1994 JAGUAR XJ6 wheel bolts

Manual Transmission & Clutch (AJ16) IBh
7.1.14 ClUTCHASSEMBLY, RENEW
SRO 33.10.01
. Remove the rear inlet manifold securing nuts and
. Fit lifting eye 18G 1465 to rear inlet manifold studs and
rn Fit Service Tool MS 538 (Fig. 1) and take the weight of the
. Disconnect the exhaust system from the front pipe.
. Ease the exhaust system down for access and remove
. Remove the drive (propeller) shaft assembly and fit a
. Remove the exhaust front pipe assembly.
. Remove the clutch slave cylinder, see Sub-Section 7.1.16,
and secure the slave cylinder to one side.
. Disconnect the transmission switch connectors.
. Removethe rear mounting assembly, see Section3.1, SRO 12.45.04.
. Undothe hooknutofServiceTool MS53Btolowertherear of the transmission / engine assembly.
Disconnect the gearshift/selector shaft universal joint se-
curing nut / bolt, remove the wavy washer from the selec- tor and remove the bolts securing the remote control.
Remove the mounting rubbers and washers.
Remove the transmission switch for access to the upper
. Remove the transmission to engine adaptor plate secur-
theinjector harness mounting bracket.
tighten securing nuts.
engine with the hook.
heatshield.
blanking plug to the rear of the transmission.
right hand transmission
/ bell housing securing bolt.
ing bolts
(1 Fig. 2).
Leave two opposing bolts in place for safety.
m . Fit a suitable hoist, securely to the transmission.
= Take the weight of the transmission and remove the re-
. Remove the transmission from the rear of the engine.
. Lower the transmission and remove from the rear of the
. Hold the flywheel in one position and remove the bolts se-
maining two securing bolts.
engine.
curing the clutch cover to the flywheel.
CAUTION: Make a note of the position of any balance
weights relative to the clutch cover.
. Remove the balance weights.
Remove the clutch cover / drive plate assembly.
. Remove the eight securing bolts (1 Fig. 3) and remove the
flywheel (2 Fig. 3).
WARNING: THE TWIN-MASS FLYWHEEL IS EXTREMELY HEAVY. ASSISTANCE MAY BE REQUIRED DUR- ING REMOVAL.
Clean the face of the flywheel and dowels.
Fig. 1
Fig. 2
Fig. 3
X300 VSM Issue 1 August 1994 14

Manual Transmission & Clutch (AJ16)
. Check the flywheel face for scoring; should this be excess-
Fit a new spigot bearing to the flywheel (2 Fig. 1).
. Refit the flywheel to the crankshaft and tighten the secur-
. Fit the clutch assembly to the flywheel ensuring that the
. Align the clutch with an input shaft.
. Fit the balance weights to the clutch cover and tighten the
. Remove the input shaft.
ive,
skim within tolerance.
ing bolts (1
Fig. 1).
larger, rounded boss faces the flywheel.
securing bolts. Remove the circlip
(1 Fig. 2) securing the clutch release
arm to the pivot and remove the assembly (2 Fig. 2).
. Slacken and remove the release arm pivot pin.
. Remove the bearing (3 Fig. 2) from the release arm assem- bly (2 Fig. 21, grease the bearing seat, fit the new bearing
to the release arm assembly.
Re-assemble the release arm ensuring that the pivots are
greased.
. Select third forward gear.
. Move the transmission under the ramp and raise it into
position against the adaptor plate and secure with the
bolts.
. Remove the securing chain from the unit lift and fit front
clamp.
. Refit the transmission switch and fit the multi-plug into
the securing clip.
. Refit the clutch slave cylinder, see 33.35 01.
. Fit the mounting rubbers and spacers, reconnect the re-
. Refit the selector to the gearshift lever.
. Refit the exhaust front pipes to the manifold.
. Remove the blanking plug from the rear of the trans-
. Refit the drive (propeller) shaft.
. Refit the heat shield and reconnect the exhaust system.
. Lower the ramp.
. Remove the Service Tool MS 53B.
. Remove the engine lifting eye 18G 1465.
= Refit the injector harness mounting bracket and tighten
the rear inlet manifold securing nuts.
mote control.
mission.
Fig. 2
Issue 1 August 1994 X300 VSM 15
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Driveshafts & Final Drive
. Remove upper link assembly from differential and wide mounting bracket / 'A' frame.
. Release fixings, 'A' frame to differential, 'A' frame to wishbone tie and wide mounting bracket to 'A' frame.
. Remove wishbone tie assembly, rear mounting bracket and pendulum assembly.
. Release fixings differential nose to wide mounting bracket.
. Assembly and fitting is the reversal of this procedure, taking note of the following:
Drive shaft must be aligned in accordance with Sub
-Section 9.2.
Renew all self locking nuts.
Renew all bolts that were originally fitted with thread locking adhesive.
Replace all locking wire and split pins (cotter pins).
Tighten all fixings to the specified torque.
Correct the final drive oil level
if required.
Check and adjust rear wheel camber setting as required.
9.9 AXLE SHAFT ASSEMBLY, RENEW
SRO
47.10.01
Disconnect vehicle battery ground lead.
. Slacken appropriate axle shaft hub nut.
. Support the vehicle at the rear and remove rear road
. Remove brake caliper in accordance with 70.55.03. Sec-
wheel.
tion 12, but do not disconnect hydraulics.
Slacken hub carrier fulcrum and remove ABS sensor from
hub carrier.
. Remove axle shaft hub nut and collar.
. Remove fixings axle shaft to differential output shaft
flange, note camber shim.
. With service tools JD 1D/7 (Fig. 1) and JD ID (Fig. 21, push
shaft through hub.
. Remove axle shaft assembly.
CAUTION: Take care not to introduce debris into the hub
bearings, or damage seal.
. Prior to assembly, remove all traces of adhesive from hub
. Assembly and fitting is the reversal of this procedure
Adhesive should be applied to axle shaft splines over
a radial area of
30 to 50%.
Renew all bolts that were originally fitted with thread
locking adhesive.
Replace all locking wire and split pins (cotter pins).
Tighten all fixings to the specified torque.
Check and adjust rear wheel camber setting.
Verify operation of brakes.
Renew all self locking nuts.
splines.
taking
note of the following:
0
NQ&: The axle shaft nut is a self-locking item with a thread
insert and must NOT be reused.
Fig. 1
Fig.2
- Iss ue 1 August 1994
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7 X300 VSM

Suspension Systems
1 1.4.8 Diagnostic Procedure
Condition
Hard steering
Shimmy
I----
Bump steer (unequal
side-to-side)
Sawtooth pattern or
t excessive tire wear
Uneven tire wear
(outer or inner
shoulder)
Fronvrear
suspension noises
Possible Cause
Side-to-side difference in caster.
Tire pressure Steering gear or linkage worn or defective.
Tire
conicity
Power steering gear or linkage worn,
damaged, or incorrect adjusted.
Wear of front suspension
lower/upper
wishbone ball joints.
Unequal tire pressure.
Brake system
fault(s)
Wheel/tire imbalance or runout.
Damaged tires, unbalanced or damaged
wheels.
Incorrect wheel alignment.
Steering system malfunction
Front damper malfunction.
Loose front damper mounting.
Damaged front suspension upper
or lower
ball joints.
Damaged or worn sub
-frame to body
mounting. Damaged or worn stabilizer bar insulators.
Damaged or worn stabilizer bar link.
Damaaed or worn wheel bearina.
Rear suspension damage.
Worn steering gear mounting bracket
housing insulators.
Excessive toe
-in (high edges inboard) or
toe-out (high edges outboard).
Incorrect tire pressure.
Excessive toe.
Excessive positive or negative camber.
Loose/missing front dampers and front
damper bolt to front suspension lower
wish bone.
Action
Check the alignment and if incorrect,
adjust the caster
if needed. Inspect
components for wear or damage.
Check for abnormal loading.
Check steering system
Inspect tire for excessive wear.
Check and adjust the tire air pressure.
Note: Excessively worn or uneven tires can
cause
pull/drift.
Check steering system.
Renew ball joints.
Inflate the tires to correct and uniform
pressure.
Check the brakes.
Check wheels and tires.
Check the tires and renew
if necessary.
Balance the wheels
if necessary.
Adjust wheel alignment.
Check steering system.
Renew front damper
if necessary.
Tighten front damper mounting.
-
Renew upper and lower ball joint.
Renew rear suspension bushing.
Renew insulators.
Renew link.
Renew/adjust wheel bearing.
If the caster is uniform, check and compare
the wheelbase at the right and left sides.
If
different, inspect the suspension
components for wear and damage.
Renew bracket housing insulators.
Check and adjust toe
-in.
Correct tire pressure.
Check toe and adjust
if needed.
Check the camber and
if incorrect inspect
the related components for wear or
damage.
Tighten/renew damper bolts.
Inspect wheel hubs.
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lssue 1 August 1994 6 X300 VSM

Brakes (a)
12.1.2. Anti-lock Braking / Traction Control Operation
The rear wheels are controlled collectively on a 'select-low' principle during ABS operation. During traction control,
separate circuits allow individual control of the rear wheels. To facilitate this the valve block has four outlet ports.
The
ABS/TC CM is integrated with the valve block. The pump, motor, valve block and control module are supplied as
a unit and are non-sewiceable. Faulty units must be renewed as a whole.
Both front and rear brakes on
all vehicles are fitted with single piston caliper assemblies. Ventilated brake rotors, with
provision for parking brake shoes at the rear, are fitted all round.
0
Issue 1 August 1994 X300 VSM 3
1. Vacuum booster 9. Pressure conscious reduction valve 2. Vacuum hose 10. Ventilated brake rotor 3. Tandem master cylinder 11. Single piston caliper 4. Primary brake circuit 12. %way brake pipe connector
5. Secondary brake circuit 13. Wheel speed sensor
6. Hydraulic pump / motor unit 14. ABS warning lamp 7. Valve block 15. Brake fluid level warning lamp
8. ABS/TCCM
Fig. 1 ABS / Traction Control System
The vacuum booster (see Fig.
1) is mounted on the brake pedal box and secured by three bolts. Brake pedal force is
increased by the vacuum booster which activates the Tandem Master Cylinder (TMC) intermediate piston. Brake fluid
is supplied to the pump inlet ports on two separate circuits. The primary circuit supplies the front brakes whilst the
secondary circuit supplies the rear brakes.

12.2 FAULT DIAGNOSIS AND TESTING
rrouble
-ong brake pedal
dibration during braking
'oor braking performance
3rakes pull to one side
3rakes do not release
ixcessive pedal travel
Cause
Brake caliper piston or caliper guide
pins sticking
Worn
I damaged brake pads
Worn
1 damaged brake pads
Loose caliper mounting bolts
Insufficient grease on sliding parts
Foreign material
or scratches on
brake rotor contact surface
Damaged brake rotor contact surface
Leak
in hydraulic system
Air
in system
Worn
I damaged brake pads
Foreign material on brake pads
Brake caliper piston malfunction
Tandem master cylinder malfunction
Vacuum booster fault
Disconnected
or damaged vacuum
hose
Low brake
fluid level
Worn
I damaged brake pads
Foreign material on brake pad
Failing valves
in ABS valve block
Abnormal wear or distortion on front
brake rotor
Incorrect wheel alignment
Incorrect tire pressure
No brake pedal free play
Vacuum booster
binding
Tandem master cylinder return port faulty
Faulty valve
in ABS valve block
Leak
in hydraulic system
Air
in system
Remedy
Service or renew caliper or caliper
guide pins
Renew brake pads
Renew brake pads
Tighten caliper mounting bolts
Apply grease where necessary
Clean brake rotor contact surface
Renew brake
rotor
Repair leak. Check all pipework con-
nections. Refill and bleed the system
Check the system
for leaks and bleed
brakes
Renew brake pads
Examine brake pads and clean
or
renew as necessary
Renew faulty brake caliper piston
Service
or renew tandem master cyl- inder
Renew vacuum booster
Renew vacuum hose
Check for leaks, refill and bleed the
system
Renew brake pads
Examine brake pads and clean
or renew as necessary
Renew valve block
Examine front brake
rotor and service
or renew as necessary
Carry out wheel alignment. Refer to
Section
11, iv Service Data
Inflate tire
to correct pressure
Adjust brake pedal free play
Renew vacuum booster
Clean return
port on tandem master cy I i nder
Renew valve block
Repair leak. Check all pipework con
- nections. Refill and bleed the system
Check the system
for leaks and bleed
brakes
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Issue 1 August 1994 16 X300 VSM

12.2 (continued)
rrouble
Excessive pedal travel (Cont'd)
Brakes grab
Brakes drag
Hard brake pedal when pressed
Excessive brake noise
Cause
Worn tandem master cylinder piston
seals or scored cylinder bore
'knock back'. Excessive brake rotor
run
-out or loose wheel bearings
Brake pads contaminated by grease
or brake fluid
Brake pads distorted, cracked or
loose
Loose caliper mounting bolts or
guide pins
Seized or incorrectly adjusted parking
brake or cable
Broken or weak parking brake return
springs
Caliper pistons seized
Brake pedal binding
at pivot points
Vacuum booster binding
Tandem master cylinder faulty
Lack of vacuum
at the vacuum
booster
Tandem master cylinder
pushrod
binding
Frozen tandem master cylinder pis
-
ton
Brake caliper piston or caliper guide
pins seized
Worn brake pads
Bent or cracked parking brake shoes
Foreign objects in brake pads or
park- ing brake shoes
Broken
/ loose parking brake hold
down springs or return springs
Loose caliper mounting bolts
Remedy
Renew tandem master cylinder
Check brake rotor run
-out and renew
as necessary. Adjust wheel bearing
Renew brake pads. Check
pipework for leaks
Renew brake pads
Check caliper and repair
/ renew as
necessary
Examine parking brake and repair
/
renew as necessary
Renew parking brake return springs
Examine calipers and repair
/ renew
as necessary
Examine brake pedal bushings and
repair
/ renew as necessary
Renew vacuum booster
Examine tandem master cylinder and
repair
/ renew as necessary
Check vacuum hose. Repair or renew
as necessary
Renew tandem master cylinder
Renew tandem master cylinder
Examine caliper and renew/ repair as
necessary
Renew brake pads
Renew parking brake shoes
Examine brake pads and and parking
brake shoes. Clean or renew as
necessary
Examine parking brake assembly.
Re- pair or renew as necessary
Re
-torque caliper mounting bolts

Body Components & Trim ~
issue 1 August 1994 X300 VSM 21
13.3.17 Fascia Board, Renew
SRO 76.46.01
. Remove
the battery cover and disconnect the battery.
Remove the drivers side and passenger side underscuttle
pads, see sub
-sections 13.3.19 and 13.3.20.
. Remove the drivers airbag module, see section 15.5.
Remove the steering wheel, section 10.
Remove the drivers side and passenger side fascia closing
. Remove the fascia center veneer panel, see subsection
Remove the fascia board for access, see subsection
. Disconnect the air conditioning differential potentiometer
Remove the differential potentiometer assembly.
. Displace and reposition the through panel connectors
from the fascia assembly.
. Displace the fascia vent motor / gearbox assemblies har- ness multi-plug from the mounting bracket.
. Disconnect and reposition the fascia harness to console
harness
multi-plug from the mounting bracket.
. Disconnect the BPU harness multi-plugs.
Remove the tiestraps securing the harness to the fascia.
. Reposition the fascia on a bench.
= Displace and reposition the solar sensor assembly from
Disconnect the solar sensor harness multi-plug.
Remove the solar sensor assembly.
= Undo and remove the defrost vents securing screws.
Displace and reposition the defrost vent assemblies.
. Disconnect the tweeter speaker harness multi-plugs.
. Remove the defrost vent assemblies.
. Displace the fascia harness grommet from the fascia.
. Route the harness through the aperture.
Remove the fascia harness assembly.
. Undo and remove passenger airbag deployment door to
fascia securing bolts ( one bolt is removed with the fascia).
. Displace and remove the deployment door assembly.
. Undo and remove the passenger airbag module to fascia
. Displace and remove the airbag module assembly.
. Undo and remove the airbag module I BPU mounting
bracket assembly to fascia securing nuts 1 bolts.
= Displace and remove the mounting bracket assembly.
. Retrieve the spacing washers.
. Displace and remove the side vent outlets from the fascia.
. Displace and remove the side vent ducts securing clips.
. Displace and remove the side vent ducts.
. Undo and remove the center vent flap assembly to fascia
. Displace and remove the center vent flap assembly.
Undo and remove fascia location bracket securing nuts.
Displace and remove the location bracket.
panels, see
sub
-sections 13.3.22 and 13.3.21.
13.3.23. 13.3.17.
harness multi
-plug.
the fascia.
securing bolts.
securing nuts.