies toe wear is best checked by feel.

3261 Jaguar XJ6
Weekly checks0•15
Battery
Caution:Before carrying out any work on the
vehicle battery, read the precautions given in
"Safety first" at the start of this manual.
4Make sure that the battery tray is in good
condition, and that the clamp is tight.
Corrosion on the tray, retaining clamp and the
battery itself can be removed with a solution
of water and baking soda. Thoroughly rinse all
cleaned areas with water. Any metal parts
damaged by corrosion should be covered
with a zinc-based primer, then painted.
4Periodically (approximately every three
months), check the charge condition of the
battery as described in Chapter 5.
4If the battery is flat, and you need to jump
start your vehicle, see Roadside Repairs.
The battery is located in the left-hand,
rear corner of the engine compartment.
Check the battery terminals for signs of
corrosion and examine the battery leads
closely for signs of damage.1Check the battery lead clamps for
tightness to ensure good electrical
connections.2
Battery corrosion can be kept to a
minimum by applying a layer of
petroleum jelly to the clamps and
terminals after they are reconnected.If corrosion (white, fluffy deposits) is
evident, remove the cables from the
battery terminals, clean them with a small
wire brush, then refit them. Automotive stores
sell a tool for cleaning the battery post . . .3. . . as well as the battery cable clamps4
Bulbs and fuses
4Check all external lights and the horn. Refer
to the appropriate Sections of Chapter 12 for
details if any of the circuits are found to be
inoperative.4Visually check all accessible wiring
connectors, harnesses and retaining clips for
security, and for signs of chafing or damage.
If you need to check your
brake lights and indicators
unaided, back up to a wall or
garage door and operate the
lights. The reflected light should show if
they are working properly.
If a single indicator light, stop light or
headlight has failed, it is likely that a bulb
has blown and will need to be replaced.
Refer to Chapter 12 for details. If both stop
lights have failed, it is possible that the switch
has failed (see Chapter 9).If more than one indicator light or tail light
has failed it is likely that either a fuse has
blown or that there is a fault in the circuit.
The fuseboxes are located behind the left and
right side kick panels and in the centre
console glove box (see Chapter 12).
2
To replace a blown fuse, simply pull it out
and fit a new fuse of the correct rating
(see Chapter 12). If the fuse blows again,
it is important that you find out why - a
complete checking procedure is given in
Chapter 12.31

0•16Lubricants, fluids and tyre pressures
3261 Jaguar XJ6
Lubricants and fluids
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . Multigrade engine oil to API SG or higher (Duckhams QS, QXR, Hypergrade Plus,
Hypergrade, or 10W-40 Motor Oil)
Cooling system . . . . . . . . . . . . . . . . . . . Ethylene glycol based (phosphate free) antifreeze
(Duckhams Antifreeze and Summer Coolant)
Automatic transmission . . . . . . . . . . . . Dexron type II automatic transmission fluid (ATF) (Duckhams Uni-Matic)
Differential:
Standard differential . . . . . . . . . . . . . . SAE EP90 to API GL5 (Duckhams 80W-90S Gear Oil)
Powr-lok differential . . . . . . . . . . . . . . . SAE 90 to API GL5 (Duckhams Hypoid 90 DL)
Braking system . . . . . . . . . . . . . . . . . . . Hydraulic fluid to DOT 4 (Duckhams Universal Brake and Clutch Fluid)
Power steering (with separate reservoir) .dependent on year of manufacture and system fitted - refer to your Jaguar dealer
Power hydraulic system . . . . . . . . . . . . . Castrol or Jaguar hydraulic system mineral oil (HSMO) Refer to your Jaguar dealer
Tyre pressures
Note:Tyre pressures must always be checked with the tyres cold to ensure accuracy.
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 psi (2.3 bar)
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 psi (2.3 bar)
Note:Jaguar state that the tyre pressures maybe reduced by up to 8 psi (0.6 bar) on the front tyres and 6 psi (0.4 bar) on the rear
tyres to increase the ride comfort. This is only allowable if the vehicle is not to be driven at speeds in excess of 100 mph (160 kmh);
if speeds are to exceed this, the tyres must be run at the specified pressures.
Oils perform vital tasks in all engines. The
higher the engine’s performance, the greater
the demand on lubricants to minimise wear as
well as optimise power and economy.
Duckhams tailors lubricants to the highest
technical standards, meeting and exceeding
the demands of all modern engines.
HOW ENGINE OIL WORKS
• Beating friction
Without oil, the surfaces inside your engine
which rub together will heat, fuse and quickly
cause engine seizure. Oil, and its special
additives, forms a molecular barrier between
moving parts, to stop wear and minimise heat
build-up.
• Cooling hot spots
Oil cools parts that the engine’s water-based
coolant cannot reach, bathing the combustion
chamber and pistons, where temperatures
may exceed 1000°C. The oil assists intransferring the heat to the engine cooling
system. Heat in the oil is also lost by air flow
over the sump, and via any auxiliary oil cooler.
• Cleaning the inner engine
Oil washes away combustion by-products
(mainly carbon) on pistons and cylinders,
transporting them to the oil filter, and holding
the smallest particles in suspension until they
are flushed out by an oil change. Duckhams
oils undergo extensive tests in the laboratory,
and on the road.
Engine oil types
Mineral oilsare the “traditional” oils,
generally suited to older engines and cars not
used in harsh conditions. Duckhams
Hypergrade Plus and Hypergradeare well
suited for use in most popular family cars.
Diesel oilssuch as Duckhams Dieselare
specially formulated for Diesel engines,
including turbocharged models and 4x4s.
Synthetic oilsare the state-of-the-art in
lubricants, offering ultimate protection, but at
a fairly high price. One such is Duckhams QS,
for use in ultra-high performance engines.
Semi-synthetic oilsoffer high performance
engine protection, but at less cost than full
synthetic oils. Duckhams QXRis an ideal choice
for hot hatches and hard-driven cars.
For help with technical
queries on lubricants,
call Duckhams Oils
on 0181 290 8207
Choosing your engine oil
Note: It is
antisocial and
illegal to dump oil
down the drain.
To find the
location of your
local oil recycling
bank, call this
number free.

The maintenance intervals in this manual are provided with the
assumption that you, not the dealer, will be carrying out the work.
These are the minimum maintenance intervals recommended by us for
vehicles driven daily. If you wish to keep your vehicle in peak condition
at all times, you may wish to perform some of these procedures moreoften. We encourage frequent maintenance, because it enhances the
efficiency, performance and resale value of your vehicle.
When the vehicle is new, it should be serviced by a factory-
authorised dealer service department, in order to preserve the factory
warranty.
Maintenance schedule 1•3
1
3261 Jaguar XJ6
Weekly, or every 250 miles (400 km)
m mCarry out all the operations given in “Weekly
checks”at the start of this manual.
m
mRenew the fuel filter (Section 18)
m mCheck the ignition system components (Section 19)
m mCheck the crankcase ventilation system
(Section 20)
m mCheck the condition and tension of the drivebelt(s)
(Section 21)
m mCheck the front wheel bearing adjustment and
repack with grease (Section 22)
m mCheck the propshaft fasteners are tightened to the
specified torque (Section 23)
m mCheck the front wheel alignment (Section 24)
m mCheck the headlight beam alignment (Section 25)
Every 7500 miles (12 000 km)
or 6 months, whichever comes first
In addition to the operations listed previously, carry out the following:
m mRenew the engine oil and filter (Section 3)
m mCheck the spark plugs (Section 4)
m mCheck the power hydraulics fluid level (Section 5)
m mCheck the battery (Section 6)
m mCheck all pipes and hoses for signs of damage or
leakage (Section 7)
m mCheck the automatic transmission fluid level
(Section 8)
m mCheck the differential oil level (Section 9)
m mCheck the condition of the exhaust system
(Section 10)
m mCheck the brake pads and discs for wear and
adjust the handbrake (Section 11)
m mCheck the steering and suspension components
for wear or damage and check the wheel nuts are
tightened to the correct torque (Section 12)
m mCheck the condition of the seat belts (Section 13)
m mLubricate all locks and hinges, and exposed cables
(Section 14)
m mCarry out a road test (Section 15)
Every 2 years, regardless of mileage
m
mRenew the coolant (Section 30)
Every 60 000 miles (96 000 km)
In addition to the operations listed previously, carry out the following:
m
mCheck the handbrake shoes for wear (Section 29)
Every 30 000 miles (48 000 km)
or 2 years, whichever comes first
In addition to the operations listed previously, carry out the following:
m mRenew the automatic transmission fluid and filter
(Section 26)
m mRenew the differential oil (Section 27)
m mRenew the brake fluid (Section 28)
Every 15 000 miles (24 000 km)
or 12 months, whichever comes first
In addition to the operations listed previously, carry out the following:
m mRenew the spark plugs (Section 16)
m mRenew the air cleaner element (Section 17)

Maintenance - component location 1•5
1
3261 Jaguar XJ6
Front underbody view
1 Air conditioning compressor
2 Drivebelts
3 Anti-roll bar
4 Alternator
5 Lower radiator hose
6 Lower control arm
7 Steering gear boot
8 Steering gear
9 Engine sump drain plug
10 Exhaust system
11 Outer tie-rod end
Rear underbody view (typical)
1 Rear suspension control arms
2 Differential drain plug
3 Differential filler plug
(not visible)
4 Exhaust pipe
5 Driveshaft
6 Silencers
7 Handbrake cable
8 Fuel filter