1994 JAGUAR XJ6 lamps

Terrn(s1 Abbreviation Definition Previously used (if applicable) term(s) (or Eng- lish Eauivalentl
5
Babbitt metal
backlight
back
-up lamp
balk ring
t
battery positive Voltage B+
Barometric Absolute Pressure BARO
Sensor
base Idle
base timing
battery
before bottom dead center BBDC
before top dead center BTDC
blower BLR
Body Processor Module BPM
British Standards BS
I British Standards Automotive BSAu
brake horsepower
brake mean effective pressure BMEP
brake
ontoff BOO
brake rotor
I bottom dead center BDC
bypass air BPA
bumper guard
I
bushing I
rotating component of manual transmission
which prevents premature engagement of
gears
The positive Voltage from
a battery or any
circuit connected directly to it.
sensor measuring the pressure of
surrounding air at any given temperature
and altitude
Idle
rpm determined by the throttle lever
being hard
-set on the throttle body with the
IAC solenoid disconnected
Spark advance in degrees before top dead
center of the base engine without any control
from the PCM
Electrical storage device producing DC
Voltage by means of electrochemical
reaction
event occurring before BDC
event (usually ignition) occurring before TDC
Device which supplies a current of air at
moderate pressure, e.g. heater or
AJC blower
Control module for body electrical systems,
e.g. interior lamps, windshield wash wipe
control etc..
standard specification issued by the British
Standards Institution
effective horsepower developed by an
engine or motor, as measured by a brake
applied to its output shaft
that part of the effective pressure developed
in a cylinder that would result in a cylinder
output equal to the bhp of the engine
indicates the position of the brake pedal
process of bedding
-in the internal working
surfaces of e.g. an engine by avoiding excess
build
-up of heat
lowest point of piston travel in a
reciprocating engine
mechanical control of throttle bypass air
cylindrical plain bearing white
metal
backlight,
rear screen reversing lamp
baulk ring
B+,
+ve, VSS
BARO, APS
CCM (Central
Control Module).
CPU
brake disc
running
-in
overrider bush
Issue 1 August 1994 8 X300 VSM

Fuel, Emission Control & Engine Management (AJ16)
5.1.6 THROTTLE ASSEMBLY (SUPERCHARGED), RENEW
SRO 18.30.17 THROTTLE POTENTIOMETER
SRO 19.70.07 THROTTLE HOUSING GASKET
SRO 19.70.04 THROTTLE HOUSING
J 12-62 2
Fig. 1
Remove
. Disconnect battery.
. Remove the intercooler intake elbow.
. Raise vehicle on a four-post ramp.
. Remove the rear air duct to throttle body connecting hose.
Undo and remove bolts securing EGR supply pipe to manifold.
Remove EGR supply pipe gasket.
Reposition EGR sensor harness multi-plug from mounting bracket.
. Release throttle outer cable abutment from abutment bracket.
. Disconnect throttle inner cable from throttle linkage.
. Disconnect and remove return spring.
. Disconnect speed control actuator vacuum hose.
. Release cooling system pressure by slowly undoing the tank cap.
Tighten cap after pressure release.
. Remove abutment bracket assembly.
Disconnect idle speed actuator harness multi
-plug.
. Disconnect throttle potentiometer harness multi-plug.
. Fit pipe clamps to throttle housing cooling hoses and disconnect hoses from throttle housing.
Remove
the oil filter cartridge and gasket.
Remove speed control speed control bracket to throttle lever clevis pin and pin
circlip.
e
0
0
0
Issue 1 August 1994 10 X300 VSM

Fuel, Emission Control & Engine Management (AJ16)
5.1.8
SRO
SRO IDLE
SPEED CONTROL VALVE/ GASKETS (NORMALLY ASPIRATED), RENEW
18.30.74 IDLE SPEED CONTROL VALVE
18.30.77 IDLE SPEED CONTROL VALVE GASKET
Remove
. Disconnect battery.
9 Remove the intake elbow to throttle housing hose.
Disconnect idle speed control valve multi-plug.
. Disconnect throttle potentiometer multi-plug.
. Remove clevis pin circlip.
. Reposition link arm from quadrant.
. Disconnect kick down cable (where fitted) from quadrant.
Open throttle fully and disconnect inner cable from quad-
Carefully release throttle against stop.
rant.
Fit pipe clamps
to throttle body heater feed and return
hose.
Disconnect feed hose from throttle body stub pipe.
rn Remove throttle body assembly from inlet manifold.
Remove idle speed control valve from throttle body.
. Remove gasket.
. Retrieve distance piece from throttle body recess. Fig.
1
Refit in the
reverse order of the removal procedure.
0
0
0
0
Issue 1 August 1994 12 X300 VSM

Exhaust System (AJ16)
9
/ 7 I
3;

Fig. 1 Components of the Exhaust System (AJ16 Normally aspirated)
J?3-Z2l
Heated oxygensensorsarefittedtothedownpipeassembly (1 Fig.l)which isconnectedtothemanifold (2 Fig.1). There
are two sensors for the ROW and Japan (3 Fig.1) and two additional sensors (4 Fig.1) for NAS markets.
The sensors are located upstream and downstream of catalytic converters.
Apart from two heated oxygen sensors, the exhaust system for vehicles destined for the Japanese market are also
fitted with two exhaust gas temperature sensors
(5 Fig.1).
The exhaust system is held in a predetermined position by a fixing arrangement to the manifold by exhaust centre
mountings (6 Fig.l), by rear axis mountings (7 Fig.l), and tail pipe mountings (8 Fig.1).
Clamps (9 Fig.1) used on each slip joint are welded to the pipes and tightened to a higher torque setting than non- welded clamps.
The exhaust system must be free of leaks, binding, grounding and excessive vibrations. These conditions are usually
caused by loose, broken, or misaligned clamps, shields, brackets, or pipes. Should any of these conditions
exist,check the exhaust system components and alignment. Adjust and renew if necessary. Do not attempt to service brackets,
clamps and insulators.
Issue 1 August 1994 2 X300 VSM

Also look for loose and rusted flange connections, loose or damaged exhaust shields
or clamp and loose or broken exhaust outlet pipe brackets.
6.1.2.1 Symptom Chart
I Condition I Possible Cause
Noises and exhaust fumes Exhaust leak.
Misaligned exhaust.
Loose clamps or fasteners.
Restricted exhaust system.
Electronic engine controls.
Fuel System.
Restricted exhaust system.
Engine lacking
power Ignition system.
Exhaust System (AJ16)
6.1.2 DIAGNOSIS AND TESTING
m: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. NEVER ATTEMPT
TO SERVICE ANY PART OF THE SYSTEM UNTIL IT HAS COOLED. EXHAUST GASES CONTAIN CARBON
MONOXIDE WHICH CAN BE HARMFUL TO HEALTH AND ARE POTENTIALLY LETHAL. LEAKS MUST BE
REPAIRED IMMEDIATELY.
NEVER OPERATE THE ENGINE
IN ENCLOSED AREAS.
External leaks in the exhaust system are often accompanied by noises and exhaust fumes, therefore a visual inspection
usually detects the location of the leak. When checking for exhaust leakage or noise, inspect the entire system for
burned
-out holes, loose or corroded clamps, muffler or exhaust inlet pipe.
Examine the under body for greyish
-white or black exhaust soot which indicates the exhaust leakage at that point.
The effect of a small leak can be magnified by holding a rag over the tailpipe outlet while listening to the leak.
If this is carried out, ensure that gases are not inhaled
-see WARNING.
When testing for a rattle or vibration condition it is helpful to use a rubber mallet. Tap on the exhaust components to
simulate the bouncing action of the exhaust while watching for exhaust-to-body /chassis contact.
6.1.2.2 Test A, Exhaust Leakage or Noise
Test Step
Step
1A Clamps and Brackets
Check for broken or loose clamps and/or exhaust
outlet pipe frame brackets.
Are clamps and exhaust outlet pipe frame brackets
OK?
Step 2A System Components
Check catalytic converters, muffler.
Are system components OK?
Step 3A Exhaust Manifold
Inspect exhaust manifold for loose fasteners and
cracks.
Is exhaust manifold OK?
Action
Refer to Test Step 1A.
Go to Test Step IB, Restricted exhaust system test. .-
Go to Test Step 1B
Result Action
yes
1
Go to Step 2A
no Service and renew as necessary.
Restart engine.
If noise still exists
go to Step 2
yes Go to step 3A
no Renew exhaust outlet pipe frame brackets, exhaust
inlet pipe and/ or muffler as necessary.
If noise still persists, go to Step 3
yes
no Go to Test Step 1B Restricted exhaust system test.
Tighten fasteners or renew exhaust manifold.
X300 VSM 5 Issue 1 August 1994

b Exhaust System (V12)
8
Fig.

P
Components of the Exhaust System
130 -2 33
Two heated oxygen sensors are fitted to the downpipe assembly (1 Fig.1) which is connected to the manifold and two
on the underfloor catalytic converter assembly in front of the catalysts. There are two sensorsfor the ROW and Japan
markets (2 Fig.1) and two additional sensors (3 Fig.1) for the NAS markets.
The sensors are located on A
-bank and B-bank, upstream and downstream of catalytic converters.
Apart from two heated oxygen sensors, the exhaust system for vehicles destined for the Japanese market are also
fitted with two gas temperature sensors
(4 Fig.1).
The exhaust system is held in a predetermined position by a fixing arrangement to the manifold by exhaust centre
mountings (5 Fig.l), by rear axis mountings (6 Fig.1). and tail pipe mountings (7 Fig.1).
Clamps (8 Fig.1) used on each slip joint are welded to the pipes and tightened to a higher torque setting than non- welded clamps. ~ ~~~
Issue 1 August 1994 2 X300 VSM

Exhaust System (V12)
The exhaust system must be free of leaks, binding, grounding and excessive vibrations. These conditions are usually
caused by loose, broken, or misaligned clamps, shields, brackets, or pipes.
Should any
of the above mentioned conditions exist, check the exhaust system components and alignment.
Adjust and renew if necessary.
Do not attempt to service brackets clamps and insulators.
6.2.2 DIAGNOSIS AND TESTING
The standard exhaust system Diagnosis and Testing procedures are given in Section 6.1 (Exhaust System (AJ16)).
X300 VSM 3 Issue 1 August 1994

Manual Transmission & Clutch (AJ16)
. Remove front clamp from unit lift.
. Raise / lower unit with jack, no stands.
. Traverse lift under ramp and take weight of transmission.
. Adjust jacking platform angles to suit transmission.
. Adjust side and rear clamps to suit transmission and tighten clamp wing nuts.
. Fit the safety chain assembly to left hand arm of lift, and secure with peg.
Pass safety chain over transmission and engage in front arm of lift. Tighten the safety chain adjuster.
. Remove remaining transmission to adaptor plate securing bolts and carefully lower transmission from engine.
. Remove transmission from ramp area.
. Remove clutch release bearing assembly from release lever.
. Remove clutch release lever retaining clip and remove lever.
. Remove release lever pivot pin.
Remove transmission switch.
. Remove rear mounting spring retainer securing nut.
. Reposition selector shaft pin cover.
0
Remove rear mounting spring retainer and remove rear mounting assembly.
Remove selector shaft yoke to selector shaft retaining pin and remove the yoke.
. Remove slave cylinder securing studs.
. Remove the transmission from the unit lift.
. Remove transmission drain plug and allow to drain, refit
the drain plug.
Fit new transmission to unit lift.
Fill transmission with oil and refit the level plug.
. Clean components and mating faces.
. Fit the slave cylinder mounting studs.
. Lubricate the selector output shaft.
. Fit selector shaft yoke (3 Fig. 1) to selector shaft and secure
with retaining pin (2 Fig. 1).
Reposition the retaining cover (1 Fig. 1) over the selector
shaft yoke retaining pin. -
. Fit the transmission rear mounting assembly and secure
with bolt.
. Fit reverse lamp switch.
. Lubricate the clutch release lever.
. Fit and align lever to transmission and engage onto pivot
pin.
Fit and fully seat lever to pivot retaining clip.
= Lubricate release bearing housing.
9 Fit and fully seat bearing assembly to lever.
. Select third gear.
. Move transmission to vehicle and raise into position.
Fia. 1
. Insert transmission input shaft into clutch and fully seat transmission against adaptor plate, ensuring that trans- mission is in line as it is fitted and seated to the plate.
X300 VSM 3 Issue 1 August 1994