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Jaguar XJ6 Service and Repair Manual

1. 33 34 to 33 35 mm 1 3126 to 1 3130 inches Oil clearance 0 020 to 0 050 mm 0 0008 to 0 0020 inch Valve clearances 0 30 to 0 36 mm 0 012 to 0 014 inch Oil pump Outer rotor to body clearance maximum 0 2 mm 0 0079 inch Outer rotor OD 69 774 to 69 825 mm 2 7470 to 2 7490 inches Rotor thickness inner and outer 27 962 to 27 975 mm 1 1008 to 1 1013 inches Clearance over rotors maximum 0 1 mm 0 0039 inch Auxiliary shaft renewal 9 Camshafts and lifters removal inspection and refitting 10 CHECK ENGINE light See Chapter 6 Crankshaft front oil seal renewal 7 Crankshaft rear oil seal renewal 15 Cylinder compression check See Chapter 2B Cylinder he
2. 30 Crankcase ventilation system check 20 Differential oil level check 9 Differential oil renewal 27 Drivebelt check and renewal 21 Engine oil and filter renewal 3 Exhaust system check 10 Front wheel alignment check 24 Front wheel bearing check and adjustment 22 Fuel filter renewal 18 General information 1 General lubrication 14 Handbrake shoes check 29 Headlight beam check 25 Hose and fluid leak check 7 Ignition system check
3. 0 02 to 0 05 mm 0 0008 to 0 0020 inch Crankshaft and connecting rods Connecting rod journal Diameter 52 97 to 52 99 mm 2 0856 to 2 0861 inches Taper and out of round limits 0 008 mm 0 0003 inch maximum Bearing oil clearance 3 6 litre 0 040 to 0 083 mm 0 0016 to 0 0033 inch 3 2 and 4 0 litre 0 025 to 0 0068 mm 0 0010 to 0 0027 inch Connecting rod side clearance endplay 0 127 to 0 228 mm 0 005 to 0 009 inch Main bearing journal Diameter 76 217 to 76 233 mm 3 0007 to 3 0012 inches Taper and out of round limits 0 008 mm 0 0003 inch maximum Bearing oil clearance 0 040 to 0 083 mm 0 0016 to 0 0033 inch Crankshaft endplay standard 0 101 to 0 254 mm 0 004 to 0 010 inch CHECK ENGINE light
4. 9 Drivebelt check adjustment and renewal See Chapter 1 General information 1 Ignition coil check and renewal 8 Ignition system check 6 Ignition system general information and precautions 5 Spark plug renewal See Chapter 1 Spark plug lead distributor cap and rotor check and renewal See Chapter 1 Starter motor removal and refitting 15 Starter motor testing in vehicle 14 Starter solenoid removal and refitting 16 Starting system general information and precautions 13 5 1 Specifications Contents Easy suitable for novice with little experience Fairly easy suitable for beginner with some experience Fairly difficult suitable for competent DIY mechanic Difficult suitable for experienced DIY mechanic Very difficult suitable for expert DIY or professional Degrees of difficulty 5 4 3 2 1 1 General information The engine ele
5. See Chapter 2B Water pump removal and refitting See Chapter 3 2A 1 Specifications Contents Easy suitable for novice with little experience Fairly easy suitable for beginner with some experience Fairly difficult suitable for competent DIY mechanic Difficult suitable for experienced DIY mechanic Very difficult suitable for expert DIY or professional Degrees of difficulty 5 4 3 2 1 Torque wrench settings Nm lbf ft Camshaft bearing cap bolts 23 to 27 16 to 20 Camshaft sprocket bolts 23 to 27 16 to 20 Crankshaft damper to crankshaft bolt 3 2 and 3 6 litre 204 151 4 0 litre 180 to 220 133 to 162 Crankshaft pulley to damper bolts 23 to 27 16 to 20 Crankshaft rear oil seal retainer bolts 23 to 27 16 to 20 Crankshaft sensor bolts 23 to 27 16 to 20 Cylinder head bolts Step 1
6. 60 44 Step 2 Tighten an additional 90 1 4 turn Driveplate bolts 123 to 149 91 to 110 Engine mounts To engine block 49 to 66 36 to 39 To chassis 22 to 24 16 to 18 Exhaust manifold heat shield fasteners 23 to 27 16 to 20 Exhaust manifold nuts 23 to 27 16 to 20 Intake manifold nuts 23 to 27 16 to 20 Oil pump bolts 23 to 27 16 to 20 Sump bolts 23 to 27 16 to 20 Sump bolts adapter to pan 49 to 54 36 to 40 Timing chain cover 23 to 27 16 to 20 Valve cover screws
7. 14 Centre console removal and refitting 24 Cowl cover removal and refitting 28 Dashboard trim panels removal and refitting 26 Door removal refitting and adjustment 19 Door latch lock cylinder and handles removal and refitting 20 Door trim panel removal and refitting 18 Door window glass removal and refitting 22 Door window glass regulator removal and refitting 21 Front spoiler removal and refitting 13 Front wing removal and refitting 15 General information 1 Hinges and locks maintenance 7 Instrument cluster housing removal and refitting 25 Outside mirrors removal and refitting 23 Radiator grille removal and refitting 12 Seats removal and refitting 29 Steering column cover removal
8. 7 Wheel alignment general information 21 Wheel bearing lubrication See Chapter 1 Wheels and tyres general information 20 10 1 Specifications Contents Easy suitable for novice with little experience Fairly easy suitable for beginner with some experience Fairly difficult suitable for competent DIY mechanic Difficult suitable for experienced DIY mechanic Very difficult suitable for expert DIY or professional Degrees of difficulty 5 4 3 2 1 1 2 Front suspension left corner 1 Anti roll bar bushing bracket 2 Anti roll bar link 3 Anti roll bar 4 Coil spring pan 5 Lower control arm 6 Coil spring 7 Upper control arm 8 Lower balljoint 9 Steering knuckle 10 Tie rod end 11 Tie rod 12 Steering gear boot 10 2 Suspension and steering systems 1 1 Front suspension and steering systems 1 Anti roll bar 2 Anti roll bar bushing brackets 3 Anti roll bar links 4 Lower control arms 5 Steering knuckles 6 Tie rod ends 7 Tie rods 8 Steering gear boots 9 Steering gear 10 Suspension crossmember 11 Lower control arm crossbrace 3261 Jaguar XJ6 1 General information Warning Whenever any of the suspension or steering fasteners are loosened or removed they must be inspected and if necessary replac
9. 1 5 3 6 2 4 Displacement 3 2 litre engine 3239 cc 3 6 litre engine 3590 cc 4 0 litre engine 3980 cc Bore 91 0 mm 3 583 inches Stroke 3 2 litre engine 83 0 mm 3 268 inches 3 6 litre engine 92 0 mm 3 622 inches 4 0 litre engine 102 0 mm 4 016 inches Camshafts and lifters Journal diameter 26 9370 to 26 9494 mm 1 0605 to 1 0610 inches Bearing oil clearance 0 037 to 0 063 mm 0 0014 to 0 0024 inch Runout limit 0 0406 mm 0 0016 inch Lobe lift maximum variation between lobes 0 0127 mm 0 005 inch Valve lifter Diameter
10. 2015 mm Overall height unladen 1358 mm Wheelbase 2870 mm Weights Kerb weight 1770 kg Maximum gross vehicle weight 2190 kg Maximum towing weight Braked trailer 1500 kg Unbraked trailer 750 kg Maximum axle load Front axle 1050 kg Rear axle 1170 kg Maximum roof rack load 100 kg Reference REF 1 Radio cassette unit anti theft system precaution Some models are equipped with an audio system which includes an anti theft feature to deter thieves If the power source to the unit is cut the anti theft system will activate Even if the power source is immediately reconnected the radio cassette unit will not function until the correct security code has been entered There
11. 1 Information sensors 4 On Board Diagnosis OBD system description and fault code access 3 6 1 Specifications Contents Easy suitable for novice with little experience Fairly easy suitable for beginner with some experience Fairly difficult suitable for competent DIY mechanic Difficult suitable for experienced DIY mechanic Very difficult suitable for expert DIY or professional Degrees of difficulty 5 4 3 2 1 1 General information To minimise pollution of the atmosphere from incompletely burned and evaporating gases and to maintain good driveability and fuel economy a number of emission control systems are used on these vehicles They include the Air Injection Reactor AIR system Crankcase Ventilation system Exhaust Gas Recirculation EGR system Electronic Fuel Injection EFI system Evaporative Emission Control EVAP system Three way catalytic converter TWC system The sections in this chapter include general descriptions checking procedures within the scope of the home mechanic and component renewal procedures when possible for each of the systems listed above Before assuming an emissions control system is malfunctioning check the fuel and ignition systems carefully Chapters 4 and 5 The diagnosis of some emission control devices requ
12. 10 to 12 7 to 9 Note Refer to Part B for additional specifications 2A 2 Engine in car repair procedures 3261 Jaguar XJ6 1 General information This Part of Chapter 2 is devoted to in car repair procedures for the in line six cylinder engines All information concerning engine removal and refitting and engine block and cylinder head overhaul can be found in Part B of this Chapter The following repair procedures are based on the assumption that the engine is installed in the car If the engine has been removed from the car and mounted on a stand many of the steps outlined in this Part of Chapter 2 will not apply We have photographed some in car engine procedures with the engine on a stand for photographic purposes The Specifications included in this Part of Chapter 2 apply only to the procedures contained in this Part Part B of Chapter 2 includes the Specifications necessary for cylinder head and engine block rebuilding 2 Repair operations possible with the engine in the car Many repair operations can be accomplished without removing the engine from the car Clean the engine compartment and the exterior of the engine with some type of degreaser before any work is done It will make the job easier and help keep dirt out of the internal areas of the engine Depending on the components involved it may be helpful to remove the bonnet to improve access to the engine as repairs are performed ref
13. See Chapter 6 Crankshaft inspection 19 Crankshaft refitting and main bearing oil clearance check 23 Crankshaft removal 14 Cylinder head cleaning and inspection 10 Cylinder head dismantling 9 Cylinder head reassembly 12 Cylinder compression check 4 Cylinder honing 17 Engine block cleaning 15 Engine block inspection 16 Engine overhaul dismantling sequence 8 Engine overhaul general information 2 Engine overhaul reassembly sequence 21 Engine rebuilding alternatives 7 Engine removal and refitting 6 Engine removal methods and precautions
14. See Chapter 1 Torque wrench settings Nm lbf ft Front suspension Balljoints Retaining bolts 55 to 62 41 to 45 Ball stud nuts 47 to 68 35 to 50 Lower control arm Spring pan bolts 26 to 34 19 to 25 Pivot nuts bolts 43 to 68 32 to 50 Shock absorber Lower nut 61 to 68 45 to 50 Upper nut 35 to 43 26 to 31 Anti roll bar Bushing bracket bolts Upper 22 to 28 16 to 20 Lower 24 to 30 18 to 22 Link nuts 55 to 60 41 to 44 Upper control arm pivot nuts bolts 61 to 75 45 to 55 Rear suspension Carrier to control arm bolt nut 70
15. 19 Intensive maintenance 2 Power hydraulic system fluid level check 5 Propshaft check 23 Road test 15 Seat belt check 13 Spark plug check 4 Spark plug renewal 16 Steering and suspension check 12 1 1 Contents Easy suitable for novice with little experience Fairly easy suitable for beginner with some experience Fairly difficult suitable for competent DIY mechanic Difficult suitable for experienced DIY mechanic Very difficult suitable for expert DIY or professional Degrees of difficulty 5 4 3 2 1 Lubricants and fluids Refer to Weekly checks Capacities Engine oil Including oil filter 8 0 litres Cooling system All models approximate From dry
16. 5 General information 1 Initial start up and running in after overhaul 26 Main and connecting big end bearings inspection and selection 20 Pistons connecting rods inspection 18 Pistons connecting rods refitting and big end bearing oil clearance check 25 Pistons connecting rods removal 13 Piston rings refitting 22 Rear main oil seal refitting 24 Vacuum gauge diagnostic checks 3 Valves servicing 11 2B 1 Specifications Contents Easy suitable for novice with little experience Fairly easy suitable for beginner with some experience Fairly difficult suitable for competent DIY mechanic Difficult suitable for experienced DIY mechanic Very difficult suitable for expert DIY or professional Degrees of difficulty 5 4 3 2 1 Engine block Deck warpage limit 0 076 mm 0 0
17. 280 to 320 40 to 46 Vacuum hose attached to fuel pressure regulator 210 to 260 30 to 38 Fuel system hold pressure 145 21 Fuel injector resistance 2 0 to 3 0 ohms Idle speed Must be set by authorised service department Torque wrench settings Nm lbf ft Throttle body mounting bolts 19 14 Fuel rail mounting bolts 12 9 Accelerator cable removal refitting and adjustment 10 Air cleaner assembly removal and refitting 9 Catalytic converter See Chapter 6 CHECK ENGINE light See Chapter 6 Electronic Fuel Injection EFI system check 12 Electronic Fuel Injection EFI system component check and renewal 13 Electronic Fuel Injection EFI system general information 11 Exhaust manifold removal and refitting See Chapter 2A
18. 10 6 to 11 3 bar 150 to 160 psi High compression models 11 3 to 12 1 bar 160 to 170 psi Maximum variation between cylinders 0 8 bar 10 psi Oil pressure engine warm At idle 2 1 bar 30 psi minimum At 4000 rpm 4 9 bar 70 psi minimum Cylinder head Resurfacing limit 0 25 mm 0 010 inch maximum Minimum thickness see text 3 6 litre 129 6 mm 5 101 inches 3 2 and 4 0 litre 129 7 mm 5 108 inches Valves and related components Valve stem to guide clearance 0 038 to 0 076 mm 0 0015 to 0 0030 inch Valve springs free length 40 13 mm 1 580 inches Valve lifter Diameter 33 34 to 33 35 mm 1 3126 to 1 3130 inches Lifter to bore clearance
19. Worn or damaged distributor components Chapter 5 Faulty emission system Chapter 6 Vacuum leak Chapter 4 Fuel rail feed inlet hose has hardened resulting in knocking noise near dash see Chapter 4 Engine lacks power Incorrect ignition timing Chapter 5 Excessive play in distributor shaft Chapter 5 Worn rotor distributor cap or wires Chapters 1 and 5 Faulty or incorrectly gapped spark plugs Chapter 1 Fuel injection system malfunctioning Chapter 4 Faulty coil Chapter 5 Brakes binding Chapter 1 Automatic transmission fluid level incorrect Chapter 1 Fuel filter clogged and or impurities in the fuel system Chapter 1 Emission control system not functioning properly Chapter 6 Low or uneven cylinder compression pressures Chapter 2 Engine rattles at start up Failure of upper timing chain tensioner Chapter 2 Engine backfires Emissions system not functioning properly Chapter 6 Ignition timing incorrect Chapter 1 Faulty secondary ignition system cracked spark plug insulator faulty plug leads distributor cap and or rotor Chapters 1 and 5 Fuel injection system malfunctioning Chapter 4 Vacuum leak at fuel injector s intake manifold or vacuum hoses Chapter 4 Engine stalls Idle speed incorrect Chapter 1 Fuel filter clogged and or water and impurities in the fuel system Chapter 1 Distributor components damp or damaged Chapter 5
20. 12 8 litres Drain and refill 9 2 litres Transmission Automatic transmission approximate From dry 3 2 litre model 7 4 litres 3 6 and 4 0 litre models 8 0 litres Drain and refill 3 0 litres Differential All models approximate 2 1 litres Cooling system Antifreeze mixture 50 antifreeze Protection down to 37 C 5 F 55 antifreeze Protection down to 45 C 22 F Note Refer to antifreeze manufacturer for latest recommendations Ignition system Spark plugs Type 3 2 litre model RC12YCC 3 6 and 4 0 litre models RC9YCC Electrode gap 0 9 mm The spark plug gap quoted is that recommended by Champion for their specified plug listed above If spark p
21. 21 4 Measuring drivebelt deflection with a straightedge and ruler 21 6a To adjust the alternator power steering drivebelt loosen the outer locknut arrowed and the alternator pivot bolt turn the inner locknut anti clockwise to loosen or clockwise to tighten the belt 21 6b To adjust the air conditioning compressor drivebelt loosen the outer locknut arrowed and the compressor pivot bolts turn the inner locknut anti clockwise to loosen or clockwise to tighten the belt 3261 Jaguar XJ6 compressor belt first because of the way they are arranged on the crankshaft pulley Because of this and because belts tend to wear out more or less together it is a good idea to replace both belts at the same time Mark each belt and its appropriate pulley groove so the new belts can be installed in their proper positions 10 Take the old belts to the parts store in order to make a direct comparison for length width and design 11 After replacing a ribbed drivebelt make sure that it fits properly in the ribbed grooves in the pulleys see illustration It is essential that the belt be properly centred 12 Adjust the belt s in accordance with the procedure outlined above 22 Front wheel bearing check and adjustment 3 Check and repack 1 In most cases the front wheel bearings will not need servicing until the brake pads are changed However the bearings should be checked whenever the front of the vehicle is raised for any reason
22. Faulty emissions system components Chapter 6 Faulty or incorrectly gapped spark plugs Chapter 1 Faulty spark plug leads Chapter 1 Vacuum leak in the fuel injection system intake manifold or vacuum hoses Chapter 4 Engine runs with oil pressure light on Low oil level Chapter 1 Idle rpm too low Chapter 1 Short in wiring circuit Chapter 12 Faulty oil pressure sending unit Chapter 2 Worn engine bearings and or oil pump Chapter 2 Engine diesels continues to run after switching off Idle speed too high Chapter 4 Excessive engine operating temperature Chapter 3 Incorrect fuel octane grade Excessive fuel consumption Dirty or clogged air filter element Chapter 1 Incorrectly set ignition timing Chapter 5 Emissions system not functioning properly Chapter 6 Fuel injection internal parts worn or damaged Chapter 4 Low tyre pressure or incorrect tyre size Chapter 1 Fuel leakage and or fuel odour Leak in a fuel feed or vent line Chapter 4 Tank overfilled Fuel injector internal parts excessively worn Chapter 4 3 Cooling system Overheating Insufficient coolant in system Chapter 1 Water pump drivebelt defective or out of adjustment Chapter 1 Radiator core blocked or grille restricted Chapter 3 Thermostat faulty Chapter 3 Radiator cap not maintaining proper pressure Chapter 3 Ignition timing incorrect Chapter 5 Overcooli
23. 25 17 Measure the width of the crushed Plastigauge to determine the big end bearing oil clearance 3261 Jaguar XJ6 3261 Jaguar XJ6 3 Chapter 3 Cooling heating and air conditioning systems General Radiator cap pressure rating 13 5 to 117 5 psi Thermostat rating 180 to 207 F Torque wrench settings Nm lbf ft Coolant pipe to block 22 to 28 16 to 21 Fan assembly to drive hub nuts 22 to 28 16 to 21 Fan clutch to fan blade bolts 22 to 28 16 to 21 Thermostat cover bolts 22 to 28 16 to 21 Thermostat housing to block bolts 22 to 28 16 to 21 Water pump bolts 22 to 28 16 to 21 Air conditioning and heating system check and maintenance 13 Air conditioning compressor removal and refitting 15 Air conditioning condenser removal and refitting 16 Air conditioning evaporator and expansion valve removal and re
24. 8 Steering column switches removal and refitting 1 Warning Later models are equipped with airbags To prevent accidental deployment of the airbag which could cause personal injury or damage to the airbag system DO NOT work in the vicinity of the steering column or instrument panel The manufacturer recommends that on airbag equipped models the following procedure be performed at a dealer service department or other properly equipped repair facility because of the special tools and techniques required to disable the airbag system Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 1 Disconnect the negative battery cable 2 Remove the steering wheel Chapter 10 3 Remove the lower steering column cover see Chapter 11 4 Remove the switch retaining screw s see illustration Body electrical system 12 5 12 3261 Jaguar XJ6 1993 to 1994 relay location details 8 4 Remove the switch retaining screws disconnect the electrical connectors and pull the switches outward arrowed 5 Disconnect the electrical connectors from underneath the steering column and remove the switch or switches from the vehicle 6 Refitting is the reverse of removal 9 Ignition switch and key lock cylinder removal and refitting 2 Warning Later models are equipped with airbags To prevent accidental deplo
25. 9 Refit the switch assembly and the switch plate bolts but don t tighten the bolts yet 10 Plug in the brake light and cruise control connectors 11 The holes in the switch plate are slotted for adjustment While an assistant presses the brake pedal verify that the brake lights come on with the pedal released make sure the brake lights are off If the lights don t come on when the pedal is depressed or stay on when the pedal is released adjust the switch by moving the plate until proper operation is achieved Tighten the switch plate bolts 12 After tightening the switch plate bolts check the switch again to make sure it performs properly 9 14 Braking system 13 6a To remove the brake light switch remove the three mounting plate screws arrowed 13 6b and carefully pry the switch plate away from the pedal box be careful not to damage the gasket 13 7a To check the brake light switch connect an ohmmeter to the switch terminals with the switch plunger released there should be no continuity infinite resistance 13 7b With the switch plunger depressed there should be continuity zero resistance 13 8 If you re replacing the switch remove these two nuts arrowed and transfer the retaining plate to the new switch 3261 Jaguar XJ6 3261 Jaguar XJ6 10 Chapter 10 Suspension and steering systems General Power steering fluid type
26. If topping up is necessary first wipe clean the area around the filler cap with a clean cloth then unscrew the cap and position it clear of the reservoir 3 Carefully add fluid avoiding spilling it on the surrounding paintwork Use only the specified hydraulic fluid After filling the correct level refit the cap and tighten it securely Wipe off any spilt fluid 4 Screenwash additives not only keep the winscreen clean during foul weather they also prevent the washer system freezing in cold weather which is when you are likely to need it most Don t top up using plain water as the screenwash will become too diluted and will freeze during cold weather On no account use coolant antifreeze in the washer system this could discolour or damage paintwork Screen washer fluid level If topping up is necessary add water and a screenwash additive in the quantities recommended on the bottle 2 The screen washer fluid reservoir is located in the front right hand corner of the engine compartment The level is visible through the reservoir body 1 3261 Jaguar XJ6 Weekly checks 0 13 Power steering fluid level Before you start 4 Park the vehicle on level ground 4 Set the steering wheel straight ahead 4 The engine should be turned off Safety first l The need for frequent topping up indicates a leak which should be investigated immediately For the check to be accurate the steering must not b
27. c Use new gaskets hangers and clamps when refitting exhaust system components d Apply anti seize compound to the threads of all exhaust system fasteners during reassembly e Be sure to allow sufficient clearance between newly installed parts and all points on the underbody to avoid overheating the floor pan and possibly damaging the interior carpet and insulation Pay particularly close attention to the catalytic converter and its heat shield Warning The catalytic converter operates at very high tem peratures and takes a long time to cool Wait until it s completely cool before attempting to remove the converter It s a good idea to wear suitable gloves Failure to observe these points could result in serious burns 4 14 Fuel and exhaust systems 14 1c On dual silencer models check the condition of the mount arrowed and the clamps 14 1a The rear tailpipe section is fastened to the chassis with a special rubber mount arrowed that pivots with road movement Check for deterioration and alignment 14 1b Check the condition of the flexible rubber mounts that hang the silencer to the chassis 14 4 Use penetrating spray on the exhaust flange nuts before attempting to remove them 3261 Jaguar XJ6 3261 Jaguar XJ6 5 Chapter 5 Engine electrical systems Ignition system Ignition timing all models Not adjustable Ignition coil resistance
28. or Chapter 1 dependent on system fitted 2 Raise and support the front of the vehicle on axle stands 3 Turn the steering wheel from lock to lock several times and recheck the fluid level 4 Start the engine Turn the steering wheel from lock to lock again three or four times and recheck the fluid level one more time 5 Lower the car to the ground Run the engine and again turn the wheels from lock to lock several more times Set the wheels straight ahead and recheck the fluid level 20 Wheels and tyres general information 1 All vehicles covered by this manual are equipped with steel belted radial tyres Use of other size or type of tyres may affect the ride and handling of the vehicle Don t mix different types of tyres such as radials and bias belted on the same vehicle as handling may be seriously affected It s recommended that tyres be replaced in pairs on the same axle but if only one tyre is being replaced be sure it s the same size structure and tread design as the other 2 Because tyre pressure has a substantial effect on handling and wear the pressure on all tyres should be checked at least once a month or before any extended trips see Chapter 1 3 Wheels must be replaced if they are bent dented leak air have elongated bolt holes are heavily rusted out of vertical symmetry or if the wheel nuts won t stay tight Wheel repairs that use welding or peening are not recommended 4 Tyre and wheel bal
29. 2 7 4 9 10 9 11 11 4 11 10 Calipers 9 3 Camshafts 2A 9 Capacities 1 2 Carpets 11 1 Cassette REF 1 Catalytic converter 6 12 Central locking 12 13 Centre console 11 11 Charcoal canister 6 11 Charging 1 10 Charging system 5 5 Circuit breakers 12 3 CO emissions mixture REF 11 Coil HT 5 3 Coil spring 10 5 10 6 Compression check 2B 3 Compressor 3 13 Condenser 3 13 Connecting rods 2B 9 2B 12 2B 17 2B 18 Console 11 11 11 12 Continuity check 12 2 Control arms 10 5 10 6 10 8 Conversion factors REF 2 Coolant 0 11 0 16 1 2 1 20 3 2 Coolant reservoir 3 4 3 5 Coolant temperature sensor 6 3 Cooling fans 3 3 Cooling system fault finding REF 14 Cooling heating and air conditioning systems 3 1 et seq Courtesy lights 12 12 Cowl cover 11 14 Crankcase ventilation system 1 16 6 11 Crankshaft 2A 5 2A 17 2B 10 2B 13 2B 16 position sensor 6 7 Cruise control 12 13 Crushing 0 5 Cylinder head 2A 13 2B 6 2B 7 2B 8 Cylinder honing 2B 12 D Dashboard 11 13 Dents 11 2 Differential 8 1 8 5 oil 1 2 1 11 1 20 Dimensions REF 1 Direction indicators 12 4 12 11 12 12 Discs 9 4 Distributor 5 4 Doors 11 7 11 8 11 9 11 10 11 10 REF 9 Drivebelt 1 16 Driveplate 2A 16
30. Caution Do not clean the throttle position sensor with any solvents or sprays Just wipe it off with a clean soft cloth 15 Refitting of the throttle body is the reverse of removal 16 Be sure to tighten the throttle body mounting bolts to the torque listed in this Chapter s Specifications Adjustment 17 Remove the air intake duct to expose the throttle body and butterfly valve 18 Make sure the throttle body is clean and free of burrs nicks or carbon build up see illustration 19 Measure the clearance between the butterfly valve throttle plate and the wall of the throttle body see illustration It should be 0 05 mm 0 002 inch 20 If the gap is incorrect loosen the throttle stop locknut see illustration and turn the throttle stop screw until the correct clearance is attained 21 Refit the air intake duct and surrounding components Idle Speed Control ISC motor Note The minimum idle speed is pre set at the factory and should not require adjustment under normal operating conditions however if the throttle body has been replaced or you suspect the minimum idle speed has been tampered with for example if the idle speed screw was removed from the throttle body have the vehicle checked by a dealer service department or a qualified automotive repair workshop Check 22 Start the engine and allow it to reach normal operating temperature Switch on the Fuel and exhaust systems 4 11 4 13 9 Remove the
31. because antifreeze tends to leak through very minute openings Engines do not normally consume coolant Therefore if the level goes down find the cause and correct it The exact mixture of antifreeze to water you should use depends on the relative weather conditions The mixture should contain at least 50 percent antifreeze but should never contain more than 70 percent antifreeze Consult the mixture ratio chart on the antifreeze container before adding coolant Hydrometers are available at most car accessory outlets to test the ratio of antifreeze to water see illustration Use antifreeze which meets the vehicle manufacturer s specifications 3 Thermostat check and renewal 2 Warning Do not attempt to remove the radiator cap coolant or thermostat until the engine has cooled completely Check 1 Before assuming the thermostat is responsible for a cooling system problem check the coolant level Chapter 1 drivebelt tension Chapter 1 and temperature gauge or light operation 2 If the engine takes a long time to warm up as indicated by the temperature gauge or heater operation the thermostat is probably stuck open Renew the thermostat 3 If the engine runs hot use your hand to check the temperature of the lower radiator hose Warning Do this check with the engine off Do not get your hands near the fan blades If the hose is not hot but the engine is the thermostat is probably stuck in the close
32. 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 in transferring 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 oils are the traditional oils generally suited to older engines and cars not used in harsh conditions
33. s car If your car won t start even though the starter motor turns as normal Is there fuel in the tank Is 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 A Check that the spark plug HT leads are securely connected by pushing them onto the plugs and distributorery connections B Check 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 Roadside repairs 0 7 When jump starting a car using a booster battery observe the following precautions 4 Before connecting the booster battery make sure that the ignition is switched off 4 Ensure that all electrical equipment lights heater wipers etc is switched off 4 Take note of any special precautions printed on the battery case 4 Make sure that the booster b
34. 10 11 REF 11 U UK readers information 0 4 REF 3 Universal joint 8 1 8 2 8 5 Upholstery 11 1 V Vacuum gauge checks 2B 3 Valve cover 2A 3 Valve lifters 2A 9 Valves 2B 8 Vehicle identification REF 4 REF 9 Vehicle support REF 1 Vinyl trim 11 1 Voltage checks 12 1 REF 24 Index 3261 Jaguar XJ6 W Washer fluid 0 12 Water pump 3 6 Weekly checks 0 10 et seq Weights REF 1 Wheel alignment 1 18 10 11 Wheel bearings 1 17 10 8 REF 10 Wheel changing 0 8 Wheels 10 11 REF 11 Windows 11 10 11 11 12 13 Windscreen 11 3 REF 8 Wing 11 6 Wiper blades 0 13 Wiper motor 12 8 Wiring diagrams 12 15 et seq Working facilities REF 7 Index REF 25 3261 Jaguar XJ6 Almost every car you ve ever loved loathed or desired is gathered under one roof at the Haynes Motor Museum Over 300 immaculately presented cars and motorbikes represent every aspect of our motoring heritage from elegant reminders of bygone days such as the superb Model J Duesenberg to curiosities like the bug eyed BMW Isetta There are also many old friends and flames Perhaps you remember the 1959 Ford Popular that you did your courting in The magnificent Red Collection is a spectacle of classic sports cars including AC Alfa Romeo Austin Healey Ferrari Lamborghini Maserati MG Riley Porsche and Triumph A Perfect Day Out Ea
35. 15 3 Loosen the ball stud nut fit a small puller and pop the ball stud loose from the steering knuckle 3261 Jaguar XJ6 14 2 To remove the centre pad from the steering wheel simply pry it off 14 3 After removing the steering wheel nut make a pair of alignment marks on the steering wheel and steering shaft to ensure proper reassembly 16 2 Cut off the boot clamps arrowed and slide the boot off the steering gear 17 Steering gear removal and refitting 3 Warning On models with an airbag do not apply excessive force or severe shock to the steering column shaft or accidental deployment of the airbag could occur 1 Using a large syringe or hand pump empty the power steering fluid reservoir 2 Loosen the wheel nuts raise the vehicle and support it securely on axle stands Remove the wheels 3 Mark the relationship of the steering shaft U joint to the steering gear pinion shaft see illustration to ensure proper alignment when they re reassembled Remove the nut and bolt that clamp the U joint to the pinion shaft 4 Disconnect the power steering pressure and return lines from the steering gear Place a container under the lines to catch spilled fluid Plug the lines to prevent excessive fluid loss and contamination Discard the sealing washers new ones should be used when reassembling 5 Disconnect the tie rod ends from the steering knuckle arms see Section 17 6 Remove the nuts and bolts from the steering gea
36. 2 Push inward and rotate the bulb anti clockwise to remove it from the holder 3 Renew the bulb refit the lamp lens and test the bulb operation Body electrical system 12 11 12 20 9 Disconnect the electrical connector remove the retaining nuts arrowed then detach the horn s 21 1 The front direction indicator rear parking and side marker light bulbs are accessible after removing the lens screws 3261 Jaguar XJ6 19 2 Remove the headlight housing retaining nuts arrowed from the backside of the radiator support 20 3 Check for power at the horn terminal with the horn button depressed Rear direction indicator brake tail and reversing lights 4 Open the boot and remove the plastic knobs securing the tail light housing trim cover see illustration 5 Remove two more plastic knobs and detach the tail light bulb cluster from the rear tail light housing The defective bulb can then be pulled out of the socket and replaced see illustration Number plate light 6 Remove the lens retaining screws see illustration 7 Detach the lens and renew the defective bulb High mounted brake light 8 The brake light cover is retained by screws Remove the cover and renew the bulb Interior lights 9 Remove the overhead console Chapter 11 Detach the bulb from the retaining clips and renew the bulb see illustration Instrument cluster illumination 10 To gain access to the instrument cluster illumination light
37. 2 Using a gasket scraper remove all traces of gasket material from the engine block Be very careful not to nick or gouge the gasket sealing surfaces 3 Remove the main bearing caps and separate the bearing inserts from the caps and the engine block Tag the bearings indicating which cylinder they were removed from and whether they were in the cap or the engine block then set them aside 4 Remove all of the threaded oil gallery plugs from the engine block The plugs are usually very tight they may have to be drilled out and the holes retapped Use new plugs when the engine is reassembled 5 If the engine is extremely dirty it should be taken to an automotive machine workshop to be steam cleaned or hot tanked 6 After the engine block is returned clean all oil holes and oil galleries one more time Brushes specifically designed for this purpose are available at most car accessory outlets Flush the passages with warm water until the water runs clear dry the engine block thoroughly and wipe all machined surfaces with a light rust preventive oil If you have access to compressed air use it to speed the drying process and to blow out all the oil holes and galleries Warning Wear eye protection when using compressed air 7 If the engine block isn t extremely dirty or sludged up you can do an adequate cleaning job with hot soapy water and a stiff brush Take plenty of time and do a thorough job Regardless of the cleaning metho
38. 3 Warning Do not start this procedure until the engine is completely cool 1 Disconnect the negative battery cable and drain the cooling system see Chapter 1 Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 2 Refer to Section 4 to remove the mechanical fan and clutch if applicable to your model 3 Refer to Chapter 1 for removal of the drivebelts 3 6 Cooling heating and air conditioning systems 6 3 Remove the mounting nuts arrowed to take the oil cooler out 7 3 Check the weep hole arrowed for signs of leakage pump removed for clarity grey discolouration is normal large brown stains indicates seal failure 3261 Jaguar XJ6 5 17 The recovery bottle arrowed on 1988 and 1989 models is located in the footwell disconnect the hoses and the two mounting screws 6 2 Disconnect the two metal oil lines arrowed where they mount to the bottom of the cooler use two spanners 4 Remove the water pump mounting bolts see illustration Note 1 The water pump is sold as a complete assembly including the rear housing with the hose connections Unless the rear housing is corroded or cracked many Jaguar mechanics only refit the pump assembly itself using the original rear housing with all its hoses intact However if the engine has a great deal of years or mileage on it it would be a good idea to renew thos
39. 42 Also check the reference voltage to the MAF sensor from the computer Backprobe terminal number 6 and make sure that approximately 5 volts is present Renewal 43 Disconnect the electrical connector from the MAF sensor 44 Remove the air cleaner assembly see Chapter 4 45 Remove the four bolts and separate the MAF sensor from the air intake duct 46 Refitting is the reverse of removal Intake air temperature IAT sensor General description 47 The intake air temperature sensor is located inside the air intake duct This sensor acts as a resistor which changes value according to the temperature of the air entering the engine Low temperatures produce a high resistance value for example at 68 F the value is 2 0 to 2 6 k ohms while high temperatures produce low resistance values at 176 F the resistance is 260 to 330 ohms The ECU supplies around 5 volts reference voltage to the air temperature sensor The voltage will change according to the temperature of the incoming air The voltage will be high when the air temperature is cold and low when the air temperature is warm Any problems with the air temperature sensor will usually set a code 8 1988 and 1989 or code 16 1990 to 1994 Check 48 To check the air temperature sensor disconnect the two prong electrical connector and turn the ignition key ON but do not start the engine 49 Measure the voltage reference voltage which should be approximately 5 volts
40. Duckhams Hypergrade Plus and Hypergrade are well suited for use in most popular family cars Diesel oils such as Duckhams Diesel are specially formulated for Diesel engines including turbocharged models and 4x4s Synthetic oils are 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 oils offer high performance engine protection but at less cost than full synthetic oils Duckhams QXR is 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 3261 Jaguar XJ6 1 Chapter 1 Routine maintenance and servicing Air cleaner element renewal 17 Automatic transmission fluid and filter renewal 26 Automatic transmission fluid level check 8 Battery check and general information 6 Brake fluid renewal 28 Braking system general check and adjustment 11 Coolant renewal
41. Engine electrical systems 5 7 5 14 5 With the ignition key ON engine not running check for battery voltage to the starter relay 15 4a Disconnect the solenoid electrical connector at the harness connector located near the bulkhead behind the cylinder head arrowed 15 4b From underneath the vehicle remove the battery terminal from the solenoid cylinder head removed for clarity 3261 Jaguar XJ6 6 Working forward of the transmission reach up into the engine bellhousing area under the intake manifold and remove the lower starter mounting bolt 7 Tilt the starter down and carefully lower the starter assembly through the front ahead of the transmission 8 Refitting is the reverse of removal 16 Starter solenoid removal and refitting 2 1 Remove the starter motor see Section 15 2 Scribe or paint a mark across the starter motor and solenoid assembly 3 Disconnect the strap from the solenoid to the starter motor terminal if equipped 4 Remove the screws which secure the solenoid to the starter drive end housing see illustration 5 Separate the solenoid from the starter 6 Refitting is the reverse of removal Be sure to align the paint or scribe mark 5 8 Engine electrical systems 3261 Jaguar XJ6 15 5 The upper starter bolt can be reached from underneath the vehicle using a long extension and swivel socket cylinder head removed for clarity 16 4 Remove the three solenoid mounting screws arrowed
42. Note Prior to removing the piston connecting rod assemblies remove the cylinder head s the sump and the oil pump transfer tubes by referring to Chapter 2A 1 Use your fingernail to feel if a ridge has formed at the upper limit of ring travel about 1 4 inch down from the top of each cylinder If carbon deposits or cylinder wear have produced ridges they must be completely removed with a special tool see illustration Follow the manufacturer s instructions provided with the tool Failure to remove the ridges before attempting to remove the piston connecting rod assemblies may result in piston damage 2 After the cylinder ridges have been removed turn the engine upside down so the crankshaft is facing up Remove the screws and the front and rear baffle plates from the bottom of the engine block see illustration 3 Before the connecting rods are removed check the endplay with a feeler gauge Slide the blade between the first connecting rod and the crankshaft throw until the play is removed see illustration The endplay is equal to the thickness of the feeler gauge s If the endplay exceeds the specified service limit new connecting rods will be required If new rods or a new crankshaft are installed the endplay may fall under the service limit if it does the rods will have to be machined to restore it consult an automotive machine workshop for advice if necessary Repeat the procedure for the remaining connecting
43. Use a proper tow rope they are not expensive The vehicle being towed must display an ON TOW sign in its rear window Always turn the ignition key to the on position when the vehicle is being towed so that the steering lock is released and that the direction indicator and brake lights will work Only attach the tow rope to the towing eyes provided On some models with energy absorbing bumpers there are no front towing eyes on these vehicles the tow rope should be attached around the rear arm of the lower control arm so that the rope passes on the inside of the coil spring Before being towed release the handbrake and select neutral on the transmission Note that greater than usual pedal pressure will be required to operate the brakes since the vacuum servo unit is only operational with the engine running On models with power steering greater than usual steering effort will also be required The driver of the car being towed must keep the tow rope taut at all times to avoid snatching Make sure that both drivers know the route before setting off Only drive at moderate speeds and keep the distance towed to a minimum Drive smoothly and allow plenty of time for slowing down at junctions On models with automatic transmission special precautions apply If in doubt do not tow or transmission damage may result Caution On models with automatic transmission if the vehicle is to be towed with its rear wheels
44. Wiring diagrams general information 29 12 1 Contents Easy suitable for novice with little experience Fairly easy suitable for beginner with some experience Fairly difficult suitable for competent DIY mechanic Difficult suitable for experienced DIY mechanic Very difficult suitable for expert DIY or professional Degrees of difficulty 5 4 3 2 1 to earth somewhere in that area probably where the insulation has rubbed through The same test can be performed on each component in the circuit even a switch Earth check Perform an earth test to check whether a component is properly earthed Disconnect the battery and connect one lead of a self powered test light known as a continuity tester to a known good earth Connect the other lead to the wire or earth connection being tested If the bulb goes on the earth is good If the bulb does not go on the earth is not good Continuity check A continuity check is done to determine if there are any breaks in a circuit if it is passing electricity properly With the circuit off no power in the circuit a self powered continuity tester can be used to check the circuit Connect the test leads to both ends of the circuit or to the power end and a good earth and if the test light comes on the circuit is passing current properly If the light doesn t come on there is a break somewhere in the ci
45. an EPA approved recovery recycling unit by a dealer service department or an automotive air conditioning repair facility Always wear eye protection when disconnecting air conditioning system fittings 1 Have the refrigerant discharged by an automotive air conditioning technician 2 Disconnect the battery negative cable Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 3 Remove the drivebelt from the compressor see Chapter 1 4 Detach the electrical connector and disconnect the flexible refrigerant lines see illustration 5 Unbolt the compressor and lift it from the vehicle see illustration 6 If a new or rebuilt compressor is being installed drain the fluid from the new unit by opening the drain plug and by tilting the compressor to the rear so that any remaining oil will come out the ports in the back normally covered by the plate and hard lines Refit the drain plug and end plate and add 199 cc 7 fluid ounces of new oil of a type compatible with the type refrigerant in your system 7 Refitting is the reverse of removal Renew any O rings with new ones specifically made for the type of refrigerant in your system and lubricate them with refrigerant oil also designed specifically for your refrigerant 8 Have the system evacuated recharged and tested by the workshop that discharged it 16 Air conditioning conden
46. at 68 F Primary resistance 0 4 to 0 5 ohms Secondary resistance 6 0 to 6 5 k ohms Charging system Charging voltage 13 9 to 15 1 volts Standard amperage No load Less than 10 amps Full load 30 amps or more Amplifier check and renewal 7 Alternator removal and refitting 12 Battery cables check and renewal 4 Battery check maintenance and charging See Chapter 1 Battery emergency jump starting 2 Battery removal and refitting 3 Charging system check 11 Charging system general information and precautions 10 CHECK ENGINE light See Chapter 6 Distributor removal and refitting
47. b On 1992 to 1994 models disconnect the negative battery lead for 30 seconds or more to erase the stored fault codes Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 9 A stored code can also be cancelled on early models by removing the cable from the battery negative terminal but other items with memory such as the clock and radio presets will also be cancelled 10 If the diagnosis code is not cancelled it will be stored by the ECU and appear with any new codes in the event of future trouble 11 Should it become necessary to work on engine components requiring removal of the battery terminal always check to see if a diagnostic code has been recorded before disconnecting the battery 4 Information sensors Note Refer to Chapters 4 and 5 for additional information on the location and the diagnostic procedures for the output actuators ISC motor air supplementary valve distributor amplifier etc that are not directly covered in this section Coolant temperature sensor General description 1 The coolant temperature sensor is a thermistor a resistor which varies the value of its voltage output in accordance with temperature changes which is threaded into the thermostat housing As the sensor temperature DECREASES the resistance values will INCREASE As the sensor Emissions and engine control systems 6
48. crankshaft pulley 16 Attach a lifting sling to the engine Position a hoist and connect the sling to it Take up the slack until there is slight tension on the hoist 17 With a trolley jack and piece of wood supporting the bottom of the transmission sump refer to Chapter 8 and remove the driveshaft and rear transmission mount Warning Do not place any part of your body under the engine transmission when it s supported only by a hoist or other lifting device 18 With the hoist taking the weight of the engine unbolt the engine mounts see Part A of this Chapter 19 Recheck to be sure nothing is still connecting the engine or transmission to the vehicle Disconnect and label anything still remaining 20 Slowly lift the engine transmission out of the vehicle see illustration It may be necessary to pry the mounts away from the frame brackets 21 Move the engine away from the vehicle and carefully lower the hoist until the engine transmission can be set on the floor Refer to Chapter 7 and remove the transmission and converter Refer to Part A of this Chapter for removal of the flywheel With the flywheel removed remove the four large bolts and the transmission adapter plate from the engine see illustration 22 Refer to Part A of this Chapter for removal of the rear main seal retainer plate from the back of the engine then lift the engine to a position where it can be attached to a sturdy engine stand Refitting 23 C
49. gauge If the pointer moves with the back of the gauge earthed the problem lies in the wire between the gauge and the sender unit If the pointer does not moves with the back of the gauge earthed check for voltage at the other terminal of the gauge If voltage is present renew the gauge 12 Instrument cluster removal and refitting 1 Warning Later models are equipped with airbags To prevent accidental deployment of the airbag which could cause personal injury or damage to the airbag system DO NOT work in the vicinity of the steering column or instrument panel The manufacturer recommends that on airbag equipped models the following procedure be performed at a dealer service department or other properly equipped repair facility because of the special tools and techniques required to disable the airbag system Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 1 Disconnect the negative battery cable 2 Remove the instrument cluster housing see Chapter 11 3 Remove the instrument cluster mounting screws see illustration Separate the instrument cluster from the cluster housing 4 Refitting is the reverse of removal 13 Radio and speakers removal and refitting 2 Warning Later models are equipped with airbags To prevent accidental deployment of the airbag which could cause personal injury or
50. good condition and tight d Check the fusible link if equipped located between the starter solenoid and the alternator or the large main fuses in the engine compartment If it s burned determine the cause repair the circuit and renew the link or fuse the vehicle won t start and or the accessories won t work if the fusible link or fuse blows e Check all the in line fuses that are in series with the charging system circuit see Chapter 12 The location of these fuses and fusible links may vary from year and Engine electrical systems 5 5 5 10 1 Schematic of a typical charging system 3261 Jaguar XJ6 model but the designations are the same Refer to the wiring diagrams at the end of Chapter 12 f Start the engine and check the alternator for abnormal noises a shrieking or squealing sound indicates a bad bushing g Check the specific gravity of the battery electrolyte If it s low charge the battery doesn t apply to maintenance free batteries h Make sure that the battery is fully charged one bad cell in a battery can cause overcharging by the alternator i Disconnect the battery cables negative first then positive Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Inspect the battery posts and the cable clamps for corrosion Clean them thoroughly if necessary see Chapter 1 Reconnect th
51. proper operation 11 2 Disconnect the heater hoses from the pipes at the bulkhead small arrows the large arrow indicates the evaporator case retaining nut metal bracing that has a very sharp edge see illustration 10 2b Apply some heavy duct tape to the edge of the brace before beginning work in this area or you could injure your hands 4 On the passenger s side under the dash remove the screws holding the plastic cover where the heater pipes enter the heater air conditioning housing see illustration 5 With the cover off there is access to remove the four Allen bolts holding the two pipes to the heater core see illustration 6 Move to the right side and unbolt the climate control computer and pull it down and away from the heater air conditioning housing see illustrations 7 Remove the four small screws and remove the plastic plate over the heater core right behind where the climate control computer had been see illustration 8 Carefully slide the heater core out from the right side of the heating air conditioning housing see illustration Note Keep plenty of towels or rags on the carpeting to catch any coolant that may drip 9 Refitting is the reverse order of removal When refitting the heater core make sure all of the foam insulation strips are in place and refit new O rings where the heater pipes enter the core see illustration 10 Refill the cooling system reconnect the battery and run the engine Check
52. remove the air intake plenum and intake Fuel and exhaust systems 4 13 4 3261 Jaguar XJ6 13 36 and remove the fuel rail with the fuel injectors attached 13 37 Remove the fuel injector retaining clips from the fuel rail using a small screwdriver 13 45 Disconnect the fuel pressure regulator from the fuel return line 13 38b Pick out the old injector seal but make sure the injector body is not damaged in the process 13 38a If you plan to refit the original injectors remove and discard the O rings and grommets and fit new ones 13 49 Check for battery voltage to the supplementary air valve manifold as a single unit and have it repaired by a dealer service department Refer to Chapter 2 for removal and refitting procedures 14 Exhaust system servicing general information Warning Inspection and repair of exhaust system components should be done only after the components have cooled 1 The exhaust system consists of the exhaust manifold catalytic converter the silencer the tailpipe and all connecting pipes brackets hangers and clamps The exhaust system is attached to the body with mounting brackets and rubber hangers see illustrations If any of these parts are damaged or deteriorated excessive noise and vibration will be transmitted to the body Note The exhaust system configuration changes with later model updates Earlier models 1988 and 1989 are equipped with a pre catalytic converter near the exh
53. s Umwelt Diesel engine U Universal joint or U joint A double pivoted connection for transmitting power from a driving to a driven shaft through an angle A U joint consists of two Y shaped yokes and a cross shaped member called the spider V Valve A device through which the flow of liquid gas vacuum or loose material in bulk may be started stopped or regulated by a movable part that opens shuts or partially obstructs one or more ports or passageways A valve is also the movable part of such a device Valve clearance The clearance between the valve tip the end of the valve stem and the rocker arm or tappet The valve clearance is measured when the valve is closed Vernier caliper A precision measuring instrument that measures inside and outside dimensions Not quite as accurate as a micrometer but more convenient Viscosity The thickness of a liquid or its resistance to flow Volt A unit for expressing electrical pressure in a circuit One volt that will produce a current of one ampere through a resistance of one ohm W Welding Various processes used to join metal items by heating the areas to be joined to a molten state and fusing them together For more information refer to the Haynes Automotive Welding Manual Wiring diagram A drawing portraying the components and wires in a vehicle s electrical system using standardised symbols For more information refer to the Haynes Automotive Electrical and
54. stall frequently during hot weather If stalling occurs the engine will restart after a cool down period Dual fuel pumps can be installed by a dealer service department or other qualified repair facility to remedy this problem Preliminary inspection 1 Should the fuel system fail to deliver the proper amount of fuel or any fuel at all inspect it as follows Remove the fuel filler cap Have an assistant turn the ignition key to the ON position engine not running while you listen at the fuel filler opening You should hear a whirring sound that lasts for a couple of seconds On 1988 to 1990 models listen behind the left rear wheel external fuel pump for the fuel pump sound 2 If you don t hear anything check the fuel pump relay see illustration 2 3a b or c and 4 2 Fuel and exhaust systems 2 3c On 1992 models the fuel pump relay is located in the left rear corner of the engine compartment 3261 Jaguar XJ6 2 3a Relay locations on a 1988 model 2 3b Relay locations on a 1989 model circuit If all circuits are intact and not damaged check the inertia switch Note The inertia switch is a special device that shuts down power to the ignition and the fuel pump in the event of an accident See Chapter 12 for checking and resetting procedures for the inertia switch 3 Remove the relay and check for battery voltage to the fuel pump relay connector see illustration If there is battery voltage present check the relay
55. terminal of the battery Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 8 Disconnect the electrical connector from the air pump clutch 9 Loosen the clips from the air inlet and outlet hose and separate them from the air injection pump 10 Loosen the adjuster and pivot bolts see illustration and nuts but do not remove them from the air injection pump brackets 6 8 Emissions and engine control systems 3261 Jaguar XJ6 5 2 Schematic of the Air Injection Reactor AIR system 5 6 Location of the AIR diverter valve on a 1992 model check the hoses for cracking and the electrical connector for security 5 10 Loosen the pivot bolt and then the adjustment nut to remove the drivebelt from the air pump The adjustment nut has a lock bolt that must be loosened before the pump will move down the adjuster 5 5 Location of the AIR pump relay on a 1992 model 11 Swing the pump toward the engine and remove the drivebelt from the pump 12 Remove the link arm through bolt 13 Remove the pivot bolt and front spacer rear cone and air injection pump from the engine compartment 14 Remove the nut securing the front pulley on the air injection pump 15 Remove the clutch snap ring and the clutch 16 Refitting is the reverse of removal 6 Exhaust Gas Recirculation EGR system Note 1 Some 1990 models have the EGR vacuum hose routed
56. the bearing inserts may be the wrong size which means different ones will be required Before deciding that different inserts are needed make sure that no dirt or oil was between the bearing inserts and the connecting rod or cap when the clearance was measured Also recheck the journal diameter If the Plastigauge was wider at one end than the other the journal may be tapered refer to Section 19 Final connecting rod refitting 19 Carefully scrape all traces of the Plastigauge material off the rod journal and or bearing face Be very careful not to scratch the bearing use your fingernail or the edge of a credit card to remove the Plastigauge 20 Make sure the bearing faces are perfectly clean then apply a uniform layer of clean moly base grease or engine assembly lube to both of them You ll have to push the piston higher into the cylinder to expose the face of the bearing insert in the connecting rod be sure to slip the protective hoses over the connecting rod bolts first 21 At this time remove the original connecting rod bolts nuts and replace them with new bolts nuts They are of a design which requires they be used only once The old ones are OK for Plastigauge checking but for final assembly use only new connecting rod bolts nuts Refit the rod cap and tighten the nuts to the torque listed in this Chapter s Specifications Again work up to the torque in three steps 22 Repeat the entire procedure for the remaini
57. try swapping the jumper wires on the control circuit terminals 6 With the jumper wires connected check for continuity between the power circuit terminals Now there should be continuity 8 If the relay fails any of the above tests renew it 7 Direction indicator hazard flasher general information Warning Later model vehicles are equipped with airbags To prevent accidental deployment 6 3 Most relays are marked on the outside to easily identify the control circuit and power circuits 12 4 Body electrical system 3261 Jaguar XJ6 1990 to 1992 relay location details of the airbag which could cause personal injury or damage to the airbag system DO NOT work in the vicinity of the steering column or instrument panel The manufacturer recommends that on airbag equipped models the following procedure be performed at a dealer service department or other properly equipped repair facility because of the special tools and techniques required to disable the airbag system The direction indicator and hazard flasher systems are governed by the central processing unit The central processing unit requires special testers and diagnostic procedures which are beyond the scope of this manual If the direction indicator hazard flasher system fails and the indicator bulbs are in working condition take the vehicle to a dealer service department or an automotive electrical specialist for further diagnosis and repair
58. 2 Filters automatic transmission fluid 1 19 fuel 1 15 oil 1 6 Fire 0 5 Fluids 0 16 Fuel and exhaust systems 4 1 et seq REF 11 Fuel filter 1 15 Fuel gauge 12 7 Fuel pressure relief 4 2 Fuel system fault finding REF 14 Fume or gas intoxication 0 5 Fuses 0 15 12 2 G Gaiters 10 9 Gashes 11 2 Gaskets REF 5 Glass 11 3 11 10 11 11 12 13 Glossary of technical terms REF 3 REF 18 et seq Glove box 11 13 Grille 11 5 H Handbrake 1 12 1 20 9 1 9 10 9 11 REF 8 Handles 11 9 11 10 Hazard flasher 12 4 HC emissions REF 11 Headlights 1 18 12 9 12 10 12 11 Heated rear window 12 8 Heater 3 2 3 7 3 9 3 10 3 11 3 12 High mounted brake light 12 12 Hinges 11 3 Horn 12 11 Hoses 1 10 Hub bearings 1 17 10 8 Hydraulic system 0 16 Hydrofluoric acid 0 5 I Idle Speed Control ISC motor 4 11 Ignition switch 12 6 Ignition system 1 15 In tank fuel pumps 4 4 Indicators 12 4 12 11 12 12 Inertia switch 4 1 12 12 Information sensors 6 3 Injectors 4 12 Instruments 1 14 11 12 12 6 12 7 12 12 Intake Air Temperature IAT sensor 6 7 Intake manifold 2A 4 Interior lights 12 12 Introduction 0 4 J Jacking REF 1 Joint mating faces REF 5 Jump starting 0 7 K Kickdown cable 7 2 Kn
59. 5 Brake fluid level check See Chapter 1 Brake hoses and lines inspection and renewal 8 Brake hydraulic system bleeding 9 Brake light switch check and renewal 13 Brake servo general information removal and refitting 7 Disc brake caliper removal overhaul and refitting 4 Disc brake pads renewal 3 General information 1 Handbrake cable adjustment 10 Handbrake cables renewal 11 Handbrake shoes check and renewal 12 Master cylinder removal overhaul and refitting 6 9 1 Specifications Contents Easy suitable for novice with little experience Fairly easy suitable for beginner with some experience Fairly difficult suitable for competent DIY mechanic Difficult suitable for experienced DIY mechanic Very difficult suitable for expert DIY or professional Degrees of difficulty 5 4 3 2 1 1 General information All models covered by this manual
60. 5 Circuit breakers general information Circuit breakers generally protect components such as electric windows central locking and headlights On some models the circuit breaker resets itself automatically so an electrical overload in the circuit will cause it to fail momentarily then come back on If the circuit doesn t come back on check it immediately Once the condition is corrected the circuit breaker will resume its normal function Some circuit breakers have a button on top and must be reset manually To test a circuit breaker use an ohmmeter to check continuity between the terminals A reading of zero to 1 0 ohms indicates a good circuit breaker An open circuit reading on the meter indicates a bad circuit breaker 6 Relays general information and testing 2 General information Several electrical accessories in the vehicle such as the fuel injection system electric windows central locking etc use relays to transmit the electrical signal to the component Relays use a low current circuit the control circuit to open and close a high current circuit the power circuit If the relay is defective that component will not operate properly The relays are mounted throughout the vehicle see illustrations If a faulty relay is suspected it Body electrical system 12 3 12 3261 Jaguar XJ6 1988 to 1989 relay location details can be removed and tested using the procedure below or by a dealer servi
61. 6 Suspension and steering systems 5 Braking system continued Brake pedal feels spongy when depressed Air in hydraulic lines Chapter 9 Master cylinder mounting bolts loose Chapter 9 Master cylinder defective Chapter 9 Brake pedal travels to the floor no resistance Little or no fluid in the master cylinder reservoir caused by leaking caliper piston s damaged or disconnected brake lines Chapter 9 Handbrake does not hold Handbrake cable or handbrake shoes improperly adjusted Chapter 9 Handbrake shoes need replacement Chapter 9 Note Before attempting to diagnose the suspension and steering systems perform the following preliminary checks a Tyres for wrong pressure and uneven wear b Steering universal joints from the column to the steering gear for loose connectors or wear c Front and rear suspension and the rack and pinion assembly for loose or damaged parts d Out of round or out of balance tyres bent rims and loose and or rough wheel bearings Vehicle pulls to one side Mismatched or uneven tyres Chapter 10 Broken or sagging springs Chapter 10 Wheel alignment out of specifications Chapter 10 Front brakes dragging Chapter 9 Abnormal or excessive tyre wear Wheel alignment out of specifications Chapter 10 Sagging or broken springs Chapter 10 Tyre out of balance Chapter 10 Worn shock absorber Chapter 10 Overloaded vehicle Tyres not rotated regular
62. Chapter 7 and remove the transmission If it s leaking now would be a very good time to renew the front pump seal O ring 2A 16 Engine in car repair procedures 13 9 Measure the outer rotor to body clearance with feeler gauges arrowed 13 10 With a straightedge held tight to the pump surface measure the clearance over the rotors with feeler gauges 13 11 Oil pressure relief valve components A Relief valve cap B Tube C Spring D Valve 13 14 Apply a thin coat anaerobic sealant Loctite 510 or 518 to the pump cover sealing surface 13 17 Refit the original shim pack arrowed if the original pump is being used if a new pump is being installed refit a 0 38 mm 0 015 inch shim pack 3261 Jaguar XJ6 13 18 Check the oil pump and crankshaft sprocket alignment with a straightedge add or subtract shims until the sprockets are aligned for smooth chain operation 2 Use a centre punch or paint to make alignment marks on the driveplate and crankshaft to ensure correct alignment during refitting see illustration 3 Remove the bolts that secure the driveplate to the crankshaft If the crankshaft turns wedge a screwdriver through a hole in the driveplate to keep it from turning see illustration 4 Remove the driveplate from the crankshaft A spacer is located behind the driveplate see illustration Pry it off and store it with the driveplate Warning The ring gear teeth may be sharp wear gloves to protect your h
63. Driveshafts 8 1 8 4 8 5 REF 10 Drivetrain 1 14 8 1 et seq Note References throughout this index are in the form Chapter number page number 3261 Jaguar XJ6 Index REF 23 E Earth check 12 2 ECU 6 2 EGR gas temperature sensor 6 7 Electric shock 0 5 Electric windows 12 13 Electrical equipment 1 14 REF 9 Electrical system fault finding 12 1 REF 17 Electronic control system and ECU 4 9 6 2 Electronic Fuel Injection EFI system 4 9 4 10 Emissions and engine control systems 6 1 et seq Engine electrical systems 5 1 et seq Engine in car repair procedures 2A 1 et seq Engine fault finding ref 13 ref 14 Engine oil 0 11 0 16 1 2 1 6 Engine removal and overhaul procedures 2B 1 et seq Environmental considerations REF 5 Evaporative Emission Control EVAP system 6 10 Evaporator and expansion valve 3 14 Exhaust emission checks REF 11 Exhaust Gas Recirculation EGR system 6 9 Exhaust manifolds 2A 4 Exhaust system 1 11 4 2 4 14 REF 10 Expansion tank 3 4 3 5 F Fans 3 3 Fault finding REF 12 et seq ABS 9 2 automatic transmission 7 1 REF 15 brakes REF 15 REF 16 cooling system REF 14 electrical system 12 1 REF 17 engine REF 13 REF 14 fuel system REF 14 suspension and steering systems REF 16 REF 17 Filling bodywork repair 11
64. Electronic Systems Manual Serpentine drivebelt 3261 Jaguar XJ6 REF 22 Index A ABS fault finding 9 2 Accelerator cable 4 8 Acknowledgements 0 4 Aerial 12 8 Air cleaner 1 14 4 7 Air conditioning 3 2 3 7 3 10 3 11 3 13 3 14 Air induction system 4 9 Air Injector Reactor AIR system 6 8 Air intake plenum 4 13 Airbag 0 5 12 14 Alternator 5 6 Amplifier 5 3 Anti lock Brake system ABS 9 2 Anti roll bar 10 3 Anti theft system REF 1 Antifreeze 0 11 0 16 1 2 1 20 3 2 Asbestos 0 5 ATF 0 16 Automatic transmission 7 1 et seq fault finding 7 1 REF 15 fluid 0 16 1 2 1 11 1 19 filter 1 19 Auxiliary shaft 2A 8 B Balljoints 10 4 Battery 0 5 0 15 1 9 5 1 5 1 Big end bearings 2B 13 2B 17 Bleeding brake system 9 10 power steering 10 11 Block 2B 10 2B 11 Blower motors 3 7 Body corrosion REF 11 Body electrical system 12 1 et seq Bodywork and fittings 11 1 et seq Bonnet 11 3 11 4 Boot 11 7 lid 11 3 11 6 11 7 Boots steering 10 9 Brake fluid 0 12 0 16 1 20 Brake lights 12 12 switch 9 13 Brake servo 1 12 Braking system 1 12 9 1 et seq fault finding REF 15 REF 16 MOT checks REF 8 to REF 10 Bulbs 0 15 12 11 Bumpers 11 5 Burning 0 5 C Cables 4 8 5 2 7
65. H Halfshaft A rotating shaft that transmits power from the final drive unit to a drive wheel usually when referring to a live rear axle Harmonic balancer A device designed to reduce torsion or twisting vibration in the crankshaft May be incorporated in the crankshaft pulley Also known as a vibration damper Hone An abrasive tool for correcting small irregularities or differences in diameter in an engine cylinder brake cylinder etc Hydraulic tappet A tappet that utilises hydraulic pressure from the engine s lubrication system to maintain zero clearance constant contact with both camshaft and valve stem Automatically adjusts to variation in valve stem length Hydraulic tappets also reduce valve noise I Ignition timing The moment at which the spark plug fires usually expressed in the number of crankshaft degrees before the piston reaches the top of its stroke Inlet manifold A tube or housing with passages through which flows the air fuel mixture carburettor vehicles and vehicles with throttle body injection or air only port fuel injected vehicles to the port openings in the cylinder head J Jump start Starting the engine of a vehicle with a discharged or weak battery by attaching jump leads from the weak battery to a charged or helper battery L Load Sensing Proportioning Valve LSPV A brake hydraulic system control valve that works like a proportioning valve but also takes into consideration the amount o
66. If an accidental mix up occurs refer to the firing order Specifications at the beginning of this Chapter Every 15 000 miles or 12 months 1 15 1 19 11a Unsnap the distributor cap retaining clips pull the cap up and away to access the rotor 19 11b Shown here are some of the common defects to look for when inspecting the distributor cap typical cap shown If in doubt about its condition fit a new one 19 12a Pull off the rotor arrowed and inspect it thoroughly 19 12b Check the ignition rotor for wear and corrosion as indicated here if in doubt about its condition buy a new one 3261 Jaguar XJ6 18 3 Remove the banjo bolt from the outlet side B detach the fitting from the inlet side A and unscrew the filter mounting bolt C 18 4 On 1991 to 1994 models slide back the locking collars and remove the inlet and outlet fuel lines 20 Crankcase ventilation system check 1 Refer to Chapter 6 21 Drivebelt check and renewal 2 Check 1 The drivebelts or V belts as they are sometimes called are located at the front of the engine and play an important role in the overall operation of the vehicle and its components Due to their function and material make up the belts are prone to failure after a period of time and should be inspected and adjusted periodically to prevent major engine damage 2 The number of belts used on a particular vehicle depends on the accessories installed The main belt transmits p
67. If it s stuck very carefully pry up at the transmission end beyond the gasket surface Caution Though the cylinder head is aluminium it is still heavy large and awkward to handle To avoid damaging the body during removal use an engine hoist to lift the cylinder head out of the engine compartment or have an assistant help you 14 With the cylinder head on a workbench remove all external components from the cylinder head to allow for thorough cleaning and inspection See Chapter 2 Part B for cylinder head servicing procedures Refitting 15 The mating surfaces of the cylinder head and engine block must be perfectly clean when the cylinder head is installed 16 Use a gasket scraper to remove all traces of carbon and old gasket material then clean the mating surfaces with lacquer thinner or acetone If there s oil on the mating surfaces when the cylinder head is installed the gasket may not seal correctly and leaks could develop When working on the engine block stuff the cylinders with clean workshop rags to keep out debris Use a vacuum cleaner to remove material that falls into the cylinders Caution Use care when cleaning the cylinder head gasket surface The cylinder head and engine block are aluminium and can be easily damaged by using sharp scraping tools Gasket removal solvents are available from car accessory outlets and may be useful for safe removal of gasket material 17 Check the engine block and cylinde
68. In addition to the specified intervals the brakes should be inspected every time the wheels are removed or whenever a defect is suspected Any of the following symptoms could indicate a potential brake system defect The vehicle pulls to one side when the brake pedal is depressed the brakes make squealing or dragging noises when applied brake pedal travel is excessive the pedal pulsates brake fluid leaks usually onto the inside of the tyre or wheel 2 The disc brakes have built in electrical wear indicators which cause a warning lamp to illuminate on the instrument panel when they re worn to the renewal point When the warning light comes on replace the pads immediately or expensive damage to the discs can result 3 Loosen the wheel nuts 4 Raise the vehicle and place it securely on axle stands 5 Remove the wheels Disc brakes 6 There are two pads an outer and an inner in each caliper The pads are visible through inspection holes in each caliper see Haynes Hint 7 Check the pad thickness by looking at each end of the caliper and through the inspection hole in the caliper body If the lining material is less than the thickness listed in this Chapter s Specifications replace the pads Note Keep in mind that the lining material is riveted or bonded to a metal backing plate and the metal portion is not included in this measurement 8 If it is difficult to determine the exact thickness of the remaining pad material by t
69. Page 0 4 Notes for UK readers Page 0 4 Safety first Page 0 5 Roadside repairs Introduction Page 0 6 If your car won t start Page 0 6 Jump starting Page 0 7 Wheel changing Page 0 8 Identifying leaks Page 0 9 Towing Page 0 9 Weekly checks Introduction Page 0 10 Underbonnet check points Page 0 10 Engine oil level Page 0 11 Coolant level Page 0 11 Brake fluid level Page 0 12 Screen washer fluid level Page 0 12 Power steering fluid level Page 0 13 Wiper blades Page 0 13 Tyre condition and pressure Page 0 14 Battery Page 0 15 Bulbs and fuses Page 0 15 Lubricants fluids and tyre pressures Page 0 16 MAINTENANCE Routine maintenance and servicing Page 1 1 Servicing specifications Page 1 2 Maintenance schedule Page 1 3 Maintenance procedures Page 1 6 Contents 3261 Jaguar XJ6 REPAIRS amp 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 transmission Page 7 1 Drivetrain Page 8 1 Brakes and suspension Braking system Page 9 1 Suspension and steering systems Page 10 1 Body equipment Bodywo
70. Several items including a torque wrench and special grease are required for this procedure see illustration 2 With the vehicle securely supported on axle stands spin each wheel and check for noise rolling resistance and freeplay 3 Grasp the top of each tyre with one hand and the bottom with the other Move the wheel in and out on the spindle If there s any noticeable movement the bearings should be checked and then repacked with grease or renewed if necessary 4 Remove the wheel 5 Remove the brake caliper see Chapter 9 and hang it out of the way on a piece of wire A wood block of the appropriate width can be slid between the brake pads to keep them separated if necessary Also remove the brake disc 6 Pry the dust cap out of the hub using a screwdriver or a hammer and chisel see illustration 7 Straighten the bent ends of the cotter pin then pull the cotter pin out of the nut lock see illustration Discard the cotter pin and use a new one during reassembly 8 Remove the locknut nut and washer from the end of the spindle 9 Pull the hub out slightly then push it back into its original position This should force the outer bearing off the spindle enough so it can be removed see illustration 10 Pull the hub off the spindle Note Sometimes the inner wheel bearing and grease seal remain attached to the spindle Grasp the back of the seal with both hands and pull forward to remove them 11 If the grease seal is n
71. Tap the top edge of the ring compressor to make sure it s contacting the engine block around its entire circumference 11 Gently tap on the top of the piston with the end of a wooden hammer handle see illustration while guiding the end of the connecting rod into place on the crankshaft journal The piston rings may try to pop out of the ring compressor just before entering the cylinder bore so keep some downward pressure on the ring compressor Work slowly and if any resistance is felt as the piston enters the cylinder stop immediately Find out what s hanging up and fix it before proceeding Caution Do not for any reason force the piston into the cylinder you might break a ring and or the piston 12 Once the piston connecting rod assembly is installed the big end bearing oil clearance must be checked before the rod cap is permanently bolted in place 13 Cut a piece of the appropriate size Plastigauge slightly shorter than the width of the big end bearing and lay it in place on the number one connecting rod journal parallel with the journal axis see illustration 14 Clean the connecting rod cap bearing face remove the protective hoses from the connecting rod bolts and refit the rod cap Make sure the mating mark on the cap is on the same side as the mark on the connecting rod Check the cap to make sure the front mark is facing the timing chain of the engine 15 Apply a light coat of oil to the under sides of the nuts
72. Wait a few minutes to allow the oil to drain into the pan then check the level on the oil dipstick see Weekly checks If the oil level is at or near the H mark refit the filler cap hand tight start the engine and allow the new oil to circulate 17 Allow the engine to run for about a minute While the engine is running look under the vehicle and check for leaks at the sump drain plug and around the oil filter If either is leaking stop the engine and tighten the plug or filter slightly 18 Wait a few minutes to allow the oil to trickle down into the pan then recheck the level on the dipstick and if necessary add enough oil to bring the level to the H mark 19 During the first few trips after an oil change make it a point to check frequently for leaks and proper oil level 20 The old oil drained from the engine cannot be reused in its present state and should be disposed of Check with your local authority or with a local garage to see whether they will accept the oil for recycling Don t pour used oil into drains or onto the ground After the oil has cooled it can be drained into a suitable container capped plastic jugs topped bottles etc for transport to an approved disposal site 4 Spark plug check 2 1 Spark plug renewal requires a spark plug socket which fits onto a ratchet spanner This socket is lined with a rubber grommet to protect the porcelain insulator of the spark plug and to hold the plug while yo
73. a brush through all oil holes and galleries and flush them with running water 6 After rinsing dry the engine block and apply a coat of light rust preventive oil to all machined surfaces Wrap the engine block in a plastic bag to keep it clean and set it aside until reassembly 18 Pistons connecting rods inspection 2 1 Before the inspection process can be carried out the piston connecting rod assemblies must be cleaned and the original piston rings removed from the pistons Note Always use new piston rings when the engine is reassembled 2 Using a piston ring refitting tool carefully remove the rings from the pistons Be careful not to nick or gouge the pistons in the process 3 Scrape all traces of carbon from the top of the piston A hand held wire brush or a piece of fine emery cloth can be used once the majority of the deposits have been scraped away Do not under any circumstances use a wire brush mounted in a drill motor to remove deposits from the pistons The piston material is soft and may be eroded away by the wire brush 4 Use a piston ring groove cleaning tool to remove carbon deposits from the ring grooves If a tool isn t available a piece broken off the old ring will do the job Be very careful to remove only the carbon deposits don t remove any metal and do not nick or scratch the sides of the ring grooves see illustrations 5 Once the deposits have been removed clean the piston connecting rod assemb
74. a new O ring when replacing the filter 30 Coolant renewal 2 Warning Do not allow engine coolant antifreeze to come in contact with your skin or painted surfaces of the vehicle Rinse off spills immediately with plenty of water Antifreeze is highly toxic if ingested Never leave antifreeze laying around in an open container or in puddles on the floor children and pets are attracted by it s sweet smell and may drink it Check with local authorities about disposing of used antifreeze Your local authority may have collection centres which will see that antifreeze is disposed of safely 1 Periodically the cooling system should be drained flushed and refilled to replenish the antifreeze mixture and prevent formation of rust and corrosion which can impair the performance of the cooling system and cause engine damage When the cooling system is serviced all hoses and the radiator cap should be checked and renewed if necessary Draining 2 Apply the handbrake and block the wheels If the vehicle has just been driven wait several hours to allow the engine to cool down before beginning this procedure 3 Remove the expansion tank pressure cap see illustration 4 Move a large container under the radiator drain to catch the coolant Then using a large screwdriver open the radiator drain plug and direct the coolant into the container see illustration 27 Differential oil renewal 2 1 Drive the car for several miles to
75. a rule of thumb blue smoke signifies oil being burnt engine wear while black smoke signifies unburnt fuel dirty air cleaner element or other carburettor or fuel system fault An exhaust gas analyser capable of measuring carbon monoxide CO and hydrocarbons HC is now needed If such an instrument cannot be hired or borrowed a local garage may agree to perform the check for a small fee CO emissions mixture At the time of writing the maximum CO level at idle is 3 5 for vehicles first used after August 1986 and 4 5 for older vehicles From January 1996 a much tighter limit around 0 5 applies to catalyst equipped vehicles first used from August 1992 If the CO level cannot be reduced far enough to pass the test and the fuel and ignition systems are otherwise in good condition then the carburettor is badly worn or there is some problem in the fuel injection system or catalytic converter as applicable HC emissions With the CO emissions within limits HC emissions must be no more than 1200 ppm parts per million If the vehicle fails this test at idle it can be re tested at around 2000 rpm if the HC level is then 1200 ppm or less this counts as a pass Excessive HC emissions can be caused by oil being burnt but they are more likely to be due to unburnt fuel Diesel models The only emission test applicable to Diesel engines is the measuring of exhaust smoke density The test involves accelerating the engine
76. achieved deburr the filed ends of the rings with a fine whetstone 6 Excess end gap isn t critical unless it s greater than Specifications Again double check to make sure you have the correct rings for your engine 7 Repeat the procedure for each ring that will be installed in the first cylinder and for each ring in the remaining cylinders Remember to keep rings pistons and cylinders matched 8 Once the ring end gaps have been checked corrected the rings can be installed on the pistons 9 The oil control ring lowest one on the piston is usually installed first It s composed of three separate components Slip the spacer expander into the groove see illustration If an anti rotation tang is used make sure it s inserted into the drilled hole in the ring groove Next refit the lower side rail Don t use a piston ring refitting tool on the oil ring side rails as they may be damaged Instead place one end of the side rail into the groove between the spacer expander and the ring land hold it firmly in place and slide a finger around the piston while pushing the rail into the groove see illustrations Next refit the upper side rail in the same manner 10 After the three oil ring components have been installed check to make sure that both Engine removal and overhaul procedures 2B 15 2B 22 3 When checking piston ring end gap the ring must be square in the cylinder bore this is done by pushing the ring down wit
77. alternately as the feed positive and earth side Some vehicles may have an anti theft system incorporated into the locks If you are unable to locate the trouble using the following general paragraphs consult a dealer service department or other properly equipped repair facility 1 Always check the circuit protection first Some vehicles use a combination of circuit breakers and fuses 2 Operate the door lock switches in both directions Lock and Unlock with the engine off Listen for the click of the solenoids operating 3 Test the switches for continuity Renew the switch if there s not continuity in both switch positions 4 Check the wiring between the switches control unit and solenoids for continuity Repair the wiring if there s no continuity 5 Check for a bad earth at the switches or the control unit 6 If all but one lock solenoid operates remove the trim panel from the affected door see Chapter 11 and check for voltage at the solenoid while the lock switch is operated see illustration One of the wires should have voltage in the Lock position the other should have voltage in the Unlock position 7 If the inoperative solenoid is receiving voltage renew the solenoid 8 If the inoperative solenoid isn t receiving voltage check for an open or short in the wire between the lock solenoid and the control unit Note It s common for wires to break in the portion of the harness between the body and door opening and c
78. amp sturdy and short chubby types Pliers Long nosed Side cutters electrician s Circlip internal and external Cold chisel 25 mm Scriber Scraper Centre punch Pin punch Hacksaw Brake hose clamp Brake clutch bleeding kit Selection of twist drills Steel rule straight edge Allen keys inc splined Torx type Selection of files Wire brush Axle stands Jack strong trolley or hydraulic type Light with extension lead Sockets and reversible ratchet drive Clutch plate alignment set Piston ring compressor Spline bit set Valve spring compressor 3261 Jaguar XJ6 Tools and working facilities REF 7 Special tools The tools in this list are those which are not used regularly are expensive to buy or which need to be used in accordance with their manufacturers instructions Unless relatively difficult mechanical jobs are undertaken frequently it will not be economic to buy many of these tools Where this is the case you could consider clubbing together with friends or joining a motorists club to make a joint purchase or borrowing the tools against a deposit from a local garage or tool hire specialist It is worth noting that many of the larger DIY superstores now carry a large range of special tools for hire at modest rates The following list contains only those tools and instruments freely available to the public and not those special tools produced by the vehicle manufacturer specifically for its dealer n
79. and should be used with caution Be sure to follow the instructions on the container 8 Clean the lifters with solvent and dry them thoroughly Compressed air will speed the drying process and can be used to clean out the oil passages Don t mix them up during cleaning keep them in a box with numbered compartments 9 Clean all the valve springs spring seats keepers and retainers with solvent and dry them thoroughly Work on the components from one valve at a time to avoid mixing up the parts 10 Scrape off any heavy deposits that may have formed on the valves then use a motorised wire brush to remove deposits from the valve heads and stems Again make sure that the valves don t get mixed up Inspection Note Be sure to perform all of the following inspection procedures before concluding that machine workshop work is required Make a list of the items that need attention The inspection procedures for the lifters and camshafts can be found in Part A Cylinder head 11 Inspect the cylinder head very carefully for cracks evidence of coolant leakage and other damage If cracks are found check with an automotive machine workshop concerning repair If repair isn t possible a new cylinder head should be obtained 12 A common problem on aluminium engines is erosion of the cylinder head or engine block coolant passages due to improper sealing Using a new cylinder head gasket held against the cylinder head trace the bolt ho
80. and connect the negative lead to the negative post 11 Crank the engine and take the voltmeter readings as soon as a steady figure is indicated Do not allow the starter motor to turn for more than 15 seconds at a time A reading of nine volts or more with the starter motor turning at normal cranking speed is normal If the reading is nine volts or more but the cranking speed is slow the motor is faulty If the reading is less than nine volts and the cranking speed is slow the solenoid contacts are probably burned the starter motor is bad the battery is discharged or there is a bad connection 15 Starter motor removal and refitting 2 1 Detach the cable from the negative terminal of the battery Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 2 Raise the vehicle and support it securely using axle stands 3 Drain the transmission fluid see Chapter 7 and remove the transmission fluid filler tube from the transmission 4 Detach the electrical connectors from the starter solenoid assembly see illustrations 5 Place a trolley jack under the tail section of the transmission remove the rear trans mission mount see Chapter 7 and lower the transmission slightly to gain access to the upper transmission bellhousing bolts Using an extension with a swivel socket remove the upper starter mounting bolt see illustration
81. and the condenser they must be in place when these components are reinstalled 5 16 The low coolant level sensor can be tested with an ohmmeter resistance should be below 150 ohms gently use a pair of long neck pliers to move the sensor up and down in the tank to get a reading 17 A coolant recovery bottle is used on 1988 and 1989 models located in the passenger s inner wing The plastic inner wing splash shield must be removed for access to the recovery bottle see Chapter 11 Disconnect the recovery hose and remove the mounting screws to renew the recovery bottle see illustration Models from 1990 on do not have the recovery bottle but do have a larger expansion tank 18 Refitting of either expansion tank or recovery bottle is the reverse of removal 6 Engine oil cooler renewal 2 1 Models from 1988 through 1991 have a engine oil cooler mounted ahead of the radiator The engine s mechanical fan draws air through the oil cooler cooling off hot engine oil that is circulated from the engine by steel tubes Access to the cooler is with the grille removed refer to Chapter 11 for grille removal 2 To renew the oil cooler first disconnect the two fittings connecting the lines to the cooler see illustration Caution The engine should be cool for this procedure and you should have a small drain pan handy because the fittings are on the bottom of the cooler and will probably drip some oil on dismantling 3 Remove
82. and the throttle link slot see illustration 6 Test drive the vehicle to determine if the cruise control is now working If it isn t take it to a dealer service department or an automotive electrical specialist for further diagnosis and repair 24 Electric window system description and check 2 1 The electric window system operates electric motors mounted in the doors which lower and raise the windows The system consists of the control switches relays the motors regulators glass mechanisms and associated wiring 2 The electric windows can be lowered and raised from the master control switch by the driver or by remote switches located at the individual windows Each window has a separate motor which is reversible The position of the control switch determines the polarity and therefore the direction of operation 3 The circuit is protected by a fuse Each motor is also equipped with an internal circuit breaker this prevents one stuck window from disabling the whole system 4 The electric window system will only operate when the ignition switch is ON In addition many models have a window lockout switch at the master control switch which when activated disables the switches at the rear windows and sometimes the switch at the passenger s window also Always check these items before diagnosing a window problem 5 These procedures are general in nature so if you can t find the problem using them take the vehicle
83. are equipped with hydraulically operated front and rear disc brake systems Both front and rear brakes are self adjusting Hydraulic system The hydraulic system is divided into two separate circuits The master cylinder has separate reservoirs for the two circuits and in the event of a leak or failure in one hydraulic circuit the other circuit will remain operative All models are equipped with an Anti lock Braking System ABS Brake servo A hydraulic brake servo system is used on all models covered by this manual This system uses hydraulic pressure from an engine driven pump on models equipped with a power hydraulic system and an electric pump on models without the power hydraulic system Handbrake The handbrake lever operates the rear brakes through cable actuation It s activated by a lever mounted in the centre console The handbrake assembly uses a pair of brake shoes located inside the rear hub brake disc Brake pad wear warning system The brake pad wear warning system turns on a red light in the instrument cluster when the brake pads have worn down to the point at which they must be replaced Do NOT ignore this reminder If you don t renew the pads shortly after the brake pad wear warning light comes on the brake discs will be damaged The wear sensors are attached to the brake pads Once the pads wear down to the point at which they re flush with the sensor the disc grinds away the side of the se
84. battery 6 Label and disconnect the electrical wires from the coil terminals 7 Remove the coil mounting fasteners see illustration 8 Refitting is the reverse of removal 9 Distributor removal and refitting 2 Note The timing on this ignition system cannot be adjusted by turning the distributor Ignition timing is maintained by the ECU at all times In the event the distributor must be removed from the engine be sure to follow the precautions described in this section and mark the engine and distributor with paint to ensure correct refitting If the distributor is not marked and the crankshaft is turned while the distributor is out of the engine have the distributor installed by a dealer service department The distributor must be installed using a special alignment tool Removal 1 Detach the battery negative cable Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 2 Disconnect the electrical connectors from the distributor 3 Look for a raised 1 on the distributor cap This marks the location for the number one cylinder spark plug lead terminal If the cap does not have a mark for the number one terminal locate the number one spark plug and trace the wire back to the terminal on the cap 4 Remove the distributor cap see Chapter 1 and rotate the engine until the rotor is pointing toward the number one
85. bellcrank assembly bolts arrowed and separate it from the throttle body 13 18 The area inside the throttle body near the throttle plate suffers from sludge build up because the PCV hose vents crankcase vapour into the intake duct 13 19 Measure clearance between the butterfly valve and the throttle body 3261 Jaguar XJ6 13 7 Push up on the clip and remove the harness connector from the MAF sensor 13 8 Remove the air intake duct clamp from the MAF sensor housing 13 20 Adjust the butterfly angle by loosening the locknut on the throttle stop and turning the adjustment bolt headlights or heated rear window and confirm that the engine rpm decreases at first and then increases This check monitors the ISC motor as it is signalled by the computer to increase idle speed due to additional amperage required from the charging system As the headlights draw current from the charging system the alternator will create resistance on the belt as it works to produce the additional energy If the rpm does not increase check the ISC motor 23 Check for approximately 11 2 volts to the ISC stepper motor see illustrations Disconnect the ISC harness connector and working on the harness side check for 11 2 volts with the ignition key ON engine not running Also check the corresponding terminals for the correct voltage amounts If the correct voltage does not exist check the wiring harness Refer to the wiring diagrams at the end of Chapte
86. brake line use one spanner to hold the hose fitting just below the bracket lower spanner then break loose the nut on the metal line upper spanner to disconnect the flex hose from the bracket remove the centre nut arrowed just above the bracket 3261 Jaguar XJ6 6 Carefully check to make sure the suspension and steering components do not make contact with the hoses Have an assistant push on the vehicle and also turn the steering wheel from lock to lock during inspection 7 Bleed the brake system see Section 9 Metal brake line renewal 8 When replacing brake lines use the proper parts only Do not use copper line for any brake system connections Purchase steel brake lines from a dealer or motor factors 9 Unless you re using factory renewal brake lines you may need a tubing bender to bend the lines to the proper shape 10 First remove the line you intend to renew lay it on a clean workbench and measure it carefully Obtain a new line of the same length and bend it to match the pattern of the old line Warning Do not crimp or damage the line No bend should have a smaller radius than 9 16 inch Make sure the protective coating on the new line is undamaged at the bends 11 When refitting the new line make sure it s well supported by the brackets the routing matches the original and there s plenty of clearance between moving or hot components 12 After refitting check the master cylinder fluid
87. brake pads worn out The noise comes from the wear sensor rubbing against the disc Replace pads with new ones immediately Chapter 9 Brake roughness or chatter pedal pulsates Excessive lateral disc runout Chapter 9 Parallelism not within specifications Chapter 9 Uneven pad wear caused by caliper not sliding due to improper clearance or dirt Chapter 9 Defective disc Chapter 9 Excessive pedal effort required to stop vehicle Malfunctioning power brake servo Chapter 9 Partial system failure Chapter 9 Excessively worn pads Chapter 9 Piston in caliper stuck or sluggish Chapter 9 Brake pads contaminated with oil or grease Chapter 9 New pads installed and not yet seated It will take a while for the new material to seat against the disc Accumulator in power hydraulic system defective see a Jaguar dealer Excessive brake pedal travel Partial brake system failure Chapter 9 Insufficient fluid in master cylinder Chapters 1 and 9 Air trapped in system Chapters 1 and 9 Dragging brakes Master cylinder pistons not returning correctly Chapter 9 Restricted brakes lines or hoses Chapters 1 and 9 Incorrect handbrake adjustment Chapter 9 Grabbing or uneven braking action Malfunction of power brake servo unit Chapter 9 Binding brake pedal mechanism Chapter 9 Brake pads contaminated with oil or grease Chapter 9 3261 Jaguar XJ6 REF 16 Fault finding
88. circuit check and component renewal 3 Warning Later models are equipped with airbags To prevent accidental deployment of the airbag which could cause personal injury or damage to the airbag system DO NOT work in the vicinity of the steering wheel or instrument panel Jaguar recommends that on airbag equipped models the following procedure should be left to a dealer service department or other repair workshop because of the special tools and techniques required to disable the airbag system 1 Disconnect the battery negative cable Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 2 There are two blower motors one under the left side of the dash and one behind the glove compartment see illustration If the blower doesn t work check the fuse and all connections in the circuit for looseness and corrosion Make sure the battery is fully charged To access the right blower remove the glove compartment liner the glove compartment door and the right lower dash panel see Chapter 11 Warning When working around the area behind the glove box watch out for a strip of sheet metal bracing that has a very sharp edge see illustration Apply some heavy duct tape to the edge of the brace before beginning work in this area or you could injure your hands Cooling heating and air conditioning systems 3 7 3 8 4
89. conditioning housing 8 At the bottom left and bottom right of the housing pull off the rubber drain tubes that go into the flooring 9 Remove the four rod type support braces Two support the dash and two connect the case to the floor of the car see illustrations 3 14 Cooling heating and air conditioning systems 17 5 Left duct large arrow can be removed by pulling off the clip small arrow right duct pulls out without a clip 17 9a Unbolt the four support braces small arrows from the case large arrow and floor 17 9b Black case support rods are held with nuts arrowed the gold dash support rods are retained by a bolt nut to the dash 3261 Jaguar XJ6 17 2 Use two spanners when disconnecting the air conditioning lines arrowed at the bulkhead on the backside of the expansion valve one spanner holds the body of the expansion valve 17 4 Remove the housing retaining nut arrowed on the engine side of the bulkhead near the expansion valve another nut is on the right near the heater core pipes 10 With everything disconnected pull the heat air conditioning housing back and out from under the dash Caution Do not force anything If the unit gets stuck determine where the inter ference is before a duct wire or hose is broken 11 Pry off the series of black metal clips connecting the main housing to the evaporator case then separate the evaporator case and pull out the evaporator core Note When re
90. damage to the airbag system DO NOT work in the vicinity of the steering column or instrument panel The manufacturer recommends that on airbag equipped models the following procedure be performed at a dealer service department or other properly equipped repair facility because of the special tools and techniques required to disable the airbag system Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 1 Disconnect the negative battery cable Radio 2 Remove the radio trim bezel Chapter 11 3 Remove the retaining screws see illustration pull the radio control panel outward to access the backside and disconnect the electrical connectors and aerial lead Detach the retaining clips and separate the radio from the control panel 4 Refitting is the reverse of removal Speakers 5 Remove the door trim panel Chapter 11 6 Remove the nuts from the speaker mounting studs see illustration Disconnect the electrical connector and remove the speaker from the vehicle 7 Refitting is the reverse of removal Body electrical system 12 7 12 3261 Jaguar XJ6 12 3 Remove the instrument cluster retaining screws arrowed then separate the instrument cluster from the cluster housing 13 3 Remove the retaining screws arrowed and pull the radio control panel out enough to unplug the connectors 13 6 Remove the nuts
91. engine has springs with white stripes they have already been replaced and only broken ones need be replaced 19 Stand each spring on a flat surface and check it for squareness see illustration If any of the springs are distorted or sagged renew all of the springs 20 Check the spring retainers and keepers for obvious wear and cracks Any questionable parts should be renewed as extensive damage will occur if they fail during engine operation 21 If the inspection process indicates that the valve components are in generally poor condition and worn beyond the limits specified which is usually the case in an engine that s being overhauled reassemble the valves in the cylinder head and refer to Section 11 for valve servicing recommendations 11 Valves servicing 5 1 Because of the complex nature of the job and the special tools and equipment needed servicing of the valves the valve seats and the valve guides commonly known as a valve job should be done by a professional 2 The home mechanic can remove and dismantle the cylinder head s do the initial cleaning and inspection then reassemble and deliver them to a dealer service department or an automotive machine workshop for the actual service work Doing the inspection will enable you to see what condition the cylinder head s and valvetrain components are in and will ensure that you know what work and new parts are required when dealing with an automotive machine wo
92. filament burns out or the lens cracks the entire unit is simply replaced Serpentine drivebelt A single long wide accessory drivebelt that s used on some newer vehicles to drive all the accessories instead of a series of smaller shorter belts Serpentine drivebelts are usually tensioned by an automatic tensioner Shim Thin spacer commonly used to adjust the clearance or relative positions between two parts For example shims inserted into or under bucket tappets control valve clearances Clearance is adjusted by changing the thickness of the shim Slide hammer A special puller that screws into or hooks onto a component such as a shaft or bearing a heavy sliding handle on the shaft bottoms against the end of the shaft to knock the component free Sprocket A tooth or projection on the periphery of a wheel shaped to engage with a chain or drivebelt Commonly used to refer to the sprocket wheel itself Starter inhibitor switch On vehicles with an automatic transmission a switch that prevents starting if the vehicle is not in Neutral or Park Strut See MacPherson strut T Tappet A cylindrical component which transmits motion from the cam to the valve stem either directly or via a pushrod and rocker arm Also called a cam follower Thermostat A heat controlled valve that regulates the flow of coolant between the cylinder block and the radiator so maintaining optimum engine operating temperature A thermostat is
93. for leaks and proper system operation 12 Heater and air conditioning control assembly check removal and refitting 4 Warning Later models are equipped with airbags To prevent the accidental deploy ment of the airbag which could cause personal injury or damage to the airbag system DO NOT work in the vicinity of the steering wheel or instrument panel The manufacturer recommends that on airbag equipped models the following procedure should be left to a dealer service department or other repair workshop because of the special tools and techniques required to disable the airbag system Removal and refitting 1 Disconnect the battery negative cable Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 2 Refer to Chapter 11 for removal of the console heater control radio assembly trim bezel 3 Remove the mounting screws retaining the heater air conditioning control assembly to the console see illustrations Pull the assembly out and disconnect the electrical connectors 3 10 Cooling heating and air conditioning systems 11 4 Remove these screws small arrows to remove the plastic plate over the heater core pipes on the left side 11 5 With the cover off remove the Allen bolts arrows indicate three of the four to pull the coolant pipes out of the left side of the heater core 11 6a Remove thr
94. from the transmission housing with degreasing agents and or steam cleaning Then drive the vehicle at low speeds so air flow will not blow the leak far from its source Raise the vehicle and determine where the leak is coming from Common areas of leakage are a Sump pan Chapters 1 and 7 b Dipstick filler tube see below c Transmission fluid cooler lines Chapter 7 d Speedometer sensor Chapter 7 Make sure the dipstick is a tight fit inside the filler tube If the seal at the top of the dipstick is worn or damaged replace the seal or the dipstick If fluid continues to leak from the top of the dipstick tube inspect the breather which is a plastic cap secured by a clip to the top of the extension housing This breather can be plugged by the noise deadening foam installed in the transmission tunnel causing transmission fluid to leak from the top of the dipstick tube Transmission fluid brown or has a burned smell Transmission fluid burned Chapter 1 Shift cable problems Chapter 7 deals with adjusting the shift cable Common problems which may be attributed to a poorly adjusted shift cable are a Engine starting in gears other than Park or Neutral b Indicator on shift lever pointing to a gear other than the one actually being used c Vehicle moves when in Park Refer to Chapter 7 for the shift cable adjustment procedure Transmission will not downshift with accelerator pedal pressed to the floor Kickdown cable
95. from the retaining studs arrowed to remove the speaker 14 Electric aerial removal and refitting 2 Aerial motor assembly 1 Remove the aerial mast retaining nut see illustration 2 Working in the boot pry out the plastic clips securing the driver s side boot finishing panels to allow access to the aerial motor assembly 3 Detach the motor assembly retaining bolts see illustration Disconnect the electrical connector and earth strap then remove the aerial motor assembly from the vehicle 4 Refitting is the reverse of removal Aerial mast 5 Remove the aerial mast retaining nut see illustration 14 1 6 With an assistant controlling the ignition switch turn the ignition key and the radio to the ON position Guide the aerial mast out of the body as the cable unwinds from the motor assembly see illustration Note the direction the teeth on the aerial cable are facing for refitting purposes 7 To refit the aerial mast insert the aerial cable into the motor assembly with the cable teeth facing the direction as noted above Have your assistant turn the ignition key and the radio to the ON position Guide the cable and aerial mast through the opening as the cable winds back into the motor assembly 8 Refit the aerial mast retaining nut 15 Windscreen wiper motor removal and refitting 2 1 Pull the wiper arm nut cover back to access the wiper arm nuts Remove the nuts and pull the wiper arm straight off the s
96. fuel tank retaining straps see illustration 11 Pull the fuel tank out into the boot area Be careful to angle the fuel filler neck away from the body 12 Remove the tank from the vehicle 13 Refitting is the reverse of removal 8 Fuel tank cleaning and repair general information 5 1 Any repairs to the fuel tank or filler neck should be carried out by a professional who has experience in this critical and potentially dangerous work Even after cleaning and flushing of the fuel system explosive fumes can remain and ignite during repair of the tank 2 If the fuel tank is removed from the vehicle it should not be placed in an area where sparks or open flames could ignite the fumes coming out of the tank Be especially careful inside garages where a natural petrol type appliance is located because the pilot light could cause an explosion 9 Air cleaner assembly removal and refitting 1 1 Detach the clips and remove the air filter cover and the filter element see Chapter 1 2 Remove the bolts and remove the air cleaner assembly from the engine compartment see illustrations 3 Refitting is the reverse of removal Fuel and exhaust systems 4 7 4 7 7b Direct low pressure compressed air into the hole for the overflow line if clogged 7 8 Remove the bolts arrowed from the spare tyre bracket and lift out the assembly 7 9a Disconnect the flexible fuel lines from the metal fuel lines 7 9b Disconnect the vapour
97. gauge should be at least above the bottom mark Warm oil and contaminates will flow out more easily Turn off the engine when it s warmed up Remove the oil filler cap located next to the valve cover 6 Raise the vehicle and support it on axle stands Warning To avoid personal injury never get beneath the vehicle when it is supported by only by a jack The jack provided with your vehicle is designed solely for raising the vehicle to remove and replace the wheels Always use axle stands to support the vehicle when it becomes necessary to place your body underneath the vehicle 7 Being careful not to touch the hot exhaust components place the drain pan under the drain plug in the bottom of the pan and remove the plug see illustration You may want to wear gloves while unscrewing the plug the final few turns if the engine is really hot 8 Allow the old oil to drain into the pan It may be necessary to move the pan farther under the engine as the oil flow slows to a trickle Inspect the old oil for the presence of metal shavings and chips 9 After all the oil has drained wipe off the drain plug with a clean rag Even minute metal particles clinging to the plug would immediately contaminate the new oil 10 Clean the area around the drain plug opening refit the plug and tighten it securely but do not strip the threads 11 Move the drain pan into position under the oil filter 12 Remove all tools rags etc from under the vehi
98. hole to make sure the lubricant level is even with the bottom of the hole 10 2 Check the exhaust system hangers arrowed for damage and cracks 3261 Jaguar XJ6 8 4a The automatic transmission dipstick arrowed is located in a tube which extends forward from the transmission 8 4b Check the automatic transmission fluid with the engine idling at operating temperature and the gear selector in Park then add fluid to bring the level to the upper mark silencer and catalytic converter If the components can come in contact with the body or suspension parts secure the exhaust system with new mounts 5 Check the running condition of the engine by inspecting inside the end of the tailpipe The exhaust deposits here are an indication of engine state of tune If the pipe is black and sooty or coated with white deposits the engine is in need of a tune up including a thorough fuel system inspection 11 Braking system general check and adjustment 2 Warning The dust created by the brake system may contain asbestos which is harmful to your health Never blow it out with compressed air and don t inhale any of it An approved filtering mask should be worn when working on the brakes Do not under any circumstances use petroleum based solvents to clean brake parts Use brake system cleaner only Try to use non asbestos replacement parts whenever possible Note For detailed photographs of the brake system refer to Chapter 9 1
99. immediately with soap and water Mop up any spills immediately and do not store fuel soaked rags where they could ignite The fuel system is under constant pressure so if any fuel lines are to be disconnected the fuel pressure in the system must be relieved first see Chapter 4 for more information When you perform any kind of work on the fuel system wear safety glasses and have a Class B type fire extinguisher on hand 1 The canister type filter is mounted underneath the car on the passenger s side frame rail just in front of the left rear tyre 2 Depressurise the fuel system refer to Chapter 4 then disconnect the cable from the negative terminal of the battery 3 On 1988 to 1990 models detach the banjo bolt from the outlet side of the filter then remove the union from the inlet side of the filter Unscrew the filter mounting bolt and remove the filter see illustration 4 On 1991 to 1994 models the fuel filter has quick disconnect fittings that do not require 8 Clean and lubricate the handbrake cable along with the cable guides and levers This can be done by smearing some of the chassis grease onto the cable and its related parts with your fingers 9 Open the bonnet and smear a little chassis grease on the bonnet latch mechanism Have an assistant pull the bonnet release lever from inside the car as you lubricate the cable at the latch 10 Lubricate all the hinges door bonnet etc with engine oil to keep them in prop
100. in this Chapter s Specifications The front cap should be installed first then cap number 7 then alternately tighten the first and last caps to bring the camshaft down evenly Next refit caps 4 2 3 5 and 6 27 Align the intake camshaft with the special camshaft positioning tool as described in paragraph 5 Engage the outer sprocket with the chain slip the sprocket over the end of the camshaft then turn it until there is no slack in the chain to the right of the camshaft sprocket facing the front of the engine Now align the inner sprocket with the camshaft until the bolt holes align and mesh the splines between the two sprocket halves see illustrations Tighten the inner sprocket bolts to the camshaft and bend the locking sheetmetal tabs over the bolts 28 Keeping the slack in the chain to the left of the exhaust camshaft refit the exhaust camshaft outer sprocket meshed with the chain over the end of the exhaust camshaft Insert the timing chain tensioner tool Jaguar tool no 18G 1436 at the upper tensioner mounting point see illustration Note The chain tensioner tool applies pressure to the upper timing chain to simulate the effect of the tensioner which is operated by engine oil pressure when the engine is running 29 Align the exhaust camshaft to TDC with the special timing gauge tool Tighten the centre bolt in the tensioner tool to 4 to 6 Nm When the chain is tensioned align the inner exhaust sprocket with
101. in the same position it was in before removal Also check the rotor to see if it s aligned with the mark you made on the edge of the distributor base 9 Refit the distributor hold down bolt s 10 The remainder of refitting is the reverse of removal 10 Charging system general information and precautions The charging system includes the alternator an internal voltage regulator a charge indicator light load dump module the battery an ignition ON relay an in line fuse and the wiring between all the components see illustration The charging system supplies electrical power for the ignition system the lights the radio etc The alternator is driven by a drivebelt at the front of the engine The purpose of the voltage regulator is to limit the alternator s voltage to a preset value This prevents power surges circuit overloads etc during peak voltage output The alternator load dump module protects the electrical circuits from excessive voltage surges When the battery cables are removed large amounts of transient voltage is released through the electrical circuits This device diverts up to 30 load volts of excess voltage to earth by way of a voltage dependent resistor The in line fuse is a special fuse installed into the circuit with the engine compartment wiring harness see Chapter 12 The in line fuse protects the electrical system in the event of excess voltage surges or a power to earth short circuit Refer to Cha
102. inch 62 Refitting is the reverse of removal Tighten the crankshaft sensor bolt to the torque listed in this Chapter s Specifications Emissions and engine control systems 6 7 6 3261 Jaguar XJ6 4 51 The air intake temperature sensor resistance will DECREASE when the temperature of the air INCREASES 4 57 Location of the crankshaft position sensor 5 Air Injector Reactor AIR system General information 1 The air injection reactor system reduces carbon monoxide and hydrocarbon content in the exhaust gases by injecting fresh air into the hot exhaust gases leaving the exhaust ports When fresh air is mixed with hot exhaust gases oxidation is increased reducing the concentration of hydrocarbons and carbon monoxide and converting them into harmless carbon dioxide and water 2 The air injection system is composed of an air pump diverter valve bypass check valve air injection manifold vacuum delay valve vacuum control solenoid air pump magnetic clutch air pump clutch relay and hoses see illustration The air pump is driven by a belt from the crankshaft and supplies compressed air to the exhaust manifold s The check valve prevents the reverse flow of exhaust gases into the system The vacuum operated early models or electrically operated later models air cut off valve prevents air from being drawn into the exhaust when the air pump is switched off System vacuum to the air cut off valve is controlled by the
103. incorrectly through the bulkhead securing straps thereby restricting the vacuum signal to the EGR valve Remove the EGR vacuum hose from the bulkhead harness and refit a new hose Secure it to the engine compartment using tie wraps and do not allow any restrictions in the hose Note 2 Some models have copper sealing washers that soften and leak around the EGR valve causing engine performance and starting problems Refit steel washers and pipe adapters into the EGR system Contact a Jaguar dealer for the VIN numbers and years of the models that are affected by this defect 1 To reduce oxides of nitrogen emissions some of the exhaust gases are recirculated through the EGR valve to the intake manifold to lower combustion temperatures 2 The EGR system consists of the EGR valve an EGR solenoid an EGR gas temperature sensor and the transfer pipe see illustration Check EGR valve 3 Start the engine and allow it to idle 4 Detach the vacuum hose from the EGR valve and attach a hand vacuum pump in its place see illustration 5 Apply vacuum to the EGR valve Vacuum should remain steady and the engine should run poorly Note This action will raise the pintle and allow exhaust gases to recirculate into the intake system and cause rough running condition at idle Double check the movement of the pintle by checking the diaphragm using the tip of your finger see illustration If the EGR diaphragm moves smoothly and holds steady whe
104. is extremely flammable so take extra precautions when you work on any part of the fuel system See the Warning in Section 2 Note 1 On early models 1988 to 1990 an electric fuel pump is attached to the chassis next to the fuel tank On later models 1991 to 1994 the fuel pump is inside the fuel tank Note 2 On 1988 to 1990 models the fuel pump may chatter excessively and the engine may stall frequently during hot weather If stalling occurs the engine will restart after a cool down period Dual fuel pumps can be installed by a dealer service department or other qualified repair facility to remedy this problem 1 Remove the fuel tank filler cap to relieve any pressure in the fuel tank Relieve the fuel pressure see Section 2 2 Disconnect the cable from the negative terminal of the battery Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery External fuel pumps 3 Raise the vehicle and support it securely on axle stands 4 Disconnect the fuel lines from the fuel pump 5 Disconnect the electrical connectors from the fuel pump see illustration 3 4a 6 Remove the fuel pump bracket retaining nuts see illustration 7 Carefully withdraw the fuel pump from the rubber case inside the fuel pump bracket and angle the fuel pump over the rear suspension and out near the wheel on the left side of the vehicle 8 Refitting is
105. is installed start off with a 0 38 mm 0 015 inch thick shim pack refit the drive sprocket and align the sprocket as follows 18 Use a straightedge to check the alignment of the oil pump sprocket with the crankshaft sprocket see illustration If they are not aligned increase or decrease the shim pack at the oil pump sprocket until alignment is correct then secure the oil pump sprocket bolts by bending up the sheetmetal tabs Note You may be able to use all or part of the original shim pack from the original oil pump if a new pump is being fitted If required shims are available in 0 127 mm 0 005 inch 0 254 mm 0 010 inch and 0 508 mm 0 020 inch sizes 19 Fit new O rings to each end of the transfer tubes and refit the tubes into the transfer housing Note Use petroleum jelly to lubricate the O rings 20 Apply a thin coat of RTV sealant to the engine block mounting surface of the transfer housing Lift the transfer housing and tubes into place and push the front of the tubes in the back of the oil pump until you can start the transfer housing to engine block bolts Tighten the bolts to the torque listed in this Chapter s Specifications 21 Refit the remaining parts in the reverse order of removal 22 Add oil start the engine and check for oil pressure and leaks 23 Recheck the engine oil level 14 Driveplate removal and refitting 4 Removal 1 Raise the car and support it securely on axle stands then refer to
106. is performed involving ignition components This not only includes the amplifier coil distributor and spark plug leads but related components such as connectors tachometer and other test equipment also Note Because of the complexity and the special tools required to test the amplifier the following procedure only describes a test to verify battery voltage is reaching the amplifier If the wiring harness and the relays are working properly and battery voltage is available to the amplifier have the ignition system and the ECU diagnosed by a dealer service department Check 1 Disconnect the amplifier electrical connector see illustration 2 Turn the ignition key ON engine not running check for battery voltage see illustration to the amplifier 3 If no battery voltage is present check the harness from the ignition switch to the amplifier Refer to the wiring diagrams at the end of Chapter 12 Renewal 4 Disconnect the negative battery terminal Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 5 Remove the amplifier mounting bolts see illustration 6 Refitting is the reverse of removal 8 Ignition coil check and renewal 2 Check 1 Detach the cable from the negative terminal of the battery Caution If the stereo in your vehicle is equipped with an anti theft system make Engine electrical sys
107. last test point with voltage Most of the time the problem can be traced to a loose connection Note Keep in mind that some circuits receive voltage only when the ignition key is in the Accessory or Run position Finding a short One method of finding shorts in a circuit is to remove the fuse and connect a test light or voltmeter in its place There should be no voltage present in the circuit Move the wiring harness from side to side while watching the test light If the bulb goes on there is a short Airbag system general information 28 Bulb renewal 21 Central locking system description and check 25 Circuit breakers general information 5 Cruise control system description and check 23 Direction indicators hazard flashers general information 7 Electric aerial removal and refitting 14 Electric side view mirrors description and check 26 Electric sunroof description and check 27 Electric window system description and check 24 Electrical fault finding general information 2 Fuel o
108. lobe on the camshaft could be the cause 13 If the compression is unusually high the combustion chambers are probably coated with carbon deposits If that s the case the cylinder head s should be removed and decarbonised 14 If compression is way down or varies greatly between cylinders it would be a good idea to have a leak down test performed by an automotive repair workshop This test will pinpoint exactly where the leakage is occurring and how severe it is 5 Engine removal methods and precautions If you ve decided that an engine must be removed for overhaul or major repair work several preliminary steps should be taken Locating a suitable place to work is extremely important Adequate work space along with storage space for the vehicle will be needed If a workshop or garage isn t available at the very least a flat level clean work surface made of concrete or asphalt is required Cleaning the engine compartment and engine before beginning the removal procedure will help keep tools clean and organised An engine hoist or A frame will also be necessary Make sure the equipment is rated in excess of the combined weight of the engine and transmission Safety is of primary importance considering the potential hazards involved in lifting the engine out of the vehicle If the engine is being removed by a novice a helper should be available Advice and aid from someone more experienced would also be helpful
109. micrometer and record the measurements Inspection 19 After the camshaft has been removed from the engine cleaned with solvent and dried inspect the bearing journals for uneven wear pitting and evidence of seizure If the journals are damaged the bearing surfaces in the cylinder head and caps may be damaged as well requiring renewal of the cylinder head 20 Measure the bearing journals with a micrometer to determine if they are excessively worn or out of round see illustration Compare the measurements to Specifications 21 Check the camshaft lobes for heat discolouration score marks chipped areas pitting and uneven wear Measure the lobe heights with a micrometer and record the measurements see illustrations If there is variance of more than 0 005 inch the camshaft and lifters must be renewed If the lobes are in good condition the camshaft can be reused 22 Inspect the top bottom and side surfaces of the lifters for wear grooving or scoring If the lifters are damaged the camshaft and its lifters must be renewed as a set Engine in car repair procedures 2A 11 2A 10 13 Remove the two bolts and the upper timing chain guide arrowed 10 14 Pull the inner sprocket from the outer sprocket of each camshaft 10 17 A magnet can be used to remove the lifters arrowed 10 18 The valve adjustment shims arrowed fit into a pocket in the valve spring retainer use a magnet to remove the shims and keep them wit
110. new engine During an overhaul the piston rings are replaced and the cylinder walls are reconditioned rebored and or honed If a rebore is done by an automotive machine workshop new oversize pistons will also be installed The main bearings big end bearings and camshaft bearings are generally replaced with new ones and if necessary the crankshaft may be reground to restore the journals Generally the valves are serviced as well since they re usually in less than perfect condition at this point While the engine is being overhauled other components such as the distributor starter and alternator can be rebuilt as well The end result should be a like new engine that will give many trouble free miles Note Critical cooling system components such as the hoses drivebelts thermostat and water pump should be replaced with new parts when an engine is overhauled The radiator should be checked carefully to ensure that it isn t clogged or leaking see Chapter 3 If you purchase a 2 4a The oil pressure sender unit arrowed is located in the right front corner of the engine block near the oil filter 2 4b The oil pressure can be checked by removing the sender unit and refitting a pressure gauge in its place rebuilt engine or short block some rebuilders will not warranty their engines unless the radiator has been professionally flushed Also we don t recommend overhauling the oil pump always refit a new one when an e
111. of a moving vehicle into heat Double overhead cam DOHC An engine that uses two overhead camshafts usually one for the intake valves and one for the exhaust valves Drivebelt s The belt s used to drive accessories such as the alternator water pump power steering pump air conditioning compressor etc off the crankshaft pulley Driveshaft Any shaft used to transmit motion Commonly used when referring to the axleshafts on a front wheel drive vehicle Drum brake A type of brake using a drum shaped metal cylinder attached to the inner surface of the wheel When the brake pedal is pressed curved brake shoes with friction linings press against the inside of the drum to slow or stop the vehicle E EGR valve A valve used to introduce exhaust gases into the intake air stream Electronic control unit ECU A computer which controls for instance ignition and fuel injection systems or an anti lock braking system For more information refer to the Haynes Automotive Electrical and Electronic Systems Manual Electronic Fuel Injection EFI A computer controlled fuel system that distributes fuel through an injector located in each intake port of the engine Emergency brake A braking system independent of the main hydraulic system that can be used to slow or stop the vehicle if the primary brakes fail or to hold the vehicle stationary even though the brake pedal isn t depressed It usually consists of a hand lever that actuates
112. of the crankshaft Slip the spacer off and clean the varnish off the seal surface see illustration 10 Clean the bore in the cover and coat the outer edge of the new seal with engine oil or multi purpose grease Apply moly base grease to the seal lip 11 Lubricate the spacer with clean engine oil and refit it onto the crankshaft Using a socket with an outside diameter slightly smaller than the outside diameter of the seal carefully drive the new seal into place with a hammer see illustration Make sure it s installed squarely and driven in to the same depth as the original If a socket isn t available a short section of large diameter pipe will also work Note The new seal comes with a plastic installer guide Do not remove this guide until refitting is completed The guide keeps the seal lip properly oriented over the crankshaft 12 Refit the Woodruff key then refit the damper Tighten the damper bolt to the torque listed in this Chapter s Specifications Note The damper bolt can be used to pull the damper back onto the crankshaft but make sure the damper is perfectly aligned with the Woodruff key 13 The rest of the assembly is the reverse of the removal procedure 14 Run the engine and check for oil leaks at the front seal 8 Timing chains and sprockets removal inspection and refitting 3 Caution If the timing chain broke during engine operation the valves may have come in contact with the pistons causing
113. of the power hydraulic system this weekly check is not applicable l It is essential to use the correct power steering fluid this being dependent on the year of manufacture and type of system fitted A label attached to the fluid reservoir will indicate the specification of fluid However if necessary refer to the driver s handbook supplied with the vehicle or to your local Jaguar dealer 3261 Jaguar XJ6 0 14 Weekly 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 that the 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
114. of the removal procedure Be sure to tighten all fasteners to the torque listed in this Chapter s Specifications 4 Shock absorber front removal and refitting 2 Note Always renew both left and right shocks at the same time to prevent handling peculiarities and abnormal ride quality 1 Loosen but do not remove the front wheel nuts Raise the front of the vehicle and support it on axle stands Remove the wheels 2 Support the lower control arm with a trolley jack see illustration Place a block of wood between the jack head and the control arm to protect the arm and spring plate 3 Remove the nut and bolt that attach the lower end of the shock absorber to the lower control arm see illustration 4 Remove the nut that attaches the upper end of the shock to the body see illustration 5 Remove the shock absorber 6 Refitting is the reverse of removal Tighten the fasteners to the torque listed in this Chapter s Specifications 5 Balljoints check and renewal 3 Check 1 Raise the vehicle and support it securely on axle stands 2 Visually inspect the rubber boot between the balljoints and the steering knuckle for cuts tears or leaking grease If you note any of these conditions renew the balljoint 3 Place a large crowbar between each control arm and the steering knuckle If you can see or feel any movement during either check a worn out balljoint is indicated 4 Have an assistant grasp the tyre at the top
115. of the valve guides Gently push each valve seal into place until it s seated on the guide Caution Don t hammer on the valve seals once they re seated or you may damage them Don t twist or cock the seals during refitting or they won t seat properly on the valve stems 2B 8 Engine removal and overhaul procedures 10 15 Use a small dial bore gauge to determine the inside diameter of the valve guides subtract the valve stem diameter to determine the stem to guide clearance 10 17 The margin width on each valve must be as specified if no margin exists the valve cannot be re used 10 18 Measure the free length of each valve spring with a dial or vernier caliper 10 19 Check each valve spring for squareness 3261 Jaguar XJ6 4 Beginning at one end of the cylinder head lubricate and refit the first valve Apply moly base grease or clean engine oil to the valve stem 5 Place the spring seat or shim s over the valve guide and set the valve spring and retainer in place 6 Compress the springs with a valve spring compressor and carefully refit the keepers in the upper groove then slowly release the compressor and make sure the keepers seat properly Apply a small dab of grease to each keeper to hold it in place if necessary see Haynes Hint 7 Repeat the procedure for the remaining valves Be sure to return the components to their original locations don t mix them up 13 Pistons connecting rods removal 4
116. often during the bleeding operation and add fluid as necessary to prevent the fluid level from falling low enough to allow air into the master cylinder 7 Have an assistant on hand as well as a supply of new brake fluid an empty clear plastic container a length of 3 16 inch clear tubing to fit over the bleed screws and a spanner to open and close the bleed screws 8 Beginning at the right rear wheel loosen the bleed screw slightly then tighten it to a point where it is snug but can still be loosened quickly and easily 9 Place one end of the tubing over the bleed valve and submerge the other end in brake fluid in the container see illustration 10 Have the assistant pump the brakes a few times to build pressure in the system then hold the pedal firmly depressed 11 While the pedal is held depressed open the bleed screw just enough to allow fluid to flow from the caliper Watch for air bubbles to exit the submerged end of the tube When the fluid flow slows after a couple of seconds close the screw and have your assistant release the pedal 12 Repeat Steps 10 and 11 until no more air is seen leaving the tube then tighten the bleed screw and proceed to the left rear wheel the right front wheel and the left front wheel in that order and perform the same procedure Be sure to check the fluid in the master cylinder reservoir frequently 13 Never reuse old brake fluid It contains contaminates and moisture which could damage the
117. overrunning clutch in the starter motor is slipping and the starter motor must be renewed 4 If when the switch is actuated the starter motor does not operate at all but the solenoid clicks then the problem lies with either the battery the main solenoid contacts or the starter motor itself or the engine is seized 5 If the solenoid plunger cannot be heard when the switch is actuated the battery is bad the in line fuse is burned the circuit is open the starter relay see illustration is defective or the starter solenoid itself is defective 6 To check the solenoid connect a jumper lead between the battery and the ignition switch terminal the small terminal on the solenoid If the starter motor now operates the solenoid is OK and the problem is in the ignition switch linear switch 1988 to 1992 rotary switch 1993 and 1994 or in the wiring 7 If the starter motor still does not operate remove the starter solenoid assembly for dismantling testing and repair 8 If the starter motor cranks the engine at an abnormally slow speed first make sure that the battery is charged and that all terminal connections are tight If the engine is partially seized or has the wrong viscosity oil in it it will crank slowly 9 Run the engine until normal operating temperature is reached then disconnect the coil wire from the distributor cap and earth it on the engine 10 Connect a voltmeter positive lead to the battery positive post
118. passenger compartment 9 With the compressor engaged the clutch will make an audible click and the centre of the clutch will rotate After the system reaches operating temperature feel the two pipes connected to the evaporator at the bulkhead see illustration 10 The pipe thinner tubing leading from the condenser outlet to the evaporator should be cold and the evaporator outlet line the thicker tubing that leads back to the compressor should be slightly colder 3 to 10 F If the evaporator outlet is considerably warmer than the inlet the system needs a charge Insert a thermometer in the centre air distribution duct while operating the air conditioning system the temperature of the output air should be 35 to 40 F below the ambient air temperature down to approxi mately 40 F If the ambient outside air temperature is very high say 110 F the duct air temperature may be as high as 60 F but generally the air conditioning is 30 to 50 F cooler than the ambient air If the air isn t as cold as it used to be the system probably needs a charge Further inspection or testing of the system is beyond the scope of the home mechanic and should be left to a professional 11 Inspect the sight glass see illustration If the refrigerant looks foamy when running it s low When ambient temperatures are very hot bubbles may show in the sight glass even with the proper amount of refrigerant With the proper amount of re
119. penetrating oil to the exhaust manifold mounting nuts bolts and the nuts retaining the exhaust pipes to the manifolds After the nuts have soaked remove the nuts retaining the exhaust pipes to the manifolds and the lower bolt from the heat shield see illustration 4 Remove the heat shield from the exhaust manifolds see illustration 5 Disconnect the electrical connector to the oxygen sensor Unless the oxygen sensor is being renewed leave the sensor in place 6 Remove the nuts bolts and detach the manifolds and gaskets see illustration 2A 4 Engine in car repair procedures 5 3 The various hoses should be marked to ensure correct refitting 5 6a Remove the oil filler tube bracket nuts arrowed 5 6b pull the tube up to dislodge it from the housing it won t come out but can be removed with the intake manifold 5 7a Remove the ground strap from the front stud arrowed and the engine wiring harness clips from the other studs 5 7b Remove the intake manifold bolts nuts and remove the intake manifold the upper fasteners are studs nuts while the lower row are bolts two arrowed 5 9 Refit the new intake manifold gasket over the studs arrowed refit the manifold 3261 Jaguar XJ6 Refitting 7 Use a scraper to remove all traces of old gasket material and carbon deposits from the manifold and cylinder head mating surfaces If the gasket was leaking have the manifold checked for warpage at an automot
120. punch and hammer 15 4 Drive the new seal into the retainer with a wood block 3261 Jaguar XJ6 15 5 Apply RTV sealant to the sealing surface 6 Slowly and carefully press the seal and retainer squarely onto the crankshaft see illustration The plastic sleeve may be pushed out as the retainer seats on the engine block Remove the plastic sleeve 7 Refit and tighten the retainer bolts to the torque listed in this Chapter s Specifications 8 The remaining steps are the reverse of removal 16 Engine mounts check and renewal 3 1 Engine mounts seldom require attention but broken or deteriorated mounts should be renewed immediately or the added strain placed on the driveline components may cause damage or wear Check 2 During the check the engine must be raised to remove the weight from the mounts 3 Raise the car and support it securely on axle stands then position a jack under the engine sump Place a large wood block between the jack head and the sump then carefully raise the engine just enough to take the weight off the mounts Do not position the wood block under the drain plug Warning DO NOT place any part of your body under the engine when it s supported by a jack 4 Check the front mounts to see if the rubber is cracked hardened or separated from the metal plates Sometimes the rubber will split down the centre 5 Check for relative movement between the mount plates and the engine or frame use a la
121. remember that the cleaner also removes part of the chrome so use it sparingly 3 Vinyl trim maintenance 1 Don t clean vinyl trim with detergents caustic soap or petroleum based cleaners Plain soap and water works just fine with a soft brush to clean dirt that may be ingrained Wash the vinyl as frequently as the rest of the vehicle After cleaning application of a high quality rubber and vinyl protectant will help prevent oxidation and cracks The protectant can also be applied to weather stripping vacuum lines and rubber hoses which often fail as a result of chemical degradation and to the tyres 4 Upholstery and carpets maintenance 1 1 Every three months remove the carpets or mats and clean the interior of the vehicle more frequently if necessary Vacuum the upholstery and carpets to remove loose dirt and dust 2 Leather upholstery requires special care Stains should be removed with warm water and a very mild soap solution Use a clean damp cloth to remove the soap then wipe again with a dry cloth Never use alcohol petrol nail polish remover or thinner to clean leather upholstery 3 After cleaning regularly treat leather upholstery with a leather wax Never use car wax on leather upholstery 4 In areas where the interior of the vehicle is subject to bright sunlight cover leather seats with a sheet if the vehicle is to be left out for any length of time 5 Body repair minor damage 3 Repair of
122. rods 4 Check the connecting rods and caps for identification marks If they aren t plainly marked use a small centre punch to make the appropriate number of indentations on each rod and cap 1 2 3 etc depending on the cylinder they re associated with see illustration 5 Loosen each of the connecting rod cap nuts 1 2 turn at a time until they can be removed by hand Remove the number one connecting rod cap and bearing insert Don t drop the bearing insert out of the cap Note These engines use special connecting rod and main bearing cap bolts that are designed to be used one time only They can be used during Plastigage checks but must be replaced with new bolts when the engine is finally reassembled 6 Slip a short length of plastic or rubber hose over each connecting rod cap bolt to protect the crankshaft journal and cylinder wall as the piston is removed see illustration 7 Remove the bearing insert and push the connecting rod piston assembly out through the top of the engine Use a wooden hammer handle to push on the upper bearing surface in the connecting rod If resistance is felt double check to make sure that all of the ridge was removed from the cylinder Engine removal and overhaul procedures 2B 9 2B 13 2 Remove the screws arrowed and remove the front and rear baffle plates 13 3 Check the connecting rod side clearance with a feeler gauge as shown 13 4 The connecting rods and caps should be marked b
123. s assumed at this point that the engine block and crankshaft have been cleaned inspected and repaired or reconditioned 2 Position the engine with the bottom facing up 3 Remove the main bearing cap bolts and lift out the caps Lay the caps out in the proper order 4 If they re still in place remove the old bearing inserts from the engine block and the main bearing caps Wipe the main bearing surfaces of the engine block and caps with a clean lint free cloth They must be kept spotlessly clean Main bearing oil clearance check 5 Clean the back sides of the new main bearing inserts and lay the bearing half with the oil groove in each main bearing saddle in the engine block Lay the other bearing half from each bearing set in the corresponding main bearing cap Make sure the tab on each bearing insert fits into the recess in the engine block or cap Also the oil holes in the block must line up with the oil holes in the bearing insert Caution Do not hammer the bearings into place and don t nick or gouge the bearing faces No lubrication should be used at this time 6 The thrust bearings washers must be installed in the number four main bearing cap and saddle 7 Clean the faces of the bearings in the engine block and the crankshaft main bearing journals with a clean lint free cloth Check or clean the oil holes in the crankshaft as any dirt here can go only one way straight through the new bearings 8 Once you re ce
124. sensor General description 56 The speed sensor is mounted on the differential housing and monitors vehicle speed by sensing the rotational speed of the rear axle A problem with this sensor or circuit will set a code 68 and may also be the cause of an inoperative speedometer If the speedometer doesn t work the problem lies in the speed sensor the instrument cluster the ECU or the wiring in between For further diagnosis take the vehicle to a dealer service department or other suitably equipped and qualified repair workshop Crankshaft position sensor 57 The crankshaft position sensor is located in the front timing cover near the crankshaft pulley see illustration The crankshaft position sensor relays a signal to the ECU to indicate the exact position angle of the crankshaft Check 58 The crankshaft sensor cannot be diagnosed without the proper tools The Jaguar dealer uses a diagnostic scope computer called the JDS Have the crankshaft sensor diagnosed by the dealer service department or other qualified repair workshop Renewal 59 To renew the sensor disconnect the electrical connector and remove the bolt from the crankshaft position sensor Refitting is the reverse of removal 60 To renew the crankshaft sensor gear remove the front pulley refer to Chapter 2A 61 Be sure there is a small gap between the crankshaft sensor and the teeth on the gear It should be between 0 46 to 1 07 mm 0 018 to 0 042
125. service hole in the door frame Warning The regulator arms are under pressure and can cause serious injury if the motor is removed without locking the sector gear The motor and regulator can now safely be separated 6 Refitting is the reverse of removal 11 10 Bodywork and fittings 3261 Jaguar XJ6 20 7 The outside handle retaining nuts arrowed can be reached through the access hole in the door 20 8 Detach the plastic clip securing the lock rod 20 13 After removing the cable from the latch assembly detach the handle retaining bolts then pull the handle and cable assembly free from the vehicle 21 3 Detach the window regulator bolts arrowed If the motor or regulator needs replacing it will be necessary to lock the sector gear to the regulator back plate This can be done by fastening the sector gear to the backplate with a bolt inserted through one of the holes in the backplate and sector gear and secured with a nut If none of the holes line up drill a hole through the backplate and sector gear 22 Door window glass removal and refitting 3 1 Raise the window to its full upright position then remove the door trim panel and watershield as described in Section 18 2 Tape the window to the door glass frame to secure the window in the full upright position 3 Detach the regulator assembly Section 21 and lower it to the bottom of the door 4 Remove the window frame retaining bolts see illustrations 5 R
126. several times to its maximum unloaded speed Note It is of the utmost importance that the engine timing belt is in good condition before the test is carried out Excessive smoke can be caused by a dirty air cleaner element Otherwise professional advice may be needed to find the cause 4 Checks carried out on YOUR VEHICLE S EXHAUST EMISSION SYSTEM 3261 Jaguar XJ6 REF 12 Fault finding Introduction This Section provides an easy reference guide to the more common problems which may occur during the operation of your vehicle These problems and their possible causes are grouped under headings denoting various components or systems such as Engine Cooling system etc They also refer you to the Chapter and or Section which deals with the problem Remember that successful troubleshooting is not a mysterious black art practised only by professional mechanics It is simply the result of the right knowledge combined with an intelligent systematic approach to the problem Always work by a process of elimination starting with the simplest solution and working through to the most complex and never overlook the obvious Anyone can run the petrol tank dry or leave the lights on overnight so don t assume that you are exempt from such oversights Finally always establish a clear idea of why a problem has occurred and take steps to ensure that it doesn t happen again If the electrical system fails because of a poor connect
127. spark plug terminal 5 Make a mark on the edge of the distributor base directly below the rotor tip and in line with it Also mark the distributor base and the engine block to ensure that the distributor is installed correctly see illustrations 6 Remove the distributor hold down bolt then pull the distributor out to remove it Caution DO NOT turn the crankshaft while the distributor is out of the engine or the alignment marks will be useless 5 4 Engine electrical systems 8 3a To check the primary resistance of the coil measure the resistance between the positive and the negative terminals 8 3b To check the secondary resistance of the coil measure the resistance between the positive terminal and the HT terminal 8 7 Remove the nuts from the coil mounting bracket arrowed 3261 Jaguar XJ6 9 5a Paint or scribe a mark arrowed on the edge of the distributor housing below the rotor tip to ensure that the rotor is pointing in the same direction when the distributor is reinstalled 9 5b Paint or scribe another mark across the cylinder head and the distributor body arrowed to ensure that the distributor is aligned correctly when it is reinstalled Refitting 7 Insert the distributor into the engine in exactly the same relationship to the block that it was in when removed 8 If the distributor does not seat completely recheck the alignment marks between the distributor base and the block to verify that the distributor is
128. switch mounting plate screws arrowed Lower the mounting plate and switch assembly to access the ignition switch key lock cylinder 9 5 To remove the ignition switch lock cylinder assembly drill out the centre of the two retaining bolts arrowed and remove them with a screw extractor 11 Fuel oil and temperature gauges check 1 Warning Later models are equipped with airbags To prevent accidental deployment of the airbag which could cause personal injury or damage to the airbag system DO NOT work in the vicinity of the steering column or instrument panel The manufacturer recommends that on airbag equipped models the following procedure be performed at a dealer service department or other properly equipped repair facility because of the special tools and techniques required to disable the airbag system 1 All tests below require the ignition switch to be turned to ON position when testing 2 Check the fuse if the gauge pointer does not move from the empty low or cold positions If the fuse is OK locate the particular sender unit for the circuit you re working on see Chapter 4 for fuel sender unit location Chapter 2 for oil sender unit location or Chapter 3 for temperature sender unit location Connect the sender unit connector to earth If the pointer goes to the full high or hot position renew the sender unit If the pointer stays in same position use a jumper wire to earth the terminal on the back of the
129. the ECU by the crankshaft position sensor throttle potentiometer coolant temperature sensor and MAF sensor Ignition timing is altered during warm up idling and warm running conditions by the ECU This electronic ignition system also consists of the ignition switch battery coil distributor spark plug leads and spark plugs 4 Refer to a dealer parts department or car accessory outlet for any questions concerning the availability of the distributor parts and assemblies Testing the crankshaft position sensor is covered in Chapter 6 5 When working on the ignition system take the following precautions a Do not keep the ignition switch on for more than 10 seconds if the engine will not start b Always connect a tachometer in accordance with the manufacturer s instructions Some tachometers may be incompatible with this ignition system Consult a dealer service department before buying a tachometer for use with this vehicle c Never allow the ignition coil terminals to touch earth Earthing the coil could result in damage to the igniter and or the ignition coil d Do not disconnect the battery when the engine is running 6 Ignition system check 2 Warning Because of the high voltage generated by the ignition system extreme care should be taken when working on the ignition components This not only includes the amplifier coil distributor and spark plug leads but related components such as connectors tachometer a
130. the vehicle and support it securely on axle stands Remove the wheel 2 Remove the rear caliper and brake pads the caliper bracket the brake disc the handbrake cable and the handbrake shoe assembly see Chapter 9 3 Disconnect the outer end of the propshaft from the hub carrier see Chapter 8 4 Disconnect the lower end of the shock absorber coil spring assembly from the control arm see Section 10 5 Remove the hub carrier see Section 11 6 Remove the control arm pivot bolt nut see illustration 7 Support the differential crossmember assembly with a trolley jack Place a block of wood between the jack head and the differential to protect the differential Disconnect the lower end of the differential tie bar see illustration and carefully lower the differential crossmember just enough to allow the control arm pivot bolt to be pulled out to the rear without hitting the boot well 8 Remove the control arm 9 Inspect the control arm pivot bolt bushings If they re cracked dried out or torn take the arm to an automotive machine workshop and have them replaced 10 Refitting is the reverse of removal Tighten all suspension fasteners to the torque listed in this Chapter s Specifications Tighten all brake fasteners to the torque listed in the Chapter 9 Specifications 14 Steering wheel removal and refitting 1 Warning If your car is equipped with an airbag do not attempt this procedure Have it done by a deal
131. the wheel speed sensors the electronic control unit and the modulator hydraulic control unit The sensors one at each wheel send a variable voltage signal to the electronic control unit which monitors these signals compares them to its program and determines whether a wheel is about to lock up When a wheel is about to lock up the control unit signals the hydraulic unit to reduce hydraulic pressure or not increase it further at that wheel s brake caliper Pressure modulation is handled by three electrically operated solenoid valves one for each front wheel and one for the rear wheels inside the modulator If a problem develops within the system an ABS warning light will glow on the dashboard Sometimes a visual inspection of the ABS system can help you locate the problem Carefully inspect the ABS wiring harness Pay particularly close attention to the harness and connections near each wheel Look for signs of chafing and other damage caused by incorrectly routed wires If a wheel sensor harness is damaged the sensor should be replaced the harness and sensor are integral Warning Do NOT try to repair an ABS wiring harness The ABS system is sensitive to even the smallest changes in resistance Repairing the harness could alter resistance values and cause the system to malfunction If the ABS wiring harness is damaged in any way it must be replaced Caution Make sure the ignition is turned off before unplugg
132. the axle stands and lower the vehicle Apply the handbrake lever make sure it s fully applied within three to five clicks and that it holds the vehicle on an incline If it doesn t readjust it see Section 10 12 Handbrake shoes check and renewal 2 Warning Dust created by the brake system may contain asbestos which is harmful to your health Never blow it out with compressed air and don t inhale any of it An approved filtering mask should be worn when working on the brakes Do not under any circumstances use petroleum based solvents to clean brake parts Use brake system cleaner only Check 1 The handbrake system should be checked regularly With the car parked on a hill apply the brake place the transmission in Neutral and check that the handbrake alone will hold the car be sure to stay in the car during this check However every 24 months or Braking system 9 11 9 3261 Jaguar XJ6 11 2 To disconnect the forward end of the front cable from the handbrake lever remove this cotter pin washer and clevis pin 11 3 To disconnect the rear end of the front cable from the adjuster lever remove this cotter pin washer and clevis pin arrowed 11 5 To disconnect the intermediate cable remove the cotter pins washers and clevis pins arrowed from the adjuster lever and the yoke 11 7 To disconnect the rear cables and yoke from the intermediate cable remove this cotter pin washer and clevis pi
133. the crankshaft oil holes with a stone file or scraper 4 Check the remainder of the crankshaft for cracks and other damage It should be magnafluxed to reveal hidden cracks an automotive machine workshop will handle the procedure 5 Using a micrometer measure the diameter of the main and connecting rod journals and compare the results to this Chapter s Specifications see illustration By measuring the diameter at a number of points around each journal s circumference you ll be able to determine whether or not the journal is out of round Take the measurement at each end of the journal near the crank throws to determine if the journal is tapered Crankshaft runout should be checked also but large V blocks and a dial indicator are needed to do it correctly If you don t have the equipment have a machine workshop check the runout 6 If the crankshaft journals are damaged tapered out of round or worn beyond the limits given in the Specifications have the crankshaft reground by an automotive machine workshop Be sure to use the correct size bearing inserts if the crankshaft is reconditioned 7 Check the oil seal journals at each end of the crankshaft for wear and damage If the seal has worn a groove in the journal or if it s nicked or scratched the new seal may leak when the engine is reassembled In some cases an automotive machine workshop may be able to repair the journal by pressing on a thin sleeve If repa
134. the cylinder head but with the camshaft located in the engine block Oxygen sensor A device installed in the engine exhaust manifold which senses the oxygen content in the exhaust and converts this information into an electric current Also called a Lambda sensor P Phillips screw A type of screw head having a cross instead of a slot for a corresponding type of screwdriver Plastigage A thin strip of plastic thread available in different sizes used for measuring clearances For example a strip of Plastigage is laid across a bearing journal The parts are assembled and dismantled the width of the crushed strip indicates the clearance between journal and bearing Propeller shaft The long hollow tube with universal joints at both ends that carries power from the transmission to the differential on front engined rear wheel drive vehicles Proportioning valve A hydraulic control valve which limits the amount of pressure to the rear brakes during panic stops to prevent wheel lock up R Rack and pinion steering A steering system with a pinion gear on the end of the steering shaft that mates with a rack think of a geared wheel opened up and laid flat When the steering wheel is turned the pinion turns moving the rack to the left or right This movement is transmitted through the track rods to the steering arms at the wheels Radiator A liquid to air heat transfer device designed to reduce the temperature of the coolant in an int
135. the engine B indicates the codes for the main journals bearings and C indicates the connecting rod journal grades 21 Engine overhaul reassembly sequence 1 Before beginning engine reassembly make sure you have all the necessary new parts gaskets and seals as well as the following items on hand Common hand tools A 1 2 inch drive torque wrench Piston ring refitting tool Piston ring compressor Short lengths of rubber or plastic hose to fit over connecting rod bolts Plastigauge Feeler gauges A fine tooth file New engine oil Engine assembly lube or moly base grease Gasket sealer Thread locking compound Special Jaguar tools Engine lifting brackets 18G 1465 Timing damper simulator 18E 1436 Camshaft TDC tool 18G 1433 2 In order to save time and avoid problems engine reassembly must be done in the following general order Piston rings Part B Crankshaft and main bearings Part B Piston connecting rod assemblies Part B Rear main crankshaft oil seal Part B Auxiliary shaft Part A Timing chains and sprockets Part A Oil pump Part A Timing chain cover Part A Cylinder head and lifters Part A Camshafts Part A Oil pick up Part A Sump Part A Intake and exhaust manifolds Part A Valve cover Part A Flywheel driveplate Part A 22 Piston rings refitting 3 1 Before refitting the new piston rings the ring end gaps must be checked It s assumed that the piston ring groove clearance has
136. the engine has reached normal operating temperature 7 12 Remove the front spoiler to gain access to the purge control valve see Chapter 11 Apply vacuum to the valve and make sure the valve holds vacuum 7 14 Remove the bolts arrowed and lower the charcoal canister from the wing 8 1 Schematic of the crankcase ventilation system 3261 Jaguar XJ6 obstructions to ensure complete recirculation of gasses from the crankcase back into the intake manifold In the event of clogging the pressure will increase causing blow by and oil leaks through seals and gaskets 6 Check the operation of the heating element Check for battery voltage to the element while the engine is cold If no voltage is available to the heating element check the circuit from the windscreen washer jet temperature sensor Renewal 7 Disconnect the electrical connector from the heating element see illustration 8 Remove the clamps from the hoses and separate the heating element from the engine 9 Remove the hoses from the intake manifold These crankcase ventilation hoses are specially formed and must be replaced with special factory parts from Jaguar 10 Refitting is the reverse of removal 9 Catalytic converter General description 1 To reduce hydrocarbon carbon monoxide and oxides of nitrogen emissions all vehicles are equipped with a three way catalyst system which oxidises and reduces these chemicals converting them into harmless nitrogen carbo
137. the mounting nuts to take the cooler out of the vehicle see illustration 4 The other ends of the oil cooler tubes mount to a block just below the oil filter With a drain pan handy remove the nut retaining both pipes to the block 5 Refitting the oil cooler and oil lines is the reverse of removal When refitting the lines to the block or the cooler use new O rings 7 Water pump check 1 1 A failure in the water pump can cause serious engine damage due to overheating 2 With the engine running and warmed to normal operating temperature squeeze the upper radiator hose If the water pump is working properly a pressure surge should be felt as the hose is released Warning Keep hands away from fan blades 3 Water pumps are equipped with weep or vent holes see illustration If a failure occurs in the pump seal coolant will leak from this hole In most cases it will be necessary to use a flashlight to find the hole on the water pump by looking through the space behind the pulley just below the water pump shaft 4 If the water pump shaft bearings fail there may be a howling sound at the front of the engine while it is running Bearing wear can be felt if the water pump pulley is rocked up and down Do not mistake drivebelt slippage which causes a squealing sound for water pump failure Spray automotive drivebelt dressing on the belts to eliminate the belt as a possible cause of the noise 8 Water pump and pipes renewal
138. the reverse of removal In tank fuel pumps 9 Raise the vehicle and support it securely on axle stands 10 Disconnect the fuel pump and fuel level sender unit electrical connectors and the fuel lines 11 Remove the fuel tank from the boot see Section 7 12 Disconnect the fuel lines from the evap orative flange see illustration Remove the lock ring with a hammer and brass punch tapping the lock ring anti clockwise 13 Withdraw the fuel pump module from the fuel tank Note The fuel pump module is 4 4 Fuel and exhaust systems 3 14 Connect a vacuum gauge to the vacuum line leading to the fuel pressure regulator and check the vacuum source 4 6 Remove the fuel pump mounting nuts arrowed and slide the fuel pump out of the rubber casing 1989 model shown 3261 Jaguar XJ6 3 9 Check fuel pressure without vacuum applied to the fuel pressure regulator then with vacuum applied fuel pressure should DECREASE as vacuum INCREASES 3 12 Using a pair of pliers squeeze the return line and observe the fuel pressure increase wrap a rag around the fuel line so you don t damage it indexed near the bottom therefore it will be necessary to turn the module slightly to unlock it from the rubber holder mounted on the bottom of the fuel tank 14 Renew the fuel pump module as a single unit 15 Refitting is the reverse of removal 5 Fuel level sender unit check and renewal 3 Warning Petrol is highly flammable so take pr
139. the spacer from the end of the crankshaft and clean it thoroughly 7 11 Drive the new seal squarely into the front cover with a large socket or section of pipe do not remove the plastic refitting guide arrowed until the seal is installed 10 Remove the front cover to engine block bolts see illustration Note Two of the front cover bolts are water pump assembly bolts Refer to Chapter 3 for water pump removal although only the two bolts that attach to the engine block need be removed 11 Release the rubber band from the upper tensioners and remove the upper timing chain see illustration 12 Remove the upper chain guides see illustration 13 Unbolt and remove the lower timing chain tensioner see illustration 14 Refer to Section 13 for removal of the oil pump sprocket and drive chain 15 Remove the lower timing chain from the intermediate sprocket auxiliary shaft sprocket and the crankshaft sprocket see illustration 16 Before proceeding any further apply timing marks on the crankshaft and the engine block allowing you to locate TDC position without the crankshaft pulley in place see illustration Inspection 17 Examine the sprockets for signs of wear or damage Renew the timing chain if obvious wear or damage is noted or if it is the least bit questionable Note If there is wear or damage noticed in any of the sprockets or chains the entire set must be renewed i e new chains and new sprockets 18 Correct an
140. the wheels and set the handbrake With the transmission in Park start the engine and allow it to run at normal idle speed Warning Carefully inspect the fan blades for cracks or damage before starting the engine Keep your hands and the vacuum tester clear of the fan and do not stand in front of the vehicle or in line with the fan when the engine is running Read the vacuum gauge an average healthy engine should normally produce between 17 and 22 inches of vacuum with a fairly steady needle Refer to the following vacuum gauge readings and what they indicate about the engines condition 1 A low steady reading usually indicates a leaking gasket between the intake manifold and carburettor or throttle body a leaky vacuum hose late ignition timing or incorrect camshaft timing Check ignition timing with a timing light and eliminate all other possible causes utilising the tests provided in this Chapter before you remove the timing belt cover to check the timing marks 2 If the reading is three to eight inches below normal and it fluctuates at that low reading suspect an intake manifold gasket leak at an intake port or a faulty injector 3 If the needle has regular drops of about two to four inches at a steady rate the valves are probably leaking Perform a compression or leak down test to confirm this 4 An irregular drop or down flick of the needle can be caused by a sticking valve or an ignition misfire Perform a compression or lea
141. until the seal is flush with the housing then remove the plastic fitting sleeve camshaft to ensure that they are truly at TDC see illustration It may be necessary to rotate the crankshaft slightly to allow the tool to fit into the slot Once the camshafts are positioned DO NOT rotate the crankshaft further 6 Check the TDC marks made on the distributor body and refer to Chapter 5 for removal of the distributor Note Plug the distributor hole with a rag to keep out dirt 7 Locate the upper timing chain tensioner on the right front of the cylinder head Loosen the bolt on the clamp and swing the clamp away from the tensioner return valve then remove the valve see illustration 8 Remove the tensioner bolts and pull out the tensioner 9 The camshaft bearing caps are each retained by three bolts the two front caps on each camshaft have only two bolts of which one is a cylinder head bolt that threads into the engine block If the camshafts are being removed as a step in cylinder head removal the following steps involving spacer blocks are not required just remove the bolts and caps then remove the camshafts If the procedure is being used for camshaft removal or adjustment of the lifter shims the procedure must be followed exactly to maintain the cylinder head gasket seal 10 To maintain a good seal on the cylinder head gasket if the cylinder head is not being removed a spacer block Jaguar tool no 18G 1435 is used to
142. using a swirling motion see illustration 5 It is absolutely critical that the disc not be machined to a thickness under the specified minimum allowable thickness The disc thickness can be checked with a micrometer see illustration Then compare your measurement to the minimum wear or discard thickness stamped into the hub of the disc after the disc is removed see illustration Removal 6 Cut the safety wire from the caliper bracket mounting bolts see illustration On front caliper brackets remove the ABS wheel speed sensor see illustration then remove the caliper bracket bolts and remove the bracket 7 Remove the disc retaining screw see illustration and remove the disc from the hub If the disc sticks give it a few sharp raps with a hammer see illustration If the disc is stuck to the hub spray a generous amount of penetrant onto the area between the hub and the disc and allow the penetrant a few minutes to loosen the rust between the two components If a rear disc still sticks insert a thin flat bladed screwdriver or brake adjusting tool through the hub flange rotate the star wheel on the handbrake adjusting screw and contract the handbrake shoes see illustration Braking system 9 5 9 5 4a To check disc runout mount a dial indicator as shown and rotate the disc 5 4b Using a swirling motion remove the glaze from the disc surface with sandpaper or emery cloth 5 5a The disc thickness can be ch
143. vehicle and tighten the wheel nuts to the torque listed in this Chapter s Specifications 23 Propshaft check 2 1 Referring to Chapter 8 check the propshaft centre bearing universal joint and flexible coupling for signs of wear or damage and check that the propshaft fixings are tightened to the specified torque 24 Front wheel alignment check 5 1 Accurate wheel alignment requires access to specialised test equipment and as such should be entrusted to a suitably equipped Jaguar dealer or a tyre specialist refer to Chapter 10 25 Headlight beam check 5 1 Accurate adjustment of the headlight beam is only possible using optical beam setting equipment and this work should therefore be carried out by a Jaguar dealer or garage with the necessary facilities see Chapter 12 1 18 Every 15 000 miles or 12 months 22 15 Work the grease completely into the bearing rollers 22 17 Apply a thin layer of grease to the inner and outer bearing races 22 19 After refitting the inner wheel bearing into the hub press the grease seal into place 22 20 Refit the hub assembly onto the spindle then push the grease packed outer bearing into position 22 23 Position the nut lock on the spindle nut so that it lines up with the cotter pin hole DO NOT loosen the spindle nut from its snug position 3261 Jaguar XJ6 26 Automatic transmission fluid and filter renewal 2 1 At the specified time intervals the transmission fluid s
144. voltage isn t reaching the motor check the wiring in the circuit for continuity between the switches and motors You ll need to consult the wiring diagram for the vehicle If the circuit is equipped with a relay check that the relay is earthed properly and receiving voltage 15 Test the windows after you are done to confirm proper repairs 25 Central locking system description and check 5 The central locking system operates the door lock actuators mounted in each door The system consists of the switches relays Body electrical system 12 13 12 3261 Jaguar XJ6 23 5 Check the cruise control throttle linkage for binding 24 12 If no voltage is present at the motor with the switch depressed check for voltage at the switch actuators a control unit and associated wiring Diagnosis can usually be limited to simple checks of the wiring connections and actuators for minor faults which can be easily repaired Since this system uses an electronic control unit in depth diagnosis should be left to a dealership service department Central locking systems are operated by bi directional solenoids located in the doors The lock switches have two operating positions Lock and Unlock When activated the switch sends a signal to the door lock control unit to lock or unlock the doors Depending on which way the switch is activated the control unit reverses polarity to the solenoids allowing the two sides of the circuit to be used
145. warm up the differential lubricant then raise the car and support it securely on axle stands 2 Move a drain pan rags newspapers and the required tools under the car 3 Remove the check fill plug from the differential If necessary refer to Section 9 for the check fill plug location 4 With the drain pan under the differential use a ratchet and socket to loosen the drain plug see illustration Note A special pipe plug socket may be required to complete this procedure 5 Once loosened carefully unscrew it with your fingers until you can remove it from the case Since the lubricant will be hot wear a rubber glove to prevent burns 6 Allow all of the oil to drain into the pan then replace the drain plug and tighten it securely 7 Refer to Section 9 and fill the differential with lubricant 8 Refit the fill plug and tighten it securely 9 Lower the vehicle Check for leaks at the drain plug after the first few miles of driving 28 Brake fluid renewal 2 Warning Brake fluid can harm your eyes and damage painted surfaces so use extreme caution when handling or pouring it Do not use brake fluid that has been standing open or is more than one year old Brake fluid absorbs moisture from the air Excess moisture can cause a dangerous loss of braking effectiveness 1 At the specified time intervals the brake fluid should be drained and renewed Since the brake fluid may drip or splash when pouring it place plenty of rags a
146. with and just touching the end of the crankshaft see illustration 2 Push the crankshaft all the way to the rear and zero the dial indicator Next pry the crankshaft to the front as far as possible and check the reading on the dial indicator The distance that it moves is the endplay If it s greater than that specified in this Chapter s Specifications check the crankshaft thrust surfaces for wear If no wear is evident new thrust washers should correct the endplay 3 If a dial indicator isn t available feeler gauges can be used Gently pry or push the crankshaft all the way to the front of the engine Slip feeler gauges between the crankshaft and the front face of the number 4 thrust main bearing to determine the clearance see illustration 4 Check the main bearing caps to see if they re marked to indicate their locations They should be numbered consecutively from the front of the engine to the rear If they aren t mark them with number stamping dies or a centre punch Main bearing caps generally have a cast in arrow which points to the front of the engine Loosen the main bearing cap bolts 1 4 turn at a time each stating at the ends and working toward the centre until they can be removed by hand 5 The main bearing caps are numbered on the right side with corresponding numbers stamped into the sump rail on the same side see illustration Gently tap the caps with a soft face hammer then separate them from
147. with a terminal cleaner see illustration Thoroughly wash all cleaned areas with plain water 8 Make sure the battery tray is in good condition and the hold down clamp bolt or nut is tight If the battery is removed from the tray make sure no parts remain in the bottom of the tray when the battery is reinstalled When reinstalling the hold down clamp bolt or nut do not over tighten it 9 Information on removing and refitting the battery can be found in Chapter 5 Information on jump starting can be found at the front of this manual Cleaning 10 Corrosion on the hold down components battery case and surrounding areas can be removed with a solution of water and baking soda Thoroughly rinse all cleaned areas with plain water 11 Any metal parts of the vehicle damaged by corrosion should be covered with a zinc based primer then painted Charging Warning When batteries are being charged hydrogen gas which is very explosive and flammable is produced Do not smoke or allow open flames near a charging or a recently charged battery Wear eye protection when near the battery during charging Also make sure the charger is unplugged before connecting or disconnecting the battery from the charger 12 Slow rate charging is the best way to restore a battery that s discharged to the point where it will not start the engine It s also a good way to maintain the battery charge in a vehicle that s only driven a few miles betwe
148. 0 off the number one piston is at TDC on the exhaust stroke 11 To get the piston to TDC on the compression stroke turn the crankshaft one complete revolution 360 clockwise The rotor should now be pointing at the mark on the distributor When the rotor is pointing at the number one spark plug lead terminal in the distributor cap and the ignition timing marks are aligned the number one piston is at TDC on the compression stroke Note If it s impossible to align the ignition timing marks when the rotor is pointing at the mark on the distributor body the timing chain may have jumped the teeth on the pulleys or may have been installed incorrectly 12 After the number one piston has been positioned at TDC on the compression stroke TDC for any of the remaining cylinders can be located by turning the crankshaft and following the firing order Mark the remaining spark plug lead terminal locations on the distributor body just like you did for the number one terminal then number the marks to correspond with the cylinder numbers As you turn the crankshaft the rotor will also turn When it s pointing directly at one of the marks on the distributor the piston for that particular cylinder is at TDC on the compression stroke 4 Valve cover removal and refitting 1 Removal 1 Disconnect the battery negative cable Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct ac
149. 03 inch Cylinder bore diameter Standard Size group A 90 990 to 91 003 mm 3 5823 to 3 5828 inches Size group B 91 005 to 91 018 mm 3 5829 to 3 5834 inches Oversize 0 25 mm 0 010 inch OS 91 259 to 91 272 mm 3 5929 to 3 5934 inches 0 50 mm 0 020 inch OS 91 513 to 91 526 mm 3 6029 to 3 6034 inches Pistons and rings Piston to bore clearance 0 017 to 0 043 mm 0 0007 to 0 0017 inch Piston ring end gap No 1 top compression ring 0 40 to 0 66 mm 0 016 to 0 026 inch No 2 middle compression ring 0 40 to 0 66 mm 0 016 to 0 026 inch Oil ring 0 30 to 0 55 mm 0 012 to 0 022 inch Piston ring groove clearance No 1 top compression ring 0 040 to 0 076 mm 0 0016 to 0 0030 inch No 2 middle compression ring 0 040 to 0 076 mm 0 0016 to 0 0030 i
150. 1 Cylinder head removal and refitting 4 Note The engine must be completely cool before beginning this procedure Removal 1 Disconnect the battery negative cable Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 2 Drain the coolant from the engine block and radiator see Chapter 1 3 Drain the engine oil and remove the oil filter see Chapter 1 4 Remove the bonnet for easier access if necessary see Chapter 11 5 Remove the intake manifold see Section 5 6 Remove the exhaust manifolds Section 6 7 Remove the valve cover see Section 4 8 Refer to Section 3 and Position the engine at TDC for cylinder number 1 Remove the distributor see Chapter 5 9 Remove the camshafts and sprockets see Section 10 Place the upper chain between the two upper chain guides and wrap a large rubber band around the two guides retaining the chain and guides 10 Remove the coolant housing from the cylinder head see illustration 11 Remove the cylinder head to front cover bolts see illustration 12 Using a socket and breaker bar loosen the cylinder head bolts in quarter turn increments until they can be removed by hand Loosen the cylinder head bolts using the opposite of the recommended tightening sequence see illustration 11 23 to avoid warping or cracking the cylinder head 13 Lift the cylinder head off the engine block
151. 10 Front or rear wheel alignment Chapter 10 Erratic steering when braking Wheel bearings worn Chapter 1 Broken or sagging springs Chapter 10 Leaking wheel cylinder or caliper Chapter 9 Warped discs Chapter 9 Excessive pitching and or rolling around corners or during braking Loose stabiliser bar Chapter 10 Worn shock absorbers or mounts Chapter 10 Broken or sagging springs Chapter 10 Overloaded vehicle Suspension bottoms Overloaded vehicle Worn shock absorbers Chapter 10 Incorrect broken or sagging springs Chapter 10 Defective power hydraulic system or leaking rear shock absorbers Chapter 10 Cupped tyres wear on both edges Front wheel or rear wheel alignment Chapter 10 Worn shock absorbers Chapter 10 Wheel bearings worn Chapter 10 Excessive tyre or wheel runout Chapter 10 Worn balljoints Chapter 10 Excessive tyre wear on outside edge Inflation pressures incorrect Chapter 1 Excessive speed in turns Front end alignment incorrect excessive toe in Have professionally aligned Suspension arm bent or twisted Chapter 10 Excessive tyre wear on inside edge Inflation pressures incorrect Chapter 1 Front end alignment incorrect toe out Have professionally aligned Loose or damaged steering components Chapter 10 3261 Jaguar XJ6 Fault finding REF 17 6 Suspension and steering systems continued Tyre tread wor
152. 2 3 Repair procedures REF 5 Reversing lights 7 5 12 12 Road test 1 14 Roadside repairs 0 6 et seq Routine maintenance and servicing 1 1 et seq Rust holes 11 2 S Safety first 0 5 Scalding 0 5 Scratches 11 2 Screw threads and fastenings REF 5 Seat belts 1 13 REF 9 Seats 11 14 REF 9 Self levelling rear suspension system 10 3 Servo 1 12 9 1 9 9 Shift cable 7 4 Shock absorber 10 4 10 6 REF 9 REF 10 Shoes brake 1 20 9 11 Short circuit check 12 1 Side marker lights 12 11 Spare parts REF 4 Spark plugs 1 7 1 14 Speakers 12 7 Speed sensor 6 7 Spoiler 11 5 Springs 10 5 10 6 REF 10 Starter motor 5 7 Steering See Suspension and steering systems Steering wheel and column 11 13 12 5 REF 8 Sump 2A 14 Sunroof 12 14 Supplementary air valve 4 13 Suspension and steering systems 1 12 10 1 et seq REF 9 REF 10 fault finding REF 16 REF 17 Switches 4 1 7 5 9 13 12 5 12 6 12 12 T Tail lights 12 12 Temperature gauge 12 7 Temperature sender unit 3 7 Thermostat 3 2 Throttle body 4 10 Throttle potentiometer 6 5 Tie rod ends 10 9 Timing chains 2A 6 Tools REF 5 REF 6 REF 7 Top Dead Centre TDC for number one piston 2A 2 Torque converter 7 7 Towing 0 6 Trim panels 11 7 11 13 Tyres 0 14
153. 3 6 3 5 To access the self diagnosis system fault codes locate the VCM button on the dash and with the ignition key ON engine not running press it to display the codes 3261 Jaguar XJ6 Fault code chart for 1988 and 1989 models Code System affected Probable cause 1 Oxygen sensor Open oxygen sensor circuit 2 Airflow sensor Not in operating range 3 Coolant temperature sensor Not in operating range 4 Oxygen sensor System indicates full rich 5 Throttle potentiometer airflow sensor Low throttle potentiometer signal with high airflow sensor signal 6 Throttle potentiometer airflow sensor High throttle potentiometer signal with low airflow sensor signal 7 Throttle potentiometer Idle fuel adjustment failure 8 Intake air temperature sensor Open or shorted circuit in IAT sensor harness Fault code chart for 1990 to 1994 models Code System affected Probable cause 11 Idle potentiometer Not in operating range 12 Airflow sensor Not in operating range 14 Coolant temperature sensor Not in operating range 16 Air temperature sensor Not in operating range 17 Throttle potentiometer Not in operating range 18 Throttle potentiometer airflow sensor Signal resistance low at wide open throttle 19 Throttle potentiometer airflow sensor Signal resistance high at idle 22 Heated oxygen sensor Open or short circuit 22 Fuel pump circuit Open or short circuit 23 Fuel supply Rich exhaust Indicated 24 Ignition amplifier circu
154. 3261 Jaguar XJ6 Models covered Jaguar XJ6 models with 3 2 litre 3239 cc 3 6 litre 3590 cc amp 4 0 litre 3980 cc six cylinder in line dohc petrol engines and automatic transmission Covers most features of Daimler 3 6 and 4 0 litre models Does not cover 2 9 litre 2919 cc sohc engine or manual transmission Does not cover XJR models or revised Jaguar Daimler model ranges introduced September 1994 Jaguar XJ6 Service and Repair Manual Mike Stubblefield Haynes Publishing 1997 A book in the Haynes Service and Repair Manual Series All rights reserved No part of this book may be reproduced or transmitted in any form or by any means electronic or mechanical including photocopying recording or by any information storage or retrieval system without permission in writing from the copyright holder ISBN 1 85960 261 4 British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library Printed by J H Haynes amp Co Ltd Sparkford Nr Yeovil Somerset BA22 7JJ Haynes Publishing Sparkford Nr Yeovil Somerset BA22 7JJ England Haynes North America Inc 861 Lawrence Drive Newbury Park California 91320 USA Editions Haynes S A 147 149 rue Saint Honor 75001 PARIS France Haynes Publishing Nordiska AB Fyrisborgsgatan 5 754 50 Uppsala Sverige ABCDE FGHIJ KLMNO PQRST 1 2 3 3261 248 11AA1 3261 Jaguar XJ6 LIVING WITH YOUR JAGUAR XJ6 Introduction
155. 5 Remove the fuel line from the fuel pressure regulator see illustration 46 Remove the fuel pressure regulator mounting bolts and detach the pressure regulator from the engine 47 The remainder of refitting is the reverse of removal Make sure the fuel lines are secure and there are no leaks before using the car Supplementary air valve Check 48 The supplementary air valve provides additional throttle valve bypass air during cold starting and cold running conditions below 15 F This output actuator is controlled by the computer ECU in response to information received from the coolant temperature sensor intake air temperature sensor and other information sensors working with the fuel injection system 49 Check for battery voltage to the supplementary air valve With the engine cold backprobe the electrical connector using a long pin and check for battery voltage see illustration Voltage should exist 50 Because of the special tools required to test the supplementary air valve have it tested by a dealer service department or other qualified repair facility Renewal 51 Remove the intake hoses the mounting screws and detach the supplementary air valve from the engine 52 Refitting is the reverse of removal 53 Be sure to use a new gasket when refitting the idle up valve Air intake plenum Note The air intake plenum is removed and installed as a complete unit with the intake manifold In the event of damage or leaks
156. 50 If the voltage signal is not correct have the ECU diagnosed by a dealer service department or other repair workshop 51 Measure the resistance across the air temperature sensor terminals see illustration The resistance should be HIGH when the air temperature is LOW Next start the engine and let it idle Wait awhile and let the engine reach operating temperature Turn the ignition OFF disconnect the air temperature sensor and measure the resistance across the terminals The resistance should be LOW when the air temperature is HIGH If the sensor does not exhibit this change in resistance renew it with a new part EGR gas temperature sensor 1991 to 1994 models General description 52 The EGR gas temperature sensor is mounted in the exhaust gas transfer pipe This sensor detects the temperature of the exhaust moving through the EGR valve The information is sent to the ECU so the EGR on off time is regulated precisely and efficiently Check 53 Disconnect the harness connector for the EGR gas temperature sensor and measure the resistance of the sensor at the various temperatures Refer to the Specifications listed in this Chapter for a list of the temperatures and the resistance values Removal and refitting 54 Disconnect the harness connector for the EGR gas temperature sensor and using an open end spanner remove the sensor from the EGR adapter under the intake manifold 55 Refitting is the reverse of removal Speed
157. 61 Jaguar XJ6 3 Remove two bumper retaining bolts located on the bottom side of the bumper see illustration Pull the bumper assembly out and away from the vehicle to remove it 4 Refitting is the reverse of removal 15 Front wing removal and refitting 3 1 Loosen the front wheel nuts Raise the vehicle support it securely on axle stands and remove the front wheel 2 Remove the front bumper assembly see Section 14 3 Remove the front spoiler see Section 13 4 Detach the inner wing splash shield see illustration 5 On 1988 and 1989 models remove the coolant overflow reservoir located behind the splash shield see Chapter 3 6 On models with round headlights remove the headlight bezel On models with composite headlights 1992 Vanden Plas all 1993 and later models remove the headlight see Chapter 12 7 Remove the wing mounting bolts and nuts see illustrations 8 Detach the wing It s a good idea to have an assistant support the wing while it s being moved away from the vehicle to prevent damage to the surrounding body panels 9 Refitting is the reverse of removal 16 Boot lid removal refitting and adjustment 2 Note The boot lid is heavy and somewhat awkward to remove and refit at least two people should perform this procedure Removal and refitting 1 Open the boot lid and cover the edges of the boot compartment with pads or cloths to protect the painted surfaces when the lid is removed 2 D
158. 7 Looking upward through the boot lid access hole remove the lock rod and lock cylinder retaining bolts see illustration 8 Disconnect all electrical connections and remove the lock cylinder assembly 9 Refitting is the reverse of removal 18 Door trim panel removal and refitting 2 1 Disconnect the negative cable from the battery Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 2 On front door trim panels remove the retaining screw located under the air duct door seal see illustration 3 Remove the inside handle trim bezel see illustrations Bodywork and fittings 11 7 11 17 6 Detach the clips securing the boot lamp finish panel 17 7 Disengage the lock rod A then remove the lock cylinder retaining bolts B 18 2 Lift the air duct to body seal to access the trim panel retaining screw arrowed 18 3b then detach the inside handle retaining screw and bezel 18 3a Remove the trim cover 3261 Jaguar XJ6 16 9 Loosen the bolts and move the striker assembly as necessary to adjust the boot lid flush with the quarter panels in the closed position 17 2 Remove the retaining screws arrowed then unclip the lock rod and disconnect any electrical connections 16 10 Turn the bump stops in or out so the boot lid is flush with the rear wings when in the closed position 4 Detach the wood fini
159. ENGINE light on the left side of the instrument cluster Note Not all the codes will cause the CHECK ENGINE light to activate When performing any fuel or emissions systems diagnosis always check for codes that may be stored but not indicated by the CHECK ENGINE light Obtaining fault code output 3 To obtain an output of diagnostic codes verify first that the battery voltage is above 11 volts the throttle is fully closed the transmission is in Park the accessory switches are off and the engine is at normal operating temperature 4 Turn the ignition switch to ON but don t start the engine Position II Note On 1988 and 1989 models remember to turn the ignition switch to position II without turning the key to OFF 5 Press the VCM button on the display panel see illustration and observe the LED display on the dash for the designated codes An asterisk next to the code indicates that there are multiple codes stored 6 The numerical values will be displayed on the trip computer display on the dashboard 7 If there are any malfunctions in the system the corresponding fault codes are displayed in numerical order lowest to highest Cancelling a diagnostic code 8 After the faulty component has been repaired renewed the fault code s stored in computer memory must be cancelled a On 1988 to 1991 vehicles simply drive the vehicle faster than 19 mph and the computer will automatically erase the stored fault code from memory
160. Exhaust system check See Chapter 1 Exhaust system servicing general information 14 Fuel filter renewal See Chapter 1 Fuel level sender unit check and renewal 5 Fuel lines and fittings inspection and renewal 6 Fuel pressure relief 2 Fuel pump removal and refitting 4 Fuel pump fuel pressure check 3 Fuel system check See Chapter 1 Fuel tank removal and refitting 7 Fuel tank cap gasket renewal See Chapter 1 Fuel tank cleaning and repair general information 8 General information 1 Intake manifold removal and refitting See Chapter 2A Underbonnet hose check and renewal See Chapter 1 4 1 Specifications Contents Easy suitable for novice with little experience Fairly easy suitable for beginner with some experience Fairly d
161. Fuel and exhaust systems 3261 Jaguar XJ6 13 23a To check the ISC motor turn the ignition key ON engine not running and check for the proper voltage amounts at the harness connector 1989 model shown 13 23b Later models are equipped with a different shape ISC connector but the voltage values should be the same as the early style 13 27 Use a large open end spanner to remove the ISC motor from the intake manifold 13 35 Remove the fuel rail mounting bolts arrowed 36 Remove the fuel rail with the fuel injectors attached see illustration 37 Prise off the clips and remove the fuel injector s from the fuel rail see illustration 38 If you are replacing the injector s discard the old injector If you intend to re use the same injectors renew the grommets and O rings see illustrations 39 Refitting of the fuel injectors is the reverse of removal Apply a light film of clean engine oil to the O rings before refitting them 40 Tighten the fuel rail mounting bolts to the torque listed in this Chapter s Specifications Fuel pressure regulator Check 41 Refer to the fuel pump fuel pressure check procedure see Section 3 Renewal 42 Relieve the fuel pressure see Section 2 and detach the cable from the negative terminal of the battery see the Caution at the beginning of this Section 43 Detach the vacuum hose from the regulator 44 Remove the fuel rail and the injectors as an assembly see Steps 30 to 39 4
162. Idle Speed Control ISC motor 3 Fuel pressure damper 4 Bellcrank 5 Throttle body below bellcrank 6 Intake Air Temp IAT sensor 7 Supplementary air valve 8 Mass Airflow MAF sensor 9 Throttle potentiometer under throttle body 10 Fuel rail 11 Fuel injector 13 Ignition amplifier below block valve 14 Distributor of these sensors and their corresponding ECU controlled relays are not contained within EFI components but are located throughout the engine compartment For further information regarding the ECU and its relationship to the engine electrical and ignition system see Chapter 6 12 Electronic Fuel Injection EFI system check 2 1 Check the earth wire connections for tightness Check all wiring and electrical connectors that are related to the system Loose electrical connectors and poor grounds can cause many problems that resemble more serious malfunctions 2 Check to see that the battery is fully charged as the control unit and sensors depend on an accurate supply voltage in order to properly meter the fuel 3 Check the air filter element a dirty or partially blocked filter will severely impede performance and economy see Chapter 1 4 If a blown fuse is found renew it and see if it blows again If it does search for a shorted wire in the harness related to the system 5 Check the air intake duct from the MAF sensor to the intake manifold for leaks which will result in an excessively lean mix
163. Insert the clean dipstick into the tube as far as it will go then withdraw it again Note the oil level on the end of the dipstick which should be between the upper and lower marks The M mark is for use when checking the oil level after the vehicle has been standing overnight in this case the oil level should be between the M and upper level markings Oil is added through the filler cap Unscrew the cap and top up the level a funnel may help to reduce spillage Add the oil slowly checking the level on the dipstick often Don t overfill see Car care left 1 2 3 4 Warning DO NOT attempt to remove the expansion tank pressure cap when the engine is hot as there is a very great risk of scalding Do not leave open containers of coolant about as it is poisonous Car care l Adding coolant should not be necessary on a regular basis If frequent topping up is required it is likely there is a leak Check the radiator all hoses and joint faces for signs of staining or wetness and rectify as necessary l It is important that antifreeze is used in the cooling system all year round not just during the winter months Don t top up with water alone as the antifreeze will become too diluted Coolant level The coolant level should be checked only with the engine cold The level is checked in the expansion tank on the left hand side of the engine compartment Remove the expansion tank pressure cap and che
164. Make sure the top surface of the cover aligns with the top surface of the engine block by checking with a straightedge see illustration 30 Refer to Section 11 for refitting of the cylinder head and Section 10 for refitting of the camshafts and connection of the upper timing chain to the two camshaft sprockets 31 The remainder of the refitting is the reverse of the removal procedure If your car is equipped with the hydraulic self levelling suspension refit the drive coupling and coupling disc to the intermediate shaft see illustrations 8 9a and 8 9b Coat the mounting surface of the pump with RTV sealant and make sure the tang on the pump aligns with the slot in the intermediate shaft before bolting the pump to the front cover Refer to Section 7 for refitting of the crankshaft spacer damper and puller Caution DO NOT start the engine until you re absolutely certain that the timing chains are installed correctly Serious and costly engine damage could occur if the chains are installed wrong 32 Run the engine and check for proper operation 9 Auxiliary shaft renewal 3 Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 1 Refer to Chapter 10 and remove the power steering pump without disconnecting the hoses Remove the plastic power steering pump drive coupling disc 2A 8 Engine in car repair procedures 8 28
165. Prior to refitting apply a coat of anti seize compound to the plug threads see illustration It s often difficult to insert spark plugs into their holes without cross threading them To avoid this possibility fit a short piece of 3 8 inch internal diameter ID rubber hose over the end of the spark plug see Haynes Hint The flexible hose acts as a universal joint to help align the plug with the plug hole Should the plug begin to cross thread the hose will slip on the spark plug preventing thread damage Tighten the plug to the torque listed in this Chapter s Specifications In the absence of a torque wrench tighten each plug until you feel it seat and then by a further quarter turn only Do not overtighten the spark plugs 11 Attach the plug lead to the new spark plug again using a twisting motion on the boot until it is firmly seated on the end of the spark plug 12 Follow the above procedure for the remaining spark plugs replacing them one at a time to prevent mixing up the spark plug leads 1 8 Every 7500 miles or 6 months 4 4a Spark plug manufacturers recommend using a wire type gauge when checking the gap if the wire does not slide between the electrodes with a slight drag adjustment is required 4 4b To change the gap bend the side electrode only as indicated by the arrows and be very careful not to crack or chip the porcelain insulator surrounding the centre electrode 4 6 When removing the spark plug
166. Remove the water pump mounting bolts arrows indicate five visible here 8 8a Once the water pump is removed the rear housing arrowed is held in place only by the hoses check them for leakage and condition whenever the pump is disturbed 8 8b The water pipe arrowed may need new gaskets where it meets the block the pipe is best accessed from below or with the intake manifold unbolted 9 3 The coolant temperature sender unit arrowed is located in the top of the thermostat housing it is the sender unit with the single wire 3261 Jaguar XJ6 3 Remove the screws holding the cruise control ECU in place see illustrations then remove the four screws holding the ECU mounting plate in place 4 Disconnect the vacuum lines and electrical connectors at the blower housing identifying each connection with marked masking tape for reassembly or write down the colour codes of the vacuum tubing Remove the duct tape connecting the blower housing to the duct from the heater air conditioning unit 5 Remove the two bolts holding the top of the blower housing to the cowl see illustration 6 Pull down and back on the housing until it squeezes past the metal brace below it see illustration It will take some force at first 7 To access the left blower motor remove the left hand brace rod from the steering column forward to the body see illustration then repeat Steps 4 and 5 on the left blower housing The blower housing should now
167. There are many instances when one person cannot simultaneously perform all of the operations required when lifting the engine out of the vehicle Plan the operation ahead of time Arrange for or obtain all of the tools and equipment you ll need prior to beginning the job Some of the equipment necessary to perform engine removal and refitting safely and with relative ease are in addition to an engine hoist a heavy duty trolley jack complete sets of spanners and sockets as described in the front of this manual wooden blocks and plenty of rags and cleaning solvent for mopping up spilled oil coolant and petrol If the hoist must be rented make sure that you arrange for it in advance and perform all of the operations possible without it beforehand This will save you money and time Plan for the vehicle to be out of use for quite a while A machine workshop will be required to perform some of the work which the do it yourselfer can t accomplish without special equipment These shops often have a busy schedule so it would be a good idea to consult them before removing the engine in order to accurately estimate the amount of time required to rebuild or repair components that may need work Always be extremely careful when removing and refitting the engine Serious injury can result from careless actions Plan ahead take your time and a job of this nature although major can be accomplished successfully 6 Engine removal and refitt
168. When removing the external components from the engine pay close attention to details that may be helpful or important during refitting Note the installed position of gaskets seals spacers pins brackets washers bolts and other small items 4 If you re obtaining a short block which consists of the engine block crankshaft pistons and connecting rods all assembled then the cylinder head sump and oil pump will have to be removed as well from your engine so that your short block can be turned in to the rebuilder as a core See Engine rebuilding alternatives for additional information regarding the different possibilities to be considered 5 If you re planning a complete overhaul the engine must be dismantled and the internal components removed in the following order Intake and exhaust manifolds Valve cover Upper timing chain and camshaft sprockets Camshafts Timing chain cover Cylinder head Sump Oil pump Piston connecting rod assemblies Crankshaft rear oil seal retainer Crankshaft and main bearings 6 Before beginning the dismantling and overhaul procedures make sure the following items are available Also refer to Section 21 for a list of tools and materials needed for engine reassembly Common hand tools Small cardboard boxes or plastic bags for storing parts Gasket scraper Ridge reamer Micrometers Telescoping gauges Dial indicator set Valve spring compressor Cylinder surfacing hone Piston ring groove cleani
169. With the cooling system drained below the level of the expansion tank remove the hoses the coolant level probe and the two screws mounting it to the body see illustration 15 Wash out and inspect the reservoir for cracks and chafing Renew it if damaged 16 If the low coolant level light has been showing on the instrument panel even when the coolant level is correct disconnect the sensor s connector and test it with an ohmmeter see illustration The sensor should be renewed if the resistance at the connections is over 150 ohms Caution Using a long necked funnel to add coolant can damage the sensor which is just below the expansion tank filler neck Cooling heating and air conditioning systems 3 5 3 5 5a At the left side of the radiator disconnect the automatic transmission cooler lines small arrows and the lower radiator hose larger arrow 5 5b Disconnect the power steering cooler lines small arrows at the right side of the radiator and the upper radiator hose large arrow 3261 Jaguar XJ6 5 3 Remove the clamp and the hose going to the expansion tank 5 6 Remove the bolts arrowed and take off the radiator cowl panel 5 14 The expansion tank is located on the left inner wing A Hose to recovery tank where applicable B Hose to radiator C Hose to thermostat housing D Hose to water pump housing E Mounting screws F Low coolant level sensor 5 8 There are rubber mounts arrowed for the radiator
170. a Drill a small hole in the intermediate shaft seal thread a sheet metal screw into it and use a small slide hammer pull the seal out of the cover 8 28b Drive the new seal in with a seal driver or socket to the same depth as the original seal 8 29 Bolt the front cover on hand tight use a straightedge to make sure the cover s top surface is level with the top of the engine block then tighten the cover bolts 3261 Jaguar XJ6 8 23a Add oil to the reservoir in the lower tensioner 8 23b and refit the tensioner against the guide after it s installed push the tensioner guide back and forth a few times to prime the tensioner 2 Refer to Section 8 and remove the front cover and upper and lower timing chains 3 Remove the power steering drive coupling from the auxiliary shaft see illustration 4 Use a small drill to drill holes in the oil seal then use a slide hammer puller to remove the seal from the rear of the auxiliary shaft housing see illustration Caution Drill straight and carefully to avoid damaging the auxiliary shaft 5 Use a pair of snap ring pliers to remove the snap ring from the rear of the auxiliary shaft see illustration 6 Pull the auxiliary shaft out toward the front of the engine 7 Remove the three internal hex head bolts and the auxiliary shaft housing 8 Examine the surface of the auxiliary shaft it s sprocket and the distributor drive gear If there is noticeable wear or damage repla
171. a battery charger e The alternator is driven by an engine drivebelt which could cause serious injury if your hand hair or clothes become entangled in it with the engine running f Because the alternator is connected directly to the battery it could arc or cause a fire if overloaded or shorted out g Wrap a plastic bag over the alternator and secure it with rubber bands before steam cleaning the engine 11 Charging system check 2 Note 1993 and 1994 models are equipped with a Starter Logic Relay This microprocessor computer gathers information from the ignition switch linear gear position switch park neutral switch the security switch and the electronic door lock system If all the conditions are in order the computer allows battery voltage to be transferred from the ignition switch to the starter solenoid assembly If all the components of the charging system are working properly and the system still does not charge properly have the Starter Logic Relay diagnosed by a dealer service department 1 If a malfunction occurs in the charging circuit don t automatically assume that the alternator is causing the problem First check the following items a Check the drivebelt tension and its condition Renew it if worn or damaged b Make sure the alternator mounting and adjustment bolts are tight c Inspect the alternator wiring harness and the electrical connectors at the alternator and voltage regulator They must be in
172. ad removal and refitting 11 Drivebelt check adjustment and renewal See Chapter 1 Driveplate removal and refitting 14 Engine mounts check and renewal 16 Engine oil and filter change See Chapter 1 Engine overhaul general information See Chapter 2B Engine removal and refitting See Chapter 2B Exhaust manifolds removal and refitting 6 General information 1 Intake manifold removal and refitting 5 Sump removal and refitting 12 Oil pump removal inspection and refitting 13 Repair operations possible with the engine in the vehicle 2 Spark plug renewal See Chapter 1 Timing chains and sprockets removal inspection and refitting 8 Top Dead Centre TDC for number one piston locating 3 Valve cover removal and refitting 4 Valves servicing
173. ad Centre TDC for number one piston locating 1 Note The following procedure is based on the assumption that the distributor is correctly installed If you are trying to locate TDC to refit the distributor correctly piston position must be determined by feeling for compression at the number one spark plug hole then aligning the ignition timing marks see paragraph 8 1 Top Dead Centre TDC is the highest point in the cylinder that each piston reaches as it travels up the cylinder bore Each piston reaches TDC on the compression stroke and again on the exhaust stroke but TDC generally refers to piston position on the compression stroke 2 Positioning the piston s at TDC is an essential part of many procedures such as camshaft and timing chain sprocket removal and distributor removal 3 Before beginning this procedure be sure to place the transmission in Neutral and apply the handbrake or block the rear wheels Also disable the ignition system by detaching the coil wire from the centre terminal of the distributor cap and grounding it on the engine block with a jumper wire Remove the spark plugs see Chapter 1 4 In order to bring any piston to TDC the crankshaft must be turned using one of the methods outlined below When looking at the timing chain end of the engine normal crankshaft rotation is clockwise a The preferred method is to turn the crankshaft with a socket and ratchet attached to the bolt threaded into the fr
174. adapter removed from the old pump 10 10 Suspension and steering systems 18 2 Disconnect the steering fluid return hose from the upper pipe arrowed and disconnect the pressure line from the back of the pump 18 3 To detach the pump adapter from the auxiliary shaft housing remove these bolts 3261 Jaguar XJ6 17 3 Mark the relationship of the steering shaft U joint to the steering gear pinion shaft then unscrew the pressure and return line fittings arrowed plug the lines to prevent contamination from entering the system 17 6 To detach the steering gear from the vehicle remove these nuts and bolts arrowed from the mounting brackets right bracket shown left bracket similar and installed on a new or rebuilt pump This procedure requires special tools and the height of the driven coupling on the shaft must be set with a depth gauge 6 Refitting is the reverse of removal Study the accompanying photos carefully before reattaching the adapter to the auxiliary shaft housing see illustrations Be sure to tighten the fasteners securely 7 Top up the fluid level in the reservoir see Weekly checks for vehicles with a separate power steering system or Chapter 1 for vehicles with a power hydraulic system and bleed the system Section 19 19 Power steering system bleeding 1 1 To bleed the power steering system begin by checking the power steering fluid level and adding fluid if necessary see Weekly checks
175. ake Systems ABS with four wheel disc brakes are standard equipment on all Jaguar XJ6 models covered in this manual Power rack and pinion steering is also standard equipment Your Jaguar manual The aim of this manual is to help you get the best value from your vehicle It can do so in several ways It can help you decide what work must be done even should you choose to get it done by a garage It will also provide information on routine maintenance and servicing and give a logical course of action and diagnosis when random faults occur However it is hoped that you will use the manual by tackling the work yourself On simpler jobs it may even be quicker than booking the car into a garage and going there twice to leave and collect it Perhaps most important a lot of money can be saved by avoiding the costs a garage must charge to cover its labour and overheads The manual has drawings and descriptions to show the function of the various components so that their layout can be understood Tasks are described and photographed in a clear step by step sequence Notes for UK readers Because this manual was originally written in the US its layout differs from our UK originated manuals The preliminary and reference sections have been re written specifically for the UK market and the maintenance schedule has been amended to suit UK vehicles However it will be noticed that some references to components remain in the US style the UK equival
176. al to the fuel pressure regulator see Step 14 12 If the fuel pressure is low pinch the fuel return line shut see illustration and watch the gauge If the pressure doesn t rise the fuel pump is defective or there is a restriction or leak in the fuel feed line or the pump is faulty If the pressure rises sharply renew the pressure regulator 13 If the fuel pressure is too high turn the engine off Disconnect the fuel return line and blow through it to check for a blockage If there is no blockage renew the fuel pressure regulator 14 Connect a vacuum gauge to the pressure regulator vacuum hose Start the engine and check for vacuum see illustration The fuel pressure regulator receives manifold vacuum that decreases increases fuel pressure when the engine speed is raised acceleration If there isn t vacuum present check for a clogged hose or vacuum port If the amount of vacuum is adequate but the pressure is too high renew the fuel pressure regulator 15 Turn the ignition switch to OFF wait five minutes and recheck the pressure on the gauge Compare the reading with the specified hold pressure If the hold pressure is less than specified a The fuel lines may be leaking b The fuel pressure regulator may be allowing the fuel pressure to bleed through to the return line c A fuel injector or injectors may be leaking d The fuel pump may be defective 4 Fuel pump removal and refitting 3 Warning Petrol
177. also used in some air cleaners in which the temperature is regulated Thrust bearing The bearing in the clutch assembly that is moved in to the release levers by clutch pedal action to disengage the clutch Also referred to as a release bearing Timing belt A toothed belt which drives the camshaft Serious engine damage may result if it breaks in service Timing chain A chain which drives the camshaft Toe in The amount the front wheels are closer together at the front than at the rear On rear wheel drive vehicles a slight amount of toe in is usually specified to keep the front wheels running parallel on the road by offsetting other forces that tend to spread the wheels apart Toe out The amount the front wheels are closer together at the rear than at the front On front wheel drive vehicles a slight amount of toe out is usually specified Tools For full information on choosing and using tools refer to the Haynes Automotive Tools Manual Tracer A stripe of a second colour applied to a wire insulator to distinguish that wire from another one with the same colour insulator Tune up A process of accurate and careful adjustments and parts replacement to obtain the best possible engine performance Turbocharger A centrifugal device driven by exhaust gases that pressurises the intake air Normally used to increase the power output from a given engine displacement but can also be used primarily to reduce exhaust emissions as on VW
178. ample between a piston and a cylinder between a bearing and a journal etc Coil spring A spiral of elastic steel found in various sizes throughout a vehicle for example as a springing medium in the suspension and in the valve train Compression Reduction in volume and increase in pressure and temperature of a gas caused by squeezing it into a smaller space Compression ratio The relationship between cylinder volume when the piston is at top dead centre and cylinder volume when the piston is at bottom dead centre Constant velocity CV joint A type of universal joint that cancels out vibrations caused by driving power being transmitted through an angle Core plug A disc or cup shaped metal device inserted in a hole in a casting through which core was removed when the casting was formed Also known as a freeze plug or expansion plug Crankcase The lower part of the engine block in which the crankshaft rotates Crankshaft The main rotating member or shaft running the length of the crankcase with offset throws to which the connecting rods are attached Crocodile clip See Alligator clip D Diagnostic code Code numbers obtained by accessing the diagnostic mode of an engine management computer This code can be used to determine the area in the system where a malfunction may be located Disc brake A brake design incorporating a rotating disc onto which brake pads are squeezed The resulting friction converts the energy
179. ance is important in the overall handling braking and performance of the vehicle Unbalanced wheels can adversely affect handling and ride characteristics as well as tyre life Whenever a tyre is installed on a wheel the tyre and wheel should be balanced by a workshop with the proper equipment 21 Wheel alignment general information A wheel alignment refers to the adjustments made to the wheels so they are in proper angular relationship to the suspension and the ground Wheels that are out of proper alignment not only affect vehicle control but also increase tyre wear The alignment angles normally measured are camber caster and toe in see illustration Front wheel toe in and caster are adjustable camber is not adjustable Suspension and steering systems 10 11 10 3261 Jaguar XJ6 18 6a This driven coupling is the reason you can t remove the adapter from the pump at home this requires special tools and the coupling must be installed on the shaft of the new or rebuilt pump at a very precise height if you try to pry off the coupling you will damage it 18 6b The coupling disc fits onto the driven coupling on the pump side 18 6c and on the drive coupling on the auxiliary shaft side note that the two lugs on each drive coupling fit into their corresponding slots in the coupling disc 180 apart all four lugs must be properly engaged or you won t be able to bolt the adapter to the auxiliary shaft
180. and detach the headlight bezel trim cover 17 3a Remove the two retaining screws at the top and the one in the grille opening arrowed 17 3b The retaining screw at the outside lower corner can be accessed from under the bumper 3261 Jaguar XJ6 16 5 To determine if a heating element has broken check the voltage at the centre of each element If the voltage is 6 volts the element is unbroken if the voltage is 12 volts the element is broken between the centre and the positive end If there is no voltage the element is broken between the centre and earth 16 7 To find the break place the voltmeter positive lead against the heated window positive terminal place the voltmeter negative lead with the foil strip against the heating element at the positive terminal end and slide it toward the negative terminal end the point at which the voltmeter reading changes abruptly is the point at which the element is broken 5 Pull the headlight out slightly and disconnect the electrical connector from the rear of the light then remove the light from the vehicle 6 To refit position the new unit close enough to connect the electrical connector Make sure that the numbers moulded into the lens are at the top 7 Refit and tighten the retaining ring Test the headlight operation 8 The remainder of the refitting is the reverse of removal Halogen gas filled bulbs 9 Disconnect the electrical connector from the bulb assembly Rotate the headli
181. and separate the solenoid from the starter assembly 3261 Jaguar XJ6 6 Chapter 6 Emissions and engine control systems EGR gas temperature sensor resistance Temperature 212 F 60 to 100 k ohms 400 F 3 to 8 k ohms 662 F 250 to 350 ohms Torque wrench setting Nm lbf ft Crankshaft sensor bolt 27 20 Air Injection Reactor AIR system 5 Catalytic converter 9 CHECK ENGINE light See Section 3 Crankcase ventilation system 8 Electronic control system and ECU 2 Evaporative Emission Control EVAP system 6 Exhaust Gas Recirculation EGR system 6 Fuel tank cap gasket renewal See Chapter 1 General information
182. and bottom and shake the top of the tyre with an in and out motion Touch the balljoint stud nut If any looseness is felt suspect a worn out balljoint stud or a widened hole in the steering knuckle If the latter problem exists the steering knuckle should be replaced as well as the balljoint Renewal 5 Loosen the wheel nuts raise the vehicle and support it securely on axle stands Remove the wheel 6 Support the lower control arm with a trolley jack see illustration 4 2 Place a block of wood between the jack head and the control arm as shown to protect the arm and spring plate Upper balljoint 7 Loosen but don t remove the ball stud nut fit a small puller see illustration and pop the ball stud loose from the steering knuckle 8 Remove the two bolts that attach the balljoint to the upper arm see illustration Count the number of shims installed and set them aside 9 Refitting is the reverse of removal Don t forget to refit the same number of shims Tighten the bolts to the torque listed in this Chapter s Specifications 10 Remove the jack from under the control arm refit the front wheel lower the vehicle and tighten the wheel nuts to the torque listed in the Chapter 1 Specifications Drive the vehicle to an alignment workshop to have the wheel alignment checked and if necessary adjusted Lower balljoint 11 Loosen but don t remove the ball stud nut then give the steering knuckle a few sharp ra
183. and refitting 27 Upholstery and carpets maintenance 4 Vinyl trim maintenance 3 Windscreen and fixed glass replacement 8 11 1 Contents Easy suitable for novice with little experience Fairly easy suitable for beginner with some experience Fairly difficult suitable for competent DIY mechanic Difficult suitable for experienced DIY mechanic Very difficult suitable for expert DIY or professional Degrees of difficulty 5 4 3 2 1 1 General information These models feature a unibody construction using a floor pan with front and rear frame side rails which support the body components front and rear suspension systems and other mechanical components Certain components are particularly vulnerable to accident damage and can be unbolted and repaired or replaced Among these parts are the body mouldings bumpers front wings bonnet and boot lids and all glass Only general body maintenance practices and body panel repair procedures within the scope of the do it yourselfer are included in this Chapter 2 Body maintenance 1 1 The condition of your vehicle s body is very important because the resale value depends a great deal on it It s much more difficult to repair a neglected or damaged body than
184. ands when handling the driveplate Refitting 5 Clean the driveplate to remove grease and oil Inspect the surface for cracks Check for cracked and broken ring gear teeth Note If there is any damage to the driveplate replace the driveplate with a new driveplate a new spacer and new bolts Improved parts are available as a set from the dealer 6 Clean and inspect the mating surfaces of the driveplate and the crankshaft If the crankshaft rear seal is leaking renew it before refitting the driveplate see Section 15 7 Position the driveplate against the crankshaft Be sure to align the marks made during removal Some models may have an alignment dowel or staggered bolt holes to ensure correct refitting Before refitting the bolts apply thread locking compound to the bolt threads 8 Wedge a screwdriver in the ring gear teeth to keep the driveplate from turning and tighten the bolts to the torque listed in this Chapter s Specifications Follow a criss cross pattern and work up to the final torque in three or four steps 9 The remainder of refitting is the reverse of the removal procedure 15 Crankshaft rear oil seal renewal 4 1 The transmission adapter plate and driveplate must be removed from the car for this procedure see Chapter 7 2 Remove the bolts and detach the oil seal retainer Remove the gasket material from the block and the seal retainer see illustration 3 Position the oil seal and retainer assembly
185. anical experience on the part of the do it yourselfer Some of the rebuilding alternatives include Individual parts If the inspection procedures reveal that the engine block and most engine components are in reusable condition purchasing individual parts may be the most economical alternative The engine block cylinder head crankshaft and piston connecting rod assemblies should all be inspected carefully Even if the engine block shows little wear the cylinder bores should be surface honed Short block A short block consists of an engine block with a crankshaft and piston connecting rod assemblies already installed All new bearings are incorporated and all clearances will be correct The existing camshafts valve train components cylinder head and external parts can be bolted to the short block with little or no machine workshop work necessary Long block A long block consists of a short block plus an oil pump sump cylinder head valve cover camshaft and valve train components timing sprockets and chain or gears and timing cover All components are installed with new bearings seals and gaskets Engine removal and overhaul procedures 2B 5 2B 3261 Jaguar XJ6 6 20 Lift the engine high enough to clear the vehicle tilting it up at the front to clear the front crossmember then move it away and lower the hoist 6 21 With the engine on the floor but still supported by the hoist remove the four large bolts arrow
186. 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 1 Tread Depth manual check Alternatively tread wear can be monitored with a simple inexpensive device known as a tread depth indicator gauge 2 Tyre Pressure Check Check the tyre pressures regularly with the tyres cold Do not adjust the tyre pres
187. arden then use a very fine rubbing compound to blend the edges of the new paint into the existing paint Finally apply a coat of wax 6 Body repair major damage 5 1 Major damage must be repaired by an auto body workshop specifically equipped to perform unibody repairs These workshops have the specialised equipment required to do the job properly 2 If the damage is extensive the body must be checked for proper alignment or the vehicle s handling characteristics may be adversely affected and other components may wear at an accelerated rate 3 Due to the fact that most of the major body components bonnet front wings etc are separate and replaceable units any seriously damaged components should be replaced rather than repaired Sometimes the components can be found in a scrapyard that specialises in used vehicle components often at considerable savings over the cost of new parts 7 Hinges and locks maintenance 1 Once every 3000 miles or every three months the hinges and latch assemblies on the doors bonnet and boot should be given a few drops of light oil or lock lubricant The door latch strikers should also be lubricated with a thin coat of grease to reduce wear and ensure free movement Lubricate the door and boot locks with spray on graphite lubricant 8 Windscreen and fixed glass replacement 5 Replacement of the windscreen and fixed glass requires the use of special fast setting adhesive cau
188. are inch x 0 070 Kilograms force per square x 14 223 Pounds force per square inch psi lbf in2 lb in2 centimetre kgf cm2 kg cm2 psi lbf in2 lb in2 Pounds force per square inch x 0 068 Atmospheres atm x 14 696 Pounds force per square inch psi lbf in2 lb in2 psi lbf in2 lb in2 Pounds force per square inch x 0 069 Bars x 14 5 Pounds force per square inch psi lbf in2 lb in2 psi lbf in2 lb in2 Pounds force per square inch x 6 895 Kilopascals kPa x 0 145 Pounds force per square inch psi lbf in2 lb in2 psi lbf in2 lb in2 Kilopascals kPa x 0 01 Kilograms force per square x 98 1 Kilopascals kPa centimetre kgf cm2 kg cm2 Millibar mbar x 100 Pascals Pa x 0 01 Millibar mbar Millibar mbar x 0 0145 Pounds force per square inch x 68 947 Millibar mbar psi lbf in2 lb in2 Millibar mbar x 0 75 Millimetres of mercury mmHg x 1 333 Millibar mbar Millibar mbar x 0 401 Inches of water inH2O x 2 491 Millibar mbar Millimetres of mercury mmHg x 0 535 Inches of water inH2O x 1 868 Millimetres of mercury mmHg Inches of water inH2O x 0 036 Pounds force per square inch x 27 68 Inches of water inH2O psi lbf in2 lb in2 Torque moment of force Pounds force inches x 1 152 Kilograms force centimetre x 0 868 Pounds force inches lbf in lb in kgf cm kg cm lbf in lb in Pounds force inches x 0 113 New
189. area of the spoiler detach the retaining screws securing the front of the spoiler see illustration 5 Pull the spoiler forward and detach it from the vehicle 6 Refitting is the reverse of removal 14 Bumpers removal and refitting 1 1 Detach the direction indicator and side marker light assemblies from the bumper s see illustrations 2 Disconnect all wire harness connectors attached to the bumper or light assemblies that would interfere with removal Bodywork and fittings 11 5 11 12 1 Removing one side at a time remove the grille insert retaining screws arrowed tilt the top edge of the grille insert forward then lift up and out to remove it 12 2 Working through the grille insert openings remove the retaining screws from each edge of the grille frame 13 4 Working through the grille area of the spoiler remove the screws arrowed retaining the front of the spoiler 14 1a Depress the retaining clips on each side of the side marker lamp assemblies then gently prise forward to remove it 14 1b then detach the direction indicator assemblies from the bumper in the same manner 13 1 Working underneath the vehicle remove the screws arrowed securing the front spoiler lower cover 13 2 Working in the front wheel openings remove the screws arrowed securing the front air dam panels 13 3 The retaining bolts arrowed securing the sides of the front spoiler are located behind the bumper 32
190. ark plug spanner with rubber insert petrol models Spark plug gap adjustment tool petrol models Set of feeler blades Brake bleed nipple spanner Screwdrivers Flat blade 100 mm long x 6 mm dia Cross blade 100 mm long x 6 mm dia Combination pliers Hacksaw junior Tyre pump Tyre pressure gauge Oil can Oil filter removal tool Fine emery cloth Wire brush small Funnel medium size Repair and overhaul tool kit These tools are virtually essential for anyone undertaking any major repairs to a motor vehicle and are additional to those given in the Maintenance and minor repair list Included in this list is a comprehensive set of sockets Although these are expensive they will be found invaluable as they are so versatile particularly if various drives are included in the set We recommend the half inch square drive type as this can be used with most proprietary torque wrenches The tools in this list will sometimes need to be supplemented by tools from the Special list Sockets or box spanners to cover range in previous list including Torx sockets Reversible ratchet drive for use with sockets Extension piece 250 mm for use with sockets Universal joint for use with sockets Torque wrench for use with sockets Self locking grips Ball pein hammer Soft faced mallet plastic aluminium or rubber Screwdrivers Flat blade long amp sturdy short chubby and narrow electrician s types Cross blade Long
191. ase with each application 14 With the brake fully depressed start the engine the pedal should move down a little when the engine starts 15 Depress the brake stop the engine and hold the pedal in for about 30 seconds the pedal should neither sink nor rise 16 If your brakes do not operate as described above when the preceding tests are performed the brake servo is either in need of repair or has failed Refer to Chapter 9 for the removal procedure Handbrake 17 Slowly pull up on the handbrake and count the number of clicks you hear until the handle is up as far as it will go The adjustment should be within the specified number of clicks listed in this Chapter s Specifications If you hear more or fewer clicks it s time to adjust the handbrake refer to Chapter 9 18 An alternative method of checking the handbrake is to park the vehicle on a steep hill with the handbrake set and the transmission in Neutral be sure to stay in the vehicle during this check If the handbrake cannot prevent the vehicle from rolling it is in need of adjustment see Chapter 9 Whenever a fault is suspected the brake discs should be removed and the handbrake assemblies themselves should be visually inspected 12 Steering and suspension check 2 Note The steering linkage and suspension components should be checked periodically Worn or damaged suspension and steering linkage components can result in excessive and abnormal tyre wear po
192. at the bulkhead leading to the air conditioning evaporator battery removed here for clarity only 13 11 The sight glass arrowed is located on the top of the receiver drier to the right of the radiator repair facility Always wear eye protection when working near air conditioning system fittings 1 Have the refrigerant discharged and recovered by an air conditioning technician 2 Disconnect the refrigerant lines see illustration from the receiver drier and cap the open fittings to prevent entry of moisture 3 Remove the three nuts holding the receiver drier to the radiator support and remove the receiver drier Note On 1993 and 1994 models the receiver drier is a long tubular style mounted to the top front of the radiator support The grille must be removed for access on these models see Chapter 11 for grille removal 4 Refitting is the reverse of removal 5 Have the system evacuated charged and leak tested by the workshop that discharged it If the receiver drier was renewed have them add new refrigeration oil to the compressor about 28 cc one ounce Use only the refrigerant oil compatible with the refrigerant of your system R 12 or R 134a 15 Air conditioning compressor removal and refitting 4 Warning The air conditioning system is under high pressure Do not loosen any hose fittings or remove any components until the system has been discharged Air conditioning refrigerant should be properly discharged into
193. atch the gauge The compression should build up quickly in a healthy engine Low compression on the first stroke followed by gradually increasing pressure on successive strokes indicates worn piston rings A low compression reading on the first stroke which doesn t build up during successive strokes indicates leaking valves or a blown cylinder head gasket a cracked cylinder head could also be the cause Deposits on the undersides of the valve heads can also cause low compression Record the highest gauge reading obtained 8 Repeat the procedure for the remaining cylinders and compare the results to this Chapter s Specifications 9 Add some engine oil about three squirts from a plunger type oil can to each cylinder through the spark plug hole and repeat the test 10 If the compression increases after the oil is added the piston rings are definitely worn If the compression doesn t increase significantly the leakage is occurring at the valves or cylinder head gasket Leakage past the valves may be caused by burned valve seats and or faces or warped cracked or bent valves 11 If two adjacent cylinders have equally low compression there s a strong possibility that the cylinder head gasket between them is blown The appearance of coolant in the combustion chambers or the crankcase would verify this condition 12 If one cylinder is 20 percent lower than the others and the engine has a slightly rough idle a worn exhaust
194. ater models 1991 to 1994 the fuel pump and fuel level sender unit are located inside the fuel tank A vapour return system routes all vapours and hot fuel back to the fuel tank through a separate return line The fuel pump will operate as long as the engine is cranking or running and the ECU is receiving ignition reference pulses from the electronic ignition system see Chapter 5 If there are no reference pulses the fuel pump will shut off after 2 or 3 seconds Inertia switch These models are equipped with an inertia switch that is wired in the circuit between the fuel pump relay the ignition switch and the fuel pump refer to the wiring diagrams at the end of Chapter 12 The inertia switch is a special electrical device that provides circuit protection by switching off the ignition and fuel pump upon impact in the event of vehicle collision Later Jaguar models are equipped with an additional specialised inertia switch This later device switches OFF all ignition fed circuits locks the fuel filler cap locks the boot only if doors are locked and unlocks the doors if they are locked during the accident All these functions are directed by the inertia switch The inertia switch is located behind the left kick panel Refer to Chapter 12 for more information Exhaust system The exhaust system includes an exhaust manifold equipped with an exhaust oxygen sensor a catalytic converter an exhaust pipe and a silencer The cata
195. ation Modifications are a continuing and unpublicised process in vehicle manufacture quite apart from major model changes Spare parts manuals and lists are compiled upon a numerical basis the individual vehicle identification numbers being essential to correct identification of the part concerned When ordering spare parts always give as much information as possible Quote the car model year of manufacture and registration chassis and engine numbers as appropriate The Vehicle Identification Number VIN plate is attached to the base of the driver s door pillar left hand wing valance and is visible once the bonnet has been opened The vehicle identification chassis number is also stamped onto a plate located inside the windscreen and may also be stamped onto the right hand inner wing panel in the engine compartment see illustrations The trim code and paint code are also stamped onto the VIN plate The engine number is stamped onto the right hand side of the cylinder block next to the distributor see illustration The automatic transmission number is stamped onto a metal label attached to the left hand side of the transmission housing just above the sump see illustration The VIN is stamped on the right inner wing panel of the engine compartment The engine identification number is stamped on the right side of the engine block just behind the distributor The transmission identification number is located on the l
196. attery is the same voltage as the discharged one in the vehicle 4 If the battery is being jump started from the battery in another vehicle the two vehicles MUST NOT TOUCH each other 4 Make sure that the transmission is in neutral or PARK in the case of automatic transmission Jump starting will get you out of trouble but you must correct whatever made the battery go flat in the first place There are three possibilities 1 The battery has been drained by repeated attempts to start or by leaving the lights on 2 The charging system is not working properly alternator drivebelt slack or broken alternator wiring fault or alternator itself faulty 3 The battery itself is at fault electrolyte low or battery worn out Connect one end of the red jump lead to the positive terminal of the flat battery Connect the other end of the red lead to the positive terminal of the booster battery Connect one end of the black jump lead to the negative terminal of the booster battery Connect the other end of the black jump lead to a bolt or bracket on the engine block well away from the battery on the vehicle to be started 1 2 3 4 Make sure that the jump leads will not come into contact with the fan drivebelts or other moving parts of the engine 5 Start the engine using the booster battery then with the engine running at idle speed disconnect the jump leads in the reverse order of connecti
197. aust manifold incorporating a single exhaust pipe to the silencer Later models are equipped with dual exhaust pipes dual catalytic converters and silencers 2 Conducting regular inspections of the exhaust system will keep it safe and quiet Look for any damaged or bent parts open seams holes loose connections excessive corrosion or other defects which could allow exhaust fumes to enter the vehicle Deteriorated exhaust system components should not be repaired they should be replaced with new parts 3 If the exhaust system components are extremely corroded or rusted together they will probably have to be cut from the exhaust system The convenient way to accomplish this is to have a silencer repair workshop remove the corroded sections with a cutting torch If however you want to save money by doing it yourself and you don t have an oxy acetylene welding outfit with a cutting torch simply cut off the old components with a hacksaw If you have compressed air special pneumatic cutting chisels can also be used If you do decide to tackle the job at home be sure to wear eye protection to protect your eyes from metal chips and work gloves to protect your hands 4 Here are some simple guidelines to apply when repairing the exhaust system a Work from the back to the front when removing exhaust system components b Apply penetrating oil to the exhaust system component fasteners to make them easier to remove see illustration
198. battery may be shorted by the tool used to loosen the cable clamps Even if only the positive cable is being renewed be sure to disconnect the negative cable from the battery first see Chapter 1 for further information regarding battery cable removal 4 Disconnect the cables from the battery then trace each of them to their opposite ends and detach them from the starter solenoid and earth terminals Note the routing of each cable to ensure correct refitting 5 If you are replacing either or both of the old cables take them with you when buying new items It is vitally important that you replace the cables with identical parts Cables have characteristics that make them easy to identify positive cables are usually red larger in cross section and have a larger diameter battery post clamp earth cables are usually black smaller in cross section and have a slightly smaller diameter clamp for the negative post 6 Clean the threads of the solenoid or earth connection with a wire brush to remove rust and corrosion Apply a light coat of battery terminal corrosion inhibitor or petroleum jelly to the threads to prevent future corrosion 7 Attach the cable to the solenoid or earth connection and tighten the mounting nut bolt securely 8 Before connecting a new cable to the battery make sure that it reaches the battery post without having to be stretched 9 Connect the positive cable first followed by the negative cable 5 Ignition syste
199. been checked and verified correct see Section 18 2 Lay out the piston connecting rod assemblies and the new ring sets so the ring sets will be matched with the same piston and cylinder during the end gap measurement and engine assembly 3 Insert the top number one ring into the first cylinder and square it up with the cylinder walls by pushing it in with the top of the piston see illustration The ring should be near the bottom of the cylinder at the lower limit of ring travel 4 To measure the end gap slip feeler gauges between the ends of the ring until a gauge equal to the gap width is found see illustration The feeler gauge should slide between the ring ends with a slight amount of drag Compare the measurement to that found in this Chapter s Specifications If the gap is larger or smaller than specified double check to make sure you have the correct rings before proceeding 5 If the gap is too small it must be enlarged or the ring ends may come in contact with each other during engine operation which can cause serious damage to the engine The end gap can be increased by filing the ring ends very carefully with a fine file Mount the file in a vice equipped with soft jaws slip the ring over the file with the ends contacting the file face and slowly move the ring to remove material from the ends see illustration Caution When performing this operation file only from the outside in and after the correct gap is
200. between two wood blocks on a workbench and drive the old seal out from the backside see illustration 4 The new seal must be driven into the retainer plate from the engine side Drive the new seal into the retainer with a wood block or a section of pipe slightly smaller in diameter than the outside diameter of the seal see illustration The seal should be driven in only until it is flush with the transmission side of the retainer Caution The new seal comes with a special plastic refitting sleeve inserted in the seal It is designed to allow the seal to slide over the end of the crankshaft without displacing the seal lip Do NOT remove this plastic sleeve until the retainer and seal have been installed on the engine 5 Lubricate the seal area of the crankshaft with engine oil Apply a bead of RTV sealant to the sealing surface of the retainer see illustration Engine in car repair procedures 2A 17 2A 14 2 Mark the driveplate and the crankshaft so they can be reassembled in the same relative position 14 3 Use a screwdriver to secure the flywheel while the bolts are removed 14 4 Pry off the driveplate spacer if a driveplate is replaced the spacer should be replaced also 15 2 Remove the bolts arrowed and the crankshaft rear oil seal retainer from the back of the engine block 15 3 After removing the retainer assembly from the engine block support it between two wood blocks and drive out the old seal with a drift
201. braking system 14 Refill the master cylinder with fluid at the end of the operation 15 Check the operation of the brakes The pedal should feel solid when depressed with no sponginess If necessary repeat the entire process Warning Do not drive the car if in doubt about the effectiveness of the brake system 10 Handbrake cable adjustment 1 1 Slowly apply the handbrake and count the number of clicks at the lever It should be fully applied within three to five clicks If the lever is still not fully applied by the fifth click adjust the handbrake cable as follows 2 Raise the vehicle and place it securely on axle stands 3 Loosen the locknut see illustration and tighten the cable adjuster until all slack has been removed Tighten the locknut Make sure the wheels turn freely with the handbrake lever released 4 Lower the vehicle and recheck the handbrake lever It should now be properly adjusted If it s now fully applied within three to five clicks raise the vehicle again and readjust the cable at the adjuster 5 Make sure the handbrake holds the vehicle on an incline 9 10 Braking system 8 3b The connection arrowed for the rear hose and line is located right above the mounting bracket for the front corner of the differential crossmember remove the hose as described in the previous illustration 9 9 When bleeding the brakes a hose is connected to the bleed screw at the caliper or wheel cylinder and then subm
202. cation 3261 Jaguar XJ6 1 Battery 2 Oil filler cap 3 Engine oil dipstick not visible 4 Automatic transmission dipstick not visible 5 Brake fluid reservoir 6 Coolant reservoir expansion tank 7 Air cleaner housing 8 Upper radiator hose 9 Spark plugs 10 Distributor 11 Windscreen washer fluid reservoir 12 Power hydraulic system fluid reservoir 13 Power steering fluid reservoir Underbonnet view from the left hand side of the vehicle Underbonnet view from the right hand side of the vehicle 1 Battery 2 Oil filler cap 3 Engine oil dipstick not visible 4 Automatic transmission dipstick not visible 5 Brake fluid reservoir 6 Coolant reservoir expansion tank 7 Air cleaner housing 8 Upper radiator hose 9 Spark plugs 10 Distributor 11 Windscreen washer fluid reservoir 12 Power hydraulic system fluid reservoir 13 Power steering fluid reservoir 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 1 General information 1 Thi
203. ce department or a repair workshop Defective relays must be replaced as a unit Testing 1 It s best to refer to the wiring diagram for the circuit to determine the proper connections for the relay you re testing However if you re not able to determine the correct connection from the wiring diagrams you may be able to determine the test connections from the information that follows 2 On most relays two of the terminals are the relay s control circuit they connect to the relay coil which when energised closes the large contacts to complete the circuit The other terminals are the power circuit they are connected together within the relay when the control circuit coil is energised 3 Relays are sometimes marked as an aid to help you determine which terminals are the control circuit and which are the power circuit see illustration As a general rule the two thicker wires connected to the relay are the power circuit the thinner wires are the control circuit 4 Remove the relay from the vehicle and check for continuity between the relay power circuit terminals There should be no continuity 5 Connect a fused jumper wire between one of the two control circuit terminals and the positive battery terminal Connect another jumper wire between the other control circuit terminal and earth When the connections are made the relay should click On some relays polarity may be critical so if the relay doesn t click
204. ce the auxiliary shaft assembly with a new one see illustration 9 If the auxiliary shaft housing has been removed clean it scrape away the old gasket material from the housing and the engine block and refit the housing with a new gasket see illustration 10 Clean the auxiliary shaft lubricate it with engine oil and refit it through the front of the block then refit the washer see illustration Refit the snap ring refer to illustration 9 4 11 The new oil seal for the rear of the auxiliary shaft comes with a plastic refitting sleeve that keeps the seal lip from folding back during refitting Keep this sleeve in place until the seal is fully installed Tap the new seal into the housing with a hammer and appropriate size socket until the seal is flush then remove the plastic sleeve see illustration 12 The remainder of the refitting is the reverse of removal Note When refitting the distributor see Chapter 5 use a new O ring to prevent oil leaks at the distributor 13 Run the engine and check for oil leaks at the power steering pump to housing interface 10 Camshafts and valve lifters removal inspection and refitting 4 Removal Note The renewal of the camshafts requires the use of several special tools Read through the procedure and acquire the special tools or their equivalent before beginning work 1 Remove the valve cover see Section 4 2 Refer to Section 3 and position the engine at TDC for number 1 cyl
205. ce beginning with illustration 12 5a Work on only one side 1 Adjuster 2 Hold down springs and washers 3 Upper return spring 4 Lower return spring 5 Handbrake shoes 9 12 Braking system 12 5a Wash down the handbrake assembly with brake cleaner before dismantling 12 5b Back off the star wheel on the adjuster then disengage the adjuster mechanism from the handbrake shoes 12 5c Remove the front hold down spring washers and pin note that one washer goes below the spring and one above it 12 5d Remove the rear hold down spring washers and pin put the parts in a plastic bag so you don t lose them 12 5e Push the shoes together and disengage the upper return spring from the rear shoe 12 5f and from the front shoe 3261 Jaguar XJ6 12 5g Pull the shoes apart and remove them with the lower spring attached as shown then disengage the lower return spring from both shoes 12 5h The handbrake shoe assembly at a time so you can use the other side as a reference during reassembly 6 Refitting is the reverse of removal 7 After refitting the brake disc adjust the handbrake shoes Temporarily refit two nuts turn the adjuster see illustration 5 7c and expand the shoes until the disc locks then back off the adjuster until you can spin the disc without the shoes dragging 8 Adjust the handbrake cable Section 10 9 Remove the axle stands and lower the vehicle Tighten the wheel nuts to the specified t
206. cessible treat it with rust inhibiting paint 12 Before filling is done block the hole in some way This can be done with sheet metal riveted or screwed into place or by stuffing the hole with wire mesh 13 Once the hole is blocked off the affected area can be filled and painted See the following subsection on filling and painting Filling and painting 14 Many types of body fillers are available but generally speaking body repair kits which contain filler paste and a tube of resin hardener are best for this type of repair work A wide flexible plastic or nylon applicator will be necessary for imparting a smooth and contoured finish to the surface of the filler material Mix up a small amount of filler on a clean piece of wood or cardboard use the hardener sparingly Follow the manufacturer s instructions on the package otherwise the filler will set incorrectly 15 Using the applicator apply the filler paste to the prepared area Draw the applicator across the surface of the filler to achieve the desired contour and to level the filler surface As soon as a contour that approximates the original one is achieved stop working the paste If you continue the paste will begin to stick to the applicator Continue to add thin layers of paste at 20 minute intervals until the level of the filler is just above the surrounding metal 16 Once the filler has hardened the excess can be removed with a body file From then on progre
207. ch and every vehicle at the Haynes Motor Museum has played its part in the history and culture of Motoring Today they make a wonderful spectacle and a great day out for all the family Bring the kids bring Mum and Dad but above all bring your camera to capture those golden memories for ever You will also find an impressive array of motoring memorabilia a comfortable 70 seat video cinema and one of the most extensive transport book shops in Britain The Pit Stop Cafe serves everything from a cup of tea to wholesome home made meals or if you prefer you can enjoy the large picnic area nestled in the beautiful rural surroundings of Somerset The Museum is situated on the A359 Yeovil to Frome road at Sparkford just off the A303 in Somerset It is about 40 miles south of Bristol and 25 minutes drive from the M5 intersection at Taunton Open 9 30am 5 30pm 10 00am 4 00pm Winter 7 days a week except Christmas Day Boxing Day and New Years Day Special rates available for schools coach parties and outings Charitable Trust No 292048 gt John Haynes O B E Founder and Chairman of the museum at the wheel of a Haynes Light 12 lt Graham Hill s Lola Cosworth Formula 1 car next to a 1934 Riley Sports lt The Model J Duesenberg Derham Tourster Only eight of these magnificent cars were ever built this is the only example to be found outside the United States of America Preserving Our Motoring Heritage
208. ck that the coolant level is upto the base of filler neck If topping up is necessary add a mixture of water and antifreeze to the expansion tank until the coolant level is upto the base of the filler neck Once the level is correct securely refit the pressure cap 1 2 3261 Jaguar XJ6 0 12 Weekly checks Brake fluid level Warning l Brake fluid can harm your eyes and will damage painted surfaces so use extreme caution when handling and pouring it l Do not use fluid that has been standing open for some time as it absorbs moisture from the air which can cause a dangerous loss of braking effectiveness Safety first l If the reservoir requires repeated topping up this is an indication of a fluid leak somewhere in the system which should be investigated immediately l If a leak is suspected the car should not be driven until the braking system has been checked Never take any risks where brakes are concerned Make sure that your car is on level ground The fluid level in the reservoir will drop slightly as the brake pads wear down but the fluid level must never be allowed to drop below the MIN mark The brake fluid reservoir is located on the right hand rear corner of the engine compartment on top of the master cylinder 1 The upper MAX and lower MIN fluid level markings are on the side of the brake fluid reservoir The fluid level must always be kept between these two marks 2
209. cks rust and corrosion see illustration 10 12 Look for stripped threads in the threaded holes It s also a good idea to have the engine block checked for hidden cracks by an automotive machine workshop that has the special equipment to do this type of work especially if the vehicle had a history of overheating or using coolant If defects are found have the engine block repaired if possible or renewed If the top of the engine block has been eroded by coolant leakage and the erosion is near the cylinder bores the engine block must be renewed 3 Check the cylinder bores for scuffing and scoring 4 Check the cylinders for taper and out of round conditions as follows see illustrations 5 Measure the diameter of each cylinder at the top just under the ridge area centre and bottom of the cylinder bore parallel to the crankshaft axis 6 Next measure each cylinder s diameter at the same three locations perpendicular to the crankshaft axis 7 The taper of each cylinder is the difference between the bore diameter at the top of the cylinder and the diameter at the bottom The out of round specification of the cylinder bore Engine removal and overhaul procedures 2B 11 2B 16 4a Measure the diameter of each cylinder at 90 to engine centreline A and parallel to engine centreline B out of round is the difference between A and B taper is the difference between A and B at the top of the cylinder and A and B at the bo
210. cle being careful not to spill the oil in the drain pan then lower the vehicle 13 Loosen the oil filter see illustration by turning it anti clockwise with the filter wrench Any standard filter wrench should work Once the filter is loose use your hands to unscrew it from the block Just as the filter comes away from the block immediately tilt the open end up to prevent the oil inside the filter from spilling out Warning The engine exhaust pipes may still be hot so be careful 14 With a clean rag wipe off the mounting surface on the block If a residue of old oil is allowed to remain it will smoke when the block is heated up It will also prevent the new filter from seating properly Also make sure that the none of the old gasket remains stuck to the mounting surface It can be removed with a scraper if necessary 15 Compare the old filter with the new one to make sure they are the same type Smear some engine oil on the rubber gasket of the new filter and screw it into place see illustration Because over tightening the filter will damage the gasket do not use a filter wrench to tighten the filter Tighten it by hand until the gasket contacts the seating surface Then seat the filter by giving it an additional 3 4 turn 16 Add new oil to the engine through the oil filler cap next to the valve cover Use a spout or funnel to prevent oil from spilling onto the top of the engine Pour three litres of fresh oil into the engine
211. connectors disconnected measure the resistance of each injector see illustration Each injector should measure about 2 0 to 3 0 ohms If not the injector is probably faulty 10 The remainder of the system checks should be left to a Jaguar service department or other qualified repair workshop as there is a chance that the control unit may be damaged if not performed properly 13 Electronic Fuel Injection EFI system component check and renewal 3 Warning Petrol is extremely flammable so take extra precautions when you work on any part of the fuel system See the Warning in Section 2 Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Throttle body Check 1 Verify that the throttle linkage operates smoothly 2 Start the engine detach each vacuum hose and using your finger check the vacuum at each port on the throttle body with the engine at idle and above idle The vacuum available from the throttle body is ported Raise the engine rpm and watch as vacuum increases It may be necessary to use a vacuum gauge Refer to Chapter 2B for additional information concerning vacuum checks Renewal Warning Wait until the engine is completely cool before beginning this procedure 3 Detach the cable from the negative terminal of the battery see the Caution at the beginning of this Section 4 Drain the rad
212. coolant housing arrowed from the cylinder head 11 11 Remove the bolts arrowed securing the cylinder head to the front cover 21 There are variations in cooling holes in some models Before refitting the cylinder head gasket carefully check all of the passages and bolt holes in the new cylinder head gasket to be sure it matches your engine block Also make sure the new cylinder head gasket you re using is equipped with the improved oil transfer hole seal see illustration Position the cylinder head gasket over the dowel pins in the engine block make sure TOP is facing up see illustration 22 Carefully place the cylinder head on the engine block without disturbing the gasket 23 Refit NEW cylinder head bolts and following the recommended sequence tighten the bolts in two steps to the torque listed in this Chapter s Specifications see illustration Step 2 of the tightening sequence requires the bolts to be tightened and additional 90 An angle torque attachment for your torque wrench is available at car accessory outlets This tool provides precision when the angle torque method is required and its use is highly recommended If the tool is not available paint a mark on the edge of each cylinder head bolt and tighten the bolt until the mark is 90 from the starting point After the cylinder head bolts are tightened tighten the cylinder head to timing cover bolts 24 The remaining refitting steps are the revers
213. covers will allow access to a variety of electrical heating and air conditioning components 2 Detach the retaining screws along the edges of the knee bolster see illustration 3 Pull outward on the lower edge of the knee bolster and detach it from the vehicle 4 Refitting is the reverse of removal Centre trim panel 5 Carefully pull outward to detach the centre trim panel from the instrument panel see illustration 6 Refitting is the reverse of removal Glove box 7 Detach the passenger side knee bolster as described in Steps 2 and 3 8 Remove the glove box door hinge bolts see illustration 9 Open the glove box door then detach it from the vehicle 10 Detach the heater duct and the relay mounting panel from the bottom of the glove box 11 Detach the remaining screws securing the upper edge of the glove box see illustration 12 Disconnect the lamp from the glove box and remove the assembly from the vehicle 13 Refitting is the reverse of removal 27 Steering column cover removal and refitting 2 Warning Later models are equipped with airbags To prevent the accidental deploy ment of the airbag which could cause Bodywork and fittings 11 13 11 3261 Jaguar XJ6 26 2 Remove the retaining screws along the outer edge of the knee bolster then remove it from the vehicle 26 5 Grasp the centre trim panel with both hands then unsnap the retaining clips arrowed from the dashboard assembly 26 8 Wi
214. ct the electrical connectors from the sensor pigtail lead 21 Unscrew the oxygen sensor from the exhaust system see illustration Caution Excessive force may damage the threads 22 Anti seize compound must be used on the threads of the sensor to facilitate future removal The threads of new sensors will already be coated with this compound but if an old sensor is removed and reinstalled recoat the threads 23 Refit the sensor and tighten it securely 24 Reconnect the electrical connectors to the main engine wiring harness 25 Lower the vehicle and reconnect the cable to the negative terminal of the battery Throttle potentiometer General description 26 The throttle potentiometer is located on the end of the throttle shaft on the bottom section of the throttle body By monitoring the output voltage from the throttle potentiometer the ECU can alter fuel delivery based on throttle valve angle driver demand A broken or loose throttle potentiometer will cause bursts of fuel from the injectors and an unstable idle because the ECU thinks the throttle is moving Throttle body removal procedures are covered in Chapter 4 Check 27 Check for the proper reference voltage to the throttle potentiometer Carefully back probe the throttle potentiometer electrical connector using a pin on the reference voltage wire and ground see illustration With the ignition key ON engine not running the reference voltage should be about 5 0
215. ctrical systems include all ignition charging and starting components Because of their engine related functions these components are discussed separately from chassis electrical devices such as the fuses relays lights etc which are included in Chapter 12 Always observe the following precautions when working on the electrical systems a Be extremely careful when servicing engine electrical components They are easily damaged if checked connected or handled improperly b Never leave the ignition switch on for long periods of time 10 minutes maximum with the engine off c Don t disconnect the battery cables while the engine is running d Maintain correct polarity when connecting a battery cable from another vehicle during jump starting e Always disconnect the negative cable first and hook it up last or the battery may be shorted by the tool being used to loosen the cable clamps It s also a good idea to review the safety related information regarding the engine electrical systems in the Safety first section near the front of this manual before beginning any operation included in this Chapter 2 Battery emergency jump starting 1 See Jump starting in Roadside repairs at the front of this Manual 3 Battery removal and refitting 1 1 Disconnect the negative terminal then the positive terminal from the battery On 1989 to 1992 models the battery is located in the engine compartment on the pass
216. cturer recommends that on airbag equipped models the following procedure should be left to a dealer service department or other repair workshop because of the special tools and techniques required to disable the airbag system 1 Disconnect the battery negative cable Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 2 Drain the cooling system see Chapter 1 Disconnect the heater hoses where they enter the bulkhead see illustration Note Use compressed air in one of the pipes to blow out any remaining coolant and collect it This will prevent any spills on the carpeting when the heater core is removed Plug the pipes to prevent any remaining coolant from spilling out 3 Refer to Chapter 11 for removal of the under dash panels on both the driver and passenger sides and removal of the glovebox Warning When working around the area behind the glove box watch out for a strip of sheet Cooling heating and air conditioning systems 3 9 3 3261 Jaguar XJ6 10 11a Separate the housing halves the blower motor arrowed is attached to a plastic plate sandwiched between the two housing halves 10 11b Loosen the clamp bolt arrowed on the motor bracket and then pull the motor and fan out as an assembly 10 12 Inside the blower case are the blower and isolation relays arrowed while the case is apart test these relays for
217. d also have plenty of rags or newspapers handy for mopping up any spills 3 Access to the underside of the vehicle is greatly improved if the vehicle can be lifted on a hoist driven onto ramps or supported by axle stands 4 If this is your first oil change get under the vehicle and familiarise yourself with the location of the oil drain plug The engine and 3 2 These tools are required when changing the engine oil and filter 1 Drain pan It should be fairly shallow in depth but wide in order to prevent spills 2 Rubber gloves When removing the drain plug and filter it is inevitable that you will get oil on your hands the gloves will prevent burns 3 Breaker bar Sometimes the oil drain plug is pretty tight and a long breaker bar is needed to loosen it 4 Socket To be used with the breaker bar or a ratchet must be the correct size to fit the drain plug 5 Filter wrench This is a metal band type wrench which requires clearance around the filter to be effective 6 Filter wrench This type fits on the bottom of the filter and can be turned with a ratchet or breaker bar different size spanners are available for different types of filters exhaust components will be warm during the actual work so try to anticipate any potential problems before the engine and accessories are hot 5 Park the vehicle on a level spot Start the engine and allow it to reach its normal operating temperature the needle on the temperature
218. d fit tightly onto the end of the plug If it doesn t remove the lead and use pliers to carefully crimp the metal connector inside the lead boot until the fit is snug 7 Using a clean rag wipe the entire length of the lead to remove built up dirt and grease Once the lead is clean check for burns cracks and other damage Do not bend the lead sharply because the conductor might break 8 Disconnect the spark plug lead from the distributor cap Again pull only on the rubber boot Check for corrosion and a tight fit Reinsert the lead in the distributor cap 9 Inspect the remaining spark plug leads making sure that each one is securely fastened at the distributor and spark plug when the check is complete 10 If new spark plug leads are required purchase a set for your specific engine model Remove and replace the leads one at a time to avoid mix ups in the firing order 11 Detach the distributor cap by unsnapping the cap retaining clips Look inside it for cracks carbon tracks and worn burned or loose contacts see illustrations 12 Pull the rotor off the distributor shaft and examine it for cracks and carbon tracks see illustrations Replace the cap and rotor if any damage or defects are noted 13 It is common practice to refit a new cap and rotor whenever new spark plug leads are installed When refitting a new cap remove the leads from the old cap one at a time and attach them to the new cap in the exact same location Note
219. d 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 6 Roadside 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 If it s a model with automatic transmission make sure the selector is in P or N Open the bonnet and make sure that the battery terminals are clean and tight Switch 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
220. d move the boot lid into correct alignment Move it only a little at a time Tighten the hinge bolts or nuts and carefully lower the boot lid to check the alignment 9 If necessary after refitting the entire boot lid striker assembly can be adjusted up and down as well as from side to side on the boot lid so the lid closes securely and is flush with the rear quarter panels To do this scribe a line around the boot lid striker assembly to provide a reference point Then loosen the bolts and reposition the striker as necessary see illustration Following adjustment retighten the mounting bolts 10 Adjust the bump stops on the boot lid so the boot lid is flush with the rear wings when closed see illustration 11 The boot lid latch assembly as well as the hinges should be periodically lubricated with white lithium base grease to prevent sticking and wear 17 Boot lid latch and lock cylinder removal and refitting 1 Boot lid latch 1 Open the boot and scribe a line around the boot lid latch assembly for a reference point to help aid the refitting procedure 2 The boot lid latch is retained by three Phillips head screws see illustration For adjustment procedures see Section 16 3 Disengage the lock rod from the latch 4 Disconnect all electrical connectors and remove the latch 5 Refitting is the reverse of removal Boot lock cylinder 6 Remove the plastic clips securing the boot light finish panel see illustration
221. d 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 an
222. d position preventing the coolant inside the engine from travelling through the radiator Renew the thermostat Do not drive the vehicle without a thermostat The computer may stay in open loop and emissions and fuel economy will suffer 4 If the lower radiator hose is hot it means that the coolant is flowing and the thermostat is open Consult the Troubleshooting section at the front of this manual for further diagnosis Renewal 5 Disconnect the battery negative cable Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 6 Drain the coolant from the radiator see Chapter 1 7 Remove the bolts from the thermostat cover see illustration If the cover doesn t 3 2 Cooling heating and air conditioning systems 3261 Jaguar XJ6 2 4 An inexpensive hydrometer can be used to test the condition of your coolant 3 7 Remove the two bolts small arrows holding the thermostat cover to the housing large arrow pull loose tap it with a soft faced hammer Do not use a screwdriver between the cover and the thermostat housing 8 Remove the thermostat noting the direction in which it was installed in the housing and thoroughly clean the sealing surfaces 9 Refit a new O ring onto the thermostat see illustration Make sure it is evenly fitted all the way around 10 Apply a bead of RTV sealant to the thermostat housing Refit t
223. d take off the panel see illustration 7 Lift out the radiator Be aware of dripping fluids and the sharp fins Take care not to damage the radiator fins by contact with other parts 8 With the radiator removed it can be inspected for leaks damage and internal blockage If repairs are necessary have a radiator specialist or dealer service department perform the work as special techniques are required Check the rubber mounting pads on the bottom of the radiator see illustration If they re cracked or damaged get new ones before refitting the radiator 9 Bugs and dirt can be cleaned from the radiator with compressed air and a soft brush Don t bend the cooling fins as this is done Warning Wear eye protection Refitting 10 Refitting is the reverse of the removal procedure Be sure the rubber mounts are in place on the bottom of the radiator 11 After refitting fill the cooling system with the proper mixture of antifreeze and water Refer to Chapter 1 if necessary 12 Start the engine and check for leaks Allow the engine to reach normal operating temperature indicated by both radiator hoses becoming hot Recheck the coolant level and add more if required 13 On automatic transmission equipped models check and add fluid as needed and check the power steering fluid level as well Expansion tank and coolant reservoir removal and refitting 14 The expansion tank is located at the top of the left hand side inner wing
224. d used be sure to clean all oil holes and galleries very thoroughly dry the engine block completely and coat all machined surfaces with light oil 8 The threaded holes in the engine block must be clean to ensure accurate torque readings during reassembly Run the proper size tap into each of the holes to remove rust corrosion thread sealant or sludge and restore damaged threads see illustration If possible use compressed air to clear the holes of debris produced by this operation 9 Refit the main bearing caps and tighten the bolts finger tight 10 After coating the sealing surfaces of the new core plugs with suitable sealant refit them in the engine block see illustration Make sure they re driven in straight and seated properly or leakage could result Special tools are available for this purpose but a large socket with an outside diameter that will just slip into the core plug a 1 2 inch drive extension and a hammer will work just as well 11 Apply non hardening sealant such as Permatex no 2 or Teflon pipe sealant to the new oil gallery plugs and thread them into the holes in the engine block Make sure they re tightened securely 12 If the engine isn t going to be reassembled right away cover it with a large plastic trash bag to keep it clean 16 Engine block inspection 2 1 Before the engine block is inspected it should be cleaned as described in Section 15 2 Visually check the engine block for cra
225. damage Check the valve clearance see Section 10 before removal of the cylinder head bent valves usually will have excessive clearance indicating damage that will require machine workshop work to repair Note 1 This procedure requires that the sump be removed see Section 12 In a professional workshop this would be performed as an in car procedure with specialised tools to remove the front suspension Given the equipment available to the average home mechanic this alternate procedure requires removal of the engine from the car Note 2 If your engine is a 4 0 litre built after serial number 9J160552 and you re experiencing an engine rattle on cold starts that disappears after the engine is warmed up the problem could be a defective upper tensioner A newly designed replacement upper tensioner is available from the dealer and should solve the problem It can be installed easily without pulling the cylinder head or front cover or can be installed during a chain removal procedure Removal 1 Disconnect the negative cable from the battery Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 2 Block the rear wheels and set the handbrake 3 Refer to Part B of this Chapter for engine removal procedures 4 Refer to Section 4 and remove the valve cover 5 Refer to Section 3 and position the engine at TDC for cylinder
226. department or other repair workshop because of the special tools and techniques required to disable the airbag system 1 Refer to Chapter 11 for removal of the glove compartment under dash panels and console Note The removal of the heater evaporator housing is difficult and time consuming much more so than the removal of the heater core see Section 11 For some home mechanics the job is better left to a Jaguar dealership or other qualified repair workshop 2 Disconnect the air conditioning lines from the backside of the expansion valve at the bulkhead just to the right of the engine using two spanners see illustration Cap the open fittings and expansion valve after dismantling to prevent the entry of air or dirt 3 Refer to Section 11 for moving the climate control computer aside and disconnecting the heater core pipes 4 From the engine side of the bulkhead near the expansion valve remove the nut retaining the heat air conditioning assembly housing see illustration Another mounting nut is on the left side under the wiper motor see illustration 11 2 5 Disconnect the defroster ducts on the left and right side of the evaporator housing see illustration 6 Identify all of the vacuum motor lines with masking tape and a felt pen then disconnect the lines Note Most vacuum lines are colour coded Make notes on which ones go to which devices 7 Tag and disconnect the wiring plugs connected to the heating air
227. der If the seal housing is unshouldered the seal should be fitted with its face flush with the housing top face unless otherwise instructed Screw threads and fastenings Seized nuts bolts and screws are quite a common occurrence where corrosion has set in and the use of penetrating oil or releasing fluid will often overcome this problem if the offending item is soaked for a while before attempting to release it The use of an impact driver may also provide a means of releasing such stubborn fastening devices when used in conjunction with the appropriate screwdriver bit or socket If none of these methods works it may be necessary to resort to the careful application of heat or the use of a hacksaw or nut splitter device Studs are usually removed by locking two nuts together on the threaded part and then using a spanner on the lower nut to unscrew the stud Studs or bolts which have broken off below the surface of the component in which they are mounted can sometimes be removed using a stud extractor Always ensure that a blind tapped hole is completely free from oil grease water or other fluid before installing the bolt or stud Failure to do this could cause the housing to crack due to the hydraulic action of the bolt or stud as it is screwed in When tightening a castellated nut to accept a split pin tighten the nut to the specified torque where applicable and then tighten further to the next split pin hole Never
228. do the test 4 Cylinder compression check 2 1 A compression check will tell you what mechanical condition the upper end pistons rings valves cylinder head gasket of your engine is in Specifically it can tell you if the compression is down due to leakage caused by worn piston rings defective valves and seats or a blown cylinder head gasket Note The engine must be at normal operating temperature and the battery must be fully charged for this check 2 Begin by cleaning the area around the spark plugs before you remove them compressed air should be used if available otherwise a small brush or even a bicycle tyre pump will work The idea is to prevent dirt from getting into the cylinders as the compression check is being done 3 Remove all of the spark plugs from the engine see Chapter 1 4 Block the throttle wide open 5 Detach the coil wire from the centre of the distributor cap and ground it on the engine block Use a jumper wire with alligator clips on each end to ensure a good earth Also remove the fuel pump relay see Chapter 4 to disable the fuel pump during the compression test Engine removal and overhaul procedures 2B 3 2B 3 4 The vacuum gauge is easily attached to a port on the intake manifold and can tell a lot about an engine s state of tune 3261 Jaguar XJ6 6 Refit the compression gauge in the spark plug hole see illustration 7 Crank the engine over at least seven compression strokes and w
229. drop straight down and out 8 If the blower motor does not operate disconnect the electrical connectors at the blower motor and connect the black wire terminal to chassis ground and the purple wire terminal to a fused source of battery voltage If the blower doesn t operate it should be renewed If it does operate there is a problem in the feed or earth circuit 9 If the motor is good but doesn t operate at any speed the problem could be in the heater air conditioning control assembly or the heating air conditioning computer Diagnosis either of these electronic com ponents is beyond the scope of the home mechanic and should be referred to your Jaguar dealer or other qualified repair facility 10 If either blower motor must be renewed remove the five clips and one screw holding the blower housing halves together see illustration 3 8 Cooling heating and air conditioning systems 10 2a The right blower housing arrowed is located behind the glove box area of the dash 10 2b Apply heavy duct tape to the sharp edge of this brace dotted line when working behind the glove box area of the dash the metal is very sharp 10 3a Remove the screw A holding the wiring harness in place then remove the two lower cruise control ECU screws B 10 3b then remove the upper ECU screw arrowed and pull down the ECU then remove the ECU mounting plate 10 5 Two bolts arrow indicates the left bolt hold the to
230. e Transmission Windshield Windscreen Wrench Spanner 3261 Jaguar XJ6 REF 4 Buying spare parts Spare parts are available from many sources including maker s appointed garages accessory shops and motor factors To be sure of obtaining the correct parts it will sometimes be necessary to quote the vehicle identification number If possible it can also be useful to take the old parts along for positive identification Items such as starter motors and alternators may be available under a service exchange scheme any parts returned should be clean Our advice regarding spare parts is as follows Officially appointed garages This is the best source of parts which are peculiar to your car and which are not otherwise generally available eg badges interior trim certain body panels etc It is also the only place at which you should buy parts if the vehicle is still under warranty Accessory shops These are very good places to buy materials and components needed for the maintenance of your car oil air and fuel filters light bulbs drivebelts greases brake pads touch up paint etc Components of this nature sold by a reputable shop are usually of the same standard as those used by the car manufacturer Besides components these shops also sell tools and general accessories usually have convenient opening hours charge lower prices and can often be found close to home Some accessory shops have parts counters
231. e positive cable then the negative cable 2 Using a voltmeter check the battery voltage with the engine off It should be approximately 12 volts see illustration 3 Start the engine and check the battery voltage again It should now be approximately 13 5 to 15 1 volts 4 Turn on the headlights The voltage should drop and then come back up if the charging system is working properly 5 If the voltage reading is greater than the specified charging voltage renew the alternator 6 If you have an ammeter connect it up to the charging system according to its maker s instructions If you don t have a professional type ammeter you can also use an inductive type current indicator This device is inexpensive readily available at car accessory outlets and accurate enough to perform simple amperage checks like the following test 7 With the engine running at 2000 rpm check the reading on the ammeter with all accessories and lights off no load then again with the high beam headlights on and the heater blower switch turned to the HI position full load Compare your readings to the standard amperage listed in this Chapter s Specifications 8 If the ammeter reading is less than standard amperage repair or renew the alternator 9 If the alternator is working but the charging system still does function properly check the operation of the load dump module see illustration Have this component checked at a dealer service departme
232. e Specifications to make sure it s correct 15 If the clearance is not as specified the bearing inserts may be the wrong size which means different ones will be required see Section 20 Before deciding that different inserts are needed make sure that no dirt or oil was between the bearing inserts and the caps or engine block when the clearance was measured If the Plastigauge is noticeably wider at one end than the other the journal may be tapered see Section 19 16 Carefully scrape all traces of the Plastigauge material off the main bearing journals and or the bearing faces Don t nick or scratch the bearing faces Final crankshaft refitting 17 Carefully lift the crankshaft out of the engine Clean the bearing faces in the engine block then apply a thin uniform layer of clean moly base grease or engine assembly lube to each of the bearing surfaces Coat the thrust washers as well 18 Lubricate the crankshaft surfaces that contact the oil seals with moly base grease engine assembly lube or clean engine oil 19 Make sure the crankshaft journals are clean then lay the crankshaft back in place in the engine block Clean the faces of the bearings in the main bearing caps then apply lubricant to them Refit the main bearing caps in their respective positions with the arrows pointing toward the front of the engine Note Be sure to refit the thrust washers lubricated with the number 4 main journal The upper block side thr
233. e a calibrated ignition tester available at most car accessory outlets remove a plug lead from a cylinder connect the spark plug boot to the tester and clip the tester to a good earth if there is enough voltage to fire the plug sparks will be clearly visible between the electrode tip and the tester body 3261 Jaguar XJ6 9 Check for battery voltage to the Ignition ON relay see illustration If battery voltage does not exist check the circuit from the ignition ON relay to the battery refer to the wiring diagrams at the end of Chapter 12 Note See Chapter 12 for the location of the Ignition ON relay 10 Check the operation of the crankshaft position sensor see Chapter 6 11 If all the checks are correct check the voltage signal from the computer Using an LED type test light backprobe the coil power lead negative terminal on the ignition coil see illustration Remove the coil secondary wire and earth the terminal to the engine Now have an assistant crank the engine over and observe that the test light pulses on and off If there is no flashing from the test light most likely the computer is damaged Have the ECU diagnosed by a dealer service department 12 Additional checks should be performed by a dealer service department or an automotive repair workshop 7 Amplifier check and renewal 2 Warning Because of the high voltage generated by the ignition system extreme care should be taken whenever an operation
234. e airbag system DO NOT work in the vicinity of the steering column or instrument panel The manufacturer recommends that on airbag equipped models the following procedure be performed at a dealer service department or other properly equipped repair facility because of the special tools and techniques required to disable the airbag system Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 1 Remove the lower trim cover s see illustration 2 To remove the vehicle condition monitor VCM switch assembly simply depress the switch retaining clip and lower the switch assembly from the instrument panel see illustration 3 To remove the headlight switch assembly detach the switch knob and remove the hex nut securing the switch to the instrument panel see illustration Depress the retaining clip securing the switch disconnect the electrical connectors and remove the switch assembly from the instrument panel 4 Refitting is the reverse of removal 12 6 Body electrical system 10 1 Remove the lower trim cover s from the instrument panel switch assembly 10 2 Depress the clip on the front lower the switch assembly from the instrument panel and unplug the connectors 10 3 Detach the headlight switch knob then remove the hex nut securing the switch to the instrument panel arrowed 3261 Jaguar XJ6 9 4 Remove the
235. e around the latches to aid alignment when refitting then detach the retaining bolts from the inner footwell see illustration and remove the latch 3 Refitting is the reverse of removal Cable 4 Disconnect the bonnet release cable as described in Section 11 5 Detach all cable retaining clips located in the engine compartment 6 Working in the passenger compartment remove the driver s side kick panel surrounding the bonnet release lever Pull the release lever forward and detach the release cables from the handle and bracket assembly see illustration 11 6 Remove the driver s side kick panel to access the bonnet release cables from the passenger compartment 11 4 Bodywork and fittings 3261 Jaguar XJ6 10 11 Adjust the position of the bonnet striker by loosening the locknut A then adjust the height of the bonnet striker B by turning it in or out with a screwdriver 10 12 Remove the rubber bumper then loosen the locknut A adjust the bonnet bumper bolt B in or out so the bonnet is flush with the wings in the closed position 11 1 Remove the cable retaining bolt s arrowed then disengage the cable from the latch assembly 11 2 Bonnet latch retaining bolts arrowed are located on both sides of the engine compartment 7 Attach a piece of thin wire or string to the end of the cables to help aid the refitting process 8 Working in the engine compartment pull the cables and grommet out of the bulkhead unti
236. e garages If none of these facilities are available consult your local Environmental Health Department or the National Rivers Authority for further advice With the universal tightening up of legislation regarding the emission of environmentally harmful substances from motor vehicles most current vehicles have tamperproof devices fitted to the main adjustment points of the fuel system These devices are primarily designed to prevent unqualified persons from adjusting the fuel air mixture with the chance of a consequent increase in toxic emissions If such devices are encountered during servicing or overhaul they should wherever possible be renewed or refitted in accordance with the vehicle manufacturer s requirements or current legislation 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 3261 Jaguar XJ6 REF 6 Tools and working facilities Introduction A selection of good tools is a fundamental requirement for anyone contemplating the maintenance and repair of a motor vehicle For the owner who does not possess any their purchase will prove a considerable expense offsetting some of the savings made by doing it yourself However provided that the tools purchased meet the relevant national safety standards and are of good quality they will last for many years and prove an extremely worthwhile investment T
237. e hoses as well in which case the new rear housing can be installed Note 2 There are three different lengths of water pump bolts The longer bolts retain the pump and rear housing to the engine see illustration 7 3 5 If the pump doesn t come loose right away tap it with a soft faced hammer to break the gasket seal Be careful not to hit the radiator fins with the pump during removal 6 Thoroughly clean all sealing surfaces removing all traces of gasket or sealant from the back of the pump and the face of the housing 7 Apply a bead of RTV sealant to the sealing surface on the back of the pump Refit the pump and bolts tightening the bolts to the torque listed in this Chapter s Specifications 8 Refit the remaining parts in the reverse order of removal Note If the pump has been renewed after many miles of usage it s a good idea to also renew the hoses connected to the water pump housing see illustrations Refer to Chapter 2A for intake manifold removal to access the coolant pipes and hoses If you have noticed water leaks or stains on the left side of the engine the leaks may be coming from these pipes and hoses 9 Refill the cooling system see Chapter 1 run the engine and check for leaks and proper operation 9 Coolant temperature sender unit check and renewal 2 Warning Do not start this procedure until the engine is completely cool Check 1 If the coolant temperature gauge is inoperative check the f
238. e hoses which connect the steel brake lines with the front and rear brake assemblies should be inspected for cracks chafing of the outer cover leaks blisters and other damage These are important and vulnerable parts of the brake system and inspection should be complete A light and mirror will prove helpful for a thorough check If a hose exhibits any of the above conditions renew it with a new one Flexible hose renewal 2 Clean all dirt away from the ends of the hose 3 To disconnect the hose at the frame end use a second spanner on the hex shaped fitting on the end of the flexible hose and loosen the nut on the metal brake line see illustrations If the nut is stuck soak it with penetrating oil After the hose is disconnected from the metal line remove the nut right above the bracket and detach the hose from the bracket 4 To detach the flexible hose from the caliper simply unscrew it 5 Refitting is the reverse of the removal procedure Make sure the brackets are in good condition and the locknuts are tightened securely Braking system 9 9 9 7 5 Use a flare nut spanner to loosen the fittings then pull the lines back from the brake servo and plug them to prevent contamination 7 6 Pry off the two rubber caps from the pedal box 7 7 To detach the brake servo from the pedal box remove these four nuts arrowed lower right nut not visible in this photo 8 3a To remove a front flexible brake hose from a metal
239. e instant photos or sketch the locations of components and brackets 8 Remove the cooling fan s and radiator see Chapter 3 9 Disconnect the heater hoses 10 Release the residual fuel pressure in the tank by removing the petrol cap then detach the fuel lines connecting the engine to the chassis see Chapter 4 Plug or cap all open fittings 2B 4 Engine removal and overhaul procedures 4 6 A compression gauge with a threaded fitting for the spark plug hole is preferred over the type that requires hand pressure to maintain the seal be sure to block open the throttle valve as far as possible during the compression check 6 7 Label both ends of each wire and hose before disconnecting it 3261 Jaguar XJ6 11 Disconnect the throttle linkage transmission linkage and dipstick tube and speed control cable if equipped from the engine see Chapters 4 and 7 12 Refer to Part A of this Chapter and remove the intake and exhaust manifolds 13 Unbolt the power steering pump see Chapter 10 Tie the pump aside without disconnecting the hoses Refer to Part A for removal of the hydraulic pump if equipped from the timing chain cover 14 On air conditioned models unbolt the compressor and set it aside Do not disconnect the refrigerant hoses Note Wire the compressor out of the way with a coat hanger don t let the compressor hang on the hoses 15 Refer to Part A of this Chapter and remove the drivebelts water pump pulley and
240. e of removal Refer to Section 10 for replacing the camshaft sprockets and adjusting the timing chain and tensioner Refill the cooling system see Chapter 1 25 Run the engine and check for oil or coolant leaks Adjust the ignition timing see Chapter 5 and road test the car 12 Sump removal and refitting 4 Removal 1 Note The sump cannot be removed with the engine in the chassis without lowering the front suspension and crossmember This is a difficult procedure for the home mechanic without a vehicle hoist and some other specialised tools The other alternative requires the engine be removed from the car and mounted on a stand as we have illustrated here Refer to Part B of this Chapter for engine removal procedures 2 Drain the engine oil and remove the oil filter see Chapter 1 3 Remove the bolts and detach the sump see illustration 4 If it s stuck pry it loose very carefully with a small screwdriver or putty knife see illustration Don t damage the mating surfaces of the pan and engine block or oil leaks could develop 2A 14 Engine in car repair procedures 3261 Jaguar XJ6 11 21a Only use a head gasket with the improved oil transfer seal right arrow the older style left arrow is prone to oil leaks 11 21b Place the new head gasket over the dowels in the engine block note the markings for UP or TOP printed on the gasket 11 23 Cylinder head bolt TIGHTENING sequence 12 3 Remove the sump bolts ar
241. e right and one on the left and a heater core located within the heater air conditioning assembly which is under the dash and behind the console Hoses connect the heater core to the engine cooling system Heater function is controlled by the heater air conditioning control head on the dashboard Hot engine coolant is circulated through the heater core When the heater mode is activated a flap door opens to expose the heater box to the passenger compartment A fan switch on the control head activates the blower motor which forces air through the core heating the air Air conditioning system The air conditioning system consists of a condenser mounted in front of the radiator an evaporator mounted in the heat air conditioning assembly behind the console and under the centre of the dash a compressor mounted on the engine a filter drier which contains a high pressure relief valve and the plumbing connecting all of the above A blower fan forces the warmer air of the passenger compartment through the evaporator core sort of a radiator in reverse transferring the heat from the air to the refrigerant The liquid refrigerant boils off into low pressure vapour taking the heat with it when it leaves the evaporator The compressor keeps refrigerant circulating through the system pumping the warmed coolant through the condenser where it is cooled and then circulated back to the evaporator 2 Antifreeze coolant general i
242. e to check both sides of the disc see illustration If pulsating has 9 4 Braking system 4 7 Remove the piston seal from the caliper bore using a wooden or plastic tool metal tools may damage the cylinder bore 5 3 The brake pads on this vehicle were obviously neglected as they wore down to the rivets and cut deep grooves into the disc this disc must be replaced 3261 Jaguar XJ6 4 2 Use a flare nut spanner to protect the brake hose fitting when unscrewing it from the caliper 4 5 With the caliper padded to catch the piston use compressed air to force the piston out of its bore make sure your fingers are not between the piston and the caliper been noticed during application of the brakes suspect disc runout 4 To check disc runout place a dial indicator at a point about 1 2 inch from the outer edge of the disc see illustration Set the indicator to zero and turn the disc The indicator reading should not exceed the specified allowable runout limit If it does the disc should be refinished by an automotive machine workshop Note It is recommended that the discs be resurfaced regardless of the dial indicator reading as this will impart a smooth finish and ensure a perfectly flat surface eliminating any brake pedal pulsation or other undesirable symptoms related to questionable discs At the very least if you elect not to have the discs resurfaced remove the glazing from the surface with emery cloth or sandpaper
243. e turned once the engine has been stopped Wipe clean the area around the reservoir cap then remove the cap noting that it unscrews in a clockwise direction see arrow on cap 1 Wipe clean the cap dipstick then insert it fully into the reservoir and withdraw it 2 Note the fluid level on the end of the dipstick If the fluid is cold vehicle not having been used the fluid level should be upto the COLD level marking 1 If the vehicle has been driven and the fluid is hot then the fluid level should be upto the upper HOT level marking 2 3 If necessary top up the reservoir with the specified type of fluid note that the type of fluid differs according to model see Lubricants fluids and tyre pressures on page 0 16 Once the level is correct securely refit the reservoir cap Do not overfill the reservoir 4 Wiper blades Check the condition of the wiper blades if they are cracked or show signs of deterioration or if the glass swept area is smeared renew them For maximum clarity of vision wiper blades should be renewed annually 1 To remove a wiper blade pull the arm fully away from the screen until it locks Swivel the blade then depress the locking clip at the base of the mounting block and slide the blade off the arm 2 Warning l This check applies only to vehicles fitted with a separate power steering system For vehicles fitted with power steering where the fluid reservoir is part
244. ecautions when you work on any part of the fuel system See the Warning in Section 2 Note Some 1994 models may be equipped with faulty fuel level sender units A tight float rod bushing may cause the float to stick and indicate high fuel levels while the tank is almost empty Check 1 Before performing any tests on the fuel level sender unit completely fill the tank with fuel 2 Remove the boot liner see Chapter 12 to expose the fuel level sender unit access cover 3 Disconnect the fuel level sender unit electrical connector located on the access cover Note 1991 to 1994 models are equipped with a fuel pump module and a sender unit assembly while 1988 and 1989 models are equipped with only the fuel level sender unit inside the tank 4 Position the ohmmeter probes on the electrical connector terminals see illustration and check for resistance Use the 200 ohm scale on the ohmmeter 5 With the fuel tank completely full the resistance should be about 18 to 20 ohms 6 Reconnect the electrical connector and drive it until the tank is nearly empty 7 Check the resistance The resistance of the sender unit should be about 190 to 200 ohms 8 If the readings are incorrect renew the sender unit Note The test can also be performed with the fuel level sender unit removed from the fuel tank Using an ohmmeter check the resistance of the sender unit with the swing arm completely down tank empty and with the arm up tank fu
245. ecked with a micrometer 5 5b Compare your measurement with the minimum thickness stamped into the disc 5 6a Before you can remove the caliper mounting bracket bolts arrowed and the bracket you ll have to cut the safety wire between them with a pair of diagonal cutters rear bracket shown 5 6b On front caliper brackets remove the ABS wheel speed sensor bolt centre arrow and pull out the sensor before removing the bracket bolts upper and lower arrows and bracket 3261 Jaguar XJ6 5 7a Using an impact driver if necessary remove the disc retaining screw then remove the disc from the hub 5 7c If a rear disc is stuck to the hub insert a suitable tool through the hub flange and retract the handbrake shoes 5 7b If the disc is stuck to the hub give it a few sharp raps with a hammer Refitting 8 Place the disc on the hub and refit the disc retaining screw Tighten the screw securely 9 Refit the caliper mounting bracket using a new safety wire on the mounting bolts 10 Refit the brake pads and caliper see Section 3 Tighten all fasteners to the torque listed in this Chapter s Specifications 11 Refit the wheel and wheel nuts then lower the vehicle to the ground Tighten the wheel nuts to the specified torque see Chapter 1 Specifications Depress the brake pedal a few times to bring the brake pads into contact with the disc 12 Adjust the handbrake shoes if necessary 13 Check the operation of the brakes care
246. ed and pull off the transmission adapter plate incorporated throughout The refitting of manifolds and external parts is all that s necessary Engines in this rebuilt form are available from Jaguar dealers and some independent rebuilders Give careful thought to which alternative is best for you and discuss the situation with local automotive machine shops auto parts dealers and experienced rebuilders before ordering or purchasing replacement parts 8 Engine overhaul dismantling sequence 1 It s much easier to dismantle and work on the engine if it s mounted on a portable engine stand A stand can often be rented quite cheaply from an equipment rental yard Before the engine is mounted on a stand the driveplate and rear oil seal retainer should be removed from the engine 2 If a stand isn t available it s possible to dismantle the engine with it blocked up on the floor Be extra careful not to tip or drop the engine when working without a stand 3 If you re going to obtain a rebuilt engine all external components must come off first to be transferred to the replacement engine just as they will if you re doing a complete engine overhaul yourself These include Alternator and brackets Emissions control components Distributor spark plug leads and spark plugs Thermostat and housing cover Water pump EFI components Intake exhaust manifolds Oil filter Engine mounts Driveplate Transmission adapter plate Note
247. ed by the alternator This Chapter covers repair and service procedures for the various electrical components not associated with the engine Information on the battery alternator distributor and starter motor will be found in Chapter 5 It should be noted that when portions of the electrical system are serviced the cable should be disconnected from the negative battery terminal to prevent electrical shorts and or fires 2 Electrical fault finding general information A typical electrical circuit consists of an electrical component any switches relays motors fuses fusible links in line fuses or circuit breakers related to that component and the wiring and electrical connectors that link the component to both the battery and the chassis To help you pinpoint an electrical circuit problem wiring diagrams are included at the end of this Chapter Before tackling any troublesome electrical circuit first study the appropriate wiring diagrams to get a complete understanding of what makes up that individual circuit Trouble spots for instance can often be narrowed down by noting if other components related to the circuit are operating properly If several components or circuits fail at one time chances are the problem is in a fuse or earth connection because several circuits are often routed through the same fuse and earth connections Electrical problems usually stem from simple causes such as loose or corroded connec
248. ed with new ones of the same part number or of original equipment quality and design Torque wrench settings must be followed for proper reassembly and component retention Never attempt to heat straighten or weld any suspension or steering component Instead renew any bent or damaged part The front suspension see illustrations consists of unequal length upper and lower control arms shock absorbers and coil springs The upper ends of the shocks are attached to the body the lower ends are attached to the lower control arms The upper ends of the coil springs are seated against the suspension crossmember the lower ends are seated against removable plates which are bolted to the lower control arms The steering knuckles are attached to balljoints in the upper and lower control arms An anti roll bar is attached to the suspension crossmember with a pair of bushing brackets and to the lower control arms via a connecting link at each end The independent rear suspension see illustration uses control arms and integral shock absorber coil spring units The upper ends of the shocks are attached to the body the lower ends are connected to the control arms The steering system consists of the steering wheel a steering column a universal joint on the lower end of the steering shaft a rack and pinion power steering gear a power steering pump and a pair of tie rods which connects the steering gear to the steering knuckles see illustrati
249. ee bolster 11 13 L Latch 11 4 11 7 11 9 Leaks 0 9 1 10 7 2 Locknuts locktabs and washers REF 5 Locks 11 3 11 7 11 9 12 6 Lubricants 0 16 M Main bearings 2B 13 2B 16 Manifolds 2A 4 Manual valve 7 7 Mass Airflow MAF sensor 6 6 Master cylinder 9 6 Mirrors 11 11 12 14 REF 8 MOT test checks REF 8 et seq Mounts 2A 18 7 8 Multi Point Fuel Injection MPFI system 4 1 3261 Jaguar XJ6 N Neutral start switch 7 5 Notes for UK readers 0 4 REF 3 Number plate light 12 12 O Obtaining diagnostic code output 6 3 Oil cooler 3 6 Oil filter 1 6 Oil gauge 12 7 Oil pump 2A 15 Oil seals 2A 5 2A 17 2B 17 7 7 8 4 8 5 REF 5 Oil differential 1 2 1 11 1 20 Oil engine 0 11 0 16 1 2 1 6 On Board Diagnosis OBD system 6 2 Open circuit check 12 2 Output shaft 7 7 Oxygen sensor 6 4 P Pads brake 9 1 9 2 Painting 11 2 Parking lights 12 11 Piston rings 2B 15 Pistons 2B 9 2B 12 2B 17 Poisonous or irritant substances 0 5 Power hydraulic system 0 16 fluid 1 9 Power steering 10 10 10 11 fluid 0 13 0 16 Propshaft 1 18 8 1 8 2 8 3 Punctures 0 8 R Radiator 3 4 grille 11 5 Radio 12 7 REF 1 Rear lights 12 12 Receiver drier 3 12 Regulator window 11 10 Relays 1
250. ee screws one arrowed one at the top back and one below to take out the climate control computer on right side of heater air conditioning assembly 11 6b Pull away the climate control computer arrowed 11 7 Remove the four screws arrowed and the heater core cover plate 11 8 Pull the heater core out to the right 3261 Jaguar XJ6 11 9 Retain the original foam insulation on the heater core or transfer to the new core and replace the two O rings arrowed 12 3a Remove these six screws arrowed to release the control panel radio assembly from the console 4 Refitting is the reverse of the removal procedure 5 Run the engine and check for proper functioning of the heater and air conditioning if equipped Control checks 6 The climate control system uses an all electronic control panel that sends digital information to the climate control computer There is little the home mechanic can do to troubleshoot or test the system The factory recommends that diagnosis be performed at a dealership 7 If there is a problem in just one area of climate control put the controls through their entire range of operation and check the system responses i e set the controls to COLD the fan to low and the temperature to 65 F In this mode the Manual LED should be lit and the air conditioning compressor should engage Try all of the fan speeds and try the temperature on HOT then feel for warm air coming from the ducts Note Betwee
251. eels tilt in at the top the camber is negative The amount of tilt is measured in degrees from vertical and this measurement is called the camber angle This angle affects the amount of tyre tread which contacts the road and compensates for changes in the suspension geometry when the vehicle is cornering or travelling over an undulating surface Caster is the tilting of the front steering axis from the vertical A tilt toward the rear is positive caster and a tilt toward the front is negative caster Caster is adjusted by moving shims from one side of the upper control arm balljoint to the other 10 12 Suspension and steering systems 3261 Jaguar XJ6 3261 Jaguar XJ6 11 Chapter 11 Bodywork and fittings Body maintenance 2 Body repair major damage 6 Body repair minor damage 5 Bonnet removal refitting and adjustment 10 Bonnet and boot lid support struts removal and refitting 9 Bonnet release latch and cable removal and refitting 11 Boot lid removal refitting and adjustment 16 Boot lid latch and lock cylinder removal and refitting 17 Bumpers removal and refitting
252. eft side of the transmission housing just above the sump The VIN is also present on the left side of the dashboard 3261 Jaguar XJ6 General repair procedures REF 5 Whenever servicing repair or overhaul work is carried out on the car or its components it is necessary to observe the following procedures and instructions This will assist in carrying out the operation efficiently and to a professional standard of workmanship Joint mating faces and gaskets When separating components at their mating faces never insert screwdrivers or similar implements into the joint between the faces in order to prise them apart This can cause severe damage which results in oil leaks coolant leaks etc upon reassembly Separation is usually achieved by tapping along the joint with a soft faced hammer in order to break the seal However note that this method may not be suitable where dowels are used for component location Where a gasket is used between the mating faces of two components ensure that it is renewed on reassembly and fit it dry unless otherwise stated in the repair procedure Make sure that the mating faces are clean and dry with all traces of old gasket removed When cleaning a joint face use a tool which is not likely to score or damage the face and remove any burrs or nicks with an oilstone or fine file Make sure that tapped holes are cleaned with a pipe cleaner and keep them free of jointing compound if this is being
253. either front or rear brakes mechanically through a series of cables and linkages Also known as a handbrake or parking brake Endfloat The amount of lengthwise movement between two parts As applied to a crankshaft the distance that the crankshaft can move forward and back in the cylinder block Engine management system EMS A computer controlled system which manages the fuel injection and the ignition systems in an integrated fashion Exhaust manifold A part with several passages through which exhaust gases leave the engine combustion chambers and enter the exhaust pipe F Fan clutch A viscous fluid drive coupling device which permits variable engine fan speeds in relation to engine speeds Feeler blade A thin strip or blade of hardened steel ground to an exact thickness used to check or measure clearances between parts Firing order The order in which the engine cylinders fire or deliver their power strokes beginning with the number one cylinder Flywheel A heavy spinning wheel in which energy is absorbed and stored by means of momentum On cars the flywheel is attached to the crankshaft to smooth out firing impulses Free play The amount of travel before any action takes place The looseness in a linkage or an assembly of parts between the initial application of force and actual movement For example the distance the brake pedal moves before the pistons in the master cylinder are actuated F
254. embly to the side a little to provide clearance for pulling out the pivot bolt 7 5 To detach the upper control arm from the crossmember remove the nut at the rear and pull the bolt out from the front note the fitted order of the spacer washers 3261 Jaguar XJ6 and support it securely on axle stands Remove the wheel 2 Refit the special spring compressor tool JD115 as shown see illustrations 3 Tighten the tool until the spacer is tight against the spring pan then remove the spring pan bolts see illustration 4 Slowly back off the wingnut on the special tool until all tension is relieved from the spring Remove the tool remove the pan and remove the coil spring 5 Refitting is the reverse of removal Place the coil spring in position with the spring pan below it refit the special tool and carefully tighten the wingnut until the spring is compressed enough to allow the pan to be positioned and bolted to the lower control arm Be sure to tighten the pan bolts to the torque listed in this Chapter s Specifications 9 Lower control arm removal and refitting 3 Warning The lower control arms cannot be removed without a special spring compressor tool Jaguar tool JD115 Do not try to remove a lower control arm without this tool or you could be seriously injured 1 Loosen the wheel nuts raise the vehicle and support it securely on axle stands Remove the wheel 2 Remove the spring pan and the coil spring see Sec
255. emove the window frame and glass assembly by pulling it up and out see illustration 6 Refitting is the reverse of removal 23 Outside mirrors removal and refitting 2 1 Raise the window to the fully closed position and remove the upper half of the door trim panel see Section 18 2 Detach the trim cover retaining screws see illustration 3 Disconnect the wiring plug from the mirror 4 Remove the three mirror retaining screws and detach the mirror from the vehicle see illustration 5 Refitting is the reverse of removal 24 Centre console removal and refitting 3 Floor console 1 Disconnect the negative battery cable Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 2 Pry out the gear selector trim bezel see illustration 3 Open the console compartment and remove the screws securing the ash tray Pull the ash tray back towards the compartment to remove it see illustrations 4 Working through the ash tray opening detach the plastic wingnuts securing the rear edge of the radio trim bezel see illustration 5 Apply the handbrake then move the gear Bodywork and fittings 11 11 11 22 4a Front door window frame screws 22 4b Rear door window frame screws 22 5 After removing the window frame retaining screws pull the window and frame assembly up and out to remove it 3261 Jaguar XJ6 23 2 Remo
256. en Most motors are audible Can you hear the motor running b If you can t and have already verified that the blower switch and the blower motor resistor are good the blower motor itself is probably bad see Section 10 15 If the carpet under the heater core is damp or if antifreeze vapour or steam is coming through the vents the heater core is leaking Remove it see Section 11 and refit a new unit most radiator shops will not repair a leaking heater core 16 Inspect the drain hose from the heat AC assembly at the right side of the bulkhead make sure it is not clogged see illustration If there is a humid mist coming from the system ducts this hose may be plugged In some early models the hose may have been pinched during assembly or blocked with insulation or underseal 14 Air conditioning receiver drier removal and refitting 4 Warning The air conditioning system is under high pressure Do not loosen any hose fittings or remove any components until the system has been discharged Air conditioning refrigerant should be properly discharged into an EPA approved recovery recycling unit by a dealer service depart ment or an automotive air conditioning 3 12 Cooling heating and air conditioning systems 13 16 This drain hose arrowed from the heater air conditioning unit should be kept clear to allow drainage of condensation 3261 Jaguar XJ6 13 9 Feel the inlet small arrow and outlet large arrow pipes
257. en starts Maintaining the battery charge is particularly important in the winter when the battery must work harder to start the engine and electrical accessories that drain the battery are in greater use 13 It s best to use a one or two amp battery charger sometimes called a trickle charger They are the safest and put the least strain on the battery They are also the least expensive For a faster charge you can use a higher amperage charger but don t use one rated more than 1 10th the amp hour rating of the battery Rapid boost charges that claim to restore the power of the battery in one to two hours are hardest on the battery and can damage batteries not in good condition This type of charging should only be used in emergency situations 14 The average time necessary to charge a battery should be listed in the instructions that come with the charger As a general rule a trickle charger will charge a battery in 12 to 16 hours 7 Hose and fluid leak check 1 1 Visually inspect the engine joint faces gaskets and seals for any signs of water or oil leaks Pay particular attention to the areas around the camshaft cover cylinder head oil filter and sump joint faces Bear in mind that over a period of time some very slight seepage from these areas is to be expected what you are really looking for is any indication of a serious leak see Haynes Hint Should a 1 10 Every 7500 miles or 6 months 6 6a Battery term
258. en disconnect the battery negative cable Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 11 8 Bodywork and fittings 18 6 Detach the screws along the top edge of the lower trim panel 18 7a Prise out the courtesy lamp lens 18 7b Remove the retaining screw from inside the lamp housing 18 8a Push up on the bottom to detach the armrest pull handle trim cover 18 8b Remove the screws behind the armrest pull handle trim cover 18 9 Disengage the retaining clips along the outer edge of the door trim panel 3261 Jaguar XJ6 18 4 Gently prise out the clips securing the wood finish panel 18 5 Detach the screws located behind the wood finisher panel then remove the upper portion of the door trim panel 2 Open the door all the way and support it on jacks or blocks covered with rags to prevent damaging the paint 3 Remove the door trim panel and water deflector as described in Section 18 4 Unplug all electrical connections ground wires and harness retaining clips from the door Note It is a good idea to label all connections to aid the reassembly process 5 From the door side detach the rubber conduit between the body and the door then carefully pull the wiring harness through the conduit hole and remove it from the door 6 Mark around the door hinges with a pen or a scribe to ease alignment during reassembly 7 On front do
259. en sensor to produce a voltage output which varies from 0 1 volts high oxygen lean mixture to 0 9 volts low oxygen rich mixture The ECU constantly monitors this variable voltage output to determine the ratio of oxygen to fuel in the mixture The ECU alters the air fuel mixture ratio by controlling the pulse width open time of the fuel injectors A mixture ratio of 14 7 parts air to 1 part fuel is the ideal mixture ratio for minimising exhaust emissions thus allowing the catalytic converter to operate at maximum efficiency This ratio of 14 7 to 1 is the one which the ECU and the oxygen sensor attempt to maintain at all times 8 The oxygen sensor produces no voltage when it is below its normal operating temperature of about 600 F During this initial period before warm up the ECU operates in open loop mode 9 If the engine reaches normal operating temperature and or has been running for two or more minutes and if the oxygen sensor is producing a steady signal voltage below 0 45 volts at 1500 or more rpm the ECU will set a Code 4 1988 and 1989 or 26 1990 to 1994 10 When there is a problem with the oxygen sensor or its circuit the ECU operates in the open loop mode that is it controls fuel delivery in accordance with a programmed default value instead of feedback information from the oxygen sensor 11 The proper operation of the oxygen sensor depends on four conditions a Electrical The low voltages generated by the
260. enger side bulkhead and on 1993 and 1994 models it is located in the boot Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 2 Remove the battery hold down clamp 3 Lift out the battery Be careful it s heavy 4 While the battery is out inspect the carrier tray for corrosion 5 If you are replacing the battery make sure that you get one that s identical with the same dimensions amperage rating cold cranking rating etc as the original 6 Refitting is the reverse of removal 4 Battery cables check and renewal 1 Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 1 Periodically inspect the entire length of each battery cable for damage cracked or burned insulation and corrosion Poor battery cable connections can cause starting problems and decreased engine performance 2 Check the cable to terminal connections at the ends of the cables for cracks loose wire strands and corrosion The presence of white fluffy deposits under the insulation at the cable terminal connection is a sign that the cable is corroded and should be renewed Check the terminals for distortion missing mounting bolts and corrosion 3 When removing the cables always disconnect the negative cable first and hook it up last or the
261. ent of US components and various other US words is given in the Section headed Use of English It should be remembered that the project vehicle used in the main Chapters of this manual was a left hand drive US model therefore the position of the steering wheel steering column and pedals etc will be on the opposite side of the vehicle on UK models References to right and left will need to be considered carefully to decide which applies to UK models eg the headlight dipped beams should be adjusted to dip to the left of the headlight vertical line described in Chapter 12 instead of to the right on US models In other instances no reference is made to the location of a particular item but that item may be located on the opposite side of the vehicle on UK models Reference to the underbonnet photos at the start of Chapter 1 will give the reader the location of the engine compartment components on UK models All specifications in the main Chapters of the manual appear in Imperial form the equivalent metric values can be calculated using the Conversion factors page The only other major difference between UK and US models is in the level of emission control equipment fitted to the vehicle To meet the strict emission standards present in the US all vehicles for that market are fitted with various emission control systems see Chapter 6 most of which are not fitted to the corresponding UK model especially so on early mode
262. ep children away from the battery 5 Note the external condition of the battery If the positive terminal and cable clamp on your vehicle s battery is equipped with a rubber protector make sure it isn t torn or damaged It should completely cover the terminal Look for any corroded or loose connections cracks in the case or cover or loose hold down clamps Also check the entire length of each cable for cracks and frayed conductors 6 If corrosion which looks like white fluffy deposits see illustration is evident particularly around the terminals the battery should be removed for cleaning Loosen the cable clamp bolts being careful to remove the ground cable first and slide them off the terminals see illustration Then disconnect the hold down clamp bolt and nut remove the clamp and lift the battery from the engine compartment 7 Clean the cable clamps thoroughly with a battery brush or a terminal cleaner and a solution of warm water and baking soda see illustration Wash the terminals and the top of the battery case with the same solution but make sure that the solution doesn t get into the battery When cleaning the cables terminals and battery top wear safety goggles and rubber gloves to prevent any solution from coming in contact with your eyes or hands Wear old clothes too even diluted sulphuric acid splashed onto clothes will burn holes in them If the terminals have been extensively corroded clean them up
263. eplaced with new ones of the correct size for the hole When thread locking compound is found on the threads of a fastener which is to be re used it should be cleaned off with a wire brush and solvent and fresh compound applied on reassembly Special tools Some repair procedures in this manual entail the use of special tools such as a press two or three legged pullers spring compressors etc Wherever possible suitable readily available alternatives to the manufacturer s special tools are described and are shown in use In some instances where no alternative is possible it has been necessary to resort to the use of a manufacturer s tool and this has been done for reasons of safety as well as the efficient completion of the repair operation Unless you are highly skilled and have a thorough understanding of the procedures described never attempt to bypass the use of any special tool when the procedure described specifies its use Not only is there a very great risk of personal injury but expensive damage could be caused to the components involved Environmental considerations When disposing of used engine oil brake fluid antifreeze etc give due consideration to any detrimental environmental effects Do not for instance pour any of the above liquids down drains into the general sewage system or onto the ground to soak away Many local council refuse tips provide a facility for waste oil disposal as do som
264. er any circumstances use petroleum based solvents to clean brake parts Use brake system cleaner only Note The following procedure applies to both the front and rear brake pads 1 Remove the cap from the brake fluid reservoir and siphon off about two thirds of the fluid from the reservoir Failing to do this could result in fluid overflowing when the caliper pistons are pressed into their bores 2 Loosen the wheel nuts raise the front of the vehicle and support it securely on axle stands 3 Remove the front wheels Work on one brake assembly at a time using the assembled brake for reference if necessary 4 Inspect the brake disc see Section 5 5 Follow the accompanying photos beginning with illustration 3 5a for the pad removal procedure Be sure to stay in order and read the caption under each illustration 9 2 Braking system 3 5a Before starting wash down the caliper and disc with brake cleaner 3 5b Attach a hose to the bleed screw open the bleed screw slightly and depress the piston into the caliper Tighten the bleed screw when the piston bottoms 3 5c Remove the caliper mounting bolts upper bolt arrowed use another spanner to hold the flats of the caliper guide pins while you back out the caliper bolts 3 5d Remove the caliper 3 5e and suspend it out of the way with a piece of wire 3261 Jaguar XJ6 6 Be sure to buy new pads with wear sensors Pattern pads may not have wear sensors refittin
265. er working order 11 The key lock cylinders can be lubricated with spray graphite or silicone lubricant which is available at motor factors 12 Lubricate the door weather stripping with silicone spray This will reduce chafing and retard wear 15 Road test 1 Instruments and electrical equipment 1 Check the operation of all instruments and electrical equipment 2 Make sure that all instruments read correctly and switch on all electrical equipment in turn to check that it functions properly Steering and suspension 3 Check for any abnormalities in the steering suspension handling or road feel 4 Drive the car and check that there are no unusual vibrations or noises 5 Check that the steering feels positive with no excessive sloppiness or roughness and check for any suspension noises when cornering and driving over bumps Drivetrain 6 Check the performance of the engine and transmission listening for any unusual noises 7 Make sure that the engine runs smoothly when idling and that there is no hesitation when accelerating 8 Check that the gear changing action of the transmission is smooth and progressive and that the drive is taken up smoothly from a standing start Braking system 9 Make sure that the car does not pull to one side when braking and that the wheels do not lock prematurely when braking hard 10 Check that there is no vibration through the steering when braking 11 Check that t
266. er service department or other qualified repair workshop 1 Disconnect the negative battery cable Caution If the radio in your vehicle is equipped with an anti theft system make 10 8 Suspension and steering systems 13 6 Hold the pivot bolt and unscrew the nut 13 7 Remove this nut arrowed and bolt from the lower end of each tie bar right above the control arm pivot 3261 Jaguar XJ6 11 4 Before detaching the hub carrier from the rear control arm remove the ABS sensor left arrow detach the ABS harness clip right arrow and cut the cable tie securing the harness 11 5 To detach the hub carrier from the rear control arm remove the carrier to control arm nut and bolt sure you have the correct activation code before disconnecting the battery 2 Pry off the centre pad see illustration 3 Remove the steering wheel nut and mark the relationship of the steering wheel hub to the shaft see illustration 4 Slide the steering wheel off the steering shaft see illustration 5 Refitting is the reverse of removal Make sure you align the match marks you made on the steering wheel and the shaft Tighten the steering wheel nut to the torque listed in this Chapter s Specifications 15 Tie rod ends removal and refitting 2 1 Loosen the wheel nuts raise the front of the vehicle and support it securely on axle stands Remove the front wheel 2 Back off the locknut that locks the tie rod end to the tie rod then paint an ali
267. er to Chapter 11 if necessary Cover the wings to prevent damage to the paint Special pads are available but an old bedspread or blanket will also work If vacuum exhaust oil or coolant leaks develop indicating a need for gasket or seal renewal the repairs can generally be made with the engine in the car The intake and exhaust manifold gaskets crankshaft oil seals and cylinder head gasket are all accessible with the engine in place although rear oil seal renewal involves removal of the transmission The sump is difficult for a home mechanic to replace without a hoist and other specialised equipment since the front suspension steering and crossmember must be lowered to allow enough clearance for sump removal If such equipment is not available the alternative would be to remove the engine for renewal of the sump or oil pump Note We assume that the home mechanic does not have access to the specialised equipment and have photographed our subject engine out of the car for some procedures Exterior engine components such as the intake and exhaust manifolds the water pump the starter motor the alternator the distributor and the fuel system components can be removed for repair with the engine in place Since the cylinder head can be removed with the engine in car camshaft and valve component servicing can also be accomplished Renewal of the timing chains and sprockets is also possible with the engine in car 3 Top De
268. erged in brake fluid air will be seen as bubbles in the tube and container all air must be expelled before moving to the next brake 10 3 To adjust the handbrake cable loosen the locknut then turn the adjuster to remove any slack in the cable be sure to tighten the locknut when the cable is properly adjusted 3261 Jaguar XJ6 11 Handbrake cable s renewal 2 1 Raise the vehicle and place it securely on axle stands Front cable 2 Remove the cotter pin washer and clevis pin from the forward end of the front cable see illustration Disconnect the forward end of the front cable from the handbrake lever 3 Follow the cable back to the adjuster lever and remove the cotter washer and clevis pin see illustration Remove the front cable 4 Refitting is the reverse of removal Intermediate cable 5 Remove the cotter pins washers and clevis pin from both ends of the intermediate cable see illustration Remove the cable 6 Refitting is the reverse of removal Rear cables 7 Remove the cotter pin washer and clevis pin from the intermediate cable to rear cable yoke see illustration 8 Disconnect the rear end of each cable from the handbrake assembly see illustration then pry the cable out of the carrier 9 Refitting is the reverse of removal All cables 10 Be sure to adjust the handbrake cable when you re done see Section 10 The rear wheels should turn freely with the handbrake lever released 11 Remove
269. ernal combustion engine cooling system Refrigerant Any substance used as a heat transfer agent in an air conditioning system R 12 has been the principle refrigerant for many years recently however manufacturers have begun using R 134a a non CFC substance that is considered less harmful to the ozone in the upper atmosphere Rocker arm A lever arm that rocks on a shaft or pivots on a stud In an overhead valve engine the rocker arm converts the upward movement of the pushrod into a downward movement to open a valve Adjusting spark plug gap Plastigage Gasket 3261 Jaguar XJ6 Glossary of technical terms REF 21 Rotor In a distributor the rotating device inside the cap that connects the centre electrode and the outer terminals as it turns distributing the high voltage from the coil secondary winding to the proper spark plug Also that part of an alternator which rotates inside the stator Also the rotating assembly of a turbocharger including the compressor wheel shaft and turbine wheel Runout The amount of wobble in and out movement of a gear or wheel as it s rotated The amount a shaft rotates out of true The out of round condition of a rotating part S Sealant A liquid or paste used to prevent leakage at a joint Sometimes used in conjunction with a gasket Sealed beam lamp An older headlight design which integrates the reflector lens and filaments into a hermetically sealed one piece unit When a
270. es etc for leaks A leak in the cooling system will usually show up as white or rust coloured deposits on the area adjoining the leak Where any problems of this nature are found on system components renew the component or gasket with reference to Chapter 3 5 From within the engine compartment check the security of all fuel hose attachments and pipe unions and inspect the fuel hoses and vacuum hoses for kinks chafing and deterioration 6 Also check the condition of the power steering fluid hoses and pipes 8 Automatic transmission fluid level check 1 1 The level of the automatic transmission fluid should be carefully maintained Low fluid level can lead to slipping or loss of drive while overfilling can cause foaming loss of fluid and transmission damage 2 The transmission fluid level should only be checked when the transmission is at its normal operating temperature Caution If the vehicle has just been driven for a long time at high speed or in city traffic in hot weather or if it has been pulling a trailer an accurate fluid level reading cannot be obtained Allow the fluid to cool down for about 30 minutes 3 If the vehicle has not been driven park the vehicle on level ground set the handbrake then start the engine and bring it to operating temperature While the engine is idling depress the brake pedal and move the selector lever through all the gear ranges beginning and ending in Park 4 With the engine still
271. ese models are equipped with a fuel pump relay that is located in various areas of the vehicle depending on the year On 1988 and 1989 models the fuel pump relay is under the glovebox On 1990 to 1992 models the fuel pump relay is in the engine compartment on the left side attached to the brake pedal hanger On 1993 models the fuel pump relay is in the boot On 1994 models it s in the engine compartment on the right side of the bulkhead Refer to the relay location charts in Chapter 12 for additional information 4 Start the engine and wait for the engine to stall then turn the ignition key to Off Disconnect the cable from the negative terminal of the battery before beginning any work on the fuel system Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 5 The fuel system is now depressurised Note Place a rag around the fuel line before removing any hose clamp or fitting to prevent any residual fuel from spilling onto the engine 3 Fuel pump fuel pressure check 2 Warning Petrol is extremely flammable so take extra precautions when you work on any part of the fuel system See the Warning in Section 2 Note To perform the fuel pressure test you will need to obtain a fuel pressure gauge and adapter set fuel line fittings Note On 1988 to 1990 models the fuel pump may chatter excessively and the engine may
272. essor with an adapter arrowed to remove the keepers done during the engine overhaul Note If the engine was severely overheated the cylinder head is probably warped see paragraph 12 Cleaning 2 Scrape all traces of old gasket material and sealing compound off the cylinder head gasket intake manifold and exhaust manifold sealing surfaces Be very careful not to gouge the cylinder head Special gasket removal solvents that soften gaskets and make removal much easier are available at car accessory outlets 3 Remove all built up scale from the coolant passages 4 Run a stiff wire brush through the various holes to remove deposits that may have formed in them If there are heavy deposits in the water passages the bare head should be professionally cleaned at a machine workshop 5 Run an appropriate size tap into each of the threaded holes to remove corrosion and any thread sealant that may be present If compressed air is available use it to clear the holes of debris produced by this operation Warning Wear eye protection when using compressed air 6 Clean the exhaust and intake manifold stud threads with a wire brush 7 Clean the cylinder head with solvent and dry it thoroughly Compressed air will speed the drying process and ensure that all holes and recessed areas are clean Note Decarbonising chemicals are available and may prove very useful when cleaning cylinder heads and valve train components They are very caustic
273. etects a problem three things happen the CHECK ENGINE light comes on the fault is identified and a diagnostic code is recorded and stored The ECU stores the failure code assigned to the specific problem area until the diagnosis system is cancelled Note 1988 and 1989 models are not equipped with long term memory It is possible to access the codes but the operator must remember to NOT turn the ignition key to the OFF position after the CHECK ENGINE light has been noticed The codes will be lost and it will be necessary to start the engine and operate the vehicle through a complete drive cycle to allow the fault code s to be set once again Instead of turning the ignition key to the OFF position simply stop at position II key ON but engine not running to retain the fault codes 6 2 Emissions and engine control systems 3261 Jaguar XJ6 2 10 The ECU is located behind the passenger s side glovebox near the footrest area Remove the mounting screws arrowed and carefully lower the ECU 2 The CHECK ENGINE warning light which is located on the instrument panel comes on when the ignition switch is turned to ON and the engine is not running When the engine is started the warning light should go out If the light remains on the self diagnosis system has detected a malfunction Note The CHECK ENGINE light on early models is displayed on the dashboard VCM panel on the right side Later models are equipped with a separate CHECK
274. etwork You will find occasional references to these manufacturers special tools in the text of this manual Generally an alternative method of doing the job without the vehicle manufacturers special tool is given However sometimes there is no alternative to using them Where this is the case and the relevant tool cannot be bought or borrowed you will have to entrust the work to a dealer Valve spring compressor Valve grinding tool Piston ring compressor Piston ring removal installation tool Cylinder bore hone Balljoint separator Coil spring compressors where applicable Two three legged hub and bearing puller Impact screwdriver Micrometer and or vernier calipers Dial gauge Stroboscopic timing light Dwell angle meter tachometer Universal electrical multi meter Cylinder compression gauge Hand operated vacuum pump and gauge Clutch plate alignment set Brake shoe steady spring cup removal tool Bush and bearing removal installation set Stud extractors Tap and die set Lifting tackle Trolley jack Buying tools Reputable motor accessory shops and superstores often offer excellent quality tools at discount prices so it pays to shop around Remember you don t have to buy the most expensive items on the shelf but it is always advisable to steer clear of the very cheap tools Beware of bargains offered on market stalls or at car boot sales There are plenty of good tools around at reasonable prices but always aim to purc
275. ewed After this is done if there s still some doubt regarding the condition of the valve guides they should be checked by an automotive machine workshop the cost should be minimal Valves 16 Carefully inspect each valve face for uneven wear deformation cracks pits and burned areas Check the valve stem for scuffing and galling and the neck for cracks Rotate the valve and check for any obvious indication that it s bent Look for pits and excessive wear on the end of the stem The presence of any of these conditions indicates the need for valve service by an automotive machine workshop 17 Measure the margin width on each valve see illustration Any valve with a margin narrower than 1 32 inch will have to be replaced with a new valve Valve components 18 Check each valve spring for wear on the ends and pits Measure the free length and compare it to this Chapter s Specifications see illustration Any springs that are shorter than specified have sagged and should not be re used The tension of all springs should be pressure checked with a special fixture before deciding that they re suitable for use in a rebuilt engine take the springs to an automotive machine workshop for this check Note If any valve springs are found broken on 1988 or 1989 engines all springs should be replaced with the improved springs used in 1990 after VIN 9EPCLA120245 and later engines They are identified with a white stripe If your
276. f the hub and put a little more grease outboard of the bearing 19 Place a new seal over the inner bearing and tap the seal evenly into place until it s flush with the hub see illustration 20 Carefully place the hub assembly onto the spindle and push the grease packed outer bearing into position see illustration Adjustment 21 Refit the washer and spindle nut Tighten the nut only slightly no more than 16Nm 12 lbf ft of torque 22 Rotate the hub slowly in a forward direction while tightening the spindle nut to approximately 27Nm 20 lbf ft to seat the bearings Remove any grease or burrs which could cause excessive bearing play later 23 Loosen the spindle nut 1 4 turn then using your hand not a spanner of any kind tighten the nut until it s snug Refit the nut lock and a new cotter pin through the hole in the spindle and the slots in the nut lock If the nut lock slots don t line up remove the nut lock and turn it slightly until they do see illustration 24 Bend the ends of the cotter pin until they re flat against the nut Cut off any extra length which could interfere with the dust cap 25 Refit the dust cap tapping it into place with a hammer 26 Refit the brake disc and caliper in the reverse order of removal see Chapter 9 27 Refit the wheel on the hub and tighten the wheel nuts 28 Grasp the top and bottom of the tyre and check the bearings in the manner described earlier in this Section 29 Lower the
277. f weight carried by the rear axle Locknut A nut used to lock an adjustment nut or other threaded component in place For example a locknut is employed to keep the adjusting nut on the rocker arm in position Lockwasher A form of washer designed to prevent an attaching nut from working loose M MacPherson strut A type of front suspension system devised by Earle MacPherson at Ford of England In its original form a simple lateral link with the anti roll bar creates the lower control arm A long strut an integral coil spring and shock absorber is mounted between the body and the steering knuckle Many modern so called MacPherson strut systems use a conventional lower A arm and don t rely on the anti roll bar for location Multimeter An electrical test instrument with the capability to measure voltage current and resistance N NOx Oxides of Nitrogen A common toxic pollutant emitted by petrol and diesel engines at higher temperatures O Ohm The unit of electrical resistance One volt applied to a resistance of one ohm will produce a current of one amp Ohmmeter An instrument for measuring electrical resistance O ring A type of sealing ring made of a special rubber like material in use the O ring is compressed into a groove to provide the sealing action Overhead cam ohc engine An engine with the camshaft s located on top of the cylinder head s Overhead valve ohv engine An engine with the valves located in
278. ff the element area with fine steel wool then clean it thoroughly with rubbing alcohol 11 Use masking tape to mask off the area being repaired 12 Thoroughly mix the epoxy following the instructions provided with the repair kit 13 Apply the epoxy material to the slit in the masking tape overlapping the undamaged area about 3 4 inch on either end see illustration 14 Allow the repair to cure for 24 hours before removing the tape and using the system 17 Headlights renewal 1 Warning Later models are equipped with halogen gas filled headlight bulbs which are under pressure and may shatter if the surface is damaged or the bulb is dropped Wear eye protection and handle the bulbs carefully grasping only the base whenever possible Do not touch the surface of the bulb with your fingers because the oil from your skin could cause it to overheat and fail prematurely If you do touch the bulb surface clean it with rubbing alcohol Sealed beam units 1 Remove the radiator grille see Chapter 11 2 Detach the headlight bezel trim cover see illustration 3 Remove the headlight bezel see illustrations 4 Remove the screws which secure the retaining ring and withdraw the ring Support the light as this is done see illustration Body electrical system 12 9 12 16 13 Apply masking tape to the inside of the window at the damaged area then brush on the special conductive coating 17 2 Remove the screws arrowed
279. fitting 17 Air conditioning receiver drier removal and refitting 14 Antifreeze coolant general information 2 Coolant level check See Chapter 1 Coolant temperature sender unit check and renewal 9 Cooling system check See Chapter 1 Cooling system draining flushing and refilling See Chapter 1 Drivebelt check adjustment and renewal See Chapter 1 Engine cooling fans check and renewal 4 Engine oil cooler renewal 6 General information 1 Heater and air conditioning blower motors circuit check and component renewal 10 Heater and air conditioning control assembly check removal and refitting 12 Heater core removal and refitting 11 Radiator expansion tank and coolant reservoir removal and refitting 5 Thermosta
280. fitting the evaporator core into the case be sure to refit the foam insulation in the same way it was installed originally 12 The evaporator core can be cleaned with a fin comb and blown off with compressed air 13 The expansion valve is located on the right side of the bulkhead on the engine side To renew it remove the battery Chapter 5 for better access Disconnect the lines from the back of the valve as in Step 2 Disconnect the high and low pressure hoses from the front of the expansion valve see illustration 14 If the evaporator core is renewed make sure the technician adds 1 4 ounces of new refrigerant oil of a type compatible with your type of refrigerant to the system 15 The remainder of the refitting is the reverse of the removal process Be sure to use new O rings and new gaskets on the expansion valve 16 Have the system evacuated charged and leak tested by the workshop that discharged it Cooling heating and air conditioning systems 3 15 3 17 13 Disconnect the lines at the front of the expansion valve always use two spanners to avoid twisting a line one spanner holds the body of the valve 3261 Jaguar XJ6 3261 Jaguar XJ6 4 Chapter 4 Fuel and exhaust systems Fuel system Fuel pressure kPa psi Ignition ON engine not running 260 to 300 38 to 44 Engine idling Vacuum hose detached from fuel pressure regulator
281. for proper operation Refer to the relay checking procedure in Chapter 12 Note If battery voltage is not available check for battery voltage to the main relay see illustration Refer to the relay location diagrams in Chapter 12 The main relay which is located next to the fuel pump relay supplies voltage to the fuel pump and ignition system 4 If battery voltage is present check for battery voltage directly at the fuel pump electrical connector see illustrations within two seconds of the ignition key being turned On If there is no voltage check the fuel pump circuit If there is voltage present renew the pump see Section 4 Note It will be necessary to raise the vehicle and support it securely on axle stands to gain access to the fuel pump electrical connectors Have an assistant operate the ignition key and be sure to block the front wheels to avoid any movement of the vehicle Operating pressure check 5 Relieve the fuel system pressure see Section 2 Detach the cable from the negative battery terminal Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 6 Detach the fuel line from the fuel rail and connect a fuel pressure gauge see illustrations between the fuel pulsation damper and the fuel rail Tighten the hose clamps securely 7 Attach the cable to the negative battery terminal Start the engine 8 No
282. fore if you do not know the correct security code for the unit do not disconnect the battery negative lead or remove the radio cassette unit from the vehicle The procedure for reprogramming a unit that has been disconnected from its power supply varies from model to model consult the handbook supplied with the unit for specific details or refer to your Jaguar dealer The jack supplied with the vehicle tool kit should only be used for changing the roadwheels see Wheel changing at the front of this manual When carrying out any other kind of work raise the vehicle using a hydraulic or trolley jack and always supplement the jack with axle stands positioned under the vehicle jacking points To raise the front of the vehicle place a block of wood on the jack head and position the jack underneath the centre of the front crossmember Lift the vehicle to the required height and support it on axle stands positioned underneath the vehicle jacking points on the sills To raise the rear of the vehicle place a block of wood on the jack head and position the jack underneath the centre of the rear crossmember Lift the vehicle to the required height and support it on axle stands positioned underneath the vehicle jacking points on the sills The jack supplied with the vehicle locates in the jacking points on the sills Ensure that the jack head is correctly engaged before attempting to raise the vehicle Never work under ar
283. frigerant when the air conditioning is turned off the sight glass should show refrigerant that foams then clears Note 1993 and 1994 models are equipped with R 134a refrigerant systems and do not have a sight glass Heating systems 12 If the air coming out of the heater vents isn t hot the problem could stem from any of the following causes a The thermostat is stuck open preventing the engine coolant from warming up enough to carry heat to the heater core Renew the thermostat see Section 3 b A heater hose is blocked preventing the flow of coolant through the heater core Feel both heater hoses at the bulkhead They should be hot If one of them is cold there is an obstruction in one of the hoses or in the heater core or the heater control valve is shut Detach the hoses and back flush the heater core with a water hose If the heater core is clear but circulation is impeded remove the two hoses and flush them out with a water hose c If flushing fails to remove the blockage from the heater core the core must be renewed see Section 11 13 If the blower motor speed does not correspond to the setting selected on the blower switch the problem could be a bad fuse circuit control panel or climate control computer see Sections 10 and 12 14 If there isn t any air coming out of the vents a Turn the ignition ON and activate the fan control Place your ear at the heating air conditioning register vent and list
284. 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 re
285. front shoe 12 5q and into the rear shoe 12 5r Pull the shoes apart and refit the adjuster mechanism bulbs open circuit between the switch and the bulbs or the switch is defective 5 To remove the switch reach up under the dash and unplug the two electrical connectors one for the brake lights and one for the cruise control system Locate the two pairs of leads coming down the pedal box and trace them to their connectors on or near the steering column 6 Remove the three switch plate retaining bolts and remove the switch assembly see illustrations Inspect the switch plate rubber gasket for cracks or deterioration and renew it if it s damaged or worn 7 Place the switch assembly on a workbench and connect an ohmmeter to the brake light switch terminals With the switch plunger in its normal extended position brake pedal not applied there should be no continuity infinite resistance see illustration when the plunger is depressed brake pedal applied there should be continuity zero resistance see illustration If the switch doesn t perform as described renew it If the switch works in an opposite fashion i e continuity when the plunger is free no continuity when the plunger is depressed you ve tested the cruise control switch Switch the ohmmeter leads to the other connector and recheck 8 To remove the switch from the plate remove the two small nuts on the back of the plate see illustration
286. fully if possible before driving the vehicle on public roads 6 Master cylinder removal overhaul and refitting 3 Note Although master cylinder parts and rebuild kits are available for most models we recommend replacing the master cylinder with a new or remanufactured unit if possible Removal 1 The master cylinder is connected to the brake servo which is attached to the pedal box in front of the bulkhead on the driver s side of the engine compartment 2 Remove as much fluid as you can from the reservoir with a syringe 3 Place rags under the line fittings and prepare caps or plastic bags to cover the ends of the lines once they are disconnected Caution Brake fluid will damage paint Cover all body parts and be careful not to spill fluid during this procedure 4 Disconnect the electrical connector for the low fluid level warning light see illustration 5 Loosen the brake line fittings at the master cylinder see illustration Use a flare nut spanner to prevent rounding off the nuts Pull the brake lines away from the master cylinder slightly and plug the ends to prevent contamination 6 Remove the nuts attaching the master cylinder to the servo see illustration Pull the master cylinder off the studs and lift it out of the engine compartment Again be careful not to spill fluid as this is done Overhaul 7 Follow the accompanying photo sequence beginning with illustration 6 7a Stay in order don t ski
287. g 11 Lower control arm removal and refitting 9 Power steering fluid level check See Chapter 1 Power steering pump removal and refitting 18 Power steering system bleeding 19 Self levelling rear suspension system general information 2 Shock absorber front removal and refitting 4 Shock absorber coil spring rear removal and refitting 10 Steering and suspension check See Chapter 1 Steering gear removal and refitting 17 Steering gear boots renewal 16 Steering knuckle removal and refitting 6 Steering wheel removal and refitting 14 Suspension and steering checks See Chapter 1 Tie rod ends removal and refitting 15 Tyre and tyre pressure checks See Chapter 1 Tyre rotation See Chapter 1 Upper control arm removal and refitting
288. g pads without wear sensors will cause the dash warning light to come on 7 To refit the new pads reverse the removal procedure When refitting the caliper be sure to tighten the mounting bolts to the torque listed in this Chapter s Specifications 8 After the job is completed depress the brake pedal a few times to bring the pads into contact with the discs The pedal should be at normal height above the floorpan and firm Check the brake fluid level and add enough to top it up see Chapter 1 Inspect carefully for leaks and check the operation of the brakes before placing the vehicle into normal service 9 Tighten the wheel nuts to the specified torque 4 Disc brake caliper removal overhaul and refitting 3 Warning Dust created by the brake system may contain asbestos which is harmful to your health Never blow it out with compressed air and don t inhale any of it An approved filtering mask should be worn when working on the brakes Do not under any circumstances use petroleum based solvents to clean brake parts Use brake system cleaner only Note 1 The following procedure applies to both front and rear calipers Note 2 If an overhaul is indicated explore all options before beginning the job New and factory rebuilt calipers are available on an exchange basis which makes this job quite easy If you decide to rebuild the calipers make sure a rebuild kit is available before proceeding Always rebuild the cali
289. g the positive and negative battery cables Also make sure the ignition key is in the Off position when connecting or disconnecting the battery c Do not subject EFI components emissions related components or the ECU to severe impact during removal or refitting d Do not be careless during fault diagnosis Even slight terminal contact can invalidate a testing procedure and damage one of the numerous transistor circuits e Never attempt to work on the ECU or open the ECU cover The ECU is protected by a government mandated extended warranty that will be nullified if you tamper with or damage the ECU f If you are inspecting electronic control system components during rainy weather make sure that water does not enter any part When washing the engine compartment do not spray these parts or their electrical connectors with water g These models are susceptible to ECU damage if water is allowed to build up in the front cowl drain and overspill into the dash area Inspect and clear the front cowl drain system as a regular maintenance item to keep the water draining properly Remove the duckbill type rubber hose and inspect it for clogging collapsing or deterioration ECU removal and refitting 7 Disconnect the negative cable from the battery see Chapter 5 Warning Later models are equipped with airbags To prevent the accidental deploy ment of the airbag which could cause personal injury DO NOT work in the vicinity
290. ght bulb connector 1 4 turn anti clockwise viewed from the rear see illustration 10 Withdraw the bulb assembly from the headlight housing 11 Without touching the glass with your bare fingers see the Warning at the start of the Section insert the new bulb assembly into the headlight housing and rotate the bulb socket 1 4 turn clockwise to refit it 12 Plug in the electrical connector and test headlight operation 18 Headlights adjustment 5 Note The following procedure is intended for emergency use only and we strongly recommend that the headlight aim is only checked using optical beam setting equipment It is important that the headlights are aimed correctly If adjusted incorrectly they could blind the driver of an oncoming vehicle and cause a serious accident or seriously reduce your ability to see the road The headlights should be checked for proper aim every 12 months and any time a new headlight is installed or front end body work is performed 1 Adjustment should be made with the vehicle sitting level the petrol tank half full and no unusually heavy load in the vehicle 2 Early models with sealed beam headlights have four adjusting knobs protruding through the backside of the radiator support The vertical up and down adjustment knobs are located above the headlight and the horizontal left to right adjusting knobs are located below the headlight see illustration 3 On later models with halogen bulbs adj
291. gnment mark on the threads to ensure the new tie rod end is installed in the same position see illustration 3 Loosen the nut on the tie rod ball stud then fit a small puller and pop the ball stud loose see illustration Remove the nut and separate the ball stud from the steering knuckle Unscrew the tie rod end from the tie rod 4 Refitting is the reverse of removal Make sure you thread the tie rod end all the way up to the mark on the threads but no further Tighten the ball stud nut to the torque listed in this Chapter s Specifications Tighten the locknut securely 5 Have the toe in checked and if necessary adjusted at a dealer service department or alignment workshop 16 Steering gear boots renewal 2 1 Remove the tie rod ends see Section 15 2 Cut the boot clamps at both ends of the old boots see illustration and slide off the boots 3 While the boots are removed inspect the seals in the end of the steering gear If they re leaking have them replaced by a dealer service department or other qualified repair workshop or replace the steering gear with a new or rebuilt unit see Section 17 4 Slide the new boots into place and refit new boot clamps 5 Refit the tie rod ends see Section 15 Suspension and steering systems 10 9 10 14 4 To remove the steering wheel simply pull it straight off 15 2 Back off this locknut and mark the threads to ensure that the new tie rod end is installed properly
292. ground remove the trim cap where fitted and slacken each wheel nut by half a turn Remove the jack and wheelbrace its holder which is located behind the spare wheel 1 2 3 4 Securely tighten the wheel nuts in a diagonal sequence then where necessary refit the wheel trim cap Stow the tolls and punctured wheel and back in the luggage compartment and secure them in position Note that the wheel nuts should be slackened and retightened to the specified torque at the earliest possible opportunity 7 5 6 Preparation When a puncture occurs stop as soon as it is safe to do so Park on firm level ground if possible and well out of the way of other traffic Use hazard warning lights if necessary If you have one use a warning triangle to alert other drivers of your presence Apply the handbrake and engage first or reverse gear or Park on models with automatic transmission Chock the wheel diagonally opposite the one being removed a couple of large stones will do for this If the ground is soft use a flat piece of wood to spread the load under the jack Changing the wheel 3261 Jaguar XJ6 Roadside repairs 0 9 When all else fails you may find yourself having to get a tow home or of course you may be helping somebody else Long distance recovery should only be done by a garage or breakdown service For shorter distances DIY towing using another car is easy enough but observe the following points
293. guar XJ6 3 8 Align the mark on the crankshaft sensor ring arrowed with the bottom edge of the pointer on the front cover 4 2 Disconnect the PCV hose arrowed from the valve cover then pull the spark plug leads out by their boots not the leads 8 Tighten the screws to the torque listed in this Chapter s Specifications in three or four equal steps 9 Refit the remaining components start the engine and check for oil leaks 5 Intake manifold removal and refitting 2 Removal 1 Disconnect the negative cable from the battery Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 2 Refer to Chapter 4 to remove the accelerator and cruise control linkage safely relieve the fuel system pressure and disconnect the fuel supply lines 3 Label or mark and detach the PCV and vacuum hoses connected to the intake manifold see illustration 4 The intake manifold can be removed with the injectors and fuel rail still in place Disconnect the electrical connectors at each injector label them first for reassembly If the injectors are to be removed from the intake manifold refer to Chapter 4 5 Refer to Chapter 4 and remove the throttle body 6 Remove the three nuts retaining the oil filler tube bracket then pull the tube up as far as possible see illustrations 7 Remove the ground strap and intake manifold mounting nuts bo
294. h any bearing problems with the corresponding crankshaft journal 4 Dirt and other foreign particles get into the engine in a variety of ways It may be left in the engine during assembly or it may pass through filters or the PCV system It may get into the oil and from there into the bearings Metal chips from machining operations and normal engine wear are often present Abrasives are sometimes left in engine components after reconditioning especially when parts are not thoroughly cleaned using the proper cleaning methods Whatever the source these foreign objects often end up embedded in the soft bearing material and are easily recognised Large particles will not embed in the bearing and will score or gouge the bearing and journal The best prevention for this cause of bearing failure is to clean all parts thoroughly and keep everything spotlessly clean during engine assembly Frequent and regular engine oil and filter changes are also recommended 5 Lack of lubrication or lubrication breakdown has a number of interrelated causes Excessive heat which thins the oil overloading which squeezes the oil from the bearing face and oil leakage or throw off from excessive bearing clearances worn oil pump or high engine speeds all contribute to lubrication breakdown Blocked oil passages which usually are the result of misaligned oil holes in a bearing shell will also oil starve a bearing and destroy it When lack of lubrica
295. h the spark plugs out of the engine and the ignition system and fuel pump disabled crank the engine until oil pressure registers on the gauge or the light goes out 3 Refit the spark plugs hook up the plug leads and restore the ignition system and fuel pump functions 4 Start the engine It may take a few moments for the fuel system to build up pressure but the engine should start without a great deal of effort 5 After the engine starts it should be allowed to warm up to normal operating temperature While the engine is warming up make a thorough check for fuel oil and coolant leaks 6 Shut the engine off and recheck the engine oil and coolant levels 7 Drive the vehicle to an area with no traffic accelerate from 30 to 50 mph then allow the vehicle to slow to 30 mph with the throttle closed Repeat the procedure 10 or 12 times This will load the piston rings and cause them to seat properly against the cylinder walls Check again for oil and coolant leaks 8 Drive the vehicle gently for the first 500 miles no sustained high speeds and keep a constant check on the oil level It is not unusual for an engine to use oil during the running in period 9 At approximately 500 to 600 miles change the oil and filter 10 For the next few hundred miles drive the vehicle normally Do not pamper it or abuse it 11 After 2000 miles change the oil and filter again and consider the engine run in 2B 18 Engine removal and overhaul procedures
296. h the top of a piston as shown 22 4 With the ring square in the cylinder measure the end gap with a feeler gauge 22 5 If the end gap is too small clamp a file in a vice and file the ring ends from the outside in only to enlarge the gap slightly 22 9a Refit the spacer expander in the oil control ring groove 22 9b DO NOT use a piston ring refitting tool when refitting the oil ring side rails 3261 Jaguar XJ6 the upper and lower side rails can be turned smoothly in the ring groove 11 The number two middle ring is installed next It s usually stamped with a mark which must face up toward the top of the piston Note Always follow the instructions on the ring package or box different manufacturers may require different approaches Do not mix up the top and middle rings as they have different cross sections 12 Use a piston ring refitting tool and make sure the ring s identification mark is facing the top of the piston then slip the ring into the middle groove on the piston see illustration Don t expand the ring any more than necessary to slide it over the piston 13 Refit the number one top ring in the same manner Make sure the mark is facing up Be careful not to confuse the number one and number two rings 14 Repeat the procedure for the remaining pistons and rings 23 Crankshaft refitting and main bearing oil clearance check 3 1 Crankshaft refitting is the first major step in engine reassembly It
297. h their respective lifters 10 20 Measure the bearing journals with a micrometer to check diameter measure at several places around the journal to check for taper or out of round 3261 Jaguar XJ6 10 12 Bend back the locking tabs arrowed and remove the camshaft sprocket bolts 10 21a Measure the camshaft lobe at its greatest dimension 10 21b and subtract the camshaft lobe diameter at its smallest dimension to obtain the lobe lift Refitting 23 If the valve clearance for any valve is incorrect as measured in paragraph 4 refit a thicker or thinner shim on that valve For example if the clearance had been too large by 0 004 inch compared to the recommended clearance in the Specifications replace the existing shim there with a new one that is 0 004 inch thicker If the clearance was too small use a shim that is smaller than the original Shims are identified alphabetically in sizes from 0 085 inch designated size A the smallest to 0 108 inch designated size X the thickest 24 Lubricate the lifters with a thin coat of moly based lubricant on the top bottom and sides and refit them in their original positions 25 Lubricate the camshafts with moly based grease on the journals and lobes and lay them carefully in their bearing saddles 26 Using NEW cylinder head bolts replace the spacers one at a time with the bearing caps and bolts Tighten the cap bolts then the cylinder head bolts to the torque listed
298. haft see illustration 2 Remove the screws and detach the cowl cover see Chapter 11 3 Remove the drive spindle nut see illustration 4 Remove the retaining bolts located along the top edge of the wiper motor housing and detach three retaining clips along the bottom edge of the wiper motor housing see illustration 5 Disconnect the electrical connector and remove the motor assembly from the vehicle 6 Refitting is the reverse of removal 16 Heated rear window check and repair 2 1 The heated rear window consists of a number of horizontal elements baked onto the glass surface 2 Small breaks in the element can be repaired without removing the rear window Check 3 Turn the ignition switch and heated rear window switches to the ON position 4 When measuring voltage during the next two tests wrap a piece of aluminium foil around the tip of the voltmeter negative probe and press the foil against the heating element with your finger see illustration Place the voltmeter positive lead against the heated window positive terminal 5 Check the voltage at the centre of each heating element see illustration 12 8 Body electrical system 14 1 The aerial mast retaining nut can be removed with an open end spanner 14 3 Remove the retaining bolts arrowed pull the aerial assembly out and unplug the electrical connectors and aerial lead 14 6 With the ignition key and the radio in the ON position guide the aerial mast
299. hase items which meet the relevant national safety standards If in doubt ask the proprietor or manager of the shop for advice before making a purchase Care and maintenance of tools Having purchased a reasonable tool kit it is necessary to keep the tools in a clean and serviceable condition After use always wipe off any dirt grease and metal particles using a clean dry cloth before putting the tools away Never leave them lying around after they have been used A simple tool rack on the garage or workshop wall for items such as screwdrivers and pliers is a good idea Store all normal spanners and sockets in a metal box Any measuring instruments gauges meters etc must be carefully stored where they cannot be damaged or become rusty Take a little care when tools are used Hammer heads inevitably become marked and screwdrivers lose the keen edge on their blades from time to time A little timely attention with emery cloth or a file will soon restore items like this to a good finish Working facilities Not to be forgotten when discussing tools is the workshop itself If anything more than routine maintenance is to be carried out a suitable working area becomes essential It is appreciated that many an owner mechanic is forced by circumstances to remove an engine or similar item without the benefit of a garage or workshop Having done this any repairs should always be done under the cover of a roof Wherever possible an
300. he above method or if you are at all concerned about the condition of the pads remove the caliper s then remove the pads from the calipers for further inspection see Chapter 9 9 Once the pads are removed from the calipers clean them with brake cleaner and re measure them with a ruler or a vernier caliper 10 Measure the disc thickness with a micrometer to make sure that it still has service life remaining If any disc is thinner than the specified minimum thickness replace it refer to Chapter 9 Even if the disc has service life remaining check its condition Look for scoring gouging and burned spots If these conditions exist remove the disc and have it resurfaced see Chapter 9 11 Before refitting the wheels check all brake lines and hoses for damage wear deformation cracks corrosion leakage bends and twists particularly in the vicinity of the rubber hoses at the calipers see illustration Check the clamps for tightness and the connections for leakage Make sure that all hoses and lines are clear of sharp edges moving parts and the exhaust system If any of the above conditions are noted repair reroute or replace the lines and or fittings as necessary see Chapter 9 Hydraulic brake servo check 12 Sit in the driver s seat and perform the following sequence of tests 13 Start the engine run it for about a minute and turn it off Then firmly depress the brake several times the pedal travel should decre
301. he VECI label in your particular vehicle should always be checked for up to date information 2 Electronic control system and ECU General description Note These models are susceptible to ECU damage if water is allowed to build up in the front cowl drain and overspill into the dash area near the computer Inspect and clear the front cowl drain as a regular maintenance item to keep the water draining properly Remove the duckbill type rubber hose and inspect it for clogging collapsing or deterioration 1 The Lucas LH Engine Management system controls the fuel injection system by means of a microcomputer known as the Electronic Control unit ECU 2 The ECU receives signals from various sensors which monitor changing engine operating conditions such as intake air mass intake air temperature coolant temperature engine rpm acceleration deceleration exhaust oxygen content etc These signals are utilised by the ECU to determine the correct injection duration 3 The system is analogous to the central nervous system in the human body The sensors nerve endings constantly relay signals to the ECU brain which processes the data and if necessary sends out a command to change the operating parameters of the engine body 4 Here s a specific example of how one portion of this system operates An oxygen sensor located in the exhaust manifold constantly monitors the oxygen content of the exhaust gas If the percentage of o
302. he brake calipers or on the brake backplates Repair or renew leaking components Slowly spin each wheel while your assistant depresses and releases the footbrake Ensure that each brake is operating and does not bind when the pedal is released 3 Checks carried out WITH THE VEHICLE RAISED AND THE WHEELS FREE TO TURN 3261 Jaguar XJ6 MOT test checks REF 11 Examine the handbrake mechanism checking for frayed or broken cables excessive corrosion or wear or insecurity of the linkage Check that the mechanism works on each relevant wheel and releases fully without binding It is not possible to test brake efficiency without special equipment but a road test can be carried out later to check that the vehicle pulls up in a straight line Fuel and exhaust systems Inspect the fuel tank including the filler cap fuel pipes hoses and unions All components must be secure and free from leaks Examine the exhaust system over its entire length checking for any damaged broken or missing mountings security of the retaining clamps and rust or corrosion Wheels and tyres Examine the sidewalls and tread area of each tyre in turn Check for cuts tears lumps bulges separation of the tread and exposure of the ply or cord due to wear or damage Check that the tyre bead is correctly seated on the wheel rim that the valve is sound and properly seated and that the wheel is not distorted or damaged Check that the tyre
303. he handbrake operates correctly without excessive movement of the lever and that it holds the car stationary on a slope 12 Test the operation of the brake servo unit as follows With the engine off depress the footbrake four or five times to exhaust the vacuum Hold the brake pedal depressed then start the engine As the engine starts there should be a noticeable give in the brake pedal as vacuum builds up Allow the engine to run for at least two minutes and then switch it off If the brake pedal is depressed now it should be possible to detect a hiss from the servo as the pedal is depressed After about four or five depressions no further hissing should be heard and the pedal should feel considerably harder 1 14 Every 7500 miles or 6 months 17 1 Detach the clips and separate the cover then slide the filter element out of the housing 3261 Jaguar XJ6 14 6 Grease fittings for the rear driveshafts are located in the centre on each U joint Every 15 000 miles 24 000 km or 12 months hand tools to remove Simply slide back the locking collars and remove the inlet and outlet fuel lines see illustration Detach the filter mounting bracket and discard the old filter in a proper container 5 Note the direction of the arrow on the outside of the filter it should be pointed towards the front of the car Make sure the new filter is installed so that it s facing the proper direction Note Always refit new copper wa
304. he oil filter Leaking antifreeze often leaves a crystalline deposit like this Gearbox oil can leak from the seals at the inboard ends of the driveshafts A leak occurring at a wheel is almost certainly brake fluid Power steering fluid may leak from the pipe connectors on the steering rack 3261 Jaguar XJ6 0 10 Weekly 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 Keeping an eye on tyre condition and pressures will not only help to stop them wearing out prematurely but could also save your life 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 If 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 If 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 A Engine oil level dipstick B Engine oil filler cap C Coolant expans
305. he switch to earth Leaving the switch connected connect a jumper wire between this wire and earth If the mirror works normally with this wire in place repair the faulty earth connection 9 If the mirror still doesn t work remove the mirror and check the wires at the mirror for voltage Check with ignition ON and the mirror selector switch on the appropriate side Operate the mirror switch in all its positions There should be voltage at one of the switch to mirror wires in each switch position except the neutral off position 10 If there s not voltage in each switch position check the circuit between the mirror and control switch for opens and shorts 11 If there s voltage remove the mirror and test it off the vehicle with jumper wires Renew the mirror if it fails this test 27 Electric sunroof description and check 2 1 The electric sunroof is powered by a single motor in the roof behind the overhead console The power circuit is protected by a fuse 2 The control switches tilt and slide send an earth signal to the sunroof motor when the switches are pressed Power is supplied to the motor from the relay With the ignition ON but the engine OFF operate the sunroof control switch through the tilt and slide functions 3 Listen carefully for the sound of the sunroof motor running in the roof 4 If the motors can be heard but the sunroof glass doesn t move there s probably a problem with the drive mechanis
306. he thermostat and housing positioning the jiggle pin at the highest point Note The thermostat is usually marked TOP on the radiator side for proper orientation 11 Tighten the cover fasteners to the torque listed in this Chapter s Specifications 12 Refill the cooling system run the engine and check for leaks and proper operation 4 Engine cooling fans check and renewal 3 Mechanical fan 1988 to 1992 models Warning Keep hands hair tools and clothing away from the fan when the engine is running To avoid injury or damage DO NOT operate the engine with a damaged fan Do not attempt to repair fan blades renew a damaged fan Check Warning In order to check the fan clutch the engine will need to be at operating temperature so while going through checks prior to Step 6 be careful that the ignition is NOT switched on Severe personal injury can result 1 Symptoms of failure of the fan clutch are continuous noisy operation looseness vibration and evidence of silicone fluid leaks 2 Rock the fan back and forth by hand to check for excessive bearing play 3 With the engine cold turn the blades by hand The fan should turn freely 4 Visually inspect for substantial fluid leakage from the fan clutch assembly a deformed bi metal spring or grease leakage from the cooling fan bearing If any of these conditions exist renew the fan clutch 5 When the engine is fully warmed up turn off the ignition switch and disc
307. heck for signs of damage or leakage of the fluid hoses pipes or connections Also check for excessive stiffness or binding of the steering a missing split pin or locking device or severe corrosion of the body structure within 30 cm of any steering component attachment point Front and rear suspension and wheel bearings Starting at the front right hand side grasp the roadwheel at the 3 o clock and 9 o clock positions and shake it vigorously Check for free play or insecurity at the wheel bearings suspension balljoints or suspension mount ings pivots and attachments Now grasp the wheel at the 12 o clock and 6 o clock positions and repeat the previous inspection Spin the wheel and check for roughness or tightness of the front wheel bearing If excess free play is suspected at a component pivot point this can be confirmed by using a large screwdriver or similar tool and levering between the mounting and the component attachment This will confirm whether the wear is in the pivot bush its retaining bolt or in the mounting itself the bolt holes can often become elongated Carry out all the above checks at the other front wheel and then at both rear wheels Springs and shock absorbers Examine the suspension struts when applicable for serious fluid leakage corrosion or damage to the casing Also check the security of the mounting points If coil springs are fitted check that the spring ends locate in their
308. heck the engine transmission mounts If they re worn or damaged renew them 24 Attach the hoist and remove the engine from the stand Refer to Part A of this Chapter and renew the rear main seal and retainer plate then reattach the transmission adapter plate and refer to Chapter 7 for mounting the converter and transmission 25 Carefully lower the engine into the vehicle with the hoist An assistant is helpful to guide the engine clear of accessories in the engine compartment as the engine is lowered into place 26 Refit the engine mount bolts and tighten them securely Raise the back of the transmission with the trolley jack and reattach the transmission mount driveshaft and shift linkage 27 Refit the remaining components and fasteners in the reverse order of removal 28 Add coolant oil power steering and transmission fluids as needed see Chapter 1 29 Run the engine and check for proper operation and leaks Shut off the engine and recheck the fluid levels 7 Engine rebuilding alternatives The do it yourselfer is faced with a number of options when performing an engine overhaul The decision to renew the engine block piston connecting rod assemblies and crankshaft depends on a number of factors with the number one consideration being the condition of the engine block Other considerations are cost access to machine workshop facilities parts availability time required to complete the project and the extent of prior mech
309. hould be drained and renewed Since the fluid will remain hot long after driving perform this procedure only after the engine has cooled down completely 2 Before beginning work purchase the specified transmission fluid and a new filter 3 Other tools necessary for this job include axle stands to support the vehicle in a raised position a drain pan capable of holding at least eight pints newspapers and clean rags 4 Raise the vehicle and support it securely on axle stands 5 Place the drain pan under the drain plug in the bottom of the transmission sump pan Remove the plug and allow the fluid to drain see illustration 6 Refit the drain plug then move the drain pan underneath the dipstick tube Loosen the dipstick tube collar and let the remaining fluid drain see illustrations 7 Remove the sump pan mounting bolts and brackets see illustration 8 Detach the sump pan from the transmission and lower it keeping it as horizontal as possible in order not to spill too much of the remaining fluid see illustration 9 Drain the remaining fluid from the transmission sump pan clean it with solvent and dry it with compressed air Be sure to clean the metal filings from the magnet if equipped 10 Remove the screws and detach the filter from the valve body see illustrations 11 Refit the new O ring and filter being sure to tighten the bolts securely 12 Carefully clean the fluid pan to transmission sealing surface 13 Make s
310. housing 21 1 Front end alignment details A minus B C degrees camber E minus F toe in measured in inches G toe in expressed in degrees None of these three angles are adjustable on the rear wheels Even the non adjustable angles should be checked to determine if any of the suspension components are bent Getting the proper wheel alignment is a very exacting process one in which complicated and expensive machines are necessary to perform the job properly Because of this you should have a technician with the proper equipment perform these tasks We will however use this space to give you a basic idea of what is involved with a wheel alignment so you can better understand the process and deal intelligently with the workshop that does the work Toe in is the turning in of the wheels The purpose of a toe specification is to ensure parallel rolling of the wheels In a vehicle with zero toe in the distance between the front edges of the wheels will be the same as the distance between the rear edges of the wheels The actual amount of toe in is normally only a fraction of an inch Toe in is controlled by the tie rod end position on the tie rod Incorrect toe in will cause the tyres to wear improperly by making them scrub against the road surface Camber is the tilting of the wheels from vertical when viewed from one end of the vehicle When the wheels tilt out at the top the camber is said to be positive When the wh
311. ht of the headlight vertical line Adjustments are made by turning the knobs located behind the headlight housings see illustration 18 2 10 With the high beams on the high intensity zone should be vertically centred with the exact centre just below the horizontal line Note It may not be possible to position the headlight aim exactly for both high and low beams If a compromise must be made keep in mind that the low beams are the most used and have the greatest effect on safety 11 Have the headlights adjusted by a dealer service department or service station at the earliest opportunity 19 Headlight housing 1992 to 1994 models removal and refitting 1 Warning These vehicles are equipped with halogen gas filled headlight bulbs which are under pressure and may shatter if the surface is damaged or the bulb is dropped Wear eye protection and handle the bulbs carefully grasping only the base whenever possible Do not touch the surface of the bulb with your fingers because the oil from your skin could cause it to overheat and fail prematurely If you do touch the bulb surface clean it with rubbing alcohol 1 Remove the headlight bulb Section 17 2 Remove the retaining nuts detach the housing and withdraw it from the vehicle see illustration 3 Refitting is the reverse of removal 20 Horn check and renewal 2 Check Note Check the fuses before beginning electrical diagnosis 1 Disconnect the electrical connector fr
312. iator see Chapter 1 4 10 Fuel and exhaust systems 12 9 Using an ohmmeter measure the resistance across both terminals of the injector 3261 Jaguar XJ6 12 7 Use a stethoscope or a screwdriver to determine if the injectors are working properly they should make a steady clicking sound that rises and falls with engine speed changes 12 8 Refit the noid light into the fuel injector electrical connector and check to see that it blinks with the engine running 5 Remove the air cleaner see Chapter 1 and the air cleaner housing see Section 9 6 Remove the air intake duct 7 Detach the electrical connector from the MAF sensor see illustration 8 Remove the clamp that retains the MAF sensor to the air intake duct see illustration and lift the MAF sensor assembly from the engine compartment 9 Detach the throttle cable from the bellcrank see Section 10 then remove the bellcrank assembly from the throttle body see illustration 10 Detach the kickdown cable from the bellcrank and set the cable and brackets aside see Chapter 7 11 Clearly label then detach all vacuum and coolant hoses from the throttle body 12 Disconnect the electrical connector from the throttle potentiometer 13 Remove the four throttle body mounting bolts and detach the throttle body from the intake manifold 14 Using a soft brush and carburettor cleaner thoroughly clean the throttle body casting then blow out all passages with compressed air
313. ic part of the vehicle 18 If the motor tested OK in the previous test but is still inoperative then the fault lies in the relay fuse or wiring The fan relay can be tested for continuity see Chapter 12 Renewal 19 Disconnect the negative battery cable Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 20 Access the 1988 through 1992 single electric fan with the grille removed see Chapter 11 for grille removal Disconnect the electrical connector and remove the bolts holding the fan assembly to the body see illustration 21 On 1993 and 1994 models remove the two bolts holding the fan shroud to the top of the radiator and lift the shroud fans assembly from the vehicle 22 If the fan on 1988 to 1992 models must be renewed renew the fan motor and shroud as a unit The fan is separate from the shroud on later models 23 Refitting is the reverse of removal If the thermostatic switch was renewed refill the cooling system 5 Radiator expansion tank and coolant reservoir removal and refitting 3 Warning Do not start this procedure until the engine is completely cool Radiator Removal 1 Disconnect the negative battery cable Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 2 Drain the coolant in
314. ide kick panel behind the fuse panel cover 3 1c A third fusebox is located in the centre console glove box 3 3 When a fuse blows the metal element between the terminals melts the fuse on the left is blown the one on the right is ok wash system radio memory and the ABS main feed and pump circuits In line fuses are located through out the vehicle depending on the year make and model Consult the wiring diagrams at the end of this Chapter for further information In line fuses also have a blade terminal design which allow fingertip removal and renewal If an electrical component fails always check the fuse first A blown fuse is easily identified through the clear plastic body Inspect the element for evidence of damage see illustration 3 3 Be sure to renew blown fuses with the correct type Fuses are usually colour coded to indicate their rating Fuses of different ratings are physically interchangeable but only fuses of the proper rating should be used Replacing a fuse with one of a different value than specified is not recommended Each electrical circuit needs a specific amount of protection The amperage value of each fuse is moulded into the fuse body If the renewal fuse immediately fails don t renew it again until the cause of the problem is isolated and corrected Don t substitute anything else for the fuse In most cases this will be a short circuit in the wiring caused by a broken or deteriorated wire
315. idling remove the dipstick from its tube see illustration Check the level of the fluid on the dipstick see illustration and note its condition 5 Wipe the fluid from the dipstick with a clean rag and reinsert it back into the filler tube until the cap seats 6 Pull the dipstick out again and note the fluid level If the transmission is cold the level should be in the COLD or COOL range on the dipstick If it is hot the fluid level should be in the HOT range If the level is at the low side of either range add the specified transmission fluid through the dipstick tube with a funnel 7 Add just enough of the recommended fluid to fill the transmission to the proper level It takes about one pint to raise the level from the low mark to the high mark when the fluid is hot so add the fluid a little at a time and keep checking the level until it is correct 8 The condition of the fluid should also be checked along with the level If the fluid at the end of the dipstick is black or a dark reddish brown colour or if it emits a burned smell the fluid should be changed see Section 26 If you are in doubt about the condition of the fluid purchase some new fluid and compare the two for colour and smell 9 Differential oil level check 1 1 The differential has a check fill plug which must be removed to check the lubricant level If the vehicle is raised to gain access to the plug be sure to support it safely on axle stands DO NOT cra
316. ifficult suitable for competent DIY mechanic Difficult suitable for experienced DIY mechanic Very difficult suitable for expert DIY or professional Degrees of difficulty 5 4 3 2 1 1 General information The fuel system consists of a fuel tank an electric fuel pump either located externally next to the fuel tank 1988 to 1990 models or in the fuel tank 1991 to 1994 models an EFI fuel pump relay and main relay an inertia switch fuel injectors and fuel rail an air cleaner assembly and a throttle body unit Multi Point Fuel Injection MPFI system Multi point fuel injection uses timed impulses to sequentially inject the fuel directly into the intake port of each cylinder The injectors are controlled by the Electronic Control Unit ECU The ECU monitors various engine parameters and delivers the exact amount of fuel in the correct sequence into the intake ports The throttle body serves only to control the amount of air passing into the system Because each cylinder is equipped with an injector mounted immediately adjacent to the intake valve much better control of the fuel air mixture ratio is possible Fuel pump and lines Fuel is circulated from the fuel tank to the fuel injection system and back to the fuel tank through a pair of metal lines running along the underside of the vehicle On early models 1988 to 1990 an electric fuel pump is attached to the chassis next to the fuel tank On l
317. il and temperature gauges check 11 Fuses general information 3 General information 1 Headlight housing 1992 to 1994 models removal and refitting 19 Headlights adjustment 18 Headlights renewal 17 Heated rear window check and repair 16 Horn check and renewal 20 Ignition switch and key lock cylinder removal and refitting 9 Inertia switch description and check 22 In line fuses general information 4 Instrument cluster removal and refitting 12 Instrument panel switches removal and refitting 10 Radio and speakers removal and refitting 13 Relays general information and testing 6 Steering column switches removal and refitting 8 Windscreen wiper motor removal and refitting 15
318. ilable for use in a grease gun 4 Grease gun A common grease gun shown here with a detachable hose and nozzle is needed for chassis lubrication After use clean it thoroughly 16 Spark plug renewal 2 Refer to Section 4 renewing the plugs regardless of their apparent condition 17 Air cleaner element renewal 1 1 The air filter is located inside a housing at the left side of the engine compartment To remove the air filter release the four spring clips that secure the two halves of the air cleaner housing together then lift the cover up and remove the air filter element see illustration Caution Never drive the car with the air cleaner removed Excessive engine wear could result and backfiring could even cause a fire under the bonnet 2 Wipe out the inside of the air cleaner housing 3 Place the new filter into the air cleaner housing making sure it seats properly 4 Refitting the cover is the reverse of removal 18 Fuel filter renewal 2 Warning Petrol is extremely flammable so take extra precautions when you work on any part of the fuel system Don t smoke or allow open flames or bare light bulbs near the work area and don t work in a garage where a natural gas type appliance such as a water heater or clothes dryer with a pilot light is present Since petrol is carcinogenic wear latex gloves when there s a possibility of being exposed to fuel and if you spill any fuel on your skin rinse it off
319. imum wear and friction Big end bearing The bearing in the end of the connecting rod that s attached to the crankshaft Bleed nipple A valve on a brake wheel cylinder caliper or other hydraulic component that is opened to purge the hydraulic system of air Also called a bleed screw Brake bleeding Procedure for removing air from lines of a hydraulic brake system Brake disc The component of a disc brake that rotates with the wheels Brake drum The component of a drum brake that rotates with the wheels Brake linings The friction material which contacts the brake disc or drum to retard the vehicle s speed The linings are bonded or riveted to the brake pads or shoes Brake pads The replaceable friction pads that pinch the brake disc when the brakes are applied Brake pads consist of a friction material bonded or riveted to a rigid backing plate Brake shoe The crescent shaped carrier to which the brake linings are mounted and which forces the lining against the rotating drum during braking Braking systems For more information on braking systems consult the Haynes Automotive Brake Manual Breaker bar A long socket wrench handle providing greater leverage Bulkhead The insulated partition between the engine and the passenger compartment C Caliper The non rotating part of a disc brake assembly that straddles the disc and carries the brake pads The caliper also contains the hydraulic components that cause the pads t
320. inal corrosion usually appears as light fluffy powder 6 6b Removing a cable from the battery post with a spanner sometimes special battery pliers are required for this if corrosion has damaged the nut hex 6 7a Remove all the corrosion from the cable clamps the inside of the clamp is tapered to match the taper on the post so don t remove too much material 6 7b Regardless of the type of tool used to clean the battery posts a clean shiny surface should be the result 3261 Jaguar XJ6 A leak in the cooling system will usually show up as white or rust coloured deposits on the area adjoining the leak leak be found renew the offending gasket or oil seal by referring to the appropriate Chapters in this manual 2 Also check the security and condition of all the engine related pipes and hoses Ensure that all cable ties or securing clips are in place and in good condition Clips which are broken or missing can lead to chafing of the hoses pipes or wiring which could cause more serious problems in the future 3 Carefully check the radiator hoses and heater hoses along their entire length Renew any hose which is cracked swollen or deteriorated Cracks will show up better if the hose is squeezed Pay close attention to the hose clips that secure the hoses to the cooling system components Hose clips can pinch and puncture hoses resulting in cooling system leaks 4 Inspect all the cooling system components hoses joint fac
321. inder 3 Refer to Chapter 5 and remove the distributor cap and set it aside along with the spark plug leads Mark the positions of the distributor body and rotor 4 Using a feeler gauge measure and record the clearance between the intake and exhaust camshaft lobes and the lifters for cylinder number 1 see illustration Rotate the crankshaft until the next cylinder in the firing order is at TDC and check and record the valve clearance for that cylinder Following the firing order check and record the valve clearance for the remaining valves with the appropriate cylinder at TDC 5 Return the engine to TDC for cylinder number 1 Using the special tool Jaguar tool no 18G 1433 check the position of each Engine in car repair procedures 2A 9 2A 9 3 Use a screwdriver to hold the drive coupling arrowed stationary while removing the bolt 9 4 Remove the auxiliary shaft seal with a small slide hammer puller 9 5 Use snap ring pliers to remove the snap ring arrowed from the shaft note the three internal hex head bolts retaining the housing to the engine block 9 8 Inspect these areas of the auxiliary shaft for wear A Oil seal surface B Bearing journal C Sprocket D Distributor drive 9 9 Refit the auxiliary shaft rear housing with a new gasket aligning the oil slot arrowed with the housing 3261 Jaguar XJ6 9 10 Refit the washer before replacing the snap ring 9 11 Tap the seal squarely into the bore with a socket
322. ine off and inspect the air conditioning hoses and connections Traces of oil usually indicate refrigerant leaks 4 Because of the complexity of the air conditioning system and the special equipment required to effectively work on it accurate troubleshooting of the system should be left to a professional technician 5 If the air conditioning system doesn t operate at all check the fuse panel and the air conditioning relay refer to Chapter 12 for relay locations and testing See Sections 4 9 and 12 for electrical checks of heating air conditioning system components 6 The most common cause of poor cooling is simply a low system refrigerant charge If a noticeable drop in cool air output occurs the following quick check will help you determine if the refrigerant level is low Checking the refrigerant charge 7 Warm the engine up to normal operating temperature 8 Place the air conditioning temperature selector at the coldest setting and put the Cooling heating and air conditioning systems 3 11 3 3261 Jaguar XJ6 12 3b Remove the four screws three are shown here holding the control assembly in the control radio housing 12 11 Check the operation of the vacuum servo motors in this case vacuum is applied to the servo on the right blower case the flapper door arrowed should operate blower at the highest setting Open the doors to make sure the air conditioning system doesn t cycle off as soon as it cools the
323. ing engine Primary operations a Clean inspect and test the battery Section 6 b Check all the engine related fluids refer to Weekly checks c Check the condition and tension of the auxiliary drivebelt Section 21 d Renew the spark plugs Section 16 e Inspect the distributor cap and rotor arm Section 19 f Check the condition of the air filter and renew if necessary Section 17 g Renew the fuel filter Section 18 h Check the condition of all hoses and check for fluid leaks Section 7 i Check the exhaust gas emissions see Chapter 6 5 If the above operations do not prove fully effective carry out the following secondary operations Secondary operations All items listed under Primary operations plus the following a Check the charging system refer to Chapter 5 b Check the ignition system refer to Chapter 5 c Check the fuel system refer to Chapter 4 d Renew the distributor cap and rotor arm Section 19 e Renew the ignition HT leads Section 19 1 6 Maintenance procedures 3261 Jaguar XJ6 Every 7500 miles 12 000 km or 6 months 3 Engine oil and filter renewal 2 1 Frequent oil changes are the best preventive maintenance the home mechanic can give the engine because ageing oil becomes diluted and contaminated which leads to premature engine wear 2 Make sure that you have all the necessary tools before you begin this procedure see illustration You shoul
324. ing 3 Note Read through the entire Section before beginning this procedure It is recommended to remove the engine and transmission from the top as a unit then separate the engine from the transmission on the workshop floor If the transmission is not being serviced it is possible to leave the transmission in the vehicle and remove the engine from the top by itself by removing the crankshaft damper and tilting up the front end of the engine for clearance but access to the upper bellhousing bolts is only practical when the rear transmission mount and driveshaft have been removed and the transmission is angled down with a trolley jack Removal 1 Relieve the fuel system pressure see Chapter 4 2 Disconnect the battery negative cable Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 3 Place protective covers on the wings and cowl and remove the bonnet see Chapter 11 4 Remove the battery and battery tray 5 Remove the air cleaner assembly see Chapter 4 6 Raise the vehicle and support it securely on axle stands Drain the cooling system and engine oil and remove the drivebelts see Chapter 1 7 Clearly label then disconnect all vacuum lines coolant and emissions hoses wiring harness connectors and earth straps Masking tape and or a touch up paint applicator work well for marking items see illustration Tak
325. ing or reattaching any electrical connections Diagnosis and repair If a dashboard warning light comes on and stays on while the vehicle is in operation the ABS system requires attention Although special electronic ABS diagnostic testing tools are necessary to properly diagnose the system you can perform a few preliminary checks before taking the vehicle to a dealer service department or other qualified repair workshop a Check the brake fluid level in the master cylinder reservoir b Verify that all ABS system electrical connectors in the engine compartment are plugged in c Check the fuses d Follow the wiring harness to each front wheel and to the differential sensor and verify that all connections are secure and that the wiring is undamaged If the above preliminary checks do not rectify the problem the vehicle should be diagnosed by a dealer service department Due to the complex nature of this system all actual repair work must be done by a dealer service department or other qualified repair workshop 3 Disc brake pads renewal 2 Warning Disc brake pads must be replaced on both front wheels or both rear wheels at the same time never renew the pads on only one wheel Also the dust created by the brake system may contain asbestos which is harmful to your health Never blow it out with compressed air and don t inhale any of it An approved filtering mask should be worn when working on the brakes Do not und
326. ining nuts from inside the door 19 7b Open the front door to access the rear door hinge to body bolts arrowed remove the door trim panel and watershield as described in Section 18 7 Working through the access hole detach the outside handle retaining nuts see illustration then pull the handle away from the door 8 Disengage the plastic clip that secures the outside handle to latch rod see illustration 9 Remove the handle and lock cylinder assembly from the vehicle 10 Refitting is the reverse of removal Inside handle and cable 11 Remove the door trim panel as described in Section 18 and peel away the watershield 12 Detach the inside handle to latch cable see illustration 20 2 13 Remove the inside handle retaining bolts see illustration 14 Pull the handle and cable assembly free and remove them from the door 15 Refitting is the reverse of removal 21 Door window glass regulator removal and refitting 3 1 To remove the window regulator assembly raise the window to its full upright position then remove the door trim panel and watershield as described in Section 18 2 Tape the window to the door glass frame to secure the window in the full upright position 3 Remove the regulator and motor mounting bolts see illustration 4 Disconnect the electrical connector from the window regulator motor 5 Slide the equaliser arms out of the window glass channel and remove the regulator and motor assembly through the
327. inkages fittings and attachments Renew any component that shows signs of wear or damage On vehicles with power steering check the security and condition of the steering pump drivebelt and hoses Check that the vehicle is standing level and at approximately the correct ride height Shock absorbers Depress each corner of the vehicle in turn then release it The vehicle should rise and then settle in its normal position If the vehicle continues to rise and fall the shock absorber is defective A shock absorber which has seized will also cause the vehicle to fail 2 Checks carried out WITH THE VEHICLE ON THE GROUND 3261 Jaguar XJ6 REF 10 MOT test checks Exhaust system Start the engine With your assistant holding a rag over the tailpipe check the entire system for leaks Repair or renew leaking sections Jack up the front and rear of the vehicle and securely support it on axle stands Position the stands clear of the suspension assemblies Ensure that the wheels are clear of the ground and that the steering can be turned from lock to lock Steering mechanism Have your assistant turn the steering from lock to lock Check that the steering turns smoothly and that no part of the steering mechanism including a wheel or tyre fouls any brake hose or pipe or any part of the body structure Examine the steering rack rubber gaiters for damage or insecurity of the retaining clips If power steering is fitted c
328. insert then lay it in place in the connecting rod Make sure the tab on the bearing fits into the recess in the rod so the oil holes line up Don t hammer the bearing insert into place and be very careful not to nick or gouge the bearing face Don t lubricate the bearing at this time 4 Clean the back side of the other bearing insert and refit it in the rod cap Again make sure the tab on the bearing fits into the recess in the cap and don t apply any lubricant It s critically important that the mating surfaces of the bearing and connecting rod are perfectly clean and oil free when they re assembled 5 Position the piston ring gaps at staggered intervals around the piston see illustration 6 Slip a section of plastic or rubber hose over each connecting rod cap bolt 7 Lubricate the piston and rings with clean engine oil and attach a piston ring compressor to the piston Leave the skirt protruding about 1 4 inch to guide the piston into the cylinder The rings must be compressed until they re flush with the piston 8 Rotate the crankshaft until the number one connecting rod journal is at BDC bottom dead centre and apply a coat of engine oil to the cylinder wall 9 With the word FRONT or the arrow on top of the piston facing the front of the engine see illustration gently insert the piston connecting rod assembly into the number one cylinder bore and rest the bottom edge of the ring compressor on the engine block 10
329. ion Compare your measurements to this Chapter s Specifications and renew the oil pump if any are beyond the maximum allowable 11 Remove the oil pressure relief valve cap Remove and clean the relief valve components see illustration 12 Clean all components with solvent and inspect them for wear and damage If excessive wear damage or if any clearance is beyond the Specifications renew the entire pump as an assembly 13 Check the oil pressure relief valve piston sliding surface and valve spring If either the spring or the valve is damaged they must be renewed as a set Refitting 14 Lubricate the drive and driven rotors with clean engine oil and place them in the case with the marks facing out Apply a thin coat of anaerobic sealant Loctite 510 or 518 to the gasket flange and refit the cover see illustration 15 Lubricate the oil pressure relief valve piston with clean engine oil and refit the valve components into the oil pump body see illustration 13 11 16 Apply a thin coat of anaerobic sealant Loctite 510 or 518 to the oil pump to engine block mounting surface position the oil pump body against the engine block and refit the mounting bolts tightening the bolts to the torque listed in this Chapter s Specifications Follow a criss cross pattern when tightening the bolts to avoid warping the oil pump body 17 If using the original oil pump refit the original sprocket shim pack see illustration If a new pump
330. ion check all other connections in the system to make sure that they don t fail as well If a particular fuse continues to blow find out why don t just replace one fuse after another Remember failure of a small component can often be indicative of potential failure or incorrect functioning of a more important component or system Engine 1 Engine backfires Engine diesels continues to run after switching off Engine hard to start when cold Engine hard to start when hot Engine lacks power Engine lopes while idling or idles erratically Engine misses at idle speed Engine misses throughout driving speed range Engine rattles at start up Engine rotates but will not start Engine runs with oil pressure light on Engine stalls Engine starts but stops immediately Engine stumbles on acceleration Engine surges while holding accelerator steady Engine will not rotate when attempting to start1 Oil puddle under engine Pinking or knocking engine sounds during acceleration or uphill Starter motor noisy or excessively rough in engagement Fuel system 2 Excessive fuel consumption Fuel leakage and or fuel odour Cooling system 3 Coolant loss External coolant leakage Internal coolant leakage Overcooling Overheating Poor coolant circulation Automatic tra
331. ion tank D Brake fluid reservoir E Screen washer fluid reservoir F Battery G Power steering fluid reservoir Underbonnet check points 3261 Jaguar XJ6 Weekly checks 0 11 Engine oil level Before you start 4 Make sure that your car is on level ground 4 Check the oil level before the car is driven or at least 5 minutes after the engine has been switched off The correct oil Modern engines place great demands on their oil It is very important that the correct oil for your car is used See Lubricants fluids and tyre pressures Car care l If you have to add oil frequently you should check whether you have any oil leaks Place some clean paper under the car overnight and check for stains in the morning If there are no leaks the engine may be burning oil see Fault finding l Always maintain the level between the upper and lower dipstick marks see photo 3 If the level is too low severe engine damage may occur Oil seal failure may result if the engine is overfilled by adding too much oil If the oil level is checked immediately after driving the vehicle some of the oil will remain in the upper engine components resulting in an inaccurate reading on the dipstick The dipstick is located at the rear of the engine on the left hand side see Under bonnet check points on page 0 10 for exact location Withdraw the dipstick Using a clean rag or paper towel remove all oil from the dipstick
332. ions must be followed when working with the battery Hydrogen gas which is highly flammable is always present in the battery cells so don t smoke and keep naked flames and sparks away from the battery The electrolyte in the battery is actually dilute sulphuric acid which will cause injury if splashed on your skin or in your eyes It will also ruin clothes and painted surfaces When removing the battery cables always detach the negative cable first and hook it up last 1 A routine preventive maintenance program for the battery in your vehicle is the only way to ensure quick and reliable starts But before performing any battery maintenance make sure that you have the proper equipment necessary to work safely around the battery see illustration 2 There are also several precautions that should be taken whenever battery maintenance is performed Before servicing the battery always turn the engine and all accessories off and disconnect the cable from the negative terminal of the battery 3 The battery produces hydrogen gas which is both flammable and explosive Never create a spark smoke or light a match around the battery Always charge the battery in a ventilated area 4 Electrolyte contains poisonous and corrosive sulphuric acid Do not allow it to get in your eyes on your skin or on your clothes and Every 7500 miles or 6 months 1 9 1 5 2 The power hydraulic system reservoir is located on the right hand inner
333. ir isn t feasible a new or different crankshaft should be installed 8 Refer to Section 20 and examine the main and big end bearing inserts 20 Main and big end bearings inspection and selection 3 Inspection 1 Even though the main and big end bearings should be replaced with new ones during the engine overhaul the old bearings should be retained for close examination as they may Engine removal and overhaul procedures 2B 13 2B 19 5 Measure the diameter of each crankshaft journal at several points to detect taper and out of round conditions 3261 Jaguar XJ6 18 10 Check the ring groove clearance with a feeler gauge at several points around the groove 18 11 Measure the piston diameter at a 90 angle to the piston pin at the bottom of the piston pin area a precision caliper may be used if a micrometer isn t available reveal valuable information about the condition of the engine see illustration 2 Bearing failure occurs because of lack of lubrication the presence of dirt or other foreign particles overloading the engine and corrosion Regardless of the cause of failure it must be corrected before the engine is reassembled to prevent it from happening again 3 When examining the bearings remove them from the engine block the main bearing caps the connecting rods and the rod caps and lay them out on a clean surface in the same general position as their location in the engine This will enable you to matc
334. ires specialised tools equipment and training If checking and servicing become too difficult or if a procedure is beyond the scope of your skills consult your dealer service department or other repair workshop This doesn t mean however that emission control systems are particularly difficult to maintain and repair You can quickly and easily perform many checks and do most of the regular maintenance at home with common tune up and hand tools Note The most frequent cause of emission problems is simply a loose or broken electrical connector or vacuum hose so always check the electrical connectors and vacuum hoses first Pay close attention to any special precautions outlined in this chapter It should be noted that the illustrations of the various systems may not exactly match the system installed on your vehicle because of changes made by the manufacturer during production or from year to year The Vehicle Emissions Control Information VECI label and a vacuum hose diagram are located under the bonnet see illustrations These contain important emissions specifi cations and setting procedures and a vacuum hose schematic with emissions 1 6a The Vehicle Emissions Control Information VECI label shows the types of emission control systems installed engine information etc 1992 model shown 1 6b Typical vacuum hose routing label 1992 model shown components identified When servicing the engine or emissions systems t
335. isconnect any cables or wire harness connectors attached to the boot lid that would interfere with removal 3 Make alignment marks around the hinge mounting bolts with a marking pen 4 While an assistant supports the boot lid remove the lid to hinge bolts on both sides and lift it off see illustration 5 Refitting is the reverse of removal Note When refitting the boot lid align the lid to hinge bolts with the marks made during removal Adjustment 6 Fore and aft and side to side adjustment of the boot lid is done by moving the bonnet in relation to the hinge plate after loosening the bolts or nuts 7 Scribe a line around the entire hinge plate as described earlier in this section so you can judge the amount of movement 11 6 Bodywork and fittings 14 3 Remove the two retaining bolts from the bottom of the bumper then remove the bumper from the vehicle 15 4 Remove the bolts arrowed securing the inner wing splash shield 15 7a Detach the wing retaining bolts arrowed at the front of the wing 15 7c Working in the wheel opening remove the wing to rocker panel bolt arrowed 15 7d Remove the wing to door pillar bolt arrow lower bolt not visible 15 7e Detach the bolts along the top of the wing 3261 Jaguar XJ6 15 7b Remove the wing to radiator support bolt arrowed 16 4 With the help of an assistant to hold the boot lid remove the retaining bolts and lift off the boot lid 8 Loosen the bolts or nuts an
336. it Open or short circuit 26 Oxygen sensor circuit Lean exhaust vacuum leak 29 ECU Self check 33 Fuel injector circuit Open or short circuit 34 Fuel injector circuit Faulty injector indicated 37 EGR solenoid circuit Short or open circuit 39 EGR circuit Faulty system operation 44 Oxygen sensor circuit Rich or lean condition 46 Idle speed control valve coil 1 Open or short circuit 47 Idle speed control valve coil 2 Open or short circuit 48 Idle speed control valve Not within specification 68 Road speed sensor Incorrect signal voltage 69 Neutral safety switch circuit Engine cranks in Drive adjust or renew switch 89 Purge control valve circuit Open or short circuit temperature INCREASES the resistance values will DECREASE A failure in this sensor circuit should set a Code 3 1988 and 1989 or 13 1990 to 1994 This code indicates a failure in the coolant temperature sensor circuit so in most cases the appropriate solution to the problem will be either repair of a connector or wire or renewal of the sensor Check 2 To check the sensor measure its resistance value see illustration while it is completely cold 60 to 80 F 1500 to 3000 ohms Next start the engine and warm it up until it reaches operating temperature The resistance should be lower 180 to 200 F 280 to 350 ohms 3 If the resistance values of the coolant temperature sensor are correct check the circuit for the proper signal vol
337. it is to repair mechanical components The hidden areas of the body such as the wheel wells the frame and the engine compartment are equally important although they don t require as frequent attention as the rest of the body 2 Once a year or every 12 000 miles it s a good idea to have the underside of the body steam cleaned All traces of dirt and oil will be removed and the area can then be inspected carefully for rust damaged brake lines frayed electrical wires damaged cables and other problems The front suspension components should be greased after completion of this job 3 At the same time clean the engine and the engine compartment with a steam cleaner or water soluble degreaser 4 The wheel wells should be given close attention since undercoating can peel away and stones and dirt thrown up by the tyres can cause the paint to chip and flake allowing rust to set in If rust is found clean down to the bare metal and apply an anti rust paint 5 The body should be washed about once a week Wet the vehicle thoroughly to soften the dirt then wash it down with a soft sponge and plenty of clean soapy water If the surplus dirt is not washed off very carefully it can wear down the paint 6 Spots of tar or asphalt thrown up from the road should be removed with a cloth soaked in solvent 7 Once every six months wax the body and chrome trim If a chrome cleaner is used to remove rust from any of the vehicle s plated parts
338. ith a standard spring compressor Caution Be very careful not to nick or otherwise damage the lifter bores when compressing the valve springs 4 Pull the valve out of the cylinder head then remove the oil seal from the guide If the valve binds in the guide won t pull through push it back into the cylinder head and deburr the area around the keeper groove with a fine file or whetstone 5 Repeat the procedure for the remaining valves Remember to keep all the parts for each valve together so they can be reinstalled in the same locations 6 Once the valves and related components have been removed and stored in an organised manner the cylinder head should be thoroughly cleaned and inspected If a complete engine overhaul is being done finish the engine dismantling procedures before beginning the cylinder head cleaning and inspection process 10 Cylinder head cleaning and inspection 2 1 Thorough cleaning of the cylinder head s and related valve train components followed by a detailed inspection will enable you to decide how much valve service work must be 2B 6 Engine removal and overhaul procedures 9 2 A small plastic bag with an appropriate label can be used to store the valve train components so they can be kept together and reinstalled in the correct guide 3261 Jaguar XJ6 9 3 Compress the spring until the keepers can be removed with a small magnetic screwdriver or needle nose pliers use a valve spring compr
339. ive machine workshop and resurfaced if necessary 8 Position new gaskets over the cylinder head studs see illustration Note The marks on the gasket should face out away from the cylinder head and the arrow should point toward the rear of the engine 9 Refit the manifolds and thread the mounting nuts bolts into place 10 Working from the centre out tighten the nuts bolts to the torque listed in this Chapter s Specifications in three or four equal steps 11 Refit the remaining parts in the reverse order of removal 12 Run the engine and check for exhaust leaks 7 Crankshaft front oil seal renewal 3 1 Disconnect the negative cable from the battery Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 2 Refer to Chapter 1 and remove the accessory drive belts 3 Refer to Chapter 3 and remove the fan shroud and fan clutch assembly 4 Remove the crankshaft damper bolt with a socket and large breaker bar see illustration To hold the crankshaft stationary remove the flywheel inspection cover see Chapter 8 and wedge a large screwdriver into the flywheel ring gear teeth Warning The damper bolt is under considerable torque so be sure the socket is firmly in place and that your hands are not in danger of hitting anything sharp 5 Use a bolt type damper puller available at most car accessory outlets to remove
340. ive damage 6 Screwdriver Used to remove the seal from the hub a long screwdriver is preferred 7 Socket breaker bar Needed to loosen the nut on the spindle if it s extremely tight 8 Brush Together with some clean solvent this will be used to remove old grease from the hub and spindle 22 6 Dislodge the dust cap by working around the outer circumference with a hammer and chisel 22 7 Remove the cotter pin and discard it use a new one when the hub is reinstalled 22 9 Pull the hub assembly forward slightly then push it back into position to dislodge the outer wheel bearing 3261 Jaguar XJ6 21 11 When refitting ribbed serpentine drivebelts make sure the belt is centred between the pulley edges arrowed it must not overlap either edge of the pulley and old bearings should never be installed on new races 15 Use high temperature front wheel bearing grease to pack the bearings Work the grease completely into the bearings forcing it between the rollers cone and cage from the back side see illustration 16 Apply a thin coat of grease to the spindle at the outer bearing seat inner bearing seat shoulder and seal seat 17 Put a small quantity of grease inboard of each bearing race inside the hub Using your finger form a dam at these points to provide extra grease availability and to keep thinned grease from flowing out of the bearing see illustration 18 Place the grease packed inner bearing into the rear o
341. jor components are beyond reconditioning it may be cost effective to buy a factory rebuilt engine from a Jaguar dealership As a final note to ensure maximum life and minimum trouble from a rebuilt engine everything must be assembled with care in a spotlessly clean environment 3 Vacuum gauge diagnostic checks 2 A vacuum gauge provides valuable information about what is going on in the engine at a low cost You can check for worn rings or cylinder walls leaking cylinder head or intake manifold gaskets incorrect carburettor adjustments restricted exhaust stuck or burned valves weak valve springs improper ignition or valve timing and ignition problems Unfortunately vacuum gauge readings are easy to misinterpret so they should be used with other tests to confirm the diagnosis Both the absolute readings and the rate of needle movement are important for accurate interpretation Most gauges measure vacuum in inches of mercury in Hg As vacuum increases or atmospheric pressure decreases the reading will decrease Also for every 1000 foot increase in elevation above sea level the gauge readings will decrease about one inch of mercury Connect the vacuum gauge directly to intake manifold vacuum not to ported above the throttle plate vacuum see illustration Be sure no hoses are left disconnected during the test or false readings will result Before you begin the test allow the engine to warm up completely Block
342. k down test and read the spark plugs 5 A rapid vibration of about four in Hg vibration at idle combined with exhaust smoke indicates worn valve guides Perform a leak down test to confirm this If the rapid vibration occurs with an increase in engine speed check for a leaking intake manifold gasket or cylinder head gasket weak valve springs burned valves or ignition misfire 6 A slight fluctuation say one inch up and down may mean ignition problems Check all the usual tune up items and if necessary run the engine on an ignition analyser 7 If there is a large fluctuation perform a compression or leak down test to look for a weak or dead cylinder or a blown cylinder head gasket 8 If the needle moves slowly through a wide range check for a clogged PCV system incorrect idle fuel mixture throttle body or intake manifold gasket leaks 9 Check for a slow return after revving the engine by quickly snapping the throttle open until the engine reaches about 2 500 rpm and let it shut Normally the reading should drop to near zero rise above normal idle reading about 5 in Hg over and then return to the previous idle reading If the vacuum returns slowly and doesn t peak when the throttle is snapped shut the rings may be worn If there is a long delay look for a restricted exhaust system often the silencer or catalytic converter An easy way to check this is to temporarily disconnect the exhaust ahead of the suspected part and re
343. ker position so the door skin is flush with the rear door front or rear quarter panel rear and provides positive engagement with the latch mechanism see illustration 20 Door latch lock cylinder and handles removal and refitting 2 Door latch 1 Raise the window then remove the door trim panel and watershield as described in Section 18 2 Working through the large access hole disengage the outside door handle to latch rod and the inside handle to latch cable see illustration 3 All door locking rods are attached by plastic clips The plastic clips can be removed by unsnapping the portion engaging the connecting rod and then by pulling the rod out of its locating hole 4 Remove the screws securing the latch to the door see illustration then remove the latch assembly from the door 5 Refitting is the reverse of removal Outside handle and door lock cylinder 6 To remove the outside handle and lock cylinder assembly raise the window then Bodywork and fittings 11 9 11 19 13 Adjust the door lock striker by loosening the hex nut and gently tapping the striker in the desired direction 20 2 Detach the outside handle to latch rod A then remove the inside handle to latch cable B 20 4 Remove the latch screws arrowed from the end of the door and pull the latch assembly through the access hole 3261 Jaguar XJ6 19 7a Work through the door access hole arrowed to remove the hinge to door reta
344. l out the stopper pin with a magnet 6 7g Remove the primary piston 6 7h Remove the secondary piston 6 7i If the secondary piston is stuck rap the master cylinder on a wood block to dislodge it 3261 Jaguar XJ6 6 7j Remove the seals and cups from the pistons be very careful not to scratch the piston surface then wash the secondary piston with clean brake fluid and inspect it if the secondary piston is damaged you must renew the master cylinder with a new or rebuilt unit a new primary piston is included with the rebuild kit 6 7l The master cylinder assembly 1 Roll pin 2 Reservoir 3 Grommets 4 End plate 5 Primary piston 6 Secondary piston stopper pin 7 Secondary piston 6 7k Refit the new O ring seals and cups as shown make sure the cups on the primary piston the one on the left face forward as shown toward the spring and the cups on the secondary piston the one on the right face out away from the piston the one on the left faces toward the primary piston the one on the right faces toward the spring will be necessary to apply pressure to the master cylinder piston and at the same time control flow from the brake line outlets it is recommended that the master cylinder be mounted in a vice Use caution not to clamp the vice too tightly or the master cylinder body might crack 10 Insert threaded plugs into the brake line outlet holes and snug them down so that there will be no air leakage past the
345. l tank Note These vehicles are susceptible to clogging of the fuel overflow line If this happens excess fuel or 4 6 Fuel and exhaust systems 7 6 Remove the clamp that retains the fuel filler assembly to the filler neck 7 7a Remove bolts arrowed that retain the fuel filler assembly to the body and slide the assembly down the filler neck of fuel tank 3261 Jaguar XJ6 5 10 Use a brass punch and remove the lock ring by tapping on it in an anti clockwise direction 5 11 Lift the fuel level sender unit assembly from the fuel tank at an angle so as not to damage the float or arm water in the fuel filler cap recess could flow into the boot causing a dangerous condition and or an unpleasant mess To correct this condition direct low pressure compressed air into the overflow hole see illustration which should be enough to clear any obstruction in the line 8 Remove the spare tyre and the spare tyre bracket assembly see illustration 9 Disconnect the fuel lines the vapour return line and the canister vent line see illustrations Note Be sure to plug the hoses to prevent leakage and contamination of the fuel system Remove the driveline to gain access to the fuel line connectors next to the tank see Chapter 8 Working under the vehicle remove the pins using a needle nose pliers turn the connectors slightly to loosen them from the grommets and pull the fuel lines out of the tank 10 Remove the retaining bolts from the
346. l you can see the wire or string Ensure that the new cable has a grommet attached then remove the old cable from the wire or string and replace it with the new cable 9 Working from passenger compartment pull the wire or string back through the bulkhead 10 Refitting is the reverse of removal Note Push on the grommet with your fingers from the engine compartment to seat the grommet in the bulkhead 12 Radiator grille removal and refitting 1 1 Using a Phillips screwdriver detach the right and left hand grille inserts from the grille assembly see illustration Note The grille can be removed without removing the inserts but reaching the mounting screws from above is quite difficult 2 Working through the grille insert openings remove the retaining screws securing both ends of the grille frame see illustration 3 Pull the grille frame forward and remove it from the vehicle 4 Refitting is the reverse of removal 13 Front spoiler removal and refitting 1 1 Working on the left side of the vehicle remove the front spoiler lower cover see illustration 2 Remove the screws securing the front air dam panels in the left and right wheel openings see illustration then detach the air dam panels from the vehicle Note It will probably be necessary to turn the wheels to the right and left for access to the screws 3 Detach the retaining bolts securing the sides of the spoiler see illustration 4 Working through the grille
347. lb housing covers 21 5 Remove the bulb cluster from the tail light housing The bulb is removed by pushing in and turning the bulb anti clockwise 22 2 The inertia switch is located behind the passengers side kick panel pull upward on the button to trip the switch push downward on the button to reset the switch 23 Cruise control system description and check 5 1 The cruise control system maintains vehicle speed with an independently operated vacuum motor located on the passenger s side inner wing in the engine compartment When the cruise control switch is turned on a vacuum actuator connected the throttle linkage is activated by vacuum from the vacuum motor The system consists of the vacuum motor vacuum actuator brake switch control switches a relay and associated vacuum hoses Some features of the system require special testers and diagnostic procedures which are beyond the scope of this manual Listed below are some general procedures that may be used to locate common problems 2 Locate and check the fuse see Section 3 3 Have an assistant operate the brake lights while you check their operation voltage from the brake light switch deactivates the cruise control 4 If the brake lights don t come on or don t shut off correct the problem and re test the cruise control 5 Visually inspect the vacuum hose connected to the vacuum motor and vacuum actuator Check the freeplay between the vacuum actuator stop
348. leads grasp only the boot and use a twisting pulling motion 4 8 Use a spark plug socket with a long extension to unscrew the spark plugs 3261 Jaguar XJ6 4 1 Tools required for changing spark plugs 1 Spark plug socket This will have special padding inside to protect the spark plug porcelain insulator 2 Torque wrench Although not mandatory use of this tool is the best way to ensure that the plugs are tightened properly 3 Ratchet to fit the plug socket 4 Extension Depending on model and accessories you may need special extensions and universal joints to reach one or more of the plugs 5 Spark plug gap gauge This gauge for checking the gap comes in a variety of styles Make sure the gap for your engine is included 4 10 Apply a coat of anti seize compound to the spark plug threads A length of 3 8 inch ID rubber hose will save time and prevent damaged threads when refitting the spark plugs 5 Power hydraulic system fluid level check 1 Caution Use only Castrol or Jaguar hydraulic system mineral oil HSMO in the power hydraulic system available at Jaguar dealer service departments 1 The power hydraulic system controls the ride levelling and the brake servo systems The fluid reservoir also supplies the power steering system on some models The level of the fluid should be carefully maintained Low fluid levels can adversely affect the riding and braking capabilities of your vehicle The power hydraulic sy
349. les and coolant passage outlines in pencil on the cylinder head Use the gasket to trace the same on the top of the engine block see illustration If the top of the engine block has eroded outside of the pattern around the water passages or cylinder head bolt holes the engine block must be renewed the manufacturer doesn t recommend resurfacing it If the cylinder head has eroded outside of the water passage holes but the erosion is away from the combustion chamber the eroded area can be built up with metal impregnated epoxy and machined flat again 13 Using a straightedge and feeler gauge check the cylinder head gasket mating surface on the engine block and cylinder head for warpage see illustration If the warpage exceeds the limit found in this Chapter s Specifications it can be resurfaced at an automotive machine workshop but no more then 0 010 inch of material should be removed If the cylinder head had been overheated take it to the machinist for inspection before proceeding further It s possible that the overheating could have annealed softened the aluminium of the cylinder head making it unsuitable for machine work In this case a new cylinder head is required Note 1 To check if a cylinder head has been machined previously measure the height between the cylinder head gasket surface and the valve cover mounting surface with a large micrometer or vernier caliper and compare with Specifications Note 2 Jag
350. level and add fluid as necessary Bleed the brake system as outlined in Section 9 and test the brakes carefully before driving the vehicle Be sure there are no leaks 9 Brake hydraulic system bleeding 2 Warning Wear eye protection when bleeding the brake system If the fluid comes in contact with your eyes immediately rinse them with water and seek medical attention Note Bleeding the hydraulic system is necessary to remove any air which has entered the system during removal and refitting of a hose line caliper or master cylinder 1 It will probably be necessary to bleed the system at all four brakes if air has entered the system due to low fluid level or if the brake lines have been disconnected at the master cylinder 2 If a brake line was disconnected at only one wheel then only that caliper or wheel cylinder must be bled 3 If a brake line is disconnected at a fitting located between the master cylinder and any of the brakes that part of the system served by the disconnected line must be bled 4 Bleed the right rear the left rear the right front and the left front caliper in that order when the entire system is involved 5 Remove any residual vacuum from the servo and pressure in the anti lock braking system if equipped by applying the brake about 30 times with the engine off 6 Remove the master cylinder reservoir cover and fill the reservoir with brake fluid Refit the cover Note Check the fluid level
351. lies with solvent and dry them with compressed air if available Make sure the oil return holes 2B 12 Engine removal and overhaul procedures 17 3a A bottle brush hone will produce better results if you have never done cylinder honing before 17 3b The cylinder hone should leave a smooth crosshatch pattern with the lines intersecting at approximately a 60 angle 18 4a The piston ring grooves can be cleaned with a special tool as shown 18 4b or a section of a broken ring 3261 Jaguar XJ6 in the back sides of the ring grooves and the oil hole in the lower end of each rod are clear 6 If the pistons and cylinder walls aren t damaged or worn excessively and if the engine block is not rebored new pistons won t be necessary Normal piston wear appears as even vertical wear on the piston thrust surfaces and slight looseness of the top ring in its groove New piston rings however should always be used when an engine is rebuilt 7 Carefully inspect each piston for cracks around the skirt at the pin bosses and at the ring lands Caution Some early 1988 3 6 litre engines before engine no 9D 121113 have incorrectly stamped pistons On these the word FRONT is actually stamped on the rear of the pistons Correct pistons will have the cast arrows on the inside of the skirt to your left when facing the word FRONT 8 Look for scoring and scuffing on the thrust faces of the skirt holes in the piston crown a
352. lk materials and some specialised tools It is recommended that these operations be left to a dealer or a workshop specialising in glass work 9 Bonnet and boot lid support struts removal and refitting 1 1 Open the bonnet or boot lid and support it securely 2 Using a small screwdriver detach the retaining clips at both ends of the support strut Then pry or pull sharply to detach it from the vehicle see illustrations 3 Refitting is the reverse of removal 10 Bonnet removal refitting and adjustment 2 Note The bonnet is heavy and somewhat awkward to remove and refit at least two people should perform this procedure Removal and refitting 1 Use blankets or pads to cover the wings and the area in front of the bonnet This will protect the body and paint as the bonnet is lifted off 2 Make marks or scribe a line around the bonnet hinge to ensure proper alignment during refitting 3 Disconnect any cables or wires that will interfere with removal 4 Have an assistant support the bonnet Remove the hinge to bonnet screws or bolts see illustration 5 Lift off the bonnet 6 Refitting is the reverse of removal Adjustment 7 Before the bonnet can be adjusted properly both bonnet striker assemblies Bodywork and fittings 11 3 11 10 4 With the help of an assistant to hold the bonnet remove the retaining bolts arrowed from each hinge plate then lift off the bonnet 3261 Jaguar XJ6 9 2b The boot lid s
353. ll see illustration The resistance should change steadily from 200 ohms to around 18 ohms Renewal Warning The fuel level in the tank must be less than half full to safely remove the fuel pump sender unit assembly from the fuel Fuel and exhaust systems 4 5 4 5 4 Connect the probes of the ohmmeter to the fuel level sender unit terminals and check the resistance of the float assembly 5 8 An accurate check of the sender unit can be made by removing it from the fuel tank and observing the resistance with the float down empty and then extended full 3261 Jaguar XJ6 4 12 Exploded view of the in tank fuel pump and the fuel tank on 1991 to 1994 models tank If there is any doubt about the amount of fuel in the tank drain the fuel tank completely before attempting this procedure Section 7 paragraph 1 9 Disconnect the cable from the negative terminal of the battery Disconnect the fuel level sender unit fuel pump electrical connector Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 10 Using a brass punch tap on the lock ring anti clockwise see illustration until the tabs align with the indentations in the fuel tank 11 Carefully angle the sender unit out of the opening without damaging the fuel level float see illustration 12 Refitting is the reverse of removal 6 Fuel lines and fittings i
354. lock solenoid while the lock switch is operated 27 9 To close the sunroof manually insert the T handle spanner in the motor shaft and rotate it clockwise 3261 Jaguar XJ6 Later models are equipped with a Supplemental Restraint System SRS more commonly known as an airbag This system is designed to protect the driver and on 1994 models the passenger from serious injury in the event of a head on or frontal collision It consists of an airbag module in the centre of the steering wheel and a passenger airbag module on the right side of the dash above the glove box on 1994 models The airbag modules contain an inflater and a sensor assembly which activates from impact energy that is transmitted through the body and steering column upon impact or collision DO NOT try to dismantle or remove any component in the vicinity of the steering column or instrument panel on models equipped with air bags Serious personal injury or damage may result The manufacturer recommends that on airbag equipped models service which requires removal of any component in the vicinity of the instrument panel or steering column should be left to a dealer service department or other properly equipped repair facility because of the special tools and techniques required to disable the air bag system 29 Wiring diagrams general information Since it isn t possible to include a complete wiring diagram for every year covered by this manual the fol
355. loor or carpets which would indicate failed seals in the brake master cylinder Check the servo unit when applicable by operating the brake pedal several times then keeping the pedal depressed and starting the engine As the engine starts the pedal will move down slightly If not the vacuum hose or the servo itself may be faulty Steering wheel and column Examine the steering wheel for fractures or looseness of the hub spokes or rim Move the steering wheel from side to side and then up and down Check that the steering wheel is not loose on the column indicating wear or a loose retaining nut Continue moving the steering wheel as before but also turn it slightly from left to right Check that the steering wheel is not loose on the column and that there is no abnormal movement of the steering wheel indicating wear in the column support bearings or couplings Windscreen and mirrors The windscreen must be free of cracks or other significant damage within the driver s field of view Small stone chips are acceptable Rear view mirrors must be secure intact and capable of being adjusted 1 Checks carried out FROM THE DRIVER S SEAT 1 Checks carried out FROM THE DRIVER S SEAT 2 Checks carried out WITH THE VEHICLE ON THE GROUND 3 Checks carried out WITH THE VEHICLE RAISED AND THE WHEELS FREE TO TURN 4 Checks carried out on YOUR VEHICLE S EXHAUST EMISSION SYSTEM 3261 Jaguar XJ6 MOT test check
356. losing the door fatigues and eventually breaks the wires 26 Electric mirrors description and check 2 1 Most electric mirrors use two motors to move the glass one for up and down adjustments and one for left right adjustments 2 The control switch has a selector portion which sends voltage to the left or right side mirror With the ignition ON but the engine OFF roll down the windows and operate the mirror control switch through all functions left right and up down for both the left and right side mirrors 3 Listen carefully for the sound of the electric motors running in the mirrors 4 If the motors can be heard but the mirror glass doesn t move there s probably a problem with the drive mechanism inside the mirror Remove and dismantle the mirror to locate the problem 5 If the mirrors don t operate and no sound comes from the mirrors check the fuse see Chapter 1 6 If the fuse is OK remove the mirror control switch from its mounting without disconnecting the wires attached to it Turn the ignition ON and check for voltage at the switch There should be voltage at one terminal If there s no voltage at the switch check for an open or short in the circuit between the fuse panel and the switch 7 If there s voltage at the switch disconnect it Check the switch for continuity in all its operating positions If the switch does not have continuity renew it 8 Re connect the switch Locate the wire going from t
357. lowing diagrams are those that are typical and most commonly needed Prior to diagnosing any circuits check the fuse and circuit breakers if equipped to make sure they are in good condition Make sure the battery is properly charged and has clean tight cable connections see Chapter 1 When checking the wiring system make sure that all electrical connectors are clean with no broken or loose pins When unplugging an electrical connector do not pull on the wires only on the connector housings themselves Body electrical system 12 15 12 3261 Jaguar XJ6 Wiring diagrams commence overleaf 12 16 Wiring diagrams 3261 Jaguar XJ6 Typical 1988 to 1992 starting and charging system Typical 1993 and 1994 starting and charging system Wiring diagrams 12 17 12 3261 Jaguar XJ6 Typical 1988 to 1992 engine management system 12 18 Wiring diagrams 3261 Jaguar XJ6 Typical 1993 and 1994 engine management system Wiring diagrams 12 19 12 3261 Jaguar XJ6 Typical engine cooling fan system Typical 1988 instrument warning light system 12 20 Wiring diagrams 3261 Jaguar XJ6 Typical 1989 to 1994 instrument warning light system Wiring diagrams 12 21 12 3261 Jaguar XJ6 Typical headlight system 12 22 Wiring diagrams 3261 Jaguar XJ6 Typical side marker and tail light system Wiring diagrams 12 23 12 3261 Jaguar XJ6 Typical hazard turn signal and stop light system 12 24 Wi
358. ls Therefore a lot of the information contained in Chapter 6 is not applicable to UK models Acknowledgements Thanks are due to Jean Preis Rich Wilson and Ray Marcuse of Silver Star Jaguar Thousand Oaks CA Rick Calaci of Conejo Imports Newbury Park CA and Jim Strohmeier and Jonathan Lund of British Motor Cars Thousand Oaks CA for providing valuable technical information Technical writers who contributed to this project include Jeff Kibler Robert Maddox and Jay Storer We take great pride in the accuracy of information given in this manual but vehicle manufacturers make alterations and design changes during the production run of a particular vehicle of which they do not inform us No liability can be accepted by the authors or publishers for loss damage or injury caused by any errors in or omissions from the information given 0 4 Introduction 3261 Jaguar XJ6 Haynes mechanic author and photographer with 1989 Jaguar XJ6 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
359. lts then detach the intake manifold from the engine see illustrations Refitting 8 Clean the mating surfaces of the intake manifold and the cylinder head mounting surface with lacquer thinner or acetone If the gasket shows signs of leaking have the manifold checked for warpage at an automotive machine workshop and resurfaced if necessary 9 Refit a new gasket then position the intake manifold on the cylinder head and refit the nuts bolts see illustration 10 Tighten the nuts bolts in three or four equal steps to the torque listed in this Chapter s Specifications Work from the centre out towards the ends to avoid warping the manifold 11 Refit the remaining parts in the reverse order of removal 12 Before starting the engine check the throttle linkage for smooth operation 13 Run the engine and check for coolant and vacuum leaks 14 Road test the car and check for proper operation of all accessories including the cruise control system 6 Exhaust manifolds removal and refitting 2 Warning The engine must be completely cool before beginning this procedure Removal 1 Disconnect the negative cable from the battery Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 2 On 1990 and later models disconnect the EGR pipe and remove the EGR valve from the top of the exhaust manifold see Chapter 6 3 Apply
360. lugs of any other type are to be fitted refer to their manufacturer s recommendations Engine firing order 1 5 3 6 2 4 Distributor rotation Clockwise Ignition timing See Chapter 5 Brakes Disc brake pad friction material minimum thickness Front 4 0 mm Rear 3 0 mm Handbrake shoe friction material minimum thickness 1 5 mm Handbrake adjustment 3 to 5 clicks Torque wrench settings Nm lbf ft Automatic transmission sump pan bolts 8 6 Automatic transmission dipstick tube nut 20 15 Spark plugs 23 to 28 17 to 21 Wheel nuts 102 75 1 2 Servicing specifications 3261 Jaguar XJ6 Cylinder location and distributor rotati
361. luid noted is from the shocks and not from any other source Also check the rubber mounts at each end for deterioration If the shock absorbers fail any of the tests above replace the shocks as a set 7 Check the tyres for irregular wear patterns and proper inflation See Weekly checks for information regarding tyre wear 8 Inspect the universal joint between the steering shaft and the steering gear housing Check the steering gear housing for grease leakage Make sure that the dust seals and boots are not damaged and that the boot clamps are not loose see illustration Check the steering linkage for looseness or damage Look for loose bolts broken or disconnected parts and deteriorated rubber bushings on all suspension and steering components see illustration While an assistant turns the steering wheel from side to side check the steering components for free movement chafing and binding If the steering components do not seem to be reacting with the movement of the steering wheel try to determine where the slack is located 9 Check the balljoints moving each lower arm up and down with a crowbar to ensure that its balljoint has no play If any balljoint does have play replace it See Chapter 10 for the front balljoint renewal procedure Check the tie rod ends for excessive play 10 Inspect the balljoint and tie rod end boots for damage and leaking grease see illustration Replace the balljoints and tie rod ends with new
362. luid to the primary piston and refit it into the bore 6 7o Using the same technique as in illustration 6 7f depress the pistons and refit the stopper pin 6 7p Refit the end plate as shown with the bend in the plate flange aligned with the groove in the master cylinder flange 6 7q Using a hammer and punch stake the end plate as shown there s a dimple in the side of the plate for this purpose 6 7r Refit the grommets 3261 Jaguar XJ6 6 7s Align the reservoir pipes with the grommets as shown 6 7u Refit the reservoir roll pin 6 7v and tap it into place 6 7t and squeeze the reservoir and master cylinder together make sure the reservoir is fully seated being drawn back into the master cylinder Wait several seconds for brake fluid to be drawn from the reservoir into the piston bore then depress the piston again removing your finger as brake fluid is expelled Be sure to put your finger back over the hole each time before releasing the piston and when the bleeding procedure is complete for that outlet renew the plug and snug it up before going on to the other port Refitting 16 Refit the master cylinder over the studs on the brake servo and tighten the mounting nuts only finger tight at this time 17 Thread the brake line fittings into the master cylinder Since the master cylinder is still a bit loose it can be moved slightly to allow the fitting threads to start easily Do not strip the
363. ly Wheel makes a thumping noise Blister or bump on tyre Chapter 10 Improper shock absorber action Chapter 10 Shimmy shake or vibration Tyre or wheel out of balance or out of round Chapter 10 Loose worn or out of adjustment wheel bearings Chapter 1 Worn tie rod ends Chapter 10 Worn balljoints Chapter 10 Excessive wheel runout Chapter 10 Blister or bump on tyre Chapter 10 Hard steering Lack of lubrication at balljoints tie rod ends and rack and pinion assembly Chapter 1 Front wheel alignment Chapter 10 Low tyre pressure s Chapter 1 Poor returnability of steering to centre Lack of lubrication at balljoints and tie rod ends Chapter 1 Binding in balljoints Chapter 10 Binding in steering column Chapter 10 Lack of lubricant in rack and pinion assembly Chapter 10 Front wheel alignment Chapter 10 Abnormal noise at the front end Lack of lubrication at balljoints and tie rod ends Chapter 1 Damaged shock absorber mounting Chapter 10 Worn control arm bushings or tie rod ends Chapter 10 Loose stabiliser bar Chapter 10 Loose wheel nuts Chapter Loose suspension bolts Chapter 10 Wander or poor steering stability Mismatched or uneven tyres Chapter 10 Lack of lubrication at balljoints and tie rod ends Chapter 1 Worn shock absorbers Chapter 10 Loose stabiliser bar Chapter 10 Broken or sagging springs Chapter
364. ly an indication that an overhaul is needed while low mileage doesn t preclude the need for an overhaul Frequency of servicing is probably the most important consideration An engine that s had regular and frequent oil and filter changes as well as other required maintenance will most likely give many thousands of miles of reliable service Conversely a neglected engine may require an overhaul very early in its life Excessive oil consumption is an indication that piston rings valve seals and or valve guides are in need of attention Make sure that oil leaks aren t responsible before deciding that the rings and or guides are bad Perform a cylinder compression check to determine the extent of the work required see Section 4 Also check the vacuum readings under various conditions see Section 3 Check the oil pressure with a gauge installed in place of the oil pressure sender unit see illustrations and compare it to this Chapter s Specifications If it s extremely low the bearings and or oil pump are probably worn out Loss of power rough running knocking or metallic engine noises excessive valve train noise and high fuel consumption rates may also point to the need for an overhaul especially if they re all present at the same time If a complete tune up doesn t remedy the situation major mechanical work is the only solution An engine overhaul involves restoring the internal parts to the specifications of a
365. ly installed 7 Before detaching any part of the fuel system be sure to relieve the pressure in the tank by removing the fuel tank cap then relieve the fuel system pressure Section 2 Cover the fitting being disconnected with a rag to absorb any fuel that may leak out 7 Fuel tank removal and refitting 3 Warning Petrol is extremely flammable so take extra precautions when you work on any part of the fuel system See the Warning in Section 2 1 This procedure is much easier to perform if the fuel tank is empty Some models may have a drain plug for this purpose If for some reason the drain plug can t be removed postpone the job until the tank is empty or siphon the fuel into an approved container using a siphoning kit available at most motor factors Warning Do not start the siphoning action by mouth 2 Remove the fuel filler cap to relieve fuel tank pressure 3 Detach the battery negative cable Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 4 If the tank is full or nearly full drain the fuel into an approved container 5 Raise the vehicle and place it securely on axle stands 6 Remove the filler neck vent tube clamp see illustration and separate the tube from the fuel filler neck 7 Remove the fuel filler assembly bolts see illustration and slide the large rubber boot down the neck of the fue
366. lytic converter is an emission control device added to the exhaust system to reduce pollutants A single bed converter is used in combination with a three way reduction catalyst See Chapter 6 for more information regarding the catalytic converter 2 Fuel pressure relief 1 Warning Petrol is extremely flammable so take extra precautions when you work on any part of the fuel system Don t smoke or allow open flames or bare light bulbs near the work area and don t work in a garage where a natural gas type appliance such as a water heater or a clothes dryer with a pilot light is present Since petrol is carcinogenic wear latex gloves when there s a possibility of being exposed to fuel and if you spill any fuel on your skin rinse it off immediately with soap and water Mop up any spills immediately and do not store fuel soaked rags where they could ignite The fuel system is under constant pressure so if any fuel lines are to be disconnected the fuel pressure in the system must be relieved first When you perform any kind of work on the fuel system wear safety glasses and have a Class B type fire extinguisher on hand 1 Before servicing any fuel system component you must relieve the fuel pressure to minimise the risk of fire or personal injury 2 Remove the fuel filler cap this will relieve any pressure built up in the tank 3 Remove the fuel pump relay from the main relay panel see illustrations Note Th
367. m general information and precautions 1 All models are equipped with a computerised ignition system The ignition system consists of the ignition coil the crankshaft position sensor the amplifier and the electronic control unit ECU The ignition ECU controls the ignition timing and advance characteristics for the engine The ignition timing is not adjustable therefore changing the position of the distributor will not change the timing in any way Note In the event the distributor must be removed from the engine be sure to follow the precautions described in Section 9 and mark the engine and distributor with paint to ensure correct refitting If the distributor is not marked and Ihe crankshaft is turned while the distributor is out of the engine have the distributor installed by a dealer service department The distributor must be installed using a special alignment tool 2 The distributor is driven by the intermediate shaft which also drives the power steering pump The crankshaft position sensor is located on the front timing cover It detects crank position by pulsing an electronic signal to the ECU This signal is sent to the ECU to provide ignition timing specifications 3 The computerised ignition system provides complete control of the ignition timing by determining the optimum timing in response to engine speed coolant temperature throttle position and vacuum pressure in the intake manifold These parameters are relayed to
368. m but not so tight that they cannot be easily loosened 11 Fill the reservoir with brake fluid of the recommended type see Recommended lubricants and fluids in Chapter 1 12 Remove one plug and push the piston assembly into the master cylinder bore to expel the air from the master cylinder A large Phillips screwdriver can be used to push on the piston assembly 13 To prevent air from being drawn back into the master cylinder the plug must be replaced and tightened before releasing the pressure on the piston assembly 14 Repeat the procedure until only brake fluid is expelled from the brake line outlet hole When only brake fluid is expelled repeat the procedure with the other outlet hole and plug Be sure to keep the master cylinder reservoir filled with brake fluid to prevent the introduction of air into the system 15 Since high pressure is not involved in the bench bleeding procedure an alternative to the removal and renewal of the plugs with each stroke of the piston assembly is available Before pushing in on the piston assembly remove the plug as described in Step 12 Before releasing the piston however instead of replacing the plug simply put your finger tightly over the hole to keep air from 9 8 Braking system 6 7m Apply some clean brake fluid to the secondary piston and refit it with the slot oriented with the stopper pin hole so that the stopper pin will go through the slot 6 7n Apply a coat of clean brake f
369. m or drive cables 5 If the sunroof does not operate and no sound comes from the motor check the fuse see Chapter 1 6 If the fuse is OK remove the control switches see Chapter 11 Disconnect the wires attached to it Turn the ignition ON and check for voltage at the switch If there s no voltage at the switch check for power and earth at the motor If power and earth exist at the motor and there s still no voltage at the switch renew the motor If there s no voltage at the motor check the relay or an open or short in the wiring between the relay and the motor 7 If there s voltage at the switch disconnect it Check the switch for continuity in all its operating positions If the switch does not have continuity renew it 8 If the switch has continuity re connect the switch Locate the wire going from the switch to earth Leaving the switch connected connect a jumper wire between this wire and earth If the motor works normally with this wire in place repair the faulty earth connection 9 The sunroof can be closed manually by inserting the T handle spanner which is located inside the overhead console Insert the spanner into the motor drive shaft and rotate the shaft clockwise see illustration 28 Airbag system general information Warning Failure to follow these precautions could result in accidental deployment of the airbag and personal injury 12 14 Body electrical system 25 6 Check for voltage at the
370. mately a 60 angle see illustration Be sure to use plenty of lubricant and don t take off any more material than is absolutely necessary to produce the desired finish Note Piston ring manufacturers may specify a smaller crosshatch angle than the traditional 60 read and follow any instructions included with the new rings c Don t withdraw the hone from the cylinder while it s running Instead shut off the drill and continue moving the hone up and down in the cylinder until it comes to a complete stop then compress the stones and withdraw the hone If you re using a bottle brush type hone stop the drill motor then turn the chuck in the normal direction of rotation while withdrawing the hone from the cylinder d Wipe the oil out of the cylinder and repeat the procedure for the remaining cylinders 4 After the honing job is complete chamfer the top edges of the cylinder bores with a small file so the rings won t catch when the pistons are installed Be very careful not to nick the cylinder walls with the end of the file 5 The entire engine block must be washed again very thoroughly with warm soapy water to remove all traces of the abrasive grit produced during the honing operation Note The bores can be considered clean when a lint free white cloth dampened with clean engine oil used to wipe them out doesn t pick up any more honing residue which will show up as grey areas on the cloth Be sure to run
371. minal see illustration The SIGNAL wire is the single wire with the rubber sheath covering its terminal 16 Monitor the voltage signal millivolts as the engine goes from cold to warm 17 The oxygen sensor will produce a steady voltage signal at first open loop of approximately 0 1 to 0 2 volts with the engine cold After a period of approximately two minutes the engine will reach operating temperature and the oxygen sensor will start to fluctuate between 0 1 to 0 9 volts closed loop If the oxygen sensor fails to reach the closed loop mode or there is a very long period of time until it does switch into closed loop mode or if the voltage doesn t fluctuate well indicating a lazy sensor renew the oxygen sensor with a new part Renewal Note Because it is installed in the exhaust manifold or pipe which contracts when cool the oxygen sensor may be very difficult to loosen when the engine is cold Rather than risk damage to the sensor assuming you are planning to reuse it in another manifold or pipe start and run the engine for a minute or two then shut it off Be careful not to burn yourself during the following procedure 18 Disconnect the cable from the negative terminal of the battery Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 19 Raise the vehicle and place it securely on axle stands 20 Disconne
372. minor scratches 1 If the scratch is superficial and does not penetrate to the metal of the body repair is very simple Lightly rub the scratched area with a fine rubbing compound to remove loose paint and built up wax Rinse the area with clean water 2 Apply touch up paint to the scratch using a small brush Continue to apply thin layers of paint until the surface of the paint in the scratch is level with the surrounding paint Allow the new paint at least two weeks to harden then blend it into the surrounding paint by rubbing with a very fine rubbing compound Finally apply a coat of wax to the scratch area 3 If the scratch has penetrated the paint and exposed the metal of the body causing the metal to rust a different repair technique is required Remove all loose rust from the bottom of the scratch with a pocket knife then apply rust inhibiting paint to prevent the formation of rust in the future Using a rubber or nylon applicator coat the scratched area with glaze type filler If required the filler can be mixed with thinner to provide a very thin paste which is ideal for filling narrow scratches Before the glaze filler in the scratch hardens wrap a piece of smooth cotton cloth around the tip of a finger Dip the cloth in thinner and then quickly wipe it along the surface of the scratch This will ensure that the surface of the filler is slightly hollow The scratch can now be painted over as described earlier in this sec
373. n after cap 5 loosen caps 6 and 7 alternately until valve spring pressure is relieved 12 Remove the four bolts in each camshaft inner sprocket see illustration The bolts are secured by sheetmetal washer plates Bend down the locking tabs with a hammer and screwdriver tip to remove the bolts Caution Stuff rags below the sprockets while removing the bolts to prevent a bolt from falling down into the front cover 13 Remove the two bolts retaining the upper chain guide to the cylinder head see illustration 14 Pull the inner sprockets from each camshaft see illustration Each camshaft sprocket is comprised of an inner and outer each with a set of fine splines that lock them together The outer sprockets with the teeth can rotate on the camshafts until the inner sprocket bolts are tightened 15 Pull the outer sprockets from the camshafts and allow the chain slacken 16 At this point the camshafts can be carefully lifted straight up and off the cylinder head Take care not to nick any of the lobes or journals during removal 17 Use a magnet to remove the lifters keeping them in order in a divided numbered box see illustration They must be returned to their original location if reusing the original camshafts 18 Removing the lifters exposes the adjusting shims sitting in a pocket in each valve spring retainer see illustration Keep the shims with their matching lifters Measure the thickness of each shim with a
374. n arrowed 11 8 The rear handbrake cable to handbrake shoe connection is hidden behind the lower part of the brake backing plate on the underside of the carrier this view is looking straight up from underneath the carrier To disconnect either rear handbrake cable swing this clip arrowed to the side and remove it the rear cable is now disconnected whenever a fault is suspected the assembly itself should be visually inspected 2 Loosen the wheel nuts raise the rear of the vehicle and place it securely on axle stands Remove the rear wheels 3 Remove the rear brake calipers and discs see Sections 3 4 and 5 Support the caliper assemblies with a coat hanger or heavy wire and do not disconnect the brake line from the caliper 4 With the disc removed the handbrake components are visible and can be inspected for wear and damage The linings should last the life of the vehicle However they can wear down if the handbrake system has been improperly adjusted There is no minimum thickness specification for the handbrake shoes but as a rule of thumb if the shoe material is less 1 32 inch thick you should renew them Also check the springs and adjuster mechanism and inspect the drum for deep scratches and other damage Renewal 5 Loosen the wheel nuts raise the rear of the vehicle and place it securely on axle stands Remove the rear wheels Remove the brake discs see Section 5 Follow the accompanying photo sequen
375. n dioxide and water 2 The catalytic converter fits into the exhaust system much like a silencer Note The exhaust system configuration changes with later model updates Older models 1988 and 1989 are equipped with a pre catalytic converter near the exhaust manifold incorporating a single exhaust pipe to the silencer Later models are equipped with dual exhaust pipes dual catalytic converters and dual silencers Check 3 Periodically inspect the catalytic converter to exhaust pipe mating flanges and bolts Make sure that there are no loose bolts and no leaks between the flanges 4 Look for dents in or damage to the catalytic converter protector If any part of the protector is damaged or dented enough to touch the converter repair or renew it 5 Inspect the heat insulator for damage Make sure there is enough clearance between the heat insulator and the catalytic converter Renewal 6 To renew the catalytic converter refer to Chapter 4 It is recommended that catalytic converters be renewed at a qualified silencer workshop because of the numerous tack welds on the exhaust pipes 6 12 Emissions and engine control systems 3261 Jaguar XJ6 8 7 Disconnect the electrical connector from the electronic heating element 3261 Jaguar XJ6 9 Chapter 9 Braking system General Brake fluid type See Chapter 1 Minimum brake pad thickne
376. n each try of the different controls wait 20 seconds or so for the heater air conditioning system to adjust before checking for a response 8 When each control button is pushed two times its LED light should go on or off Renew the control assembly if any of the warning lights don t work 9 On 1988 and 1989 models if the climate controls do not respond to any driver input check with your Jaguar dealer before renewing the ECU or control panel A service part is available a resistor JLM 1901 that can be installed at one of the control panel terminals that may fix the problem without any other parts being renewed Instructions are included with the part 10 Check the vacuum lines to the several vacuum motors that operate the heater air conditioning functions Look for pinched or blocked hoses and leaks 11 Each of the vacuum servo motors in the system can be checked with a hand held vacuum pump see illustration Apply vacuum and watch that the door or control it operates is working 12 Further diagnosis of the controls or climate control ECU are best left to a Jaguar dealership or other qualified repair facility 13 Air conditioning and heating system check and maintenance 1 Air conditioning system Warning The air conditioning system is under high pressure Do not loosen any hose fittings or remove any components until the system has been discharged Air conditioning refrigerant should be properly discharged i
377. n each one 180 13 Refit the remainder of the sump to engine block bolts hand tight until all are installed then tighten them to the torque listed in this Chapter s Specifications Lastly tighten the two adapter to sump bolts to the torque listed in this Chapter s Specifications Caution Failure to follow this tightening procedure could stress or possibly crack the adapter plate 14 The remainder of refitting is the reverse of removal Be sure to add oil and refit a new oil filter 15 Run the engine and check for oil pressure and leaks 13 Oil pump removal inspection and refitting 4 Removal 1 Remove the sump see Section 12 2 Unbolt the oil pickup tube and oil transfer housing from the engine block see illustration Note Have a drain pan under the transfer housing as oil may drip out when the housing is loosened from the engine block 3 Carefully pull the transfer housing and transfer tubes to the rear to separate them from the oil pump body 4 Bend back the locking tabs and remove the three bolts retaining the oil pump drive sprocket to the oil pump see illustration Pull the chain and sprocket from the front of the pump Note There are shims between the sprocket and the pump Collect them while pulling off the sprocket 5 Remove the bolts and detach the oil pump from the engine 6 Remove all traces of sealant and old gasket material from the oil pump body and engine block then clean the mating surface
378. n in one place Tyres out of balance Damaged or buckled wheel Inspect and replace if necessary Defective tyre Chapter 1 Excessive play or looseness in steering system Wheel bearing s worn Chapter 10 Tie rod end loose or worn Chapter 10 Steering gear loose or worn Chapter 10 Rattling or clicking noise in rack and pinion Insufficient or improper power steering fluid in steering system Chapter 10 Steering gear mounts loose Chapter 10 7 Electrical system Battery will not hold a charge Alternator drivebelt defective or not adjusted properly Chapter 1 Electrolyte level low Chapter 1 Battery terminals loose or corroded Chapter 1 Alternator not charging properly Chapter 5 Loose broken or faulty wiring in the charging circuit Chapter 5 Short in vehicle wiring Chapters 5 and 12 Internally defective battery Chapters 1 and 5 Damaged left rear window harness shorting against glass rail inside door causing battery to drain Chapter 12 Charge warning light fails to go out Faulty alternator or charging circuit Chapter 5 Alternator drivebelt defective or out of adjustment Chapter 1 Alternator voltage regulator inoperative Chapter 5 Charge warning light fails to come on when key is turned on Warning light bulb defective Chapter 12 Fault in the printed circuit dash wiring or bulb holder Chapter 12 3261 Jaguar XJ6 REF 18 Glossary of technical te
379. n ohmmeter to measure the resistance between the two sensor terminals 4 3 Check for reference voltage to the electrical connector for the coolant sensor with the ignition key ON engine not running It should be approximately 5 0 volts e The silicone boot must be installed in the correct position to prevent the boot from being melted and to allow the sensor to operate properly Check 13 Locate the oxygen sensor electrical connector and inspect the oxygen sensor heater Disconnect the oxygen sensor electrical connector and connect an ohmmeter between the two terminals see illustration It should be around 5 to 6 ohms 14 Also check for proper supply voltage to the oxygen sensor heater Measure the voltage with the electrical connector connected Insert a long pin into the backside of the electrical connector on the correct wire With the ignition key ON engine not running check for voltage There should be approximately 12 volts Note Battery voltage to the heater is supplied by the main relay 1988 to 1990 or the oxygen sensor relay 1991 to 1994 Check the oxygen sensor relay and the wiring harness if battery voltage is not available to the heater Refer to the wiring diagrams at the end of Chapter 12 and the relay locator schematics also in Chapter 12 15 Next check for a millivolt signal from the oxygen sensor Locate the oxygen sensor electrical connector and insert a long pin into the oxygen sensor signal wire ter
380. n vacuum is applied the EGR valve is working properly Warning Don t burn yourself If the EGR valve is hot wear a glove or wait until it cools a If the vacuum doesn t remain steady and the engine doesn t run poorly renew the EGR valve and recheck it b If the vacuum remains steady but the engine doesn t run poorly remove the EGR valve and check the valve and the intake manifold for blockage Clean or renew parts as necessary and recheck EGR system 6 Disconnect the hose from the EGR valve refit a vacuum gauge and check for vacuum to the EGR valve There should be vacuum present with the engine warmed to operating temperature above 140 F and between 1000 and 4000 rpm see illustration Emissions and engine control systems 6 9 6 3261 Jaguar XJ6 6 2 Schematic of the EGR system 6 4 Apply vacuum to the EGR valve and confirm that the valve opens and allows exhaust gases to circulate Once it is activated the EGR valve should hold steady no loss in vacuum 6 5 Use a fingertip to move the diaphragm inside the EGR valve 6 6 Check for vacuum to the EGR valve from the throttle body 7 Start the engine and observe the vacuum gauge At idle there should be no vacuum present Raise the engine rpm and observe the vacuum increase This is a ported vacuum source and therefore it should only register vacuum when throttled 8 Check the operation of the EGR control solenoid Check for battery voltage to the EGR con
381. nch Torque wrench settings Nm lbf ft Main bearing cap bolts 136 to 142 100 to 105 Connecting rod cap nuts 50 to 60 37 to 44 Note Refer to Part A for additional torque specifications 2B 2 Engine removal and overhaul procedures 3261 Jaguar XJ6 1 General information Included in this portion of Chapter 2 are the general overhaul procedures for the cylinder head and internal engine components The information ranges from advice concerning preparation for an overhaul and the purchase of replacement parts to detailed step by step procedures covering removal and refitting of internal engine components and the inspection of parts The following Sections have been written based on the assumption that the engine has been removed from the vehicle For information concerning in vehicle engine repair as well as removal and refitting of the external components necessary for the overhaul see Part A of this Chapter The Specifications included in this Part are only those necessary for the inspection and overhaul procedures which follow Refer to Part A for additional Specifications 2 Engine overhaul general information It s not always easy to determine when or if an engine should be completely overhauled as a number of factors must be considered High mileage is not necessari
382. nd burned areas at the edge of the crown If the skirt is scored or scuffed the engine may have been suffering from overheating and or abnormal combustion which caused excessively high operating temperatures The cooling and lubrication systems should be checked thoroughly A hole in the piston crown is an indication that abnormal combustion pre ignition was occurring Burned areas at the edge of the piston crown are usually evidence of spark knock detonation If any of the above problems exist the causes must be corrected or the damage will occur again The causes may include intake air leaks incorrect air fuel mixture incorrect ignition timing and EGR system malfunctions 9 Corrosion of the piston in the form of small pits indicates that coolant is leaking into the combustion chamber and or the crankcase Again the cause must be corrected or the problem may persist in the rebuilt engine 10 Measure the piston ring groove clearance by laying a new piston ring in each ring groove and slipping a feeler gauge in beside it see illustration Check the clearance at three or four locations around each groove Be sure to use the correct ring for each groove they are different If the clearance is greater than that listed in this Chapter s Specifications new pistons will have to be used 11 Check the piston to bore clearance by measuring the bore see Section 16 and the piston diameter Make sure the pistons and bores are cor
383. nd fuses 4 Check 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 4 Visually 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 3 1 0 16 Lubricants fluids and tyre pressures 3261 Jaguar XJ6 Lubricants and fluids Engine Multigrade engine oil to API SG or higher Duckhams QS QXR Hypergrade Pl
384. nd other test equipment also 1 With the ignition switch turned to the ON position a Battery light or an Oil Pressure light is a basic check for ignition and battery supply to the ECU 2 Check all ignition wiring connections for tightness cuts corrosion or any other signs of a bad connection 3 Use a calibrated ignition tester to verify adequate secondary voltage 25 000 volts at each spark plug see illustration A faulty or poor connection at that plug could also result in a misfire Also check for carbon deposits inside the spark plug boot 4 Check for carbon tracking on the coil If carbon tracking is evident renew the coil and be sure the secondary wires related to that coil are clean and tight Excessive wire resistance or faulty connections could damage the coil 5 Check for battery voltage to the ignition coil see illustration If battery voltage is available check the ignition coil primary and secondary resistance see Section 8 6 Check the distributor cap for any obvious signs of carbon tracking corroded terminals or cracks see Chapter 1 7 Using an ohmmeter check the resistance of the spark plug leads Each wire should measure less than 25 000 ohms 8 Check for battery voltage to the ignition amplifier see Section 7 If battery voltage does not exist check the circuit from the ignition switch refer to the wiring diagrams at the end of Chapter 12 5 2 Engine electrical systems 6 3 To us
385. nel wagon van Van Parking brake Handbrake Parking light Sidelight Pinging Pinking Piston pin or wrist pin Gudgeon pin Piston pin or wrist pin Small end little end Pitman arm Drop arm Power brake booster Servo unit Primary shoe of brake Leading shoe of brake Prussian blue Engineer s blue Pry Prise force apart Prybar Lever Prying Levering Quarter window Quarterlight Recap Retread Release cylinder Slave cylinder Repair shop Garage Replacement Renewal Ring gear of differential Crownwheel Rocker panel beneath doors Sill panel beneath doors Rod bearing Big end bearing Rotor disk Disc brake Secondary shoe of brake Trailing shoe of brake Sedan Saloon Setscrew Allen screw Grub screw Shock absorber shock Damper Snap ring Circlip Soft top Hood Spacer Distance piece Spare tire Spare wheel Spark plug wires HT leads Spindle arm Steering arm Stabilizer or sway bar Anti roll bar Station wagon Estate car Stumbles Hesitates Tang or lock Tab washer Throw out bearing Thrust bearing Tie rod or connecting rod of steering Trackrod Tire Tyre Transmission Gearbox Troubleshooting Fault finding diagnosis Trunk Boot luggage compartment Turn signal Indicator TV throttle valve cable Kickdown cable Unpublicized Unpublicised Valve cover Rocker cover Valve lifter Tappet Valve lifter or tappet Cam follower or tappet Vapor Vapour Vise Vice Wheel cover Roadwheel trim Whole drive lin
386. nformation Warning Do not allow antifreeze to come in contact with your skin or painted surfaces of the vehicle Rinse off spills immediately with plenty of water Antifreeze is highly toxic if ingested Never leave antifreeze lying around in an open container or in puddles on the floor children and pets are attracted by it s sweet smell and may drink it Check with local authorities about disposing of used antifreeze Many communities have collection centres which will see that antifreeze is disposed of safely Never dump used antifreeze on the ground or into drains Note Non toxic antifreeze is now manufactured and available at local car accessory outlets but even these types should be disposed of properly The cooling system should be filled with a water ethylene glycol based antifreeze solution which will prevent freezing down to at least 20 F or lower if local climate requires it It also provides protection against corrosion and increases the coolant boiling point The cooling system should be drained flushed and refilled every 24 000 miles or every two years see Chapter 1 The use of antifreeze solutions for periods of longer than two years is likely to cause damage and encourage the formation of rust and scale in the system If your tap water is hard i e contains a lot of dissolved minerals use distilled water with the antifreeze Before adding antifreeze to the system check all hose connections
387. ng Faulty thermostat Chapter 3 External coolant leakage Deteriorated damaged hoses loose clamps Chapters 1 and 3 Water pump seal defective Chapters 1 and 3 Leakage from radiator core or manifold tank Chapter 3 Engine drain or water jacket core plugs leaking Chapter 2 Hoses behind water pump leaking Chapter 3 Internal coolant leakage Leaking cylinder head gasket Chapter 2 Cracked cylinder bore or cylinder head Chapter 2 Coolant loss Too much coolant in system Chapter 1 Coolant boiling away because of overheating Chapter 3 Internal or external leakage Chapter 3 Faulty radiator cap Chapter 3 Poor coolant circulation Inoperative water pump Chapter 3 Restriction in cooling system Chapters 1 and 3 Water pump drivebelt defective out of adjustment Chapter 1 Thermostat sticking Chapter 3 1 Engine continued 3261 Jaguar XJ6 Fault finding REF 15 4 Automatic transmission Note Due to the complexity of the automatic transmission it is difficult for the home mechanic to properly diagnose and service this component For problems other than the following the vehicle should be taken to a dealer or transmission workshop Fluid leakage Automatic transmission fluid is a deep red colour Fluid leaks should not be confused with engine oil which can easily be blown by air flow to the transmission To pinpoint a leak first remove all built up dirt and grime
388. ng noise Electrical system 7 Battery will not hold a charge Discharge warning light fails to come on when key is turned on Discharge warning light fails to go out 3261 Jaguar XJ6 Fault finding REF 13 1 Engine Engine will not rotate when attempting to start Battery terminal connections loose or corroded Chapter 1 Battery discharged or faulty Chapter 1 Damaged left rear window harness shorting against glass rail inside door causing battery to drain Chapter 12 Automatic transmission not completely engaged in Park Chapter 7 Broken loose or disconnected wiring in the starting circuit Chapters 5 and 12 Starter motor pinion jammed in flywheel ring gear Chapter 5 Starter solenoid faulty Chapter 5 Starter motor faulty Chapter 5 Ignition switch faulty Chapter 12 Starter pinion or flywheel teeth worn or broken Chapter 5 Internal engine problem Chapter 2B Inertia switch activated Chapter 12 Starter relay defective Chapter 5 Engine rotates but will not start Fuel tank empty Battery discharged engine rotates slowly Chapter 5 Battery terminal connections loose or corroded Chapter 1 Leaking fuel injector s faulty fuel pump pressure regulator etc Chapter 4 Fuel not reaching fuel injection system Chapter 4 Ignition components damp or damaged Chapter 5 Fuel injector stuck open Chapter 4 Worn faul
389. ng pistons connecting rod assemblies 23 The important points to remember are a Keep the back sides of the bearing inserts and the insides of the connecting rods and caps perfectly clean during assembly b Make sure you have the correct piston connecting rod assembly for each cylinder c The dimple on the piston must face the front of the engine d Lubricate the cylinder walls with clean oil e Lubricate the bearing faces when refitting the rod caps after the oil clearance has been checked 24 After all the piston connecting rod assemblies have been properly installed rotate the crankshaft a number of times by hand to check for any obvious binding 25 As a final step the connecting rod endplay must be checked Refer to Section 13 for this procedure 26 Compare the measured endplay to this Chapter s Specifications to make sure it s correct If it was correct before dismantling and the original crankshaft and connecting rods were reinstalled it should still be right However if new connecting rods or a new crankshaft were installed the endplay may be inadequate If so the connecting rods will have to be removed and taken to an automotive machine workshop for resizing 26 Initial start up and running in after overhaul 1 Warning Have a suitable fire extinguisher handy when starting the engine for the first time 1 Once the engine has been installed in the vehicle double check the engine oil and coolant levels 2 Wit
390. ng tool Electric drill motor Tap and die set Wire brushes Oil gallery brushes Cleaning solvent Special Jaguar tools Engine lifting brackets 18G 1465 Timing damper simulator 18E 1436 Camshaft TDC tool 18G 1433 9 Cylinder head dismantling 2 Note New and rebuilt cylinder heads are available from Jaguar and some independent rebuilders Due to the fact that some specialised tools are necessary for the dismantling and inspection procedures and replacement parts may not be readily available it may be more practical and economical for the home mechanic to purchase a replacement cylinder head rather than taking the time to dismantle inspect and recondition the original 1 Cylinder head dismantling involves removal of the intake and exhaust valves and related components It s assumed that the lifters and camshafts have already been removed see Part A as needed 2 Before the valves are removed arrange to label and store them along with their related components so they can be kept separate and reinstalled in the same valve guides they are removed from see illustration 3 Compress the springs on the first valve with a spring compressor and remove the keepers see illustration Carefully release the valve spring compressor and remove the retainer the spring and the spring seat if used Note If your spring compressor does not have an end such as the one shown with cut outs on the side an adapter is available to use w
391. ngine is rebuilt Before beginning the engine overhaul read through the entire procedure to familiarise yourself with the scope and requirements of the job Overhauling an engine isn t difficult but it is time consuming Plan on the vehicle being tied up for a minimum of two weeks especially if parts must be taken to an automotive machine workshop for repair or reconditioning Check on availability of parts and make sure that any necessary special tools and equipment are obtained in advance Most work can be done with typical hand tools although a number of precision measuring tools are required for inspecting parts to determine if they must be renewed Often an automotive machine workshop will handle the inspection of parts and offer advice concerning reconditioning and renewal Note Always wait until the engine has been completely dismantled and all components especially the engine block have been inspected before deciding what service and repair operations must be performed by an automotive machine workshop Since the engine block s condition will be the major factor to consider when determining whether to overhaul the original engine or buy a rebuilt one never purchase parts or have machine work done on other components until the engine block has been thoroughly inspected As a general rule time is the primary cost of an overhaul so it doesn t pay to refit worn or substandard parts If it turns out that a number of ma
392. ngine control systems 6 8 Check for battery voltage to the EGR control solenoid 3261 Jaguar XJ6 7 2 Schematic of the EVAP system canister If fuel is leaking renew the canister and check the hoses and hose routing 9 Inspect the canister If it s cracked or damaged renew it 10 Check for a clogged filter or a damaged pressure relief valve Using low pressure compressed air such as from a tyre pump blow into the canister tank pipe Air should flow freely from the other pipes If a problem is found renew the canister 11 Check the operation of the thermal vacuum valve TVV With the engine cold and idling check for ported vacuum to the temperature vacuum switch Vacuum should be present see illustration Now warm the engine to operating temperature above 115 F 43 C and confirm that ported vacuum passes through the TVV see illustration Renew the valve if the test results are incorrect 12 Check the operation of the purge control valve Apply vacuum to the purge control valve using a hand held vacuum pump and observe that the valve holds vacuum steadily see illustration If the valve holds vacuum and the valve is opening it is working properly Charcoal canister renewal 13 Clearly label then detach the vacuum hoses from the canister 14 Remove the mounting clamp bolts see illustration lower the canister with the bracket disconnect the hoses from the check valve and remove it from the vehicle 15 Refit
393. nk pressure control valve purge control valve and thermal vacuum valve TVV see illustration Note 1993 and 1994 models have a purge control solenoid that is controlled by the ECU This solenoid switches vacuum to the purge control valve 3 Fuel vapours are transferred from the fuel tank and throttle body to a canister where they re stored when the engine isn t running When the engine is running the fuel vapours are purged from the canister by intake airflow and consumed in the normal combustion process Note The ECU will set a code 89 if the purge control valve is defective or the circuit has shorted 4 The fuel tank is equipped with a pressure control valve This valve opens and closes according to the pressure increase and decrease in the fuel tank Check 5 Poor idle stalling and poor driveability can all be caused by an inoperative pressure relief valve split or cracked hoses or hoses connected to the wrong fittings Check the fuel tank filler cap for a damaged or deformed gasket 6 Evidence of fuel loss or fuel odour can be caused by liquid fuel leaking from fuel lines a cracked or damaged canister an inoperative fuel tank control valve disconnected misrouted kinked deteriorated or damaged vapour or control hoses 7 Inspect each hose attached to the canister for kinks leaks and cracks along its entire length Repair or renew as necessary 8 Look for fuel leaking from the bottom of the 6 10 Emissions and e
394. ns and allows hot coolant to travel through the radiator where it is cooled before returning to the engine The cooling system is sealed by a pressure type radiator cap This raises the boiling point of the coolant and the higher boiling point of the coolant increases the cooling efficiency of the radiator If the system pressure exceeds the cap pressure relief value the excess pressure in the system forces the spring loaded valve inside the cap off its seat and allows the coolant to escape through the overflow tube into a coolant reservoir When the system cools the excess coolant is automatically drawn from the reservoir back into the radiator This type of cooling system is known as a closed design because coolant that escapes past the pressure cap is saved and reused The Jaguar cooling system on 1988 and 1989 models has both a manifold tank and a coolant recovery tank The manifold tank is the highest point in the cooling system and is the location of the radiator cap the cap is not on the radiator The recovery tank down in the passenger s footwell collects heated coolant as described above Models from 1990 to 1994 do not have a coolant recovery tank but have an enlarged manifold tank In all models the recovery tank has a sensor in it to detect a low coolant level and the instrument panel has a warning light to that effect Heating system The heating system consists of two blower fans one under the dash on th
395. nsmission 4 Engine will start in gears other than Park or Neutral Fluid leakage Shift cable problems Transmission fluid brown or has a burned smell Transmission slips shifts roughly is noisy or has no drive in forward or reverse gears Transmission will not downshift with accelerator pedal pressed to the floor Brakes 5 Brake pedal feels spongy when depressed Brake pedal travels to the floor with little resistance Brake roughness or chatter pedal pulsates Dragging brakes Excessive brake pedal travel Excessive pedal effort required to stop vehicle Grabbing or uneven braking action Noise high pitched squeal when the brakes are applied Handbrake does not hold Vehicle pulls to one side during braking Suspension and steering systems 6 Abnormal noise at the front end Abnormal or excessive tyre wear Cupped tyres Erratic steering when braking Excessive pitching and or rolling around corners or during braking Excessive play or looseness in steering system Excessive tyre wear on inside edge Excessive tyre wear on outside edge Hard steering Poor returnability of steering to centre Rattling or clicking noise in rack and pinion Shimmy shake or vibration Suspension bottoms Tyre tread worn in one place Vehicle pulls to one side Wander or poor steering stability Wheel makes a thumpi
396. nsor facing the disc the wire inside the sensor is broken the circuit is opened and the red light on the instrument panel comes on Always check the sensor s when replacing the pads If you change the pads before the warning light comes on the sensor s may still be good once the light has come on renew the sensor Service After completing any operation involving dismantling of any part of the brake system always test drive the vehicle to check for proper braking performance before resuming normal driving When testing the brakes perform the tests on a clean dry flat surface Conditions other than these can lead to inaccurate test results Test the brakes at various speeds with both light and heavy pedal pressure The vehicle should stop evenly without pulling to one side or the other Avoid locking the brakes because this slides the tyres and diminishes braking efficiency and control of the vehicle Tyres vehicle load and wheel alignment are factors which also affect braking performance 2 Anti lock Brake system ABS general information The Anti lock Brake System is designed to maintain vehicle steerability directional stability and optimum deceleration under severe braking conditions on most road surfaces It does so by monitoring the rotational speed of each wheel and controlling the brake line pressure to each wheel during braking This prevents the wheels from locking up The ABS system has three main units
397. nspection and renewal 2 Warning Petrol is extremely flammable so take extra precautions when you work on any part of the fuel system See the Warning in Section 2 Note If there is a distinct knocking noise coming from the dash when the engine is idling the fuel feed hose may have hardened restricting fuel flow and causing abnormal sounds Replace the fuel inlet feed hose with a new one Inspection 1 Once in a while you will have to raise the vehicle to service or renew some component an exhaust pipe hanger for example Whenever you work under the vehicle always inspect fuel lines and all fittings and connections for damage or deterioration 2 Check all hoses and pipes for cracks kinks deformation or obstructions 3 Make sure all hoses and pipe clips attach their associated hoses or pipes securely to the underside of the vehicle 4 Verify all hose clamps attaching rubber hoses to metal fuel lines or pipes are a tight fit between the hoses and pipes Renewal 5 If you must renew any damaged sections use hoses or pipes constructed from exactly the same material as the section you are replacing Do not refit substitutes constructed from inferior or inappropriate material or you could cause a fuel leak or a fire 6 Always before detaching or disassembling any part of the fuel line system note the routing of all hoses and pipes and the orientation of all clamps and clips to assure that new sections are identical
398. nt 12 Alternator removal and refitting 2 1 Detach the cable from the negative terminal of the battery Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 2 Detach the electrical connectors from the alternator 3 Loosen the alternator adjustment and pivot bolts see illustration and detach the drivebelt 4 Remove the adjustment and pivot bolts see illustration from the alternator adjustment bracket 5 If you are replacing the alternator take the old alternator with you when purchasing a replacement unit Make sure that the new rebuilt unit is identical to the old alternator Look at the terminals they should be the same in number size and locations as the terminals on the old alternator Finally look at the identification markings they will be stamped in the housing or printed on a tag or plaque affixed to the housing Make sure that these numbers are the same on both alternators 6 Many new rebuilt alternators do not have a pulley installed so you may have to switch the pulley from the old unit to the new rebuilt one When buying an alternator find out the policy regarding refitting of pulleys some shops will perform this service free of charge 7 Refitting is the reverse of removal 5 6 Engine electrical systems 12 3 Loosen the lock bolt and back off the adjustment bolt arrowed to remove the dri
399. ntained properly then they don t have to be rebored Honing is all that s necessary refer to Section 17 17 Cylinder honing 3 1 Prior to engine reassembly the cylinder bores must be honed so the new piston rings will seat correctly and provide the best possible combustion chamber seal Note If you don t have the tools or don t want to tackle the honing operation most automotive machine shops will do it for a reasonable fee 2 Before honing the cylinders refit the main bearing caps without bearing inserts and tighten the bolts to the specified torque 3 Two types of cylinder hones are commonly available the flex hone or bottle brush type and the more traditional surfacing hone with spring loaded stones Both will do the job but for the less experienced mechanic the bottle brush hone will probably be easier to use You ll also need some paraffin or honing oil rags and a variable speed electric drill motor The drill motor should be operated at a steady slow speed Proceed as follows a Mount the hone in the drill motor compress the stones and slip it into the first cylinder see illustration Warning Be sure to wear safety goggles or a face shield b Lubricate the cylinder with plenty of honing oil turn on the drill and move the hone up and down in the cylinder at a pace that will produce a fine crosshatch pattern on the cylinder walls Ideally the crosshatch lines should intersect at approxi
400. nto an EPA approved recovery recycling unit by a dealer service department or an automotive air conditioning repair facility Always wear eye protection when working near air conditioning system fittings 1 The following maintenance checks should be performed on a regular basis to ensure that the air conditioner continues to operate at peak efficiency a Inspect the condition of the compressor drivebelt If it is worn or deteriorated renew it see Chapter 1 b Check the drivebelt tension and if necessary adjust it see Chapter 1 c Inspect the system hoses Look for cracks bubbles hardening and deterioration Inspect the hoses and all fittings for oil bubbles or seepage If there is any evidence of wear damage or leakage renew the hose s d Inspect the condenser fins for leaves bugs and any other foreign material that may have embedded itself in the fins Use a fin comb or compressed air to remove debris from the condenser e Make sure the system has the correct refrigerant charge 2 It s a good idea to operate the system for about ten minutes at least once a month This is particularly important during the winter months because long term non use can cause hardening and subsequent failure of the seals 3 Leaks in the air conditioning system are best spotted when the system is brought up to operating temperature and pressure by running the engine with the air conditioning ON for five minutes Shut the eng
401. number 1 then mark and remove the distributor see Chapter 5 6 Refer to Section 11 and remove the cylinder head After cylinder head removal the upper timing chain will be loosely retained by the two upper chain guides which are retained by refitting a large rubber band see Section 10 Caution Do not rotate the crankshaft with the upper timing chain disconnected and the cylinder head and camshafts in place or damage could result from piston to valve contact 7 Some models may be equipped with a hydraulic pump used for the brake servo hydraulic self levelling suspension system If equipped it will be mounted to the front cover Models not equipped with this option will have a flat block off plate over the hole If equipped with the pump refer to Chapters 9 and 10 for procedures to reduce the high pressure in the brake servo system and to depressurise the self levelling system Before removing the engine unbolt the pump from the front cover and set it aside without disconnecting the hoses see illustration 8 Refer to Section 7 and remove the crankshaft pulley and damper Refer to Section 12 for removal of the sump 9 If equipped with the hydraulic pump remove the coupling disc and unbolt the drive coupling from the intermediate shaft see illustrations 2A 6 Engine in car repair procedures 8 7 Unbolt the hydraulic pump arrowed from the front cover without disconnecting the hoses 3261 Jaguar XJ6 7 9 Remove
402. o pinch the disc when the brakes are applied A caliper is also a measuring tool that can be set to measure inside or outside dimensions of an object Camshaft A rotating shaft on which a series of cam lobes operate the valve mechanisms The camshaft may be driven by gears by sprockets and chain or by sprockets and a belt Canister A container in an evaporative emission control system contains activated charcoal granules to trap vapours from the fuel system Carburettor A device which mixes fuel with air in the proper proportions to provide a desired power output from a spark ignition internal combustion engine Castellated Resembling the parapets along the top of a castle wall For example a castellated balljoint stud nut Castor In wheel alignment the backward or forward tilt of the steering axis Castor is positive when the steering axis is inclined rearward at the top Canister Brake bleeding Bearing Air filter 3261 Jaguar XJ6 Glossary of technical terms REF 19 Catalytic converter A silencer like device in the exhaust system which converts certain pollutants in the exhaust gases into less harmful substances Circlip A ring shaped clip used to prevent endwise movement of cylindrical parts and shafts An internal circlip is installed in a groove in a housing an external circlip fits into a groove on the outside of a cylindrical piece such as a shaft Clearance The amount of space between two parts For ex
403. o help the average owner to decide which tools are needed to carry out the various tasks detailed in this manual we have compiled three lists of tools under the following headings Maintenance and minor repair Repair and overhaul and Special Newcomers to practical mechanics should start off with the Maintenance and minor repair tool kit and confine themselves to the simpler jobs around the vehicle Then as confidence and experience grow more difficult tasks can be undertaken with extra tools being purchased as and when they are needed In this way a Maintenance and minor repair tool kit can be built up into a Repair and overhaul tool kit over a considerable period of time without any major cash outlays The experienced do it yourselfer will have a tool kit good enough for most repair and overhaul procedures and will add tools from the Special category when it is felt that the expense is justified by the amount of use to which these tools will be put Maintenance and minor repair tool kit The tools given in this list should be considered as a minimum requirement if routine maintenance servicing and minor repair operations are to be undertaken We recommend the purchase of combination spanners ring one end open ended the other although more expensive than open ended ones they do give the advantages of both types of spanner Combination spanners Metric 8 to 19 mm inclusive Adjustable spanner 35 mm jaw approx Sp
404. of the steering column or instrument panel The manufacturer recommends that on airbag equipped models the following procedure should be left to a dealer service department or other repair workshop because of the special tools and techniques required to disable the airbag system Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 8 Remove the lower instrument panel on the passenger side under the glove compartment see Chapter 11 9 Remove the glove compartment from the passenger compartment see Chapter 11 10 Remove the screws from the ECU bracket see illustration 11 Lower the ECU and unplug the electrical connectors 12 Refitting is the reverse of removal 3 On Board Diagnosis OBD system description and fault code access 2 Note 1990 and 1991 models may set Code 69 erroneously If the battery voltage drops sufficiently and the ignition key is switched quickly from OFF to START battery voltage will be lowered and during cranking causing a delayed park neutral signal from the decoder module to the ECU Check all the battery connections and the condition of the battery and then check the rotary switch adjustment in Chapter 7 to remedy this code General information 1 The ECU contains a built in self diagnosis system which detects and identifies malfunctions occurring in the network When the ECU d
405. of cracks in the porcelain insulator of a plug don t use it 4 Check the electrode gaps of the new plugs Check the gap by inserting the wire gauge of the proper thickness between the electrodes at the tip of the plug see illustration The gap between the electrodes should be identical to that listed in this Chapter s Specifications or on the VECI label as applicable If the gap is incorrect use the notched adjuster on the feeler gauge body to bend the curved side electrode slightly see illustration 5 If the side electrode is not exactly over the centre electrode use the notched adjuster to align them Caution If the gap of a new plug must be adjusted bend only the base of the earth electrode do not touch the tip Removal 6 To prevent the possibility of mixing up spark plug leads work on one spark plug at a time Remove the lead and boot from one spark plug Grasp the boot not the lead as shown give it a half twisting motion and pull straight up see illustration 7 If compressed air is available blow any dirt or foreign material away from the spark plug area before proceeding a common bicycle pump will also work 8 Remove the spark plug see illustration 9 Whether you are replacing the plugs at this time or intend to re use the old plugs compare each old spark plug with the chart shown on the inside back cover of this manual to determine the overall running condition of the engine Refitting 10
406. ols required If a problem is encountered seek advice from a parts specialist or a dealer service department 2 Intensive maintenance 1 If from the time the vehicle is new the routine maintenance schedule is followed closely and frequent checks are made of fluid levels and high wear items as suggested throughout this manual the engine will be kept in relatively good running condition and the need for additional work will be minimised 2 It is possible that there will be times when the engine is running poorly due to the lack of regular maintenance This is even more likely if a used vehicle which has not received regular and frequent maintenance checks is purchased In such cases additional work may need to be carried out outside of the regular maintenance intervals 3 If engine wear is suspected a compression test refer to Chapter 2 will provide valuable information regarding the overall performance of the main internal components Such a test can be used as a basis to decide on the extent of the work to be carried out If for example a compression test indicates serious internal engine wear conventional maintenance as described in this Chapter will not greatly improve the performance of the engine and may prove a waste of time and money unless extensive overhaul work is carried out first 4 The following series of operations are those which are most often required to improve the performance of a generally poor runn
407. om the horn 2 To test the horn connect battery voltage to the two terminals with a pair of jumper wires If the horn doesn t sound renew it 3 If the horn does sound check for voltage at the terminal when the horn button is depressed see illustration If there s voltage at the terminal check for a bad earth at the horn 4 If there s no voltage at the horn check the relay see Section 6 Note that most horn relays are either the four terminal or externally earthed three terminal type 5 If the relay is OK check for voltage to the relay power and control circuits If either of the circuits are not receiving voltage inspect the wiring between the relay and the fuse panel 6 If both relay circuits are receiving voltage depress the horn button and check the circuit from the relay to the horn button for continuity to earth If there s no continuity check the circuit for an open If the circuit is good renew the horn button 7 If there s continuity to earth through the horn button check for an open or short in the circuit from the relay to the horn Renewal 8 Remove the radiator grille inserts see Chapter 11 9 Disconnect the electrical connector and remove the retaining nuts securing the horn brackets see illustration 10 Refitting is the reverse of removal 21 Bulb renewal 1 Front direction indicator rear parking and side marker lights 1 Remove the lens retaining screws and the lens see illustration
408. on 2 Self levelling rear suspension system 1988 to 1992 models were equipped with a system that provided hydraulic power for the rear suspension and for the power brakes As the vehicle is loaded or unloaded the rear suspension is automatically adjusted to maintain a constant ride height The system was discontinued on 1993 and later models which are equipped with conventional shock absorber coil spring units A kit is available from your Jaguar dealer should you decide to retrofit the later conventional shocks to a pre 1993 vehicle Complete instructions for refitting the kit are included in Section 10 3 Anti roll bar front removal and refitting 2 1 Raise the front of the vehicle and support it securely on axle stands 2 Remove the bolts from the anti roll bar brackets that attach the anti roll bar to the suspension crossmember see illustration 3 Remove the nuts that attach the anti roll bar to the links see illustration If you re replacing the links themselves or removing the control arm remove the nuts attaching the links to the lower control arms Suspension and steering systems 10 3 10 1 3 Rear suspension 1 Hub carrier 2 Control arms 3 Crossmember mounting brackets 4 Crossmember 3 2 To detach the anti roll bar from the suspension crossmember remove these two bolts arrowed from each bushing bracket 3261 Jaguar XJ6 4 Remove the anti roll bar from the vehicle 5 Refitting is the reverse
409. on 6 Jump starting 3261 Jaguar XJ6 0 8 Roadside repairs The spare wheel and tools are stored in the boot Remove the carpet cover then unscrew the retainer and lift out the spare wheel from the boot Wheel changing Some of the details shown here will vary according to model For instance the location of the spare wheel and jack is not the same on all cars However the basic principles apply to all vehicles Warning Do not change a wheel in a situation where you risk being hit by other traffic On busy roads try to stop in a lay by or a gateway Be wary of passing traffic while changing the wheel it is easy to become distracted by the job in hand Finally Remove the wheel chocks Check the tyre pressure on the wheel just fitted If it is low or if you don t have a pressure gauge with you drive slowly to the nearest garage and inflate the tyre to the right pressure Have the damaged tyre or wheel repaired as soon as possible Remove the plastic cover from the end of the vehicle jack lifting point tube nearest to the wheel that is being changed Slide the lifting bracket of the jack fully into the lifting point tube Make sure the jack is located on firm ground Raise the jack until the wheel is raised clear of the ground Unscrew the wheel nuts and remove the wheel Fit the spare wheel and screw on the nuts Lightly tighten the nuts then lower the vehicle to the ground With the vehicle on the
410. on 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 more often 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 Carry out all the operations given in Weekly checks at the start of this manual Renew the fuel filter Section 18 Check the ignition system components Section 19 Check the crankcase ventilation system Section 20 Check the condition and tension of the drivebelt s Section 21 Check the front wheel bearing adjustment and repack with grease Section 22 Check the propshaft fasteners are tightened to the specified torque Section 23 Check the front wheel alignment Section 24 Check 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 Renew the engine oil and filter Section 3 Check the spark plugs Secti
411. on 4 Check the power hydraulics fluid level Section 5 Check the battery Section 6 Check all pipes and hoses for signs of damage or leakage Section 7 Check the automatic transmission fluid level Section 8 Check the differential oil level Section 9 Check the condition of the exhaust system Section 10 Check the brake pads and discs for wear and adjust the handbrake Section 11 Check the steering and suspension components for wear or damage and check the wheel nuts are tightened to the correct torque Section 12 Check the condition of the seat belts Section 13 Lubricate all locks and hinges and exposed cables Section 14 Carry out a road test Section 15 Every 2 years regardless of mileage Renew the coolant Section 30 Every 60 000 miles 96 000 km In addition to the operations listed previously carry out the following Check 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 Renew the automatic transmission fluid and filter Section 26 Renew the differential oil Section 27 Renew 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 Renew the spark plugs Section 16 Renew the air cleaner element Section 17 1 4 Maintenance component lo
412. on of hydraulic line 11 If you installed another pair of self levelling shocks or removed and installed the same pair of self levelling shocks be sure to top up the power hydraulic system reservoir see Chapter 1 11 Hub carrier rear removal and refitting 4 1 Loosen the wheel nuts raise the rear of the vehicle and support it securely on axle stands Remove the wheel 2 Remove the rear caliper and brake pads the caliper bracket the brake disc the handbrake cable and the handbrake shoe assembly see Chapter 9 3 Disconnect the outer end of the propshaft from the hub carrier see Chapter 8 4 Remove the ABS sensor the ABS harness clip and cut off the cable tie which secures the ABS harness to the carrier see illustration 5 Remove the nut and bolt which attach the carrier to the control arm see illustration 6 Remove the hub carrier assembly 7 Refitting is the reverse of removal Be sure to tighten all fasteners to the torque values listed in this Chapter s Specifications 12 Hub and bearing rear renewal 4 If you want to renew the rear hub and bearing assembly or the ABS trigger wheel remove the hub carrier see Section 11 then take the carrier to a Jaguar dealer service department or to an automotive machine workshop These parts require a hydraulic press and special fixtures to dismantle and reassemble 13 Control arm rear removal and refitting 4 1 Loosen the wheel nuts raise the rear of
413. on the ground and extra 1 7 litres of fluid should be added to the transmission prior to towing this extra fluid must be drained before driving the vehicle Even with the extra fluid added to the transmission do not tow the vehicle at speeds in excess of 30 mph 50 kmh or for a distance of greater than 15 miles 25 km If towing speed distance are to exceed these limits then the vehicle must be towed with its rear wheels off the ground Towing Puddles on the garage floor or drive or obvious wetness under the bonnet or underneath the car suggest a leak that needs investigating It can sometimes be difficult to decide where the leak is coming from especially if the engine bay is very dirty already Leaking oil or fluid can also be blown rearwards by the passage of air under the car giving a false impression of where the problem lies Warning Most automotive oils and fluids are poisonous Wash them off skin and change out of contaminated clothing without delay The smell of a fluid leaking from the car may provide a clue to what s leaking Some fluids are distinctively coloured It may help to clean the car and to park it over some clean paper as an aid to locating the source of the leak Remember that some leaks may only occur while the engine is running Sump oil Gearbox oil Brake fluid Power steering fluid Oil from filter Antifreeze Engine oil may leak from the drain plug or from the base of t
414. ones if they are damaged see Chapter 10 13 Seat belt check 1 1 Check the seat belts buckles latch plates and guide loops for any obvious damage or signs of wear 2 Make sure the seat belt reminder light comes on when the key is turned on 3 The seat belts are designed to lock up during a sudden stop or impact yet allow free movement during normal driving The retractors should hold the belt against your chest while driving and rewind the belt when the buckle is unlatched 4 If any of the above checks reveal problems with the seat belt system replace parts as necessary Note Check with your local dealer service department the seat belt system should be covered under the factory warranty 14 General lubrication 2 1 Obtain a good quality multi purpose lithium base grease You ll also need a grease gun and other materials to properly lubricate the chassis see illustration Occasionally plugs will be installed rather than grease fittings If so grease fittings will have to be purchased and installed 2 Look under the car and see if grease fittings or plugs are installed If there are plugs remove them and buy grease fittings which will thread into the component A dealer or motor factors will be able to supply the correct fittings Straight as well as angled fittings are available 3 For easier access under the car raise it with a jack and place axle stands under the chassis Make sure it s safely supported by
415. onnect the cable from the negative battery terminal Turn the fan by hand Some resistance should be felt If the fan turns easily renew the fan clutch Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Removal and refitting 6 Leave the battery cable disconnected see the Caution in Step 5 7 Remove the fan s drivebelt see Chapter 1 8 Remove the nuts holding the fan assembly to the water pump see illustration Note You ll have to walk the fan assembly forward as you loosen the nuts There is not enough room to remove them all the way at one time 9 The fan can be removed without removing the shroud if you are only renewing the fan or clutch see illustration Be careful not to allow the blades contact the radiator fins 10 Remove the two fan shroud mounting clips at the top of the shroud see illustration 11 Lift the shroud up and out of the engine compartment The bottom of the fan shroud does not have any fasteners It has two tangs on the bottom that slip out of slots in the body when pulled up 12 The fan clutch can be unbolted from the fan blade assembly for renewal see illustration Caution To prevent silicone fluid from draining from the clutch assembly into the fan drive bearing and ruining the lubricant DON T place the clutch in a position with the rear pointing down Store the clutch in its u
416. ons 8 Remove the jack supporting the control arm refit the rear wheels and lower the vehicle 9 Tighten the rear wheel nuts to the torque listed in the Chapter 1 Specifications 10 If you retrofitted conventional shocks to a vehicle formerly equipped with the self levelling rear suspension system disconnect the forward end of the hydraulic line from the valve block and refit the plug included in the kit see illustrations Then finish removing the forward section of hydraulic line and the brackets for the line see illustration Suspension and steering systems 10 7 10 10 6a Where applicable unplug the connector to the ride height sensor and fill the connector with silicone 10 6b then disconnect and remove both valve blocks 10 6c and remove all associated plumbing including the metal line arrow to the valve block in the engine compartment 3261 Jaguar XJ6 10 3 To detach the bottom of the shock absorber coil spring from the control arm remove this nut and bolt then pull out the bolt 10 4 To detach the top of the shock absorber coil spring from the body remove these bolts arrowed not all bolts are visible here 10 10a After the vehicle has been lowered disconnect the forward end of the hydraulic line from the valve block 10 10b refit the plug included in the retrofit kit 10 10c then remove these bracket screws arrowed the brackets and the forward secti
417. ont of the crankshaft Apply pressure on the bolt in a clockwise direction only Never turn the bolt anti clockwise b A remote starter switch which may save some time can also be used Follow the instructions included with the switch Once the piston is close to TDC use a socket and ratchet as described in the previous paragraph c If an assistant is available to turn the ignition switch to the Start position in short bursts you can get the piston close to TDC without a remote starter switch Make sure your assistant is out of the car away from the ignition switch then use a socket and ratchet as described in Paragraph a to complete the procedure 5 Note the position of the terminal for the number one spark plug lead on the distributor cap If the terminal isn t marked follow the plug lead from the number one cylinder spark plug to the cap 6 Use a felt tip pen or chalk to make a mark on the distributor body directly under the number one terminal see Chapter 5 7 Detach the cap from the distributor and set it aside see Chapter 1 if necessary 8 Turn the crankshaft until the small triangle cast into the front edge of the crankshaft sensor ring is aligned with the bottom edge of the timing pointer located at the front of the engine see illustration 9 Look at the distributor rotor it should be pointing directly at the mark you made on the distributor body If so you are at TDC for number 1 cylinder 10 If the rotor is 18
418. or Chapter 5 Insufficient fuel reaching the fuel injector s Chapters 1 and 4 Damaged fuel injection system speed sensors Chapter 5 Faulty fuel injection relays Chapter 5 Leaking threaded adapter on the EGR valve where fitted Chapter 6 Oil puddle under engine Sump gasket and or sump drain bolt seal leaking Chapter 2 Oil pressure sending unit leaking Chapter 2 Valve cover gaskets leaking Chapter 2 Engine oil seals leaking Chapter 2 Cylinder head rear plate gasket leaking Chapter 2 Alternator mounting bolt threads leaking oil Chapter 5 Oil cooler or oil cooler lines leaking Chapter 3 Engine misses while idling or idles erratically Vacuum leakage Chapter 2 Air filter clogged Chapter 1 Fuel pump not delivering sufficient fuel to the fuel injection system Chapter 4 Leaking head gasket Chapter 2 Timing belt chain and or sprockets worn Chapter 2 Camshaft lobes worn Chapter 2 EGR valve stuck open where fitted Chapter 6 Engine misses at idle speed Spark plugs worn or not gapped properly Chapter 1 Faulty spark plug leads Chapter 1 Vacuum leaks Chapter 1 Incorrect ignition timing Chapter 5 Uneven or low compression Chapter 2 Restricted EGR vacuum hose where fitted Chapter 6 Engine misses throughout driving speed range Fuel filter clogged and or impurities in the fuel system Chapter 1 Low fuel output at the injector
419. or activation The Loctite brand is widely used Antifreeze A substance usually ethylene glycol mixed with water and added to a vehicle s cooling system to prevent freezing of the coolant in winter Antifreeze also contains chemicals to inhibit corrosion and the formation of rust and other deposits that would tend to clog the radiator and coolant passages and reduce cooling efficiency Anti seize compound A coating that reduces the risk of seizing on fasteners that are subjected to high temperatures such as exhaust manifold bolts and nuts Asbestos A natural fibrous mineral with great heat resistance commonly used in the composition of brake friction materials Asbestos is a health hazard and the dust created by brake systems should never be inhaled or ingested Axle A shaft on which a wheel revolves or which revolves with a wheel Also a solid beam that connects the two wheels at one end of the vehicle An axle which also transmits power to the wheels is known as a live axle Axleshaft A single rotating shaft on either side of the differential which delivers power from the final drive assembly to the drive wheels Also called a driveshaft or a halfshaft B Ball bearing An anti friction bearing consisting of a hardened inner and outer race with hardened steel balls between two races Bearing The curved surface on a shaft or in a bore or the part assembled into either that permits relative motion between them with min
420. or ride quality and vehicle handling and reduced fuel economy For detailed illustrations of the steering and suspension components refer to Chapter 10 With the wheels on the ground 1 Park the vehicle on level ground turn the engine off and set the handbrake Check the tyre pressures and check that the wheel nuts are tightened to the specified torque 2 Push down at one corner of the vehicle then release it while noting the movement of the body It should stop moving and come to rest in a level position with one or two bounces When bouncing the vehicle up and down listen for squeaks and noises from the suspension components 3 If the vehicle continues to move up and down or if it fails to return to its original 1 12 Every 7500 miles or 6 months 11 11 Check along the brake hoses and at each fitting arrowed for deterioration and cracks 3261 Jaguar XJ6 You will find an inspection hole like this in each caliper placing a ruler across the hole should enable you to determine the thickness of remaining pad material for both inner and outer pads position a worn or weak shock absorber is probably the reason 4 Repeat the above check at each of the three remaining corners of the vehicle Under the vehicle 5 Raise the vehicle with a trolley jack and support it securely on axle stands See Jacking and towing for proper jacking points 6 Check the shock absorbers for evidence of fluid leakage Make sure that any f
421. orn when working on the brakes Do not under any circumstances use petroleum based solvents to clean brake parts Use brake system cleaner only Try to use non asbestos replacement parts whenever possible Every 2 years regardless of mileage 5 After the coolant stops flowing out of the radiator move the container under the engine block drain plug Remove the plug and let the coolant in the block to drain see illustration 6 While the coolant is draining from the engine block check the condition of the radiator hoses heater hoses and clamps refer to Section 7 if necessary 7 Replace any damaged clamps or hoses see Chapter 3 Flushing 8 Once the system is completely drained flush the radiator with fresh water from a garden hose until water runs clear at the drain The flushing action of the water will remove sediments from the radiator but will not remove more serious rust and scale from the engine and cooling tube surfaces 9 These deposits can be removed by using proprietary chemical cleaners It should be stressed however that these should only need to be used if the system has been neglected Follow the procedure outlined in their manufacturer s instructions If the radiator is severely corroded damaged or leaking it should be removed see Chapter 3 and taken to a radiator repair workshop 10 On 1988 and 1989 models remove the overflow hose from the coolant recovery reservoir Drain the reservoir and fl
422. orque see Chapter 1 Specifications 13 Brake light switch check and renewal 1 1 The brake light switch activates the brake lights when the brake pedal is depressed It s located at the top of the brake pedal inside the pedal box 2 If the brake lights don t come on when the brake pedal is depressed check the fuses the fuse for the left brake light is in the left fuse panel and the fuse for the right brake light is in the right panel 3 If the fuses are okay check the brake light bulbs see Chapter 12 4 If the fuses and bulbs are okay either the switch isn t getting voltage there s an open circuit between the voltage source and the switch voltage isn t reaching the brake light Braking system 9 13 9 12 5j Place the front shoe in position insert the pin through the backing plate and the shoe 12 5k and refit the hold down spring and washers 12 5i Lubricate the six friction points two arrowed on the backing plate with high temperature brake grease 3261 Jaguar XJ6 12 5l Hook the lower return spring into its hole in the front shoe 12 5m hook the other end of the lower spring into the rear shoe 12 5n stretch the spring over the top of the handbrake lever box 12 5o place the rear shoe in position insert the pin through the backing plate and the shoe and refit the rear washers and hold down spring 12 5p Hook the upper return spring into the
423. ors work through the door access hole to remove the hinge to door nuts On rear doors the hinge to body bolts are more accessible and can be removed by simply opening the front door and removing the bolts see illustrations 8 Have an assistant hold the door remove the bolts or nuts and lift the door off 9 Refitting is the reverse of removal Adjustment 10 Having proper door to body alignment is a critical part of a well functioning door assembly First check the door hinge pins for excessive play Note If the door can be lifted 1 16 inch or more without the car body moving the hinges should be replaced 11 Door to body alignment adjustments are made by loosening the hinge to body or hinge to door bolts and moving the door Proper body alignment is achieved when the top of doors are parallel with the roof section the front door is flush with the wing the rear door is flush with the rear quarter panel and the bottom of the doors are aligned with the lower rocker panel If these goals can t be reached by adjusting the hinge to body or hinge to door bolts body alignment shims may have to be purchased and inserted behind the hinges to achieve correct alignment 12 To adjust the door closed position scribe a line or mark around the striker plate to provide a reference point Check that the door latch is contacting the centre of the latch striker If not adjust the up and down position first 13 Finally adjust the latch stri
424. osition the seat all the way forward or all the way to the rear to access the front seat retaining bolts 2 Detach any bolt trim covers and remove the retaining bolts see illustration 3 Tilt the seat upward to access the underneath then unplug any electrical connectors and lift the seat from the vehicle 4 Refitting is the reverse of removal Rear seat 5 Remove retaining screws at the lower edge of the seat cushion see illustration Then lift up on the front edge and remove the cushion from the vehicle 6 Detach the retaining bolts at the lower edge of the seat back 7 Lift up on the lower edge of the seat back to release the clips securing the top Then remove it from the vehicle 8 Refitting is the reverse of removal 11 14 Bodywork and fittings 27 4 Remove the four screws securing the upper half of the steering column cover 28 2 Remove the screws arrowed located along the top of the cowl cover 29 2 Use a Torx bit to remove the front seat retaining bolts arrowed 3261 Jaguar XJ6 27 2 Pull off the knob from the instrument panel light rheostat 27 3 Remove the lower steering column cover screws 29 5 Detach the screws arrowed along the lower edge of the seat cove 3261 Jaguar XJ6 12 Chapter 12 Body electrical system 1 General information The electrical system is a 12 volt negative earth type Power for the lights and all electrical accessories is supplied by a lead acid type battery which is charg
425. ot already detached from the hub use a screwdriver to pry the seal out of the rear of the hub As this is done note how the seal is installed 12 If the inner wheel bearing is not already detached from the hub remove it at this time 13 Use solvent to remove all traces of the old grease from the bearings hub and spindle A small brush may prove helpful however make sure no bristles from the brush embed themselves inside the bearing rollers Allow the parts to air dry 14 Carefully inspect the bearings for cracks heat discoloration worn rollers etc Check the bearing races inside the hub for wear and damage If the bearing races are defective the hubs should be taken to a machine workshop with the facilities to remove the old races and press new ones in Note that the bearings and races come as matched sets Every 15 000 miles or 12 months 1 17 1 22 1 Tools and materials needed for front wheel bearing maintenance 1 Hammer 2 Grease High temperature grease that is formulated specially for front wheel bearings should be used 3 Wood block If you have a scrap piece of 2x4 it can be used to drive the new seal into the hub 4 Needle nose pliers Used to straighten and remove the cotter pin in the spindle 5 Torque wrench This is very important in this procedure if the bearing is too tight the wheel won t turn freely if it s too loose the wheel will wobble on the spindle Either way it could mean extens
426. ound or near a raised vehicle unless it is adequately supported in at least two places Jacking and vehicle support 3261 Jaguar XJ6 REF 2 Conversion factors Length distance Inches in x 25 4 Millimetres mm x 0 0394 Inches in Feet ft x 0 305 Metres m x 3 281 Feet ft Miles x 1 609 Kilometres km x 0 621 Miles Volume capacity Cubic inches cu in in3 x 16 387 Cubic centimetres cc cm3 x 0 061 Cubic inches cu in in3 Imperial pints Imp pt x 0 568 Litres l x 1 76 Imperial pints Imp pt Imperial quarts Imp qt x 1 137 Litres l x 0 88 Imperial quarts Imp qt Imperial quarts Imp qt x 1 201 US quarts US qt x 0 833 Imperial quarts Imp qt US quarts US qt x 0 946 Litres l x 1 057 US quarts US qt Imperial gallons Imp gal x 4 546 Litres l x 0 22 Imperial gallons Imp gal Imperial gallons Imp gal x 1 201 US gallons US gal x 0 833 Imperial gallons Imp gal US gallons US gal x 3 785 Litres l x 0 264 US gallons US gal Mass weight Ounces oz x 28 35 Grams g x 0 035 Ounces oz Pounds lb x 0 454 Kilograms kg x 2 205 Pounds lb Force Ounces force ozf oz x 0 278 Newtons N x 3 6 Ounces force ozf oz Pounds force lbf lb x 4 448 Newtons N x 0 225 Pounds force lbf lb Newtons N x 0 1 Kilograms force kgf kg x 9 81 Newtons N Pressure Pounds force per squ
427. out of the motor assembly note the direction of the teeth on the aerial cable 15 1 Lift up the wiper arm nut cover remove the nut and pull the wiper arm straight off the shaft 15 3 Use a spanner or socket to remove the drive spindle retaining nut 15 4 Remove the bolts A along the top edge of the housing and detach the clips B along the bottom edge 3261 Jaguar XJ6 16 4 When measuring the voltage at the heated rear window grid wrap a piece of aluminium foil around the negative probe of the voltmeter and press the foil against the element with your finger 6 If the voltage is 6 volts the element is okay there is no break If the voltage is 12 volts the element is broken between the centre of the element and the positive end If the voltage is 0 volts the element is broken between the centre of the element and earth 7 To find the break place the voltmeter positive lead against the defogger positive terminal Place the voltmeter negative lead with the foil strip against the heating element at the positive terminal end and slide it toward the negative terminal end The point at which the voltmeter deflects from zero to several volts is the point at which the heating element is broken see illustration Repair 8 Repair the break in the element using a repair kit specifically recommended for this purpose 9 Prior to repairing a break turn off the system and allow it to cool off for a few minutes 10 Lightly bu
428. out of adjustment Chapter 7 Engine will start in gears other than Park or Neutral Neutral start reversing light switch malfunctioning Chapter 7 Shift cable out of adjustment Chapter 7 Transmission slips shifts roughly is noisy or has no drive in forward or reverse gears There are many probable causes for the above problems but the home mechanic should be concerned with only one possibility fluid level Before taking the vehicle to a dealer service department or transmission repair workshop check the level and condition of the fluid as described in Chapter 1 Correct the fluid level as necessary or change the fluid if needed If the problem persists have a professional diagnose the probable cause 5 Brakes Note Before assuming that a brake problem exists make sure that a The tyres are in good condition and properly inflated Chapter 1 b The front end alignment is correct Chapter 10 c The vehicle is not loaded with weight in an unequal manner Vehicle pulls to one side during braking Incorrect tyre pressures Chapter 1 Front end out of line have the front end aligned Unmatched tyres on same axle Restricted brake lines or hoses Chapter 9 Malfunctioning caliper assembly Chapter 9 Loose suspension parts Chapter 10 Loose calipers Chapter 9 Brake pads contaminated with oil or grease Chapter 9 Noise high pitched squeal when the brakes are applied Front and or rear disc
429. ower from the crankshaft to the water pump alternator and the power steering pump The second belt transmits power from the crankshaft to the air conditioning compressor 3 With the engine off open the bonnet and locate the drivebelts With a flashlight check each belt for separation of the adhesive rubber on both sides of the core core separation from the belt side a severed core separation of the ribs from the adhesive rubber cracking or separation of the ribs and torn or worn ribs or cracks in the inner ridges of the ribs see illustrations Also check for fraying and glazing which gives the belt a shiny appearance Both sides of the belt should be inspected which means you will have to twist the belt to check the underside Use your fingers to feel the belt where you can t see it If any of the above conditions are evident replace the belt go to paragraph 7 4 Check the belt tension by pushing firmly on the belt with your thumb at a distance halfway between the pulleys and note how far the belt can be pushed deflected Measure this deflection with a ruler see illustration As a rule of thumb if the distance from pulley centre to pulley centre is between 7 and 11 inches the belt should deflect 1 4 inch If the belt travels between pulleys spaced 12 to 16 inches apart the belt should deflect 1 2 inch for a V belt or 1 4 inch for a serpentine belt Adjustment 5 There are two belt tensioning mechanisms The firs
430. ower tensioner oil reservoir with engine oil and refit it on the engine block aligning the notch in the tensioner with the lug on the back of the guide see illustrations This should remove all slack from the lower timing chain If not push the lower tensioner guide back and forth a few times to prime the tensioner 24 Refit the upper chain tensioner guide and mounting bracket to the engine block Caution Before fully tightening the mounting bracket to the engine block make sure the mount and chain guide are clear of the lower chain auxiliary sprocket and intermediate sprocket If necessary position the mount for clearance before tightening the mounting bolts 25 Refit the oil pump drive chain and sprocket to the crankshaft see Section 13 26 Refit the upper chain fixed guide to the engine block and place the upper timing chain over the intermediate sprocket and auxiliary shaft sprocket draping the excess chain over the top of the fixed guide Lubricate the chain and sprockets with clean engine oil 27 Gather the loose portion of the upper timing chain and place it between the upper guides Use a large rubber band to hold the two guides snugly around the chain see Section 11 28 If necessary renew the intermediate shaft seal see illustrations 29 Apply a thin coat of RTV sealant to the engine side of the front cover and RTV sealant to the oil pan mating surface bottom of the front cover then refit the front cover Note
431. p of the blower housing to the cowl 10 6 Pull down and out on the housing until it clears the sheet metal brace below it 3261 Jaguar XJ6 10 7 Remove this brace rod small arrow for clearance to remove the left blower motor housing large arrow 10 10 Remove the five clips two shown here with arrows and one screw holding the halves of the housing together 11 Separate the housing halves and pull up the plastic plate holding the motor and fan see illustration The fan doesn t come off the motor but loosen the clamp bolt on the motor s mount bracket and slide the motor and fan out for renewal see illustration Note Some 1988 models had problems with cracking of the fan blades and noise from the blowers These blowers and fans have been superseded with improved parts available from your Jaguar dealer 12 When either blower housing is separated you ll find two relays mounted inside see illustration These are the blower isolation relay and blower relay Before refitting the blower housing in the car refer to Chapter 12 for testing of these relays 13 Refitting is the reverse of removal Check for proper operation 11 Heater core removal and refitting 4 Warning Later model vehicles are equipped with airbags To prevent the accidental deploy ment of the airbag which could cause personal injury or damage to the airbag system DO NOT work in the vicinity of the steering wheel or instrument panel The manufa
432. p steps read each caption and study the photo carefully 8 Once you have dismantled the master cylinder clean everything thoroughly blow the parts dry with compressed air and carefully inspect the secondary piston and the bore of the master cylinder with a bright light If the secondary piston or the master cylinder bore is damaged or worn renew the master cylinder with a new or rebuilt unit Bench bleeding procedure 9 Before refitting a new or rebuilt master cylinder it should be bench bled Because it 9 6 Braking system 6 7a Knock out the roll pin that secures the reservoir to the master cylinder 6 7b Carefully pry off the reservoir by inserting a screwdriver between the reservoir and each grommet this takes firm pressure so don t slip and damage the reservoir or the master cylinder 6 7c Remove the grommets noting the position of each one 6 6 Remove the two master cylinder mounting nuts 3261 Jaguar XJ6 6 4 Trace the electrical lead back from the reservoir cap and disconnect the low fluid level sensor 6 5 Loosen the hydraulic brake line fittings with a flare nut spanner to protect the corners of the nuts Braking system 9 7 9 6 7d Pry off the end cap 6 7e Locate the stopper pin arrowed inside the forward grommet hole 6 7f insert a punch into the pocket of the primary piston place the master cylinder vertically as shown push down on the master cylinder to depress the pistons and pul
433. panel cover Miniaturised fuses are employed in the fuse blocks These compact fuses with blade terminal design allow fingertip removal and renewal If an electrical component fails always check the fuse first The best way to check the fuses is with a test light Check for power at the exposed terminal tips of each fuse If power is present on one side of the fuse but not the other the fuse is blown A blown fuse can be confirmed by visual inspection see illustration Be sure to renew blown fuses with the correct type Fuses of different ratings are physically interchangeable but only fuses of the proper rating should be used Replacing a fuse with one of a higher or lower value than specified is not recommended Each electrical circuit needs a specific amount of protection The amperage value of each fuse is moulded into the fuse body If the renewal fuse immediately fails don t renew it again until the cause of the problem is isolated and corrected In most cases this will be a short circuit in the wiring caused by a broken or deteriorated wire 4 In line fuses general information Some circuits are protected by in line fuses In line fuses are used in such circuits as the windscreen wiper system headlight 12 2 Body electrical system 3261 Jaguar XJ6 3 1a The left side fusebox is located in the passenger s side kick panel behind the fuse panel cover 3 1b The right side fusebox is located in the driver s s
434. pers in pairs never rebuild just one of them Removal 1 Loosen the wheel nuts raise the front or rear of the vehicle and place it securely on axle stands Remove the wheel 2 If you re just removing the caliper for access to other components it isn t Braking system 9 3 9 3 5f Remove the outer brake pad 3 5g Remove the inner brake pad 3 5h Pull out the wear sensor trace the sensor lead back to its plug detach the lead from the suspension and discard it 3 5i Remove the caliper guide pins and boots lower pin and boot shown 3 5j clean them off inspect the pin and boot for damage renew as necessary then lubricate the pins with brake grease and refit them in the caliper bracket 3 5k Apply anti squeal compound to the new brake pads 3261 Jaguar XJ6 3 5l Insert the new wear sensor into the inner pad as shown 3 5n Refit the outer pad 3 5m then refit the inner pad onto the caliper bracket 3 5o Refit the caliper then tighten the mounting bolts to the specified torque necessary to detach the brake line If you re removing the caliper for overhaul detach the hose from the metal line at the frame bracket see Section 8 then disconnect the brake line from the caliper with a flare nut spanner to protect the fitting see illustration Plug the metal line to keep contaminants out of the brake system and to prevent losing brake fluid 3 Refer to illustration 3 5c and unbolt the f
435. pright position if possible Cooling heating and air conditioning systems 3 3 3 4 9 The fan can be removed with the shroud in place by angling it out of the shroud 4 10 Pry out the two clips arrow indicates the left one at the top of the fan shroud and lift out the shroud 3261 Jaguar XJ6 3 9 The thermostat is fitted with the spring end towards the cylinder head use a new O ring A and position jiggle pin B up 4 8 Remove the four nuts arrows indicate three shown here holding the fan clutch assembly to the front of the water pump 4 12 Separate the fan clutch from the fan by removing the four bolts arrowed 13 Refitting is the reverse of removal Tighten the fan clutch to fan blade bolts and the fan assembly to drive hub nut to the torque listed in this Chapter s Specifications Electric fans Check Warning Keep your hands or clothing away from the fan blades at all times 14 On 1988 through 1992 models a single electric fan is mounted in front of the radiator controlled by a thermostatic switch Access to the fan is with the grille removed The 1993 and 1994 models have a fan shroud assembly that includes two electric fans and a twin thermostatic switch with the assembly mounted on the engine side of the radiator 15 If the electric fan does not come on at any time bypass the thermostatic switch by disconnecting the electrical connector at the switch and connecting the two pins with a jumper
436. ps with a hammer to pop the ball stud loose see illustration Remove the ball stud nut 10 4 Suspension and steering systems 3 3 To disconnect the anti roll bar from the link remove the upper nut arrowed to disconnect the link from the lower control arm remove the lower nut arrowed 4 2 Support the lower control arm with a jack put a block of wood between the jack head and the control arm to protect the arm and coil spring plate 4 3 To disconnect the lower end of the shock absorber from the lower control arm remove this nut and bolt 4 4 To disconnect the upper end of the shock absorber from the body remove this nut arrowed 5 7 To detach the upper balljoint from the steering knuckle loosen the ballstud nut fit a small puller and break the ballstud loose from the knuckle 5 8 Remove the bolts and shims from the upper balljoint be sure to put the shims back when refitting the new balljoint 3261 Jaguar XJ6 12 Remove the four balljoint retaining bolts see illustration 13 If the dust boot is damaged pry it out see illustration 14 Remove the balljoint 15 Refitting is the reverse of removal Tighten the balljoint bolts and the ball stud nut to the torque listed in this Chapter s Specifications 16 Remove the jack from under the control arm refit the front wheel Lower the vehicle and tighten the wheel nuts to the torque listed in the Chapter 1 Specifications 6 Steering knuckle removal and refit
437. pter 12 for additional information concerning the in line fuses and their locations 1993 and 1994 models have a Starter Logic Relay This microprocessor computer gathers information from the ignition switch linear gear position switch park neutral switch the security switch and the electronic door lock system If all the conditions are in order the computer allows battery voltage to be transferred from the ignition switch to the starter solenoid assembly The charging system doesn t ordinarily require periodic maintenance However the drivebelt battery and wires and connections should be inspected at the intervals outlined in Chapter 1 The dashboard warning light should come on when the ignition key is turned to Start then should go off immediately If it remains on there is a malfunction in the charging system Some vehicles are also equipped with a voltage gauge If the voltage gauge indicates abnormally high or low voltage check the charging system see Section 11 Be very careful when making electrical circuit connections to a vehicle equipped with an alternator and note the following a When reconnecting wires to the alternator from the battery note their polarity b Before using arc welding equipment to repair any part of the vehicle disconnect the wires from the alternator and the battery terminals c Never start the engine with a battery charger connected d Always disconnect both battery leads before using
438. r models are equipped with airbags To prevent the accidental deploy ment of the airbag which could cause personal injury or damage to the airbag system DO NOT work in the vicinity of the steering column or instrument panel The manufacturer recommends that on airbag equipped models the following procedure should be left to a dealer service department or other repair workshop because of the special tools and techniques required to disable the airbag system 1 Disconnect the negative battery cable Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 2 Remove the drivers side knee bolster see Section 26 3 Place the steering wheel in the full rearward position If the vehicle is equipped with a tilt column place the steering wheel in the lowest position 4 Remove the instrument cluster housing screws see illustration 5 Pull the instrument cluster housing outward to access the electrical connections on the backside see illustration 6 Disconnect all electrical connections from the backside of the cluster housing and remove the housing from the vehicle 7 Refitting is the reverse of removal 11 12 Bodywork and fittings 24 3b Pull the ash tray towards the rear of the vehicle to remove it don t pull it straight up 24 4 Working through the ash tray opening remove the radio trim bezel wingnuts arrowed loca
439. r 12 24 The ISC motor or stepper motor can be checked for correct operation but a special tool is required to activate the internal coils Have the stepper motor checked by a dealer service department or other qualified repair workshop 25 Reconnect the ISC motor electrical connector Renewal 26 Detach the cable from the negative terminal of the battery see Caution at the beginning of this Section 27 Use a large open end spanner and unscrew the ISC motor from the housing see illustration 28 Refitting is the reverse of removal but be sure to use a new gasket Fuel rail and fuel injectors Note If there is a distinct knocking noise coming from the dash when the engine is idling the fuel feed hose may have hardened restricting fuel flow and causing abnormal sounds Replace the fuel inlet feed hose with a new part from the dealer parts department Check 29 Refer to the fuel injection system checking procedure see Section 12 Renewal 30 Relieve the fuel pressure see Section 2 31 Detach the cable from the negative terminal of the battery see Caution at the beginning of this Section 32 Disconnect the fuel injector wiring con nectors and set the injector wire harness aside 33 Detach the vacuum sensing hose from the fuel pressure regulator 34 Disconnect the fuel lines from the fuel pressure regulator and the fuel rail see illustration 3 6a 35 Remove the fuel rail mounting bolts see illustration 4 12
440. r Lucas starter assembly The Lucas unit is distinguished by the separate earth strap from the solenoid to the starter body Bosch starter assemblies are equipped with a solid metal earthing bar The starting system circuit is equipped with a relay The relay allows the ignition switch to power the starter solenoid Always observe the following precautions when working on the starting system a Excessive cranking of the starter motor can overheat it and cause serious damage Never operate the starter motor for more than 15 seconds at a time without pausing to allow it to cool for at least two minutes b The starter is connected directly to the battery and could arc or cause a fire if mishandled overloaded or short circuited c Always detach the cable from the negative terminal of the battery before working on the starting system Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 14 Starter motor testing in vehicle 2 1 Make sure that the battery is charged and that all cables both at the battery and starter solenoid terminals are clean and secure 2 If the starter motor does not turn at all when the switch is operated make sure that the shift lever is in Neutral or Park automatic transmission or that the clutch pedal is depressed manual transmission 3 If the starter motor spins but the engine is not cranking the
441. r before refitting the new part 33 Refitting is the reverse of removal Adjustment 34 Refit the throttle body with the throttle potentiometer mounting bolts just loose enough to move the potentiometer Be sure the bolts are tight and the potentiometer does not rotate easily 35 Backprobe the signal wire and the ground wire see Step 28 and with the throttle closed idle position rotate the potentiometer until the voltmeter reads between 0 2 and 0 5 volts Note The throttle potentiometer is difficult to reach Be sure to rotate the potentiometer slowly and do not interfere with the voltmeter and the electrical connectors to the gauge 36 Rotate the throttle lever and confirm that the voltage increases to around 4 8 volts If the voltage range is correct the throttle potentiometer is installed correctly 37 Tighten the throttle potentiometer bolts If necessary use a small mirror to locate the bolts Mass airflow MAF sensor General Information 38 The mass airflow sensor MAF is located on the air intake duct This sensor uses a hot wire sensing element to measure the amount of air entering the engine The air passing over the hot wire causes it to cool Consequently this change in temperature can be converted into an analogue voltage signal to the ECU which in turn calculates the required fuel injector pulse width Check 39 Check for power to the MAF sensor Backprobe the MAF sensor electrical plug Working on the ha
442. r head mating surface for nicks deep scratches and damage from coolant corrosion If damage is slight it can be removed with a file if it s excessive machining may be the only alternative See Part B of this Chapter for procedures and criteria concerning the repair of corrosion damage 18 Use a tap of the correct size to chase the threads in the cylinder head bolt holes then clean the holes with compressed air make sure that nothing remains in the holes Warning Wear eye protection when using compressed air 19 Remove the rear cover from the cylinder head Clean the gasket surface and refit the cover with a new gasket see illustration Place the side of the gasket with the sealer bead against the cylinder head do not use sealant on this gasket 20 Fabricate two alignment studs from the old head bolts Cut off the heads then slot the ends with a hacksaw see illustration New cylinder head bolts must be used when refitting the head Engine in car repair procedures 2A 13 2A 11 19 Remove the rear cover from the cylinder head clean the gasket surfaces and refit the cover with a new gasket arrowed note that the printed on sealer bead is placed against the cylinder head 11 20 Fabricate two alignment studs from old cylinder head bolts and refit them in the engine block after the cylinder head is installed remove the two studs 3261 Jaguar XJ6 11 10 Disconnect the hoses and remove the bolts to separate the
443. r mounting brackets see illustration 7 Remove the steering gear assembly detaching the U joint as you lower it Don t damage the steering gear dust boots 8 Refitting is the reverse of removal Ensure the marks you made on the U joint and the pinion shaft are aligned before you tighten the U joint clamp bolt and nut Tighten the mounting bolts the tie rod end nuts and the U joint shaft clamping bolts to the specified torque 9 After lowering the vehicle fill the reservoir with the recommended fluid see Chapter 1 10 Bleed the power steering system see Section 19 11 Have the front wheels aligned by a dealer service department or alignment workshop after reassembly 18 Power steering pump removal and refitting 3 1 Raise the vehicle and support it securely on axle stands Remove the engine under cover 2 Loosen the hose clamp and disconnect the fluid return hose from the top of the pump see illustration and drain the power steering fluid from the reservoir into a clean container Unscrew the pressure line fitting from the back of the pump Plug the return hose and the pressure line to prevent fluid from leaking and to protect the power steering system from contamination 3 Remove the bolts see illustration that attach the power steering pump adapter to the auxiliary shaft housing 4 Remove the power steering pump and adapter 5 Take the power steering pump and adapter to a Jaguar dealer service department and have the
444. rcuit The same procedure can be used to test a switch by connecting the continuity tester to the power in and power out sides of the switch With the switch turned On the test light should come on Finding an open circuit When diagnosing for possible open circuits it is often difficult to locate them by sight because oxidation or terminal misalignment are hidden by the electrical connectors Merely wiggling an electrical connector on a sensor or in the wiring harness may correct the open circuit condition Remember this when an open circuit is indicated when diagnosing a circuit Intermittent problems may also be caused by oxidised or loose connections Electrical fault finding is simple if you keep in mind that all electrical circuits are basically electricity running from the battery through the wires switches relays fuses and fusible links to each electrical component light bulb motor etc and to earth from which it is passed back to the battery Any electrical problem is an interruption in the flow of electricity to and from the battery 3 Fuses general information The electrical circuits of the vehicle are protected by a combination of fuses circuit breakers and In line fuses The fuse blocks are located in the left and right side kick panels and in the centre console glove box see illustrations Each of the fuses is designed to protect a specific circuit and the various circuits are identified on the fuse
445. rectly matched Measure the piston across the skirt at a 90 angle to the piston pin see illustration Subtract the piston diameter from the bore diameter to obtain the clearance If it s greater than specified the engine block will have to be rebored and new pistons and rings installed 12 Check the piston to rod clearance by twisting the piston and rod in opposite directions Any noticeable play indicates excessive wear which must be corrected 13 If the pistons must be removed from the connecting rods for any reason the rods should be taken to an automotive machine workshop to be checked for bend and twist since automotive machine shops have special equipment for this purpose 14 Check the connecting rods for cracks and other damage Temporarily remove the rod caps lift out the old bearing inserts wipe the connecting rod and cap bearing surfaces clean and inspect them for nicks gouges and scratches After checking the connecting rods renew the old bearings slip the caps into place and tighten the nuts finger tight Note If the engine is being rebuilt because of a connecting rod knock be sure to refit new rods 19 Crankshaft inspection 3 1 Clean the crankshaft with solvent and dry it with compressed air if available Be sure to clean the oil holes with a stiff brush and flush them with solvent 2 Check the main and connecting rod bearing journals for uneven wear scoring pits and cracks 3 Remove all burrs from
446. replace each camshaft bearing cap as it is removed Begin by unbolting and removing intake cap no 2 Remove the large cylinder head bolt first then the cap bolts Without delay refit a spacer block with the cylinder head bolt and tighten it to 53 Nm 39 lbf ft see illustrations 11 Repeat paragraph 10 with the remainder of the intake camshaft caps in sequence After cap 5 in the sequence loosen the front and rear caps alternately until valve spring pressure is relieved from the camshaft see illustrations Note No spacer blocks are required with the number 1 camshaft caps 2A 10 Engine in car repair procedures 10 7 Loosen this bolt arrowed and swing the clamp away from the tensioner then use pliers to pull the valve out 10 10a As each cap is removed 10 10b replace it with the special spacer block arrowed and tighten the cylinder head bolt to 53 Nm 39 lbf ft 3261 Jaguar XJ6 10 4 Measure the valve clearance with a feeler gauge inserted between the heel of the camshaft lobe and the lifter 10 5 Position the camshaft alignment tool over each camshaft the projection on the tool only fits into the slot on the camshafts when they are at TDC flip the tool over to check the other camshaft 10 11a Each of the camshaft bearing caps are stamped with I intake or E exhaust and a number arrowed 10 11b After cap no 2 is replaced with a spacer repeat the procedure for the other caps in the sequence show
447. return line from the fuel tank 7 9c Disconnect the canister purge line from the fuel tank 7 9d Remove the clips arrowed that retain the fuel lines to the fuel tank using needle nose pliers 3261 Jaguar XJ6 7 10 Remove the tank strap bolts arrowed from the body 9 2a Remove the bolts arrowed from the air cleaner assembly 9 2b Also remove the bolt that retains the air intake duct to the MAF sensor and lift the assembly from the compartment 10 Accelerator cable removal refitting and adjustment 3 Removal 1 Detach the cable from the negative terminal of the battery Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 2 Loosen the locknut on the threaded portion of the throttle cable at the throttle body see illustration 3 Rotate the throttle lever then slip the throttle cable end out of the slot in the lever see illustration 4 Detach the throttle cable from the accelerator pedal see illustration 5 From inside the vehicle pull the cable through the bulkhead Refitting and adjustment 6 Refitting is the reverse of removal 7 To adjust the cable fully depress the accelerator pedal and check that the throttle is fully opened 8 If not fully opened loosen the locknuts depress accelerator pedal and adjust the cable until the throttle is fully open 9 Tighten the locknuts and recheck the adjustmen
448. rge screwdriver or pry bar to attempt to move the mounts If movement is noted lower the engine and tighten the mount fasteners 6 Rubber preservative should be applied to the mounts to slow deterioration Renewal 7 Disconnect the battery negative cable Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 8 Raise the car and support it securely on axle stands Support the engine as described in paragraph 3 Caution Ensure the cooling fan doesn t hit the shroud as the engine is raised 9 To remove either engine mount remove the nut from the engine bracket then raise the engine see illustration 10 From underneath the car lower the steering gear see Chapter 10 for access to the nut retaining the insulator to the chassis bracket 11 Refitting is the reverse of removal Use thread locking compound on the mount bolts nuts and be sure to tighten them securely 12 See Chapter 7 for transmission mount renewal 2A 18 Engine in car repair procedures 3261 Jaguar XJ6 15 6 Refit the retainer and oil seal onto the crankshaft 16 9 Front engine mount A and retaining nut to engine bracket B 3261 Jaguar XJ6 2B Chapter 2 Part B Engine removal and overhaul procedures General Cylinder compression pressure 300 rpm warm Standard
449. rill motor although it can be done just as effectively by hand with sandpaper To complete the preparation for filling score the surface of the bare metal with a screwdriver or the tang of a file or drill small holes in the affected area This will provide a good grip for the filler material To complete the repair see the subsection on filling and painting later in this Section Repair of rust holes or gashes 8 Remove all paint from the affected area and from an inch or so of the surrounding metal using a sanding disc or wire brush mounted in a drill motor If these are not available a few sheets of sandpaper will do the job just as effectively 9 With the paint removed you will be able to determine the severity of the corrosion and decide whether to replace the whole panel if possible or repair the affected area New body panels are not as expensive as most people think and it is often quicker to refit a new panel than to repair large areas of rust 10 Remove all trim pieces from the affected area except those which will act as a guide to the original shape of the damaged body such as headlight shells etc Using metal snips or a hacksaw blade remove all loose metal and any other metal that is badly affected by rust Hammer the edges of the hole in to create a slight depression for the filler material 11 Wire brush the affected area to remove the powdery rust from the surface of the metal If the back of the rusted area is ac
450. ring diagrams 3261 Jaguar XJ6 Typical interior lighting system Wiring diagrams 12 25 12 3261 Jaguar XJ6 Typical instrument cluster lighting system 12 26 Wiring diagrams 3261 Jaguar XJ6 Typical 1988 heater and air conditioning system Wiring diagrams 12 27 12 3261 Jaguar XJ6 Typical 1989 to 1992 heater and air conditioning system 12 28 Wiring diagrams 3261 Jaguar XJ6 Typical 1993 and 1994 heater and air conditioning system Wiring diagrams 12 29 12 3261 Jaguar XJ6 Typical 1988 to 1990 cruise control system Typical 1991 and 1992 cruise control system 12 30 Wiring diagrams 3261 Jaguar XJ6 Typical 1993 and 1994 cruise control system Wiring diagrams 12 31 12 3261 Jaguar XJ6 Typical 1988 central locking system 12 32 Wiring diagrams 3261 Jaguar XJ6 Typical 1989 and 1990 central locking system Wiring diagrams 12 33 12 3261 Jaguar XJ6 Typical 1991 and 1992 central locking system 12 34 Wiring diagrams 3261 Jaguar XJ6 Typical 1993 and 1994 central locking system Wiring diagrams 12 35 12 3261 Jaguar XJ6 Typical 1988 to 1992 electric windows 12 36 Wiring diagrams 3261 Jaguar XJ6 Typical 1993 and 1994 electric windows Wiring diagrams 12 37 12 3261 Jaguar XJ6 Typical 1988 to 1992 audio system Typical 1993 and 1994 audio system 12 38 Wiring diagrams 3261 Jaguar XJ6 Typical 1988 to 1990 windscreen washer and wiper
451. rk and fittings Page 11 1 Body electrical systems Page 12 1 Wiring diagrams Page 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 factors Page REF 2 Use of English Page 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 checks Page REF 8 Fault finding Page REF 12 Glossary of technical terms Page REF 18 Index Page REF 22 Contents These models are equipped with dual overhead cam in line six cylinder engines The engines feature a computer controlled ignition system and electronic fuel injection Transmissions are a four speed automatic equipped with a lock up torque converter The transmission is mounted to the back of the engine and power is transmitted to the fully independent rear axle through a two piece propshaft The differential is bolted solidly to a frame crossmember and drives the wheels through driveshafts equipped with inner and outer U joints The front suspension is fitted with upper and lower control arms coil springs and shock absorbers The rear suspension is an independent type suspension which also have coil spring shock absorber assemblies and a lower control arm The rear driveshaft acts as the upper control arm Power assisted Anti lock Br
452. rkshop 3 The dealer service department or automotive machine workshop will remove the valves and springs will recondition or renew the valves and valve seats recondition the valve guides check and renew the valve springs spring retainers and keepers as necessary replace the valve seals with new ones reassemble the valve components and make sure the installed spring height is correct The cylinder head gasket surface will also be resurfaced if it s warped 4 After the valve job has been performed by a professional the cylinder head s will be in like new condition When the cylinder heads are returned be sure to clean them again before refitting on the engine to remove any metal particles and abrasive grit that may still be present from the valve service or cylinder head resurfacing operations Use compressed air if available to blow out all the oil holes and passages 12 Cylinder head reassembly 2 1 Regardless of whether or not the cylinder head was sent to an automotive machine workshop for valve servicing make sure it s clean before beginning reassembly Renew the cylinder head rear plate gasket any time that the engine is overhauled or the cylinder head is reconditioned see Part A of this Chapter for renewal procedure 2 If the cylinder head was sent out for valve servicing the valves and related components will already be in place Begin the reassembly procedure with paragraph 8 3 Refit new seals on each
453. rms A ABS Anti lock brake system A system usually electronically controlled that senses incipient wheel lockup during braking and relieves hydraulic pressure at wheels that are about to skid Air bag An inflatable bag hidden in the steering wheel driver s side or the dash or glovebox passenger side In a head on collision the bags inflate preventing the driver and front passenger from being thrown forward into the steering wheel or windscreen Air cleaner A metal or plastic housing containing a filter element which removes dust and dirt from the air being drawn into the engine Air filter element The actual filter in an air cleaner system usually manufactured from pleated paper and requiring renewal at regular intervals Allen key A hexagonal wrench which fits into a recessed hexagonal hole Alligator clip A long nosed spring loaded metal clip with meshing teeth Used to make temporary electrical connections Alternator A component in the electrical system which converts mechanical energy from a drivebelt into electrical energy to charge the battery and to operate the starting system ignition system and electrical accessories Ampere amp A unit of measurement for the flow of electric current One amp is the amount of current produced by one volt acting through a resistance of one ohm Anaerobic sealer A substance used to prevent bolts and screws from loosening Anaerobic means that it does not require oxygen f
454. rness side with the ignition ON engine not running check for battery voltage on terminal number 5 see illustration 40 Remove the pin and backprobe the MAF sensor electrical connector terminal number 3 with the voltmeter see illustration The voltage should be less than 1 0 volt with the ignition switch ON engine not running Raise the engine rpm The signal voltage from the MAF sensor should increase to about 2 0 volts It is impossible to simulate load conditions in the driveway but it is necessary to observe the voltmeter for a fluctuation in voltage as the engine speed is raised The vehicle will not be under load conditions but MAF sensor voltage should vary slightly 41 If the voltage readings are correct check the wiring harness for open circuits or a damaged harness see Chapter 12 6 6 Emissions and engine control systems 4 29 then check the SIGNAL voltage with the throttle wide open It should be between 4 5 and 5 0 volts 4 39 Check for battery voltage to the MAF sensor on terminal number 5 4 40 With the engine idling raise the engine rpm and observe the voltage changes on terminal number 3 3261 Jaguar XJ6 4 27 Backprobe the throttle potentiometer electrical connector with a pin and with the ignition key ON engine not running there should be 5 0 volts REFERENCE available 4 28 First check the throttle potentiometer SIGNAL voltage with the throttle closed idle It should be 0 2 to 0 5 volts
455. rod into the cross shaped slot in the suspension crossmember then rotate the rod 90 so this pin on the upper end of the tool locks into the crossmember 8 2b This is how the spring compressor tool JD115 looks when it s installed note how the offset collet is oriented so that it s flush with the coil spring pan 8 3 To detach the coil spring pan from the lower control arm compress the spring and remove these six bolts arrowed 5 The shock coil spring assemblies must be dismantled and the coil springs installed on the new shocks Although the shock coil spring assembly is similar in appearance to the a MacPherson strut coil spring assembly the spring on this unit is much stiffer Therefore DO NOT attempt to take apart this unit yourself with a strut spring compressor tool Instead take the unit to a Jaguar dealer service department or to a Jaguar specialist workshop and have the springs installed on the new shocks by professionals 6 If you are retrofitting conventional shocks rather than refitting the same or another pair of self levelling shocks unplug the electrical connector at the ride height sensor and fill the connector with silicone see illustration to prevent it from shorting out and causing electrical problems Then disconnect and remove all hydraulic lines see illustrations 7 Refitting is the reverse of removal Be sure to tighten all fasteners to the torque values listed in this Chapter s Specificati
456. ront or rear caliper Overhaul 4 Before you remove the piston place a wood block between the piston and caliper to prevent damage as it is removed 5 To remove the piston from the caliper apply compressed air to the brake fluid hose connection on the caliper body see illustration Use only enough pressure to ease the piston out of its bore Remove the dust boot Warning Be careful not to place your fingers between the piston and the caliper as the piston may come out with some force Be sure to wear eye protection when using compressed air 6 Inspect the mating surfaces of the piston and caliper bore wall If there is any scoring rust pitting or bright areas renew the complete caliper unit with a new one 7 If these components are in good condition remove the piston seal from the caliper bore using a wooden or plastic tool see illustration Metal tools may damage the cylinder bore 8 Remove the caliper guide pins and the rubber dust boots from the caliper bracket 9 Wash all the components in brake system cleaner 10 Using the correct rebuild kit for your vehicle reassemble the caliper as follows 11 Submerge the new rubber seal in clean brake fluid and refit it in the lower groove in the caliper bore making sure it isn t twisted 12 Coat the piston with clean brake fluid and stretch the new dust boot over the bottom of the piston Hold the piston over the caliper bore and insert the rubber flange of the dust boot in
457. round the master cylinder to protect any surrounding painted surfaces 2 Before beginning work purchase the specified type of brake fluid 3 Remove the cap from the master cylinder reservoir 4 Using a hand suction pump or similar device withdraw the fluid from the master cylinder reservoir 5 Add new fluid to the master cylinder until it rises to the base of the filler neck 6 Bleed the brake system as described in Chapter 9 at all four brakes until new and uncontaminated fluid flows from the bleed screw 7 Refill the master cylinder with fluid and check the operation of the brakes The pedal should feel solid when depressed with no sponginess Warning Do not drive the car if you are in any doubt about the braking system 1 20 Every 30 000 miles or 2 years 27 4 The differential drain plug arrowed is accessible through a hole located in the middle of the differential support brace 30 3 Push the expansion tank pressure cap downward and rotate anti clockwise never remove it when the engine is hot 3261 Jaguar XJ6 Every 60 000 miles 96 000 km 29 Handbrake shoes check 2 1 Remove the rear discs and inspect the handbrake shoes as described in Chapter 9 If the shoes are worn or damaged they must be renewed Warning The dust created by the brake system may contain asbestos which is harmful to your health Never blow it out with compressed air and don t inhale any of it An approved filtering mask should be w
458. row at the retaining plate that holds the two hoses in place cushions fit on the mounting points and that any foam insulator strips are still in place or transferred to the new condenser 6 Reconnect the refrigerant lines using new O rings If a new condenser has been installed add 84 cc 3 fluid ounces of new refrigerant oil Note The oil and O rings must be compatible with the type of refrigerant you are using 7 Refit the remaining parts in the reverse order of removal 8 Have the system evacuated charged and leak tested by the workshop that discharged it 17 Air conditioning evaporator and expansion valve removal and refitting 4 Warning 1 The air conditioning system is under high pressure Do not loosen any hose fittings or remove any components until the system has been discharged Air conditioning refrigerant should be properly discharged into an EPA approved recovery recycling unit by a dealer service department or an automotive air conditioning repair facility Always wear eye protection when disconnecting air conditioning system fittings Warning 2 Later model vehicles are equipped with airbags To prevent the accidental deployment of the airbag which could cause personal injury or damage to the airbag system DO NOT work in the vicinity of the steering wheel or instrument panel The manufacturer recommends that on airbag equipped models the following procedure should be left to a dealer service
459. rowed 12 4 Pry at the recess in the front of the sump to break the gasket seal insert a putty knife if necessary between the sump and engine block Refitting 5 Remove all traces of old gasket material and sealant from the engine block and sump Clean the mating surface with lacquer thinner or acetone Caution Do not use a sharp scraping tool Both the sump and the engine block are aluminium and could be easily damaged 6 Make sure the threaded bolt holes in the engine block and bellhousing are clean 7 Inspect the flange of the sump for any cracks pits or scratches that could cause an oil leak 8 Remove the baffle plate at the rear of the sump see illustration Clean the sump area and the baffle then refit the baffle 9 Inspect the oil pump pickup tube for cracks or foreign material blocking the screen see illustration 10 Apply a bead of RTV sealant to the sump flange see illustration Note The sump must be installed within 5 minutes of sealer application 11 Carefully position the sump on the engine block and push it toward the transmission adapter plate as you press it against the engine block Loosely refit four bolts two on each side of the sump Tighten the four bolts in a criss cross pattern to the torque listed in this Chapter s Specifications then loosen each bolt 90 12 Refit the two engine adapter to sump bolts Tighten the two bolts to the torque listed in this Chapter s Specifications then loose
460. rtain the crankshaft is clean carefully lay it in position in the main bearings 9 Before the crankshaft can be permanently installed the main bearing oil clearance must be checked 10 Trim several pieces of the appropriate size Plastigauge they must be slightly shorter than the width of the main bearings and place one piece on each crankshaft main bearing journal parallel with the journal axis see illustration 11 Clean the faces of the bearings in the caps and refit the caps in their respective positions don t mix them up with the arrows pointing toward the front of the engine Don t disturb the Plastigauge Apply a light coat of oil to the bolt threads and the undersides of the bolt heads then refit them Note Use the old bolts for this step save the new bolts for final refitting 12 Tighten the main bearing cap bolts in three steps to the torque listed in this Chapter s Specifications Don t rotate the crankshaft at any time during this operation 13 Remove the bolts and carefully lift off the main bearing caps or cap assembly Keep them in order Don t disturb the Plastigauge or rotate the crankshaft If any of the main bearing caps are difficult to remove tap them gently from side to side with a soft face hammer to loosen them 14 Compare the width of the crushed Plastigauge on each journal to the scale printed on the Plastigauge envelope to obtain the main bearing oil clearance see illustration Check th
461. s Chapter 4 Faulty or incorrectly gapped spark plugs Chapter 1 Incorrect ignition timing Chapter 5 Cracked distributor cap disconnected distributor wires or damaged distributor components Chapter 1 Leaking spark plug leads Chapter 1 Faulty emission system components Chapter 6 Low or uneven cylinder compression pressures Chapter 2 Weak or faulty ignition system Chapter 5 Vacuum leak in fuel injection system intake manifold or vacuum hoses Chapter 4 Crankshaft sensor teeth damaged or missing see Chapter 12 Distributor installed incorrectly see Chapter 5 Engine stumbles on acceleration Spark plugs fouled Chapter 1 Fuel injection system malfunctioning Chapter 4 Fuel filter clogged Chapters 1 and 4 Incorrect ignition timing Chapter 5 Intake manifold air leak Chapter 4 Collapsed or damaged fuel tank caused by blocked EVAP system where fitted see Chapter 6 3261 Jaguar XJ6 REF 14 Fault finding 2 Fuel system Engine surges while holding accelerator steady Intake air leak Chapter 4 Fuel pump faulty Chapter 4 Loose fuel injector harness connections Chapters 4 and 6 Defective ECU Chapter 6 Pinking or knocking engine sounds during acceleration or uphill Incorrect grade of fuel Distributor installed incorrectly Chapter 5 Fuel injection system in need of adjustment Chapter 4 Improper or damaged spark plugs or wires Chapter 1
462. s the instrument cluster housing will have to be removed Chapter 11 The bulbs can then be removed and replaced from the rear of the cluster see illustration 22 Inertia switch description and check 1 1 The inertia switch is a safety mechanism which governs various electrical circuits such as the central locking electric window and ignition circuits In the event of a crash the inertia switch will automatically unlock the doors shut off power to all ignition circuits and lock the boot lid and the fuel filler cap 2 To test the inertia switch turn the ignition key to the ON position then lock the driver and passenger side doors and unlock the boot lid Then simply pull upward on the trip reset button located on top of the inertia switch All ignition circuits should shut off the doors should unlock and the boot lid should lock To reset the inertia switch simply push downward on the trip reset button see illustration 12 12 Body electrical system 21 6 Detach the lens retaining screws arrowed and the lens to access the number plate light bulbs 21 9 The interior light bulbs can be accessed after lowering the overhead console 21 10 To remove an instrument cluster bulb depress the bulbholder and rotate it anti clockwise 3261 Jaguar XJ6 21 4 The Rear direction indicator brake tail and reversing light bulbs are accessible from the boot compartment after removing the plastic knobs arrowed securing the bu
463. s Chapter is designed to help the home mechanic maintain his her vehicle for safety economy long life and peak performance 2 The Chapter contains a master maintenance schedule followed by Sections dealing specifically with each task in the schedule Visual checks adjustments component renewal and other helpful items are included Refer to the accompanying illustrations of the engine compartment and the underside of the vehicle for the locations of the various components 3 Servicing your vehicle in accordance with the mileage time maintenance schedule and the following Sections will provide a planned maintenance programme which should result in a long and reliable service life This is a comprehensive plan so maintaining some items but not others at the specified service intervals will not produce the same results 4 As you service your vehicle you will discover that many of the procedures can and should be grouped together because of the particular procedure being performed or because of the proximity of two otherwise unrelated components to one another For example if the vehicle is raised for any reason the exhaust can be inspected at the same time as the suspension and steering components 5 The first step in this maintenance programme is to prepare yourself before the actual work begins Read through all the Sections relevant to the work to be carried out then make a list and gather all the parts and to
464. s REF 9 Seat belts and seats Note The following checks are applicable to all seat belts front and rear Examine the webbing of all the belts including rear belts if fitted for cuts serious fraying or deterioration Fasten and unfasten each belt to check the buckles If applicable check the retracting mechanism Check the security of all seat belt mountings accessible from inside the vehicle The front seats themselves must be securely attached and the backrests must lock in the upright position Doors Both front doors must be able to be opened and closed from outside and inside and must latch securely when closed Vehicle identification Number plates must be in good condition secure and legible with letters and numbers correctly spaced spacing at A should be twice that at B The VIN plate and or homologation plate must be legible Electrical equipment Switch on the ignition and check the operation of the horn Check the windscreen washers and wipers examining the wiper blades renew damaged or perished blades Also check the operation of the stop lights Check the operation of the sidelights and number plate lights The lenses and reflectors must be secure clean and undamaged Check the operation and alignment of the headlights The headlight reflectors must not be tarnished and the lenses must be undamaged Switch on the ignition and check the operation of the direction indicators including
465. s are of the correct size for the vehicle that they are of the same size and type on each axle and that the pressures are correct Check the tyre tread depth The legal minimum at the time of writing is 1 6 mm over at least three quarters of the tread width Abnormal tread wear may indicate incorrect front wheel alignment Body corrosion Check the condition of the entire vehicle structure for signs of corrosion in load bearing areas These include chassis box sections side sills cross members pillars and all suspension steering braking system and seat belt mountings and anchorages Any corrosion which has seriously reduced the thickness of a load bearing area is likely to cause the vehicle to fail In this case professional repairs are likely to be needed Damage or corrosion which causes sharp or otherwise dangerous edges to be exposed will also cause the vehicle to fail Petrol models Have the engine at normal operating temperature and make sure that it is in good tune ignition system in good order air filter element clean etc Before any measurements are carried out raise the engine speed to around 2500 rpm and hold it at this speed for 20 seconds Allow the engine speed to return to idle and watch for smoke emissions from the exhaust tailpipe If the idle speed is obviously much too high or if dense blue or clearly visible black smoke comes from the tailpipe for more than 5 seconds the vehicle will fail As
466. s with lacquer thinner or acetone 7 Remove the screws and separate the front and rear pump covers from the body Lift out the drive and driven rotors see illustrations Note Mark the front face of each rotor before removing them Engine in car repair procedures 2A 15 2A 12 8 Remove the bolts arrowed and the sheetmetal baffle plate clean the sump area of the sump with the baffle removed 12 9 Lubrication system components A Oil pump B Transfer tubes C Transfer housing D Oil pump pickup 12 10 Apply a bead of RTV sealant around the perimeter of the sump mounting flange be sure to run the bead around the outside all bolt the holes 13 7a Remove the bolts and separate the front and rear pump covers 13 7b Remove the outer rotor A and inner rotor B 13 2 Unbolt the oil pump pickup A and the bolts B retaining the transfer assembly C to the engine block 13 4 Pry back the locking tabs and remove the three bolts retaining the oil pump drive sprocket to the pump 3261 Jaguar XJ6 Inspection 8 Clean and dry the pump body and both rotors Measure the outside diameter of the outer rotor and thickness of both rotors 9 Place the outer rotor into the pump body and use feeler gauges to measure the clearance between the outer rotor and the body see illustration 10 Place a straightedge across the pump body and measure between the straightedge and the rotors to check the over the rotor clearance see illustrat
467. seats and that the spring is not corroded cracked or broken If leaf springs are fitted check that all leaves are intact that the axle is securely attached to each spring and that there is no deterioration of the spring eye mountings bushes and shackles The same general checks apply to vehicles fitted with other suspension types such as torsion bars hydraulic displacer units etc Ensure that all mountings and attachments are secure that there are no signs of excessive wear corrosion or damage and on hydraulic types that there are no fluid leaks or damaged pipes Inspect the shock absorbers for signs of serious fluid leakage Check for wear of the mounting bushes or attachments or damage to the body of the unit Driveshafts fwd vehicles only Rotate each front wheel in turn and inspect the constant velocity joint gaiters for splits or damage Also check that each driveshaft is straight and undamaged Braking system If possible without dismantling check brake pad wear and disc condition Ensure that the friction lining material has not worn excessively A and that the discs are not fractured pitted scored or badly worn B Examine all the rigid brake pipes underneath the vehicle and the flexible hose s at the rear Look for corrosion chafing or insecurity of the pipes and for signs of bulging under pressure chafing splits or deterioration of the flexible hoses Look for signs of fluid leaks at t
468. sensor depend upon good clean connections which should be checked whenever a malfunction of the sensor is suspected or indicated b Outside air supply The sensor is designed to allow air circulation to the internal portion of the sensor Whenever the sensor is removed and installed or renewed make sure the air passages are not restricted c Proper operating temperature The ECU will not react to the sensor signal until the sensor reaches approximately 600 F This factor must be taken into consideration when evaluating the performance of the sensor d Unleaded fuel The use of unleaded fuel is essential for proper operation of the sensor Make sure the fuel you are using is of this type 12 In addition to observing the above conditions special care must be taken whenever the sensor is serviced a The oxygen sensor has a permanently attached pigtail and electrical connector which should not be removed from the sensor Damage to or removal of the pigtail or electrical connector can adversely affect operation of the sensor b Grease dirt and other contaminants should be kept away from the electrical connector and the louvered end of the sensor c Do not use cleaning solvents of any kind on the oxygen sensor d Do not drop or roughly handle the sensor 6 4 Emissions and engine control systems 3261 Jaguar XJ6 4 2 The coolant temperature sensor is in the thermostat housing To check the coolant temperature sensor use a
469. ser removal and refitting 4 Warning The air conditioning system is under high pressure Do not loosen any hose fittings or remove any components until the system has been discharged Air conditioning refrigerant should be properly discharged into an EPA approved recovery recycling unit by a dealer service department or an automotive air con ditioning repair facility Always wear eye protection when disconnecting air conditioning system fittings 1 Have the refrigerant discharged and recovered by an air conditioning technician 2 Remove the radiator cowl panel as described in Section 5 3 Using two spanners to avoid twisting the fittings disconnect the inlet and outlet lines from the condenser see illustration 4 Pull the condenser straight up and out of the vehicle 5 Refitting is the reverse of removal When refitting the condenser be sure the rubber Cooling heating and air conditioning systems 3 13 3 15 5 Remove the lower mounting bolts and the adjuster bolt arrowed 16 3 Disconnect the two lines then pull up on the condenser arrowed 3261 Jaguar XJ6 14 2 After the system has been discharged unbolt the two refrigerant lines left arrows from the top of the receiver drier and cap them use two spanners when loosening or tightening these lines right arrows indicate the two top mounting bolts 15 4 Disconnect the electrical connector small arrow at the compressor then disconnect the bolt large ar
470. shers where equipped 6 Refit the inlet and outlet fittings then tighten the filter mounting bracket Reconnect the battery cable start the engine and check for leaks 19 Ignition system check 2 1 The spark plug leads should be checked whenever new spark plugs are installed 2 Begin this procedure by making a visual check of the spark plug leads while the engine is running In a darkened garage make sure there is adequate ventilation start the engine and observe each plug lead Be careful not to come into contact with any moving engine parts If there is a break in the lead you will see arcing or a small spark at the damaged area If arcing is noticed make a note to obtain new leads then allow the engine to cool and check the distributor cap and rotor 3 The spark plug leads should be inspected one at a time to prevent mixing up the order which is essential for proper engine operation Each original plug lead should be numbered to help identify its location If the number is illegible a piece of tape can be marked with the correct number and wrapped around the plug lead 4 Disconnect the plug lead from the spark plug A removal tool can be used for this purpose or you can grasp the rubber boot twist the boot half a turn and pull the boot free Do not pull on the lead itself 5 Check inside the boot for corrosion which will look like a white crusty powder 6 Push the lead and boot back onto the end of the spark plug It shoul
471. shing panel see illustration 5 Unscrew the inside lock knob then remove the remaining screws securing the upper half of the door trim panel and detach it from the vehicle see illustration 6 Detach the screw from the top edge of the lower door trim panel see illustration 7 Pry out the courtesy lamp lens then detach the retaining screw from inside the lamp housing see illustrations 8 Remove the armrest trim cover then detach the retaining screws from behind the cover see illustrations 9 Insert a wide putty knife a screwdriver or a special trim panel removal tool between the trim panel and the head of the retaining clips to disengage the retaining clips along the outer edges of the door panel see illustration Pry only at the clip locations or the panel could be damaged 10 Once all of the clips are disengaged detach the trim panel unplug any electrical connectors and remove the trim panel from the door by gently pulling it up and out 11 For access to the inner door peel back the watershield taking care not to tear it To refit the trim panel first press the watershield back into place If necessary add more sealant to hold it in place 12 Refitting is the reverse of removal 19 Door removal refitting and adjustment 3 Note The door is heavy and somewhat awkward to remove and refit at least two people should perform this procedure Removal and refitting 1 Raise the window completely in the door th
472. sidual 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 4000C The rubber changes into a charre
473. slacken the nut to align the split pin hole unless stated in the repair procedure When checking or retightening a nut or bolt to a specified torque setting slacken the nut or bolt by a quarter of a turn and then retighten to the specified setting However this should not be attempted where angular tightening has been used For some screw fastenings notably cylinder head bolts or nuts torque wrench settings are no longer specified for the latter stages of tightening angle tightening being called up instead Typically a fairly low torque wrench setting will be applied to the bolts nuts in the correct sequence followed by one or more stages of tightening through specified angles Locknuts locktabs and washers Any fastening which will rotate against a component or housing during tightening should always have a washer between it and the relevant component or housing Spring or split washers should always be renewed when they are used to lock a critical component such as a big end bearing retaining bolt or nut Locktabs which are folded over to retain a nut or bolt should always be renewed Self locking nuts can be re used in non critical areas providing resistance can be felt when the locking portion passes over the bolt or stud thread However it should be noted that self locking stiffnuts tend to lose their effectiveness after long periods of use and should be renewed as a matter of course Split pins must always be r
474. solenoid vacuum valve in parallel circuit with the air pump A delay valve prevents vacuum loss to the solenoid valve during wide open throttle operation 3 Injected air is controlled by the computer the air pump clutch and the air pump clutch relay The AIR system is used during warm up 58 to 83 F to control emissions while the engine is running rich The oxygen sensor feedback system cannot function while the AIR system is operating The computer controls both systems during warm up and operating temperatures If problems occur with the AIR system relay or circuit the on board diagnosis system will set a code 66 Check 4 Check the condition of the air pump drivebelt the injection hoses and the injection manifold Make sure that all components are intact and there are no leaks 5 Check the operation of the air pump clutch relay see illustration and the air pump clutch First remove the relay and check for battery voltage to the relay Also check the relay itself Refer to the relay checking procedure in Chapter 12 Extract codes from the self diagnosis system see Section 3 and check for a code 66 AIR relay malfunction 6 Make sure the electrical connector is securely fastened to the diverter valve see illustration If everything appears OK but a fault code still sets have the system diagnosed by a dealer service department or other qualified repair workshop Air pump renewal 7 Disconnect the cable from the negative
475. ss See Chapter 1 Brake disc minimum permissible thickness Cast into disc Parallelism 0 013 mm 0 0005 inch maximum Runout 0 102 mm 0 004 inch maximum Torque wrench settings Nm lbf ft Brake servo mounting nuts 10 7 Caliper bolts front and rear 31 to 40 23 to 29 Caliper bracket bolts Front bracket 102 to 128 75 to 94 Rear bracket 55 to 62 40 to 45 Master cylinder to brake servo nuts 22 to 28 16 to 20 Wheel nuts See Chapter 1 Specifications Anti lock Brake System ABS general information 2 Brake check See Chapter 1 Brake disc inspection removal and refitting
476. ssively finer grades of sandpaper should be used starting with a 180 grit paper and finishing with 600 grit wet or dry paper Always wrap the sandpaper around a flat rubber or wooden block otherwise the surface of the filler will not be completely flat During the sanding of the filler surface the wet or dry paper should be periodically rinsed in water This will ensure that a very smooth finish is produced in the final stage 17 At this point the repair area should be surrounded by a ring of bare metal which in turn should be encircled by the finely feathered edge of good paint Rinse the repair area with clean water until all of the dust produced by the sanding operation is gone 18 Spray the entire area with a light coat of primer This will reveal any imperfections in the surface of the filler Repair the imperfections with fresh filler paste or glaze filler and once more smooth the surface with sandpaper Repeat this spray and repair procedure until you are satisfied that the surface of the filler and the feathered edge of the paint are perfect Rinse the area with clean water and allow it to dry completely 19 The repair area is now ready for painting Spray painting must be carried out in a warm dry windless and dust free atmosphere These conditions can be created if you have access to a large indoor work area but if you are forced to work in the open you will have to pick the day very carefully If you are working indoors do
477. stem fluid reservoir is located on the right inner wing of the engine compartment 1988 and 1989 models 2 The fluid level can easily be checked by viewing the reservoir sight glass A green indicator in the sight glass indicates an OK condition while a red indicator in the sight glass requires fluid to be added see illustration 3 If additional fluid is required pop open the plastic tab located on top of the reservoir cap see illustration 4 Insert the mineral oil dispensing tube into the reservoir filler hole Push down and turn until the dispensing tube is locked in place 5 Add fluid until the green indicator in the sight glass appears then release the dispensing tube by pushing downward and turning the opposite direction of refitting 1990 to 1994 models 6 The fluid level can be checked by removing the cap and observing the level of fluid on the dipstick 7 Wipe off the fluid with a clean rag reinsert it then withdraw it and read the fluid level see illustration The dipstick is marked so the fluid can be checked either cold or hot The level should be at the HOT mark if the fluid was hot to the touch It should be at the COLD mark if the fluid was cool to the touch At no time should the fluid level drop below the add mark 8 If additional fluid is required pour the specified type directly into the reservoir using a funnel to prevent spills 6 Battery check and general information 1 Warning Certain precaut
478. sures 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 bes
479. system Typical 1991 and 1992 windscreen washer and wiper system Wiring diagrams 12 39 12 3261 Jaguar XJ6 Typical 1993 and 1994 windscreen washer and wiper system 3261 Jaguar XJ6 Dimensions and weights REF 1 Jacking and vehicle support REF 1 Radio cassette unit anti theft system REF 1 Conversion factors REF 2 Use of English REF 3 Buying spare parts REF 4 Vehicle identification REF 4 General repair procedures REF 5 Tools and working facilities REF 6 MOT test checks REF 8 Fault finding REF 12 Glossary of technical terms REF 18 Index REF 22 Dimensions and weights Note All figures are approximate and may vary according to model Refer to manufacturer s data for exact figures Dimensions Overall length 4988 mm Overall width including mirrors
480. t check and renewal 3 Underbonnet hose check and renewal See Chapter 1 Water pump check 7 Water pump and pipes renewal 8 3 1 Specifications Contents Easy suitable for novice with little experience Fairly easy suitable for beginner with some experience Fairly difficult suitable for competent DIY mechanic Difficult suitable for experienced DIY mechanic Very difficult suitable for expert DIY or professional Degrees of difficulty 5 4 3 2 1 1 General information Engine cooling system All vehicles covered by this manual employ a pressurised engine cooling system with thermostatically controlled coolant circulation An impeller type water pump mounted on the front of the block pumps coolant through the engine The coolant flows around each cylinder and toward the rear of the engine Cast in coolant passages direct coolant around the intake and exhaust ports near the spark plug areas and in proximity to the exhaust valve guides A wax pellet type thermostat is located in the thermostat housing at the front of the engine During warm up the closed thermostat prevents coolant from circulating through the radiator When the engine reaches normal operating temperature the thermostat ope
481. t even with the new thrust bearings oversized thrust bearings are available There are two sizes 0 005 inch and 0 010 inch oversize 23 Refit a new rear main oil seal then bolt the retainer to the engine block see Section 24 24 Rear main oil seal refitting 2 1 The crankshaft must be installed first and the main bearing caps bolted in place then the new seal should be installed in the retainer and the retainer bolted to the engine block 2 Check the seal contact surface on the crankshaft very carefully for scratches and nicks that could damage the new seal lip and cause oil leaks If the crankshaft is damaged the only alternative is a new or different crankshaft 3 Refer to Part A of this Chapter for refitting of the new rear seal using the plastic alignment tool supplied with the engine overhaul gasket set 25 Pistons connecting rods refitting and big end bearing oil clearance check 3 1 Before refitting the piston connecting rod assemblies the cylinder walls must be perfectly clean the top edge of each cylinder must be chamfered and the crankshaft must be in place 2 Remove the cap from the end of the number one connecting rod refer to the marks made during removal Remove the original bearing inserts and wipe the bearing surfaces of the connecting rod and cap with a clean lint free cloth They must be kept spotlessly clean Big end bearing oil clearance check 3 Clean the back side of the new upper bearing
482. t Make sure the throttle closes fully when the pedal is released see illustration 10 After the cable is adjusted check the adjustment of the bellcrank Use a small clamp and a straight rod or stiff wire coat hanger and attach it to the brake master cylinder in such a way that the tip acts as a pointer Align the pointer with A automatic transmission or M manual transmission on the bellcrank see illustration depending on what type of transmission is installed in the vehicle 11 Slowly rotate the bellcrank until it reaches the throttle stop wide open throttle and check to make sure the pointer aligns with the notch in the bellcrank see illustration 12 If necessary adjust the position of the throttle stop using a spanner and turn the throttle stop screw until the bellcrank reaches the correct position Lock the throttle stop screw in place 4 8 Fuel and exhaust systems 3261 Jaguar XJ6 10 4 Remove circlip arrowed and separate cable from the accelerator pedal by pulling the pin from the pedal assembly 10 2 Loosen the locknuts on the accelerator cable 10 3 Rotate the bellcrank and remove the cable end from the slot 10 9 Make sure the throttle closes completely and there is a slight amount of flex in the cable 10 10 Attach a strong wire coat hanger to the master cylinder using a clamp and align it with the notch on the bellcrank 13 Allow the bellcrank to return to the idle position and test the adj
483. t checked by feel 3261 Jaguar XJ6 Weekly checks 0 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 4 Make 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 4 Periodically approximately every three months check the charge condition of the battery as described in Chapter 5 4 If 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 1 Check 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 clamps 4 Bulbs a
484. t one adjusts the air conditioning compressor belt which is accessible from underneath the car The second tensioning mechanism is above the alternator it adjusts the tension on the main belt the water pump alternator and power steering pump belt 6 The air conditioning compressor and the alternator each have a belt tensioning mechanism and pivot bolt s which must be loosened slightly to enable you to move the component see illustrations 7 After the bolts have been loosened belt tension can be adjusted by either loosening or tightening the locknuts on the belt tensioning adjustment rod see illustration 21 6a and b Move the component away from the engine to tighten the belt or toward the engine to loosen the belt 8 Measure the belt tension using the method described in paragraph 4 Repeat this procedure until the drivebelt is adjusted properly Renewal 9 To replace a belt loosen the drivebelt adjustment rod and pivot bolt as described above slip the belt off the crankshaft pulley and remove it If you are replacing the alternator power steering pump belt you ll have to remove the air conditioning 1 16 Every 15 000 miles or 12 months 21 3a Small cracks in the underside of a serpentine belt are acceptable lengthwise cracks or missing pieces are cause for replacement 21 3b Here are some of the more common problems associated with V belts check the belts very carefully to prevent an untimely breakdown
485. tage Turn the ignition key ON engine not running and check for reference voltage with a high impedance digital voltmeter see illustration It should be approximately 5 volts Renewal Warning Wait until the engine is completely cool before beginning this procedure 4 To remove the sensor depress the locking tabs unplug the electrical connector then carefully unscrew the sensor Caution Handle the coolant sensor with care Damage to this sensor will affect the operation of the entire fuel injection system 5 Before refitting the new sensor wrap the threads with Teflon sealing tape to prevent leakage and thread corrosion 6 Refitting is the reverse of removal Oxygen sensor Note An oxygen sensor splash shield is equipped on models from VIN 664941 mid 1990 to present This shield prevents the self diagnosis system from setting an intermittent and erroneous code 44 Whenever replacing an oxygen sensor make sure the splash shield is in place General description 7 These models are equipped with a heated oxygen sensor system The oxygen sensor is mounted ahead of the front catalytic converter and monitors the exhaust gases before they are changed The electrical heating system incorporated into the oxygen sensor allows for quicker warm up time and more efficient oxygen content monitoring The oxygen sensor monitors the oxygen content of the exhaust gas stream The oxygen content in the exhaust reacts with the oxyg
486. te the fuel pressure and compare it with the pressure listed in this Chapter s Specifications 9 Disconnect the vacuum hose from the fuel pressure regulator and hook up a hand held vacuum pump see illustration to the port on the fuel pressure regulator 10 Read the fuel pressure gauge with vacuum applied to the pressure regulator and also with no vacuum applied The fuel pressure should decrease as vacuum increases and increase as vacuum decreases Fuel and exhaust systems 4 3 4 3261 Jaguar XJ6 3 3a Checking for battery voltage at the fuel pump relay connector 1989 model 3 3b Checking for battery voltage to the main relay 1989 model 3 6a Remove the fuel line from the fuel pulsation damper 3 4b Check for battery voltage to the fuel pump on the harness connector near the fuel tank on models with in tank fuel pumps 3 4a Remove the rubber boot from the fuel pump electrical connector and check for voltage while an assistant turns the ignition key 1989 model shown 3 6b then refit the fuel pressure gauge between the fuel rail and the fuel pressure damper using a T fitting 11 Reconnect the vacuum hose to the regulator and check the fuel pressure at idle comparing your reading with the value listed in this Chapter s Specifications Disconnect the vacuum hose and watch the gauge the pressure should jump up considerably as soon as the hose is disconnected If it doesn t check for a vacuum sign
487. te the number of washers used and the order in which they re installed Put these parts in a plastic bag 6 Remove the upper control arm Inspect the bushings at either end of the arm and renew them if they re damaged or worn 7 Refitting is the reverse of removal Be sure to refit the washers in the same order in which they were removed Raise the suspension with the trolley jack to simulate normal ride height then tighten the upper control arm pivot bolt and nut to the torque listed in this Chapter s Specifications 8 Coil spring front removal and refitting 3 Warning The coil springs cannot be removed without a special spring compressor tool Jaguar tool JD115 Do not try to remove a coil spring without this special tool If you do you could be seriously injured 1 Loosen the wheel nuts raise the vehicle Suspension and steering systems 10 5 10 5 11 Strike the steering knuckle in this area to pop the lower ball stud loose from the steering knuckle 5 12 To detach the lower balljoint from the lower control arm remove these four bolts arrowed 5 13 To detach the dust boot from the steering knuckle pry the lower lip of the boot out of its groove in the knuckle 6 5 To detach the brake shield from the steering knuckle remove these three screws arrowed 6 4 To detach the ABS sensor from the steering knuckle remove this bolt 7 4 Remove these three Torx screws arrowed and move the accumulator ass
488. ted under the trim bezel 24 7 After removing the centre trim panel detach the air conditioning duct 24 8 Remove the retaining screws in the air conditioning duct opening 24 9 Remove the plastic screws arrowed from each side of the console 24 13 Remove the plastic screw then pull the overhead console down and unplug the electrical connectors 3261 Jaguar XJ6 25 4 Working in the knee bolster opening remove two retaining screws from each end of the instrument cluster housing 25 5 Pull outward on the instrument cluster housing and unplug the electrical connectors from the backside 26 Dashboard trim panels removal and refitting 2 Warning Later models are equipped with airbags To prevent the accidental deploy ment of the airbag which could cause personal injury or damage to the airbag system DO NOT work in the vicinity of the steering column or instrument panel The manufacturer recommends that on airbag equipped models the following procedure should be left to a dealer service department or other repair workshop because of the special tools and techniques required to disable the airbag system Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Knee bolster 1 Knee bolsters are located on the lower half of the instrument panel on the driver and passenger sides of the vehicle The removal of these
489. tems 5 3 5 6 5 Check for battery voltage to the coil terminal 6 9 Check for battery voltage to the IGN ON relay 6 11 Refit the LED test light to the coil negative terminal crank the engine over and observe the light flash in response to the trigger signal from the computer 7 1 Remove the clip that retains the harness connector to the amplifier 7 2 Check for battery voltage to the ignition amplifier 7 5 Remove the amplifier mountings screws arrowed and lift the unit from the engine compartment 3261 Jaguar XJ6 sure you have the correct activation code before disconnecting the battery 2 Disconnect the electrical connectors and the coil wire from the coil 3 Using an ohmmeter check the coil resistance a Measure the resistance between the positive and negative terminals see illustration Compare your reading with the specified coil primary resistance listed in this Chapter s Specifications b Measure the resistance between the positive terminal and the high tension HT terminal see illustration Compare your reading with the specified coil secondary resistance listed in this Chapter s Specifications 4 If either of the above tests yield resistance values outside the specified amount renew the coil Renewal 5 Detach the battery negative cable Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the
490. th the component in that condition If the vehicle presented is clean and evidently well cared for the tester may be more inclined to pass a borderline component than if the vehicle is scruffy and apparently neglected It has only been possible to summarise the test requirements here based on the regulations in force at the time of printing Test standards are becoming increasingly stringent although there are some exemptions for older vehicles For full details obtain a copy of the Haynes publication Pass the MOT available from stockists of Haynes manuals An assistant will be needed to help carry out some of these checks The checks have been sub divided into four categories as follows Handbrake Test the operation of the handbrake Excessive travel too many clicks indicates incorrect brake or cable adjustment Check that the handbrake cannot be released by tapping the lever sideways Check the security of the lever mountings Footbrake Depress the brake pedal and check that it does not creep down to the floor indicating a master cylinder fault Release the pedal wait a few seconds then depress it again If the pedal travels nearly to the floor before firm resistance is felt brake adjustment or repair is necessary If the pedal feels spongy there is air in the hydraulic system which must be removed by bleeding Check that the brake pedal is secure and in good condition Check also for signs of fluid leaks on the pedal f
491. th the passenger side knee bolster removed unscrew the glove box door hinge bolts 26 11 Remove the screws along the top edge arrowed pull the glove box out and remove the lamp assembly personal injury or damage to the airbag system DO NOT work in the vicinity of the steering column or instrument panel The manufacturer recommends that on airbag equipped models the following procedure should be left to a dealer service department or other repair workshop because of the special tools and techniques required to disable the airbag system 1 Remove the steering wheel Chapter 10 2 Remove the knob from the rheostat dimmer for the instrument panel lights see illustration 3 Remove the lower steering column cover screws see illustration then detach the lower cover 4 Working through the lower cover opening remove the four screws securing the upper half of the cover then pull the cover forward and out to remove it see illustration 5 Refitting is the reverse of removal 28 Cowl cover removal and refitting 2 1 Remove the windscreen wiper arms see Chapter 12 2 Remove the retaining screws located along the top of the cowl cover see illustration 3 Lift the cowl cover up slightly then detach the electrical connectors and the spray nozzle hoses from the backside of the cowl cover 4 Detach the cowl cover from the vehicle 5 Refitting is the reverse of removal 29 Seats removal and refitting 2 Front seat 1 P
492. the crankshaft damper see illustration 7 Remove the Woodruff key from the crankshaft keyway see illustration 8 Carefully pry the seal out of the front cover with a screwdriver or seal removal tool see illustration Don t scratch the bore or Engine in car repair procedures 2A 5 2A 6 3 Remove nuts small arrows retaining the exhaust pipe to the manifold flanges two for each pipe larger arrow indicates one heat shield bolt accessible from below 6 4 Remove the upper heat shield bolts arrowed 6 6 Remove the bolts and nuts and remove the front and rear exhaust manifolds 6 8 Refit new gaskets in position over the studs with the markings facing out 7 7 Carefully tap one end the Woodruff key up and out from the crankshaft keyway then grasp it with a pair of locking pliers and pull it the rest of the way out be careful not to damage the key or keyway 7 8 Remove the crankshaft seal with a screwdriver or seal puller there are two slots arrowed in the cover which allow you to pry behind the seal 7 4 Use a large breaker bar and the appropriate size socket to remove the crankshaft pulley bolt 7 5 After removing the centre bolt remove the crankshaft damper with a two bolt puller be careful not to damage the sensor ring 3261 Jaguar XJ6 damage the crankshaft in the process if the crankshaft is damaged the new seal will end up leaking 9 The crankshaft seal rides on a spacer that slips over the front
493. the bolt holes in the camshaft engage the splines between the two sprocket halves and secure the sprocket with the bolts and locking tabs Refit the clip to secure the two sprocket halves together 30 Clean the tensioner gasket surface fit a new gasket and O rings push the ratchet down and twist it to maintain the fully retracted position and refit the tensioner in place of the tensioning tool see illustration Note Align the slot in the end of the tensioner straight up and down to fit over the tang on the back of the chain tensioner guide 31 Rotate the engine and recheck that all valve clearance measurements are now correct see paragraph 4 32 The remainder of refitting is the reverse of the removal procedure Note When refitting the distributor use a new O ring where it fits into the engine block 2A 12 Engine in car repair procedures 3261 Jaguar XJ6 10 27a Each camshaft sprocket is comprised of two sections an inner A and outer B that are splined together 10 27b Push the outer sprocket over the intake camshaft until it locks in place then turn the sprocket left to remove chain slack at the right 10 28 The special tensioning tool simulates the operation of the oil driven tensioner apply 4 to 6 Nm 36 to 48 inch pounds pressure on the centre bolt arrowed 10 30 Upper timing chain tension components A Notch to align with tang on guide B Tensioner ratchet C O ring D Gasket E valve with O rings 1
494. the brake pedal until it feels hard to push this dissipates the pressure inside the accumulator then locate the hydraulic line valve block just in front of the upper end of the left rear shock see illustration Attach a plastic hose to the bleeder screw see illustration put the other end of the hose in a catch bottle crack the bleeder and drain off as much fluid as possible Disconnect the hydraulic line that connects the left shock to the valve block Now locate the other valve block just in front of the right rear shock disconnect the hydraulic line that connects the right shock to this valve block too 3 Remove the lower shock absorber to control arm nut and bolt see illustration 4 Remove the upper mounting bolts see illustration and remove the shock absorber coil spring assembly 10 6 Suspension and steering systems 9 4 To detach the lower control arm from the crossmember remove this nut and bolt arrowed unbolt and lower the steering gear before you can pull out the pivot bolt 10 2a On a vehicle equipped with self levelling rear suspension the valve block arrowed for the left rear shock is located just in front of the shock absorber 10 2b After depressurising the system attach a bleed hose to the bleed screw on the left valve block open the bleed and drain any residual fluid into a catch bottle 3261 Jaguar XJ6 8 2a When refitting the spring compressor tool JD115 insert the upper end of the
495. the engine block If necessary use the bolts as levers to remove the main bearing caps Try not to drop the bearing inserts if they come out with the caps Note The number four main bearing is the thrust bearing and is not numbered 6 Carefully lift the crankshaft out of the engine It may be a good idea to have an assistant available since the crankshaft is quite heavy With the bearing inserts in place in the engine block and main bearing caps return the main bearing caps to their respective locations on the engine block and tighten the bolts finger tight 15 Engine block cleaning 2 Caution The core plugs also known as freeze or soft plugs may be difficult or impossible to retrieve if they re driven completely into the engine block coolant passages 1 Using the blunt end of a punch tap in on the outer edge of the core plug to turn the plug sideways in the bore Then using pliers pull the core plug from the engine block see illustrations 2B 10 Engine removal and overhaul procedures 14 5 The right side of each main bearing cap is stamped with a number left arrow that corresponds to the stamped number on the pan rail right arrow 15 1a A hammer and a large punch can be used to knock the core plugs sideways in their bores 15 1b Pull the core plugs from the engine block with pliers 3261 Jaguar XJ6 14 1 Checking crankshaft endplay with a dial indicator 14 3 Checking crankshaft endplay with a feeler gauge
496. the instrument panel tell tale and the hazard warning lights Operation of the sidelights and stop lights must not affect the indicators if it does the cause is usually a bad earth at the rear light cluster Check the operation of the rear foglight s including the warning light on the instrument panel or in the switch Footbrake Examine the master cylinder brake pipes and servo unit for leaks loose mountings corrosion or other damage The fluid reservoir must be secure and the fluid level must be between the upper A and lower B markings Inspect both front brake flexible hoses for cracks or deterioration of the rubber Turn the steering from lock to lock and ensure that the hoses do not contact the wheel tyre or any part of the steering or suspension mechanism With the brake pedal firmly depressed check the hoses for bulges or leaks under pressure Steering and suspension Have your assistant turn the steering wheel from side to side slightly up to the point where the steering gear just begins to transmit this movement to the roadwheels Check for excessive free play between the steering wheel and the steering gear indicating wear or insecurity of the steering column joints the column to steering gear coupling or the steering gear itself Have your assistant turn the steering wheel more vigorously in each direction so that the roadwheels just begin to turn As this is done examine all the steering joints l
497. the stands If the wheels are to be removed at this interval for tyre rotation or brake inspection loosen the wheel nuts slightly while the car is still on the ground 4 Before beginning force a little grease out of the nozzle to remove any dirt from the end of the gun Wipe the nozzle clean with a rag 5 With the grease gun and plenty of clean rags crawl under the car and begin lubricating all the front suspension parts that are equipped with a grease fitting 6 Lubricate the rear driveshafts see illustration Wipe each fitting clean and push the nozzle firmly over it Pump the gun until grease is expelled from the U joint cap seal 7 Wipe away any excess grease from the components and the grease fitting Repeat the procedure for the remaining fittings Every 7500 miles or 6 months 1 13 1 14 1 Materials required for chassis and body lubrication 3261 Jaguar XJ6 12 8a Check the steering gear dust boots for cracks and leaking steering fluid 12 8b Check the anti roll bar bushings arrowed for deterioration at the front and the rear of the vehicle 12 10 Inspect the balljoint and tie rod end boots for tears tears or damage in either boot will allow contamination of the grease which will lead to premature failure 1 Engine oil Light engine oil in a can like this can be used for door and bonnet hinges 2 Graphite spray Used to lubricate lock cylinders 3 Grease Grease in a variety of types and weights is ava
498. then refit and tighten them to the torque listed in this Chapter s Specifications Engine removal and overhaul procedures 2B 17 2B 25 13 Lay the Plastigauge strips on each big end bearing journal parallel to the crankshaft centreline 3261 Jaguar XJ6 25 5 Stagger the ring end gaps around the piston as shown 25 9 Pistons must be installed with the arrow right arrow or FRONT facing the front of the engine left arrow indicates piston size letter 25 11 The piston can be driven gently into the cylinder bore with the end of a wooden or plastic hammer handle A Oil ring rail gaps B Second compression ring gap C Oil ring spacer gap D Top compression ring gap working up to it in three steps Note Use the old bolts for this step save the new bolts for final refitting Use a thin wall socket to avoid erroneous torque readings that can result if the socket is wedged between the rod cap and nut If the socket tends to wedge itself between the nut and the cap lift up on it slightly until it no longer contacts the cap Do not rotate the crankshaft at any time during this operation 16 Remove the nuts and detach the rod cap being careful not to disturb the Plastigauge 17 Compare the width of the crushed Plastigauge to the scale printed on the envelope to obtain the oil clearance see illustration Compare it to this Chapter s Specifications to make sure the clearance is correct 18 If the clearance is not as specified
499. these words AMERICAN ENGLISH Aluminum Aluminium Antenna Aerial Authorized Authorised Auto parts stores Motor factors Axleshaft Halfshaft Back up Reverse Barrel Choke venturi Block Chock Box end wrench Ring spanner Bushing Bush Carburetor Carburettor Center Centre Coast Freewheel Color Colour Convertible Drop head coupe Cotter pin Split pin Counterclockwise Anti clockwise Countershaft of gearbox Layshaft Dashboard Facia Denatured alcohol Methylated spirit Dome lamp Interior light Driveaxle Driveshaft Driveshaft Propeller shaft Fender Wing mudguard Firewall Bulkhead Flashlight Torch Float bowl Float chamber Floor jack Trolley jack Freeway turnpike etc Motorway Freeze plug Core plug Frozen Seized Gas tank Petrol tank Gasoline gas Petrol Gearshift Gearchange Generator DC Dynamo Ground electrical Earth Header Exhaust manifold Heat riser Hot spot High Top gear Hood engine cover Bonnet Installation Refitting Intake Inlet Jackstands Axle stands Jumper cable Jump lead Keeper Collet Kerosene Paraffin Knock pin Roll pin Lash Clearance Lash Free play Latch Catch Latches Locks License plate Number plate Light Lamp Lock for valve spring retainer Split cotter for valve spring cap Lopes Hunts Lug nut bolt Wheel nut bolt Metal chips or debris Swarf Misses Misfires AMERICAN ENGLISH Muffler Silencer Odor Odour Oil pan Sump Open flame Naked flame Pa
500. threads as the fittings are tightened 18 Tighten the brake fittings securely and the mounting nuts to the torque listed in this Chapter s Specifications 19 Fill the master cylinder reservoir with fluid then bleed the master cylinder and the brake system see Section 9 20 To bleed the master cylinder on the vehicle have an assistant pump the brake pedal several times and then hold the pedal to the floor Loosen the fitting nut to allow air and fluid to escape then tighten the nut Repeat this procedure on both fittings until the fluid is clear of air bubbles Test the operation of the brake system carefully before placing the vehicle into service 7 Brake servo general information removal and refitting 2 General information 1 A hydraulic brake servo system assists braking when the brake pedal is depressed The booster unit located between the brake pedal box and the master cylinder is operated by hydraulic pressure generated by an engine driven pump on early models or by an electric pump on later models When the engine is running the pump supplies hydraulic pressure to an accumulator The accumulator stores and regulates the pressure to the hydraulic brake servo When you depress the brake pedal the pressure in the booster helps actuate the master cylinder reducing pedal effort 2 The hydraulic brake servo isn t rebuildable if it fails it must be replaced Basic operation can be checked see Chapter 1 Sec
501. ting 3 1 Loosen the wheel nuts raise the front of the vehicle and place it securely on axle stands Remove the wheel 2 Remove the front brake caliper and mounting bracket see Chapter 9 Do not disconnect the brake hose Hang the caliper out of the way with a piece of wire 3 Remove the brake disc see Chapter 9 4 Remove the ABS sensor see illustration 5 Remove the brake shield see illustration 6 Disconnect the tie rod end from the steering knuckle see Section 15 7 Disconnect the upper and lower balljoints from the steering knuckle see Section 5 8 Remove the steering knuckle 9 Refitting is the reverse of removal Tighten the balljoint nuts and the tie rod end nuts to the specified torque Tighten the brake fasteners to the torque values listed in the Chapter 9 Specifications 7 Upper control arm removal and refitting 3 1 Loosen the wheel nuts raise the vehicle and support it securely on axle stands Remove the wheel 2 Support the lower control arm with a trolley jack see illustration 4 2 3 Disconnect the upper balljoint from the steering knuckle see Section 5 4 If you re removing the right upper control arm on a vehicle equipped with the power hydraulic system remove the three Torx screws which attach the accumulator see illustration and push the assembly aside just far enough to clear the pivot bolt 5 Remove the upper control arm pivot bolt and nut see illustration When removing the nut no
502. ting is the reverse of removal 8 Crankcase ventilation system General information 1 The crankcase ventilation system reduces hydrocarbon emissions by scavenging crankcase vapours It does this by circulating fresh air from the air cleaner through the crankcase where it mixes with blow by gases and is then re routed through a heating element to the intake manifold see illustration 2 The main components of the crankcase ventilation system are the control orifice a heating element and the vacuum hoses connecting these components with the engine 3 Piston blow by gasses are collected from the crankcase and the camshaft housing via the oil filler tube These gasses are fed into the intake manifold at part throttle through the part throttle orifice and when the engine is at full throttle the gasses are fed through the air intake elbow 4 To prevent possible icing up during cold weather operation the control orifice and the hose to the intake system is electronically heated The heater element is energised by a relay signal from the windscreen washer jet temperature sensor Check 5 Remove the tubes and elbows that connect the crankcase ventilation system and inspect them for obstructions oil deposits or clogging Make sure the ventilation system is free of all Emissions and engine control systems 6 11 6 7 11a Check for vacuum to the thermal vacuum valve TVV 7 11b Check for vacuum from the TVV before and after
503. tion Repair of dents 4 When repairing dents the first job is to pull the dent out until the affected area is as close as possible to its original shape There is no point in trying to restore the original shape completely as the metal in the damaged area will have stretched on impact and cannot be restored to its original contours It is better to bring the level of the dent up to a point which is about 1 8 inch below the level of the surrounding metal In cases where the dent is very shallow it is not worth trying to pull it out at all 5 If the back side of the dent is accessible it can be hammered out gently from behind using a soft face hammer While doing this hold a block of wood firmly against the opposite side of the metal to absorb the hammer blows and prevent the metal from being stretched 6 If the dent is in a section of the body which has double layers or some other factor makes it inaccessible from behind a different technique is required Drill several small holes through the metal inside the damaged area particularly in the deeper sections Screw long self tapping screws into the holes just enough for them to get a good grip in the metal Now the dent can be pulled out by pulling on the protruding heads of the screws with locking pliers 7 The next stage of repair is the removal of paint from the damaged area and from an inch or so of the surrounding metal This is done with a wire brush or sanding disc in a d
504. tion 15 but in depth testing of the system requires special tools so diagnosis is beyond the scope of the home mechanic If the system fails take it to a dealer service department or other qualified repair workshop for repairs However if the unit must be replaced you can do it yourself as follows Removal and refitting 3 With the engine off discharge the hydraulic accumulator by depressing the brake pedal several times until it feels hard to depress 4 Remove the master cylinder see Section 6 5 Clean the area around the return and supply tube nuts then disconnect them with a flare nut spanner see illustration Plug the lines to prevent dirt from entering the system Caution Even a particle of dirt can damage the servo system so be extremely careful to prevent dirt from entering the system while the lines are disconnected 6 To disconnect the brake servo pushrod from the brake pedal remove the access plugs from both sides of the pedal box see illustration remove the clevis pin retaining clip and drive out the clevis pin 7 Remove the four mounting nuts and remove the brake servo see illustration 8 Refitting is the reverse of removal Tighten the hydraulic line fittings securely 9 When you re done adjust the brake light switch see Section 13 8 Brake hoses and lines inspection and renewal 4 Inspection 1 About every six months with the vehicle raised and placed securely on axle stands the flexibl
505. tion 8 3 Detach the steering gear see Section 17 and lower it far enough to provide clearance for the lower control arm pivot bolt 4 Remove the pivot bolt and nut see illustration Note any washers behind the nut and store them in a plastic bag 5 Remove the lower control arm 6 Refitting is the reverse of removal Be sure to refit any washers removed Raise the suspension with the trolley jack to simulate normal ride height then tighten the pivot bolt and nut to the torque listed in this Chapter s Specifications Refer to Section 8 for coil spring refitting 10 Shock absorber coil spring rear removal and refitting 3 Note 1 Always renew both left and right shocks at the same time to prevent handling peculiarities and abnormal ride quality Note 2 If you re replacing the shock absorbers on an earlier vehicle with the self levelling system we strongly recommend and so does Jaguar that you renew the self levelling units with conventional units available at the dealer as a retrofit kit for older vehicles equipped with the self levelling system 1 Loosen the rear wheel nuts Raise the rear of the vehicle and support it securely on axle stands Remove the rear wheels Support the control arm with a trolley jack Place a block of wood on the jack head to serve as a cushion 2 If you are removing replacing the shocks on a vehicle equipped with the self levelling rear suspension system depressurise the system by pumping
506. tion is the cause of bearing failure the bearing material is wiped or extruded from the steel backing of the bearing Temperatures may increase to the point where the steel backing turns blue from overheating 6 Driving habits can have a definite effect on bearing life Low speed operation in too high a gear labouring the engine puts extremely high loads on bearings which tends to squeeze out the oil film These loads cause the bearings to flex which produces fine cracks in the bearing face fatigue failure Eventually the bearing material will loosen in pieces and tear away from the steel backing Short trip driving leads to corrosion of bearings because insufficient engine heat is produced to drive off the condensed water and corrosive gases These products collect in the engine oil forming acid and sludge As the oil is carried to the engine bearings the acid attacks and corrodes the bearing material 7 Incorrect bearing refitting during engine assembly will lead to bearing failure as well Tight fitting bearings leave insufficient bearing oil clearance and this will lead to oil starvation Dirt or foreign particles trapped behind a bearing insert result in high spots on the bearing which lead to failure Selection 8 If the original bearings are worn or damaged or if the oil clearances are incorrect see Sections 23 or 25 the following procedures should be used to select the correct new bearings for engine reassembly Ho
507. tions a blown fuse a melted fusible link or a bad relay Visually inspect the condition of all fuses wires and connections in a problem circuit before diagnosing it If testing instruments are going to be utilised use the diagrams to plan ahead of time where you will make the necessary connections in order to accurately pinpoint the trouble spot The basic tools needed for electrical fault finding include a circuit tester or voltmeter a 12 volt bulb with a set of test leads can also be used a continuity tester which includes a bulb battery and set of test leads and a jumper wire preferably with a circuit breaker incorporated which can be used to bypass electrical components Before attempting to locate a problem with test instruments use the wiring diagram s to decide where to make the connections Voltage checks Voltage checks should be performed if a circuit is not functioning properly Connect one lead of a circuit tester to either the negative battery terminal or a known good earth Connect the other lead to a electrical connector in the circuit being tested preferably nearest to the battery or fuse If the bulb of the tester lights voltage is present which means that the part of the circuit between the electrical connector and the battery is problem free Continue checking the rest of the circuit in the same fashion When you reach a point at which no voltage is present the problem lies between that point and the
508. tivation code before disconnecting the battery 2 Detach the PCV hose from the valve cover see illustration 3 Remove the spark plug leads from the spark plugs handling them by the boots and not pulling on the wires 4 Remove the valve cover mounting screws then detach the valve cover and gasket from the cylinder head If the valve cover is stuck to the cylinder head bump the end with a wood block and a hammer to jar it loose If that doesn t work try to slip a flexible putty knife between the cylinder head and valve cover to break the seal Caution Don t pry at the valve cover to cylinder head joint or damage to the sealing surfaces may occur leading to oil leaks after the valve cover is reinstalled Refitting 5 The mating surfaces of the cylinder head and valve cover must be clean when the valve cover is installed If there s residue or oil on the mating surfaces when the valve cover is installed oil leaks may develop 6 Apply RTV sealant around the two half circle rubber plugs at the rear of the cylinder head see illustration 7 Using a new gasket and spark plug tube seals refit the valve cover see illustration Engine in car repair procedures 2A 3 2A 4 6 Apply RTV sealant to the half circle plugs and insert them into the cylinder head before refitting the valve cover 4 7 Press the valve cover gasket into the groove around the valve cover and fit a new set of spark plug tube seals arrowed 3261 Ja
509. to 80 51 to 59 Rear control arm to crossmember bolt nut 85 to 105 62 to 77 Shock absorber coil spring assembly Lower shock to control arm bolt nut 160 to 200 118 to 147 Upper shock to body bolts 22 to 28 16 to 20 Steering Steering wheel to steering shaft nut 35 to 45 26 to 33 Steering shaft to steering gear pinion shaft U joint pinch bolt 19 to 24 14 to 17 Steering gear mounting bracket bolts nuts 26 to 29 19 to 21 Tie rod end to steering knuckle nut 61 to 68 45 to 50 Anti roll bar front removal and refitting 3 Balljoints check and renewal 5 Coil spring front removal and refitting 8 Control arm rear removal and refitting 13 Front wheel bearing check repack and adjustment See Chapter 1 General information 1 Hub and bearing rear renewal 12 Hub carrier rear removal and refittin
510. to a container see Chapter 1 3 Remove both the upper and lower radiator hoses and the small expansion tank hose from the top left of the radiator see illustration 4 Remove the cooling fan and shroud see Section 4 3 4 Cooling heating and air conditioning systems 4 20 Disconnect the fan s electrical connector large arrow and remove the bolts small arrows on single fan models grille is removed here 3261 Jaguar XJ6 4 15 Disconnect the electrical connector A from the thermostatic switch B in the radiator and bypass it with a jumper wire C the fan should operate now with the ignition on 4 17 Disconnect the fan wiring connector and connect jumper wires from there directly to the positive and negative terminals of the battery the purple wire s terminal should receive the battery power and the black wire s terminal should be earthed 5 If equipped with an automatic transmission disconnect the cooler lines from the radiator see illustrations Disconnect the cooling fan switch connector see illustration 4 15 Place a drip pan to catch the fluid and cap the fittings Note The transmission oil cooler lines enter the radiator on the left while the power steering cooler lines attach on the right side of the radiator On 1993 and 1994 models the cooler fittings require a spring lock coupling tool normally used on fuel lines or air conditioning lines 6 Remove the four bolts from the radiator cowl panel an
511. to a dealer service department or other properly equipped repair facility 6 If the electric windows won t operate always check the fuse first 7 If only the rear windows are inoperative or if the windows only operate from the master control switch check the rear window lockout switch for continuity in the unlocked position Renew it if it doesn t have continuity 8 Check the wiring between the switches and fuse panel for continuity Repair the wiring if necessary 9 If only one window is inoperative from the master control switch try the other control switch at the window Note This doesn t apply to the driver s door window 10 If the same window works from one switch but not the other check the switch for continuity 11 If the switch tests OK check for a short or open in the circuit between the affected switch and the window motor 12 If one window is inoperative from both switches remove the trim panel from the affected door and check for voltage at the switch and at the motor while the switch is operated see illustration 13 If voltage is reaching the motor disconnect the glass from the regulator see Chapter 11 Move the window up and down by hand while checking for binding and damage Also check for binding and damage to the regulator If the regulator is not damaged and the window moves up and down smoothly renew the motor If there s binding or damage lubricate repair or renew parts as necessary 14 If
512. to the upper groove in the bore Start with the side farthest from you and work your way around toward the front until it is completely seated Push the piston into the caliper bore until it is bottomed in the bore then seat the top of the dust boot in the groove in the piston 13 Lubricate the sliding surfaces of the guide pins with silicone based grease usually supplied in the kit then refit the new dust boots and pins into the caliper bracket Refitting 14 Refit the caliper by reversing the removal procedure see Section 3 15 If the brake hose was disconnected from the caliper bleed the brake system see Section 9 5 Brake disc inspection removal and refitting 2 Note The following procedure applies to both the front and rear brake discs Inspection 1 Loosen the wheel nuts raise the vehicle and support it securely on axle stands Remove the wheel and refit three nuts to hold the disc in place If the rear brake disc is being worked on release the handbrake 2 Remove the brake caliper as outlined in Section 4 It is not necessary to disconnect the brake hose After removing the caliper suspend it out of the way with a piece of wire 3 Visually inspect the disc surface for scoring or damage Light scratches and shallow grooves are normal after use and may not always be detrimental to brake operation but deep scoring over 0 015 inch requires disc removal and refinishing by an automotive machine shop Be sur
513. ton metres Nm x 8 85 Pounds force inches lbf in lb in lbf in lb in Pounds force inches x 0 083 Pounds force feet lbf ft lb ft x 12 Pounds force inches lbf in lb in lbf in lb in Pounds force feet lbf ft lb ft x 0 138 Kilograms force metres x 7 233 Pounds force feet lbf ft lb ft kgf m kg m Pounds force feet lbf ft lb ft x 1 356 Newton metres Nm x 0 738 Pounds force feet lbf ft lb ft Newton metres Nm x 0 102 Kilograms force metres x 9 804 Newton metres Nm kgf m kg m Power Horsepower hp x 745 7 Watts W x 0 0013 Horsepower hp Velocity speed Miles per hour miles hr mph x 1 609 Kilometres per hour km hr kph x 0 621 Miles per hour miles hr mph Fuel consumption Miles per gallon mpg x 0 354 Kilometres per litre km l x 2 825 Miles per gallon mpg Temperature Degrees Fahrenheit C x 1 8 32 Degrees Celsius Degrees Centigrade C F 32 x 0 56 It is common practice to convert from miles per gallon mpg to litres 100 kilometres l 100km where mpg x l 100 km 282 3261 Jaguar XJ6 Use of English REF 3 As the main part of this book has been written in the US it uses the appropriate US component names phrases and spelling Some of these differ from those used in the UK Normally these cause no difficulty but to make sure a glossary is printed below When ordering spare parts remember the parts list may use some of
514. trol solenoid harness see illustration If battery voltage is not available check the harness Refer to the wiring diagrams at the end of Chapter 12 9 If battery voltage is available to the EGR control solenoid have the EGR system diagnosed by a dealer service department or other qualified repair workshop EGR valve renewal 10 Detach the vacuum hose disconnect the fitting that attaches the EGR pipe to the EGR valve and remove the EGR valve from the exhaust manifold and check it for sticking and heavy carbon deposits If the valve is sticking or clogged with deposits clean or renew it 11 Refitting is the reverse of removal 7 Evaporative Emission Control EVAP system Note Some models may have charcoal canister vent plugs installed in the canister from the factory These blanking plugs must be removed to allow proper pressure and release within the EVAP system Check the charcoal canister for these additional plugs and remove them With the blanking plugs installed the fuel tank will collapse causing rough running and hesitation and loss of power under load General description 1 This system is designed to trap and store fuel that evaporates from the fuel tank throttle body and intake manifold that would normally enter the atmosphere in the form of hydrocarbon HC emissions 2 The Evaporative Emission Control EVAP system consists of a charcoal filled canister the lines connecting the canister to the fuel tank ta
515. ttom of the cylinder 16 4b The ability to feel when the telescoping gauge is at the correct point will be developed over time so work slowly and repeat the check until you re satisfied that the bore measurement is accurate 3261 Jaguar XJ6 15 8 All bolt holes in the engine block particularly the main bearing cap and cylinder head bolt holes should be cleaned and restored with a tap remove debris from holes after this is done 15 10 A large socket on an extension can be used to drive the new core plugs into the bores 16 4c The gauge is then measured with a micrometer to determine the bore size is the difference between the parallel and perpendicular readings Compare your results to this Chapter s Specifications 8 If the cylinder walls are badly scuffed or scored or if they re out of round or tapered beyond the limits given in this Chapter s Specifications have the engine block rebored and honed at an automotive machine workshop If a rebore is done oversize pistons and rings will be required 9 Using a precision straightedge and feeler gauge check the engine block deck the surface that mates with the cylinder head for distortion see illustration 10 13 If it s distorted beyond the specified limit it can be resurfaced by an automotive machine workshop 10 If the cylinders are in reasonably good condition and not worn to the outside of the limits and if the piston to cylinder clearances can be mai
516. ture Also check the condition of the vacuum hoses connected to the intake manifold 6 Remove the air intake duct from the throttle body and check for carbon and residue build up If it s dirty clean with aerosol carburettor cleaner make sure the can says it s safe for use with oxygen sensors and catalytic converters and a toothbrush 7 With the engine running place a stethoscope against each injector one at a time and listen for a clicking sound indicating operation see illustration 8 If there is a problem with an injector purchase a special injector test light noid light and refit it into the injector electrical connector see illustration Start the engine and make sure that each injector connector flashes the noid light This will test for the proper voltage signal to the injector Caution If the engine will not start and the noid light indicates that each injector is receiving the proper signal there is a good possibility that the injector s is stuck open and allowing fuel into the combustion chamber in excessive amounts If the spark plugs are fouled detach the primary low voltage wires from the ignition coil disable the fuel pump by removing the fuel pump relay see Section 2 remove the spark plugs and crank the engine over If fuel sprays from the spark plug holes the engine is flooded and the fuel must be removed from the combustion chambers 9 With the engine OFF and the fuel injector electrical
517. ty or incorrectly gapped spark plugs Chapter 1 Broken loose or disconnected wiring in the starting circuit Chapter 5 Loose distributor is changing ignition timing Chapter 1 Broken loose or disconnected wires at the ignition coil or faulty coil Chapter 5 1988 and 1989 models may have electrical connector damage between the fuel pump relay and the fuel pump Chapter 12 Coolant temperature sensor shorting on bonnet liner Chapter 11 Defective Mass Airflow MAF sensor Chapter 6 Engine hard to start when cold Battery discharged or low Chapter 1 Fuel system malfunctioning Chapter 4 Injector s leaking Chapter 4 Distributor rotor carbon tracked Chapter 5 Water enters the air cleaner housing near the left front wheel arch Chapter 4 Engine hard to start when hot Air filter clogged Chapter 1 Fuel not reaching the fuel injection system Chapter 4 Corroded battery connections especially ground Chapter 1 Fuel vaporises at fuel pump inlet Refit dual fuel pumps Chapter 4 Fuel vapours from charcoal canister enter intake during idle and cause idling stalling and starting problems Chapter 6 Starter motor noisy or excessively rough in engagement Pinion or flywheel gear teeth worn or broken Chapter 5 Starter motor mounting bolts loose or missing Chapter 5 Engine starts but stops immediately Loose or faulty electrical connections at distributor coil or alternat
518. u insert it into the spark plug hole You will also need a wire type feeler gauge to check and adjust the spark plug gap and a torque wrench to tighten the new plugs to the specified torque see illustration 2 If you are replacing the plugs purchase the new plugs adjust them to the proper gap and then replace each plug one at a time Note When buying new spark plugs it s essential that you obtain the correct plugs for your specific vehicle This information can be found in the Specifications Section at the beginning of this Chapter on the Vehicle Emissions Control Information VECI label located on the underside of the bonnet where fitted or in the owner s manual If these sources specify different plugs purchase the spark plug type specified on the VECI label because that information is provided specifically for your engine Every 7500 miles or 6 months 1 7 1 3 7 The oil drain plug arrowed is located at the rear of the sump use a ring spanner or socket to remove it 3 13 The oil filter is located on the left side of the engine use a filter wrench for removal tighten the new filter by hand 3 15 Lubricate the oil filter gasket with clean engine oil before refitting the filter 3261 Jaguar XJ6 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 3 Inspect each of the new plugs for defects If there are any signs
519. uar aluminium cylinder heads require precision machine work It is best to find a machine workshop that has considerable experience in servicing Jaguar cylinder heads 14 Examine the valve seats in each of the combustion chambers If they re pitted cracked or burned the cylinder head will require valve service that s beyond the scope of the home mechanic Engine removal and overhaul procedures 2B 7 2B 3261 Jaguar XJ6 10 12 Place the new head gasket on the engine block and trace around the water passages and bolt holes make sure there is no erosion of the aluminium beyond these lines 10 13 Check the cylinder head and engine block gasket surfaces for warpage by trying to slip a feeler gauge under a precision straightedge see the Specifications for the maximum warpage allowed and use a feeler gauge of that thickness check both the cylinder head and engine block shown 15 Check the valve stem to guide clearance with a small hole gauge and micrometer or a small dial bore gauge see illustration Also check the valve stem deflection with a dial indicator attached securely to the cylinder head The valve must be in the guide and approximately 1 16 inch off the seat The total valve stem movement indicated by the gauge needle must be noted then divided by two to obtain the actual clearance value If it exceeds the stem to guide clearance limit found in this Chapter s Specifications the valve guides should be ren
520. upport strut requires prising out a locking pin to detach it from the locating stud 9 2a Use a small screwdriver to prise the clip out of its locking groove then detach the end of the strut from the mounting stud which are located on the inside of the bonnet must first be loosened to allow correct alignment of the bonnet 8 Fore and aft and side to side adjustment of the bonnet is done by moving the bonnet in relation to the hinge plates after loosening the bolts 9 Scribe or trace a line around the entire hinge plate to judge the amount of movement 10 Loosen the nuts or bolts and move the bonnet into correct alignment Move it only a little at a time Tighten the hinge bolts or nuts and carefully lower the bonnet to check the alignment 11 After the bonnet has been aligned properly with the cowl and front wings the height and position of the bonnet striker assembly should be adjusted to provide positive engagement with the latch assembly see illustration 12 Adjust the bonnet bumpers on the wings so the bonnet is flush with the wings when closed see illustration 13 The bonnet latch assembly as well as the hinges should be lubricated with white lithium base grease to prevent sticking and wear 11 Bonnet release latch and cable removal and refitting 2 Latch 1 Disconnect the bonnet release cables by removing the cable retaining bolts and disengaging the cable from the latch assembly see illustration 2 Scribe a lin
521. ure the gasket surface on the transmission sump pan is completely clean then refit the gasket Put the sump pan in place against the transmission and refit the brackets and bolts working around the sump pan tighten each bolt a little at a time until the torque listed in this Chapter s Specifications is reached Don t overtighten the bolts Connect the dipstick tube and tighten the collar securely 14 Lower the vehicle and add the specified amount of fluid through the filler tube see Section 8 15 With the transmission in Park and the handbrake set run the engine at fast idle but don t race it 16 Move the gear selector through each position and then back to Park Check the fluid level 17 Be sure to check underneath the car for any leaks after the first few miles of driving Every 30 000 miles 48 000 km or 2 years Every 30 000 miles or 2 years 1 19 1 26 6a Unscrew the dipstick tube collar 26 6b Detach the tube and let the remaining fluid drain 26 7 Use a socket and extension to remove the transmission sump pan bolts and brackets 26 8 Lower the sump pan from the transmission 26 10a Use a Torx head driver to remove the filter bolts arrowed 3261 Jaguar XJ6 26 5 Using an Allen spanner remove the drain plug located in the bottom of the transmission sump pan 26 10b then remove the fluid filter from the transmission 26 10c Be sure to remove the old O ring from the transmission always use
522. uring the current changes which in turn measures the mass weight and volume of air entering the engine This information helps the ECU determine the amount of fuel to be injected by the injectors The throttle plate inside the throttle body is controlled by the driver As the throttle plate opens the amount of air that can pass through the system increases so the potentiometer opens further and the ECU signals the injectors to increase the amount of fuel delivered to the intake ports Refer to Chapter 6 for additional information on the fuel injection system sensors test procedures and renewal procedures Electronic control system 4 The Computer Control System controls the EFI and other systems by means of an Electronic Control Unit ECU which employs a microcomputer The ECU receives signals from a number of information sensors which monitor such variables as intake air volume intake air temperature coolant temperature engine rpm acceleration deceleration and exhaust oxygen content These signals help the ECU determine the injection duration necessary for the optimum air fuel ratio Some Fuel and exhaust systems 4 9 4 10 11 Rotate the bellcrank until it reaches wide open throttle and make sure the pointer aligns with the A on the bellcrank Adjust if necessary 11 1 Fuel injection and emission control component locations for the 3 6 litre 1989 XJ6 3261 Jaguar XJ6 1 Fuel pressure regulator under fuel rail 2
523. us 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
524. use An electrical device which protects a circuit against accidental overload The typical fuse contains a soft piece of metal which is calibrated to melt at a predetermined current flow expressed as amps and break the circuit Fusible link A circuit protection device consisting of a conductor surrounded by heat resistant insulation The conductor is smaller than the wire it protects so it acts as the weakest link in the circuit Unlike a blown fuse a failed fusible link must frequently be cut from the wire for replacement Catalytic converter Crankshaft assembly Accessory drivebelts Feeler blade 3261 Jaguar XJ6 REF 20 Glossary of technical terms G Gap The distance the spark must travel in jumping from the centre electrode to the side electrode in a spark plug Also refers to the spacing between the points in a contact breaker assembly in a conventional points type ignition or to the distance between the reluctor or rotor and the pickup coil in an electronic ignition Gasket Any thin soft material usually cork cardboard asbestos or soft metal installed between two metal surfaces to ensure a good seal For instance the cylinder head gasket seals the joint between the block and the cylinder head Gauge An instrument panel display used to monitor engine conditions A gauge with a movable pointer on a dial or a fixed scale is an analogue gauge A gauge with a numerical readout is called a digital gauge
525. used unless specifically instructed otherwise Ensure that all orifices channels or pipes are clear and blow through them preferably using compressed air Oil seals Oil seals can be removed by levering them out with a wide flat bladed screwdriver or similar tool Alternatively a number of self tapping screws may be screwed into the seal and these used as a purchase for pliers or similar in order to pull the seal free Whenever an oil seal is removed from its working location either individually or as part of an assembly it should be renewed The very fine sealing lip of the seal is easily damaged and will not seal if the surface it contacts is not completely clean and free from scratches nicks or grooves If the original sealing surface of the component cannot be restored and the manufacturer has not made provision for slight relocation of the seal relative to the sealing surface the component should be renewed Protect the lips of the seal from any surface which may damage them in the course of fitting Use tape or a conical sleeve where possible Lubricate the seal lips with oil before fitting and on dual lipped seals fill the space between the lips with grease Unless otherwise stated oil seals must be fitted with their sealing lips toward the lubricant to be sealed Use a tubular drift or block of wood of the appropriate size to install the seal and if the seal housing is shouldered drive the seal down to the shoul
526. uses first Chapter 12 2 If the temperature gauge indicates excessive temperature after running awhile see the Fault finding section at the rear of the manual 3 If the temperature gauge indicates Hot as soon as the engine is started cold disconnect the wire at the coolant temperature sender see illustration If the gauge reading drops renew the sender unit If the reading remains high the wire to the gauge may be shorted to ground or the gauge is faulty 4 If the coolant temperature gauge fails to show any indication after the engine has been warmed up approx 10 minutes and the fuses checked out OK shut off the engine Disconnect the wire at the sender unit and using a jumper wire connect the wire to a clean ground on the engine Briefly turn on the ignition without starting the engine If the gauge now indicates Hot renew the sender unit 5 If the gauge fails to respond the circuit may be open or the gauge may be faulty see Chapter 12 for additional information Renewal 6 Drain the coolant see Chapter 1 7 Disconnect the electrical connector from the sender unit 8 Using a deep socket or a spanner remove the sender unit 9 Refit the new unit and tighten it securely Do not use thread sealant as it may electrically insulate the sender unit 10 Reconnect the wiring connector refill the cooling system and check for coolant leakage and proper gauge function 10 Heating and air conditioning blower motors
527. ush it with clean water then reconnect the hose see Chapter 3 Refilling 11 Close and tighten the radiator drain Refit and tighten the engine block drain plugs 12 Make sure the heater temperature control is in the maximum heat position 13 Slowly refill the expansion tank with a mixture of antifreeze and water until the coolant reaches the base of the filler neck 14 Leave the expansion tank pressure cap off and run the engine in a well ventilated area until the thermostat opens coolant will begin flowing through the radiator and the upper radiator hose will become hot Race the engine two or three times under no load 15 Turn the engine off and let it cool Add more coolant mixture to bring the level back up to the base of the filler neck 16 Squeeze the upper radiator hose to expel air then add more coolant mixture if necessary Refit the expansion tank pressure cap 17 Start the engine allow it to reach normal operating temperature and check for leaks Every 2 years 1 21 1 3261 Jaguar XJ6 30 4 The radiator drain fitting arrowed located at the bottom of the radiator 30 5 The block drain plug arrowed is located on the right side of the block 3261 Jaguar XJ6 2A Chapter 2 Part A Engine in car repair procedures General Cylinder numbers front to rear 1 2 3 4 5 6 Firing order
528. using the floor in the work area with water will help settle the dust which would otherwise be in the air If the repair area is confined to one body panel mask off the surrounding panels This will help minimise the effects of a slight mismatch in paint colour Trim pieces such as chrome strips door handles etc will also need to be masked off or removed Use masking tape and several thickness of newspaper for the masking operations 20 Before spraying shake the paint can thoroughly then spray a test area until the 11 2 Bodywork and fittings 3261 Jaguar XJ6 spray painting technique is mastered Cover the repair area with a thick coat of primer The thickness should be built up using several thin layers of primer rather than one thick one Using 600 grit wet or dry sandpaper rub down the surface of the primer until it is very smooth While doing this the work area should be thoroughly rinsed with water and the wet or dry sandpaper periodically rinsed as well Allow the primer to dry before spraying additional coats 21 Spray on the top coat again building up the thickness by using several thin layers of paint Begin spraying at the top of the repair area and then using a side to side motion work down until the whole repair area and about two inches of the surrounding original paint is covered Remove all masking material 10 to 15 minutes after spraying on the final coat of paint Allow the new paint at least two weeks to h
529. ust washers can be rotated into position around the crankshaft with the crankshaft installed in the engine block with the thrust washer grooves facing OUT The lower thrust washers should be placed on the main bearing caps with their grooves OUT 20 For the final assembly use only new bolts for both the main bearings and the 2B 16 Engine removal and overhaul procedures 23 10 Lay the Plastigauge strips on the main bearing journals parallel to the crankshaft centreline 23 14 Compare the width of the crushed Plastigauge to the scale on the envelope to determine the main bearing oil clearance always take the measurement at the widest point of the Plastigauge Be sure to use the correct scale imperial and metric scales are included 3261 Jaguar XJ6 22 12 Refit the compression rings with a ring expander the mark must face up connecting rods Apply a light coat of oil to the bolt threads and the under sides of the bolt heads then refit them Tighten all main bearing cap bolts to the torque listed in this Chapter s Specifications starting in the centre and working out to the ends 21 Rotate the crankshaft a number of times by hand to check for any obvious binding 22 Check the crankshaft endplay with a feeler gauge or a dial indicator as described in Section 14 The endplay should be correct if the crankshaft thrust faces aren t worn or damaged and new thrust washers have been installed Note If the end play is too grea
530. ustment once again until the correct adjustment has been attained 11 Electronic Fuel Injection EFI system general information 1 These models are equipped with an Electronic Fuel Injection EFI system This fuel injection system is designed by Bosch but licensed by Lucas and is called the Lucas LH Engine Management system The EFI system is composed of three basic sub systems fuel system air induction system and electronic control system see illustration Fuel system 2 An electric fuel pump is located on the chassis of the rear suspension external 1988 to 1990 or inside the fuel tank 1991 to 1994 The fuel pump supplies fuel under constant pressure to the fuel rail which distributes fuel evenly to all injectors From the fuel rail fuel is injected into the intake ports just above the intake valves by fuel injectors The amount of fuel supplied by the injectors is precisely controlled by an Electronic Control Unit ECU A pressure regulator controls system pressure in relation to intake manifold vacuum A fuel filter between the fuel pump and the fuel rail filters fuel to protect the components of the system Air induction system 3 The air system consists of an air filter housing a Mass Air Flow MAF sensor airflow meter Intake Air Temperature IAT sensor and a throttle body The MAF sensor is an information gathering device for the ECU A heated element determines the temperature differential by meas
531. ustments are made in the same manner as described in the previous step except there are only two adjusting knobs which tilt the headlight housing to the desired angle 4 If the headlight housing has been replaced or the vehicle has suffered front end damage refer to following procedure 5 This method requires a blank wall masking tape and a level floor 6 Position masking tape vertically on the wall in reference to the vehicle centreline and the centrelines of both headlights see illustration 7 Position a horizontal tape line in reference to the centreline of all the headlights Note It may be easier to position the tape on the wall with the vehicle parked only a few inches away 12 10 Body electrical system 3261 Jaguar XJ6 18 2 The headlight horizontal adjustment knob A is located at the top of the headlight and the vertical adjustment knob B is below the headlight 17 4 Loosen the retaining ring screws arrowed a few turns rotate the retaining ring anti clockwise to remove it 17 9 Disconnect the electrical connector and rotate the bulb assembly 1 4 turn anti clockwise 18 6 Headlight adjustment details 8 Adjustment should be made with the vehicle parked 25 feet from the wall sitting level the petrol tank half full and no unusually heavy load in the vehicle 9 Starting with the low beam adjustment position the high intensity zone so it is two inches below the horizontal line and two inches to the rig
532. ve the trim cover retaining screws 23 4 Disconnect the electrical connector then detach the three mirror retaining screws and remove the mirror from the vehicle 24 3a Open the console compartment to access the ash tray screws arrowed 24 2 Carefully prise out the gear selector trim bezel selector towards the rear of the vehicle Pull up on the rear half of the radio trim bezel while gently detaching the clips securing the front then remove the bezel from the vehicle 6 Remove the radio and heater control assembly see Chapter 12 7 Remove the dashboard centre trim panel see Section 26 then remove the centre air conditioning duct from the vehicle see illustration 8 Remove the retaining screws located in the air conditioning duct opening see illustration 9 Remove the plastic screws securing the lower front section of the console see illustration 10 Unplug any electrical connectors that will interfere with the removal of the console 11 Pull the console towards the rear of the vehicle then lift the console up over the shift lever and remove it from the vehicle 12 Refitting is the reverse of removal Overhead console 13 Remove the plastic screw securing the overhead console then carefully pull the console out of the headliner see illustration 14 Disconnect the electrical connectors from the lights 15 Refitting is the reverse of removal 25 Instrument cluster housing removal and refitting 2 Warning Late
533. vebelt 12 4 Remove the pivot bolt and nut 3261 Jaguar XJ6 11 2 Connect the probes of a voltmeter to the battery terminals and observe battery voltage with the engine OFF and then with the engine running 11 9 The load dump module is located on the bulkhead next to the MAF sensor 8 After the alternator is installed adjust the drivebelt tension see Chapter 1 9 Check the charging voltage to verify proper operation of the alternator see Section 11 13 Starting system general information and precautions The sole function of the starting system is to crank the engine over quickly enough to allow it to start The starting system consists of the battery the starter motor the starter solenoid the starter relay and the electrical circuit connecting the components The solenoid is mounted directly on the starter motor The solenoid starter motor assembly is installed on the upper part of the engine next to the transmission bellhousing When the ignition key is turned to the START position the starter solenoid is actuated through the starter control circuit The starter solenoid then connects the battery to the starter The battery supplies the electrical energy to the starter motor which does the actual work of cranking the engine The starter on a vehicle equipped with an automatic transmission can be operated only when the transmission selector lever is in Park or Neutral These vehicles are equipped with either a Bosch o
534. volts Emissions and engine control systems 6 5 6 4 21 Unscrew the oxygen sensor from the exhaust system 3261 Jaguar XJ6 4 13 To test the oxygen sensor heater disconnect the electrical connector and working on the sensor side check the resistance across the two terminals Heater resistance should be 5 to 6 ohms 4 15 Refit a pin into the backside of the oxygen sensor connector into the correct terminal and check for a millivolt output signal generated by the sensor as it warms up The SIGNAL wire is easily recognised by the rubber sheath covering the terminal arrowed 28 Check the signal voltage from the potentiometer Carefully backprobe the electrical connector on the signal voltage wire with the ignition key ON engine not running see illustration There should be approximately 0 5 volts 29 Next rotate the throttle lever manually and confirm that the reference voltage increases to approximately 4 8 volts see illustration 30 If the voltage does not increase renew the throttle potentiometer with a new part Renewal 31 Remove the throttle body from the intake manifold see Chapter 4 32 Remove the two mounting bolts and separate the throttle potentiometer from the throttle body Note The throttle potentiometer is difficult to reach and adjustment requires that the home mechanic tighten the bolts after the final adjustment using a mirror Be sure to mark the mounting position of the old throttle potentiomete
535. wever if the crankshaft has been reground new undersize bearings must be installed the following procedure should not be used if undersize bearings are required The automotive machine workshop that reconditions the crankshaft will provide or help you select the correct size bearings Regardless of how the bearing sizes are determined use the oil clearance measured with Plastigage as a guide to ensure the bearings are the right size 9 If you need to use a STANDARD size main or big end bearing refit one that has the same number as the original bearing Note 4 0 litre engines after 164637 have sized crankshafts and bearings in three grades indicated by colour and letter The codes are stamped into the front throw of the crankshaft see illustration Match replacement bearings by the colour codes pink P white W or green G for main bearings red R yellow Y or blue B for the three grades of big end bearings 10 Remember the oil clearance is the final judge when selecting new bearing sizes If you have any questions or are unsure which bearings to use get help from a dealer parts or service department 2B 14 Engine removal and overhaul procedures 3261 Jaguar XJ6 20 1 When inspecting the main and big end bearings look for these problems 20 9 Later model 4 0 litre engines have graded journals and bearings with the markings indicated on the front throw of the crankshaft A indicates the front of
536. where components needed for almost any repair job can be purchased or ordered Motor factors Good factors will stock all the more important components which wear out comparatively quickly and can sometimes supply individual components needed for the overhaul of a larger assembly eg brake seals and hydraulic parts bearing shells pistons valves They may also handle work such as cylinder block reboring crankshaft regrinding etc Tyre and exhaust specialists These outlets may be independent or members of a local or national chain They frequently offer competitive prices when compared with a main dealer or local garage but it will pay to obtain several quotes before making a decision When researching prices also ask what extras may be added for instance fitting a new valve and balancing the wheel are both commonly charged on top of the price of a new tyre Other sources Beware of parts or materials obtained from market stalls car boot sales or similar outlets Such items are not invariably sub standard but there is little chance of compensation if they do prove unsatisfactory In the case of safety critical components such as brake pads there is the risk of financial loss and also of an accident causing injury or death Second hand parts or assemblies obtained from a car breaker can be a good buy in some circumstances but this sort of purchase is best made by the experienced DIY mechanic Vehicle identific
537. wing to check the fluid level on 1988 and 1989 models simply look through the sight glass and note the colour of the indicator 5 3 To add fluid remove the filler hole dust cap arrowed 5 7 On 1990 and later models remove the cap and check the fluid level on the dipstick 6 1 Tools and materials required for battery maintenance 1 Face shield safety goggles When removing corrosion with a brush the acidic particles can fly up into your eyes 2 Baking soda A solution of baking soda and water can be used to neutralise corrosion 3 Petroleum jelly A layer of this on the battery posts will help prevent corrosion 4 Battery post cable cleaner This wire brush cleaning tool will remove all traces of corrosion from the battery posts and cable clamps 5 Treated felt washers Placing one of these on each post directly under the cable clamps will help prevent corrosion 6 Puller Sometimes the cable clamps are difficult to pull off the posts even after the nut bolt has been completely loosened This tool pulls the clamp straight up and off the post without damage 7 Battery post cable cleaner Here is another cleaning tool which is a slightly different version of number 4 above but it does the same thing 8 Rubber gloves Another safety item to consider when servicing the battery remember that s acid inside the battery 3261 Jaguar XJ6 never ingest it Wear protective safety glasses when working near the battery Ke
538. wire see illustration If the fan now operates renew the thermostatic switch If the fan doesn t operate the problem is either the fan relay or the fan motor On 1993 and 1994 models with twin electric fans jumpering one set of connections in the plug from the switch should make both fans operate at slow speed fans in series and jumpering the other two should run both fans at higher speed fans in parallel In normal operation the fans operate at the higher speed only when the air conditioning is on or when coolant temperature exceeds 212 F When the coolant cools down to below 200 F the fans revert to the normal speed 16 To renew a defective thermostatic switch allow the vehicle to cool off and drain the coolant see Chapter 1 Remove the switch from the radiator and refit the new switch Connect the electrical connector and test again for proper fan operation 17 To test an inoperative fan motor one that doesn t come on when the engine gets hot or when the air conditioner is on first check the fuses and or fusible links see Chapter 12 Then disconnect the electrical connector at the motor refer to Chapter 11 for removal of the grille for access on front mounted fan models and use fused jumper wires to connect the fan directly to the battery and to chassis ground see illustration If the fan still does not work renew the fan motor Warning Do not allow the test clips to contact each other or any metall
539. wl under the vehicle when it s supported only by the jack 2 Remove the lubricant check fill plug from the differential see illustration Use a 3 8 inch drive ratchet and a short extension to unscrew the plug 3 Use your little finger as a dipstick to make sure the lubricant level is even with the bottom of the plug hole If not use a syringe or squeeze bottle to add the recommended lubricant until it just starts to run out of the opening 4 Refit the plug and tighten it securely 10 Exhaust system check 1 1 With the engine cold at least three hours after the vehicle has been driven check the complete exhaust system from its starting point at the engine to the end of the tailpipe This should be done on a hoist where unrestricted access is available 2 Check the pipes and connections for evidence of leaks severe corrosion or damage Make sure that all brackets and hangers are in good condition and tight see illustration 3 At the same time inspect the underside of the body for holes corrosion open seams etc which may allow exhaust gases to enter the passenger compartment Seal all body openings with silicone or body putty 4 Rattles and other noises can often be traced to the exhaust system especially the mounts and hangers Try to move the pipes Every 7500 miles or 6 months 1 11 1 9 2 The differential check fill plug is located on the rear of the differential housing place your finger in the filler plug
540. xygen in the exhaust gas is incorrect an electrical signal is sent to the ECU The ECU takes this information processes it and then sends a command to the fuel injection system telling it to change the air fuel mixture This happens in a fraction of a second and it goes on continuously when the engine is running The end result is an air fuel mixture ratio which is constantly maintained at a predetermined ratio regardless of driving conditions 5 In the event of a sensor malfunction a backup circuit will take over to provide driveability until the problem is identified and fixed Precautions 6 Follow these steps a Always disconnect the power by either turning off the ignition switch or disconnecting the battery terminals before removing electrical connectors Warning Later models are equipped with airbags To prevent accidental deployment of the airbag which could cause personal injury DO NOT work in the vicinity of the steering column or instrument panel The manufacturer recommends that on airbag equipped models the following procedure should be left to a dealer service department or other repair workshop because of the special tools and techniques required to disable the airbag system Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery b When refitting a battery be particularly careful to avoid reversin
541. y cylinder number if they aren t mark them with a centre punch to avoid confusion during reassembly 13 6 To prevent damage to the crankshaft journals and cylinder walls slip sections of hose over the connecting rod bolts before removing the pistons 3261 Jaguar XJ6 13 1 A ridge reamer is required to remove the ridge from the top of each cylinder do this before removing the pistons The keepers are easier to fit if a small amount of grease is applied to keep them in place 8 Repeat the procedure for the remaining cylinders Note Turn the crankshaft as needed to position the piston connecting rod assembly to be removed close to parallel with the cylinder bore i e don t try to drive it out while at a large angle to the bore 9 After removal reassemble the connecting rod caps and bearing inserts in their respective connecting rods and refit the cap nuts bolts finger tight Leaving the old bearing inserts in place until reassembly will help prevent the big end bearing surfaces from being accidentally nicked or gouged 10 Don t separate the pistons from the connecting rods see Section 18 for additional information 14 Crankshaft removal 3 Note The rear main oil seal and retainer must be removed from the engine block before proceeding with crankshaft removal see Part A of this Chapter 1 Before the crankshaft is removed check the endplay Mount a dial indicator to the front of the engine with the stem in line
542. y dismantling should be done on a clean flat workbench or table at a suitable working height Any workbench needs a vice one with a jaw opening of 100 mm is suitable for most jobs As mentioned previously some clean dry storage space is also required for tools as well as for any lubricants cleaning fluids touch up paints etc which become necessary Another item which may be required and which has a much more general usage is an electric drill with a chuck capacity of at least 8 mm This together with a good range of twist drills is virtually essential for fitting accessories Last but not least always keep a supply of old newspapers and clean lint free rags available and try to keep any working area as clean as possible Stroboscopic timing light Stud extractor set Compression tester Dial test indicator dial gauge Micrometer set 3261 Jaguar XJ6 REF 8 MOT test checks This is a guide to getting your vehicle through the MOT test Obviously it will not be possible to examine the vehicle to the same standard as the professional MOT tester However working through the following checks will enable you to identify any problem areas before submitting the vehicle for the test Where a testable component is in borderline condition the tester has discretion in deciding whether to pass or fail it The basis of such discretion is whether the tester would be happy for a close relative or friend to use the vehicle wi
543. y problems which contributed to chain failure prior to refitting of a new chain 19 Check the chain guides for grooves chips or wear in the contact surface Clean and inspect the upper and lower tensioners Refitting 20 Remove all dirt oil and grease from the timing chain area at the front of the engine 21 Recheck the crankshaft timing marks to be sure they are properly aligned see illustration 8 16 22 Refit the lower timing chain on the crankshaft intermediate shaft and auxiliary shaft sprockets The chain should be lubricated with engine oil Engine in car repair procedures 2A 7 2A 8 9a Pull the hydraulic pump coupling disc arrowed off the drive coupling 8 9b and unbolt the drive coupling arrowed from the intermediate shaft 8 10 Remove the front cover to engine block and the sump to cover bolts arrowed 8 11 Remove the upper timing chain from the intermediate sprocket arrowed 8 12 Unbolt and remove the upper chain guide right arrow and the upper chain tensioner guide left arrow 8 13 Remove the two bolts and remove the lower timing chain tensioner arrowed 3261 Jaguar XJ6 8 15 Remove the lower timing chain from the intermediate sprocket A the auxiliary shaft sprocket B and the crankshaft sprocket C 8 16 Apply paint marks on the crankshaft crankshaft sprocket and the engine block arrowed to indicate TDC position 23 Clean and lubricate the lower tensioner Fill the l
544. yment of the airbag which could cause personal injury or damage to the airbag system DO NOT work in the vicinity of the steering column or instrument panel The manufacturer recommends that on airbag equipped models the following procedure be performed at a dealer service department or other properly equipped repair facility because of the special tools and techniques required to disable the airbag system Caution If the stereo in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 1 Disconnect the negative battery cable 2 Remove the steering wheel Chapter 10 3 Remove the steering column trim covers see Chapter 11 4 Remove the steering column switch mounting plate screws see illustration 5 Remove the shear head bolts retaining the ignition switch lock cylinder assembly and separate the bracket halves from the steering column This can be accomplished by drilling out the centre of the screws and using a screw extractor to remove them see illustration 6 Place the new switch assembly in position refit the new shear head bolts and tighten them until the heads snap off 7 The remainder of the refitting is the reverse of removal 10 Instrument panel switches removal and refitting 1 Warning Later models are equipped with airbags To prevent accidental deployment of the airbag which could cause personal injury or damage to th

Jaguar XJ6 Service and Repair Manual

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