1994 JAGUAR XJ6 battery

Fuel, Emission Control & Engine Management (V12) ~~ ~
5.2.5
SRO
18.30.74 VEHICLE SET
IDLE SPEED CONTROL VALVE/ GASKETS, RENEW
SRO
18.30.73 VALVE- RIGHT HAND
SRO 18.30.76 GASKET
- RIGHT HAND
SRO
SRO 18.30.75 GASKET- LEFT HAND
18.30.72
VALVE
- LEFT HAND
Remove
. Disconnect battery.
. Drain coolant from radiator, see Section 4.2.
. Disconnect idle speed control valve multi-plug.
Disconnect all hoses linked to the idle speed control valve.
. Remove valve.
. Remove gasket.
Refit in the reverse order of the removal procedure.
5.2.6 FUEL CUT-OFF INERTIA SWITCH, RENEW
SRO
18.30.35
Remove
. Disconnect battery.
. Remove the 'A' post lower trim pad.
= Remove the EMS control module, see Section 15.
. Disconnect vehicle harness through-panel connector.
. Disconnect inertia switch multi-plug (Fig. 2).
9 Remove switch.
Refit in the reverse order
of the removal procedure. Fig.
1
Fig. 2
X300 VSM 9 Issue 1 August 1994

Manual Transmission & Clutch (AJ16)
7.1.2 MANUAL TRANSMISSION ASSEMBLY, RENEW
SRO 37.20.01
. Disconnect the battery.
. Remove inlet manifold rear securing nuts.
. Remove injector harness mounting bracket.
. Fit lifting bracket 18G 1465 and secure with the nuts.
. Fit Service Tool MS 536 (Fig. 1) across the wing channels
Fit and engage retaining hook.
. Tighten hook nut to take weight of engine.
. Disconnect lambda sensor block connectors.
. Remove the exhaust front pipe to the intermediate pipe
securing nut / bolt.
. Remove the front pipe to manifold securing nuts and
remove the front pipe assembly.
. Carefully ease exhaust system down for access.
Remove the drive (propeller) shaft assembly, see Section
. Fit blanking plug to rear of transmission.
. Remove clutch slave cylinder complete with push rod
Disconnect transmission switch multi-way connector and
. Place jack in position beneath the transmission.
. Take weight on the jack, and remove rear mounting to
. Lower jack and remove rear mounting assembly.
Remove jack and jacking channel.
. Remove mounting spring and spring mounting rubber.
. From above: undo retaining hook nut to lower rear of
transmission (do not allow engine to foul steering rack).
. From below: remove selector shaft yoke securing nut / bolt (3 Fig. 2).
. Disconnect selector shaft yoke from lower gearshift lever
and remove wavy washer.
. Remove gear selector remote control securing bolts (1 Fig. 2).
. Remove mounting rubbers and washers (2 Fig. 2).
. Reposition remote control assembly for access.
. Remove transmission-to-engine adaptor plate securing
and
align to rear lifting bracket.
9, SRO 47.15.01.
from bell housing and secure clear.
secure clear.
body securing bolts.
bolts
(1 Fig. 3).
N.&: Leave two opposing bolts in for safety.
Fig. 1
Fig.
2
Fig. 3 ~ ~ ~~ ~
Issue 1 August 1994 2 X300 VSM

Manual Transmission & Clutch (AJ16)
GEARSHIFT LEVER KNOB, RENEW
:RY 37.16.11
. Displace the gearshift lever gaiter for access and slacken
the gearshift lever knob lock nut (1 Fig. 1) and remove the
gearshift lever knob
(2 Fig. 1).
- Fit the new gearshift lever knob and align to its final posi- tion.
. Tighten the lock nut and reposition the gearshift lever
gaiter.
7.1.8 GEARSHIFT LEVER/ REMOTE CONTROL
ASSEMBLY, RENEW
SRO 37.16.20
. Disconnect the battery.
. Remove inlet manifold rear securing nuts.
. Fit lifting bracket 18G 1465 and secure with the nuts.
. Fit Service Tool MS 538 (Fig. 2) across the wing channels
and align to rear lifting bracket.
Fit and engage retaining hook.
. Tighten hook nut to take weight of engine.
Select third gear and remove the gearshift lever knob.
. Disconnect lambda sensor block connectors.
Remove the exhaust front pipe to the intermediate pipe
securing nut / bolt.
. Remove the sealing olive.
. Take the weight of the rear engine mounting using a jack,
. Remove the rear mounting securing bolts.
. Lower and remove the rear mounting assembly.
Carefully ease exhaust system down for access.
jack channel
and a suitable block.
. Remove the drive (propeller) shaft assembly, see Section 9, SRO 47.15.01.
. From above: undo retaining hook nut to lower rear of
transmission (do not allow engine to foul steering rack).
From below: slacken but do not remove the selector shaft
bolt
(3 Fig. 3).
. Remove the gear selector remote control securing bolts (1 Fig. 1) and reposition for access.
Finally remove the selector shaft bolt (3 Fig. 3).
. Remove the gear selector remote control assembly from
the selector shaft.
b: To aid removal, invert the gear selector remote con- trol assembly, i.e. gearshift lever pointing down- wards.
2
Fig. 1
Fig. 2
Fig. 3
X300 VSM 7 Issue 1 August 1994

Automatic Transmission (AJI 6)
8.1.3 TRANSMISSION CONTROL MODULE, RENEW
0 (4, OL)
SRO 44.15.32
. Raise the trunk lid and disconnect the battery.
. Remove the passenger side dash liner for access.
Displace and remove the air conditioning footwell outlet
duct.
. Release and remove the footwell carpet securing fastener:
displace and reposition the carpet for access.
Release the Transmission Control Module
(TCM) bracket
to body bracket securing nut
(1 Fig. 1).
. DisplacetheTCM mounting brackettang (2 Fig. 1)fromthe
body bracket and mounting stud.
= Reposition the TCM, release the TCM multi-pin plug lever
lock and disconnect the multi
-pin plug (3 Fig. 1).
. Release and remove the TCM mounting bracket securing
bolts and remove the TCM.
= Fit and align the new TCM to the mounting bracket.
. Fit and tighten the TCM securing bolts.
. Connect the TCM harness multi-pin plug and secure the
Position the TCM to body mounting bracket, ensuring that
Fit and tighten the TCM securing nut.
. Position the footwell carpet and fit the carpet fastener.
. Fit and align the footwell outlet duct to air conditioning
. Position and fit the duct fastener to the blower motor slot.
. Refit the dash liner.
. Reconnect the battery.
multi-pin plug lever lock.
the tang locates
in the bracket slot and stud.
unit.
1
i
J44-703 U
Fig. 1
Issue 1 August 1994 X300 VSM 7

Automatic Transmission (AJ16)
8.1.5 TRANSMISSION ROTARY SWITCH, RENEW
0 (4,OL)
SRO 44.15.36
. Check the shift cable adjustment.
. Switch the ignition ON, apply the footbrake and move the
Switch the ignition OFF and disconnect the battery.
. Open the armrest lid.
. Release and remove the ashtray securing screws.
. Displace the ashtray assembly for access.
. Disconnect the cigar lighter / illumination harness con-
. Place the ashtray assembly aside.
. Displace and remove the console veneer panel rear fin-
isher.
Carefully displace the Performance Mode switch from the
gear surround finisher.
. Disconnect the Performance Mode switch from the har-
ness multi-pin plug.
Displace and remove the Performance Mode switch sur-
round finisher.
Displace and remove the shift lever surround finisher.
. Release and remove the veneer panel wing nuts.
= Displace and remove the console finisher veneer panel.
Cut and remove the rotary switch harness securing straps.
= Disconnect the rotary switch harness multi-pin plugs.
. Reposition the tunnel carpet for access to the harness
Displace and reposition the grommet down through the
. Feed the harness through the tunnel to the underside of
. Raise the vehicle on a ramp.
. From beneath the vehicle, release and remove the rotary
switch harness to transmission
'F" clip securing nut; dis-
place and reposition the 'P' clip from the stud.
Release and remove the rotary switch harness to trans-
mission 'P' clip securing screw.
Release and remove the rotary switch protection cover
(1 Fig.1) securing bolts; displace and remove the switch
cover.
shift
lever to
'N'.
n ect o rs .
@
grommet.
tunnel.
the vehicle.
Disconnect the transmission multi-pin socket (2 Fig.1).
. Reposition the harness clear of the transmission unit.
. Release and remove the rotary switch securing nuts.
. Displace and remove the switch assembly.
. Displace and remove the 'P' clips from the harness.
. Fit and align the 'P' clips to the new harness / switch as-
. Displace the rubber sealing plug (3 Fig.1) from the rotary
sembly.
switch.
i3 2 JLL-690
Fig.
1
X300 VSM 9 Issue 1 August 1994

Automatic Transmission (AJl6)
. Ensure the shift lever is in 'N'.
. Fit and fully seat a new rotary switch to the transmission
unit.
Fit but do not fully tighten the rotary switch securing nuts.
. Fitand align ServiceTool JD161 (Fig.l)tothe rotaryswitch
. Finallytorque tighten the rotary switch securing nuts.
Displace and remove Service Tool JD161.
. Reposition and fit the rubber sealing plug to the switch.
. Reconnect the transmission unit multi-pin plug.
. Reposition the harness and feed the multi-pin plugs and
. From below the vehicle, reposition the harness 'P' clip to
. Fit and tighten the 'F" clip securing nut.
. Align the harness 'P' clip to transmission shift abutment
Fit and tighten the 'P' clip securing screw.
. Fit and align the rotary switch protection cover; fit and
torque tighten the securing bolts.
. From inside the vehicle, fit the grommet in the correct
orientation and reposition the harness in the correct posi
-
tion.
to
align the switch rotor to the switch body.
grommet through the tunnel aperture.
its mounting stud.
bracket.
. Reconnect the rotary switch harness multi-pin plugs.
. From below the vehicle, ensure that there is no excess
slack
in the switch harness that could foul the propshaft.
. Lower the vehicle on the ramp.
Reposition and fit the tunnel carpet.
Using suitabletiestraps,securethe harnesstotheconsole
= Fit and fully seat the veneer panel to the console; fit and
harness.
tighten the wing nuts.
Fit and fully seat the shift lever surround.
multi-pin plug and fully seat the switch.
Connect the Performance Mode switch to the harness
Fit and align the console veneer panel rear finisher.
9 Place the ashtray assembly in position.
= Reconnect the cigar lighter / illumination harness con-
nectors.
Reposition and
fit the ashtray assemb1y;fit and tighten the
securing screws.
. Close the armrest lid.
Reconnect the battery
Fia. 1
Issue 1 August 1994 10 X300 VSM

Automatic Transmission (AJ16)
8.1.11 TRANSMISSION INTERNAL HARNESSMULTI-
PIN SOCKET '0' RING, RENEW (4,OL)
SRO 44.24.20
. Disconnect the battery.
. Raise the vehicle on a ramp.
. Drain the transmission lubrication system, see Sub-sec-
. Remove the fluid pan, see Sub-section 8.1.7.
. Remove the fluid filter, see Sub-section 8.1.6.
. Remove the transmission speed sensor, see Sub-section
8.1.10.
. Disconnect the rotary switch harness multi-pin plug
(1 Fig. 1) from the transmission multi-pin socket.
. Release and remove the multi-pin socket to main trans-
mission casing securing nut.
. Release and remove the valve body assembly, ensuring
that the
multi-pin socket is freed from the main case aper-
ture.
. Remove the valve body harness multi-pin socket '0' ring
and discard.
. Clean the valve body and mating faces.
. Fit a new '0' ring to the multi-pin socket
. Fit thevalve body assembly to the transmission unit. Dur-
ing valve body fitment, engage the shift lever quadrant
peg into the manual valve and seat the
multi-pin socket
through the main case orifice.
m. Theflat onthesideofthe multi-pinsocket should be
located on the vertical (left-hand) side of the case.
. Fit but do not tighten the valve body assembly securing
screws.
. Gently push the valve body assembly forward to assume
this position
during the final tightening operation.
. Carry out final tightening of the valve body assembly to
main casing securing screws.
Fit and tighten the harness
multi-pin socket to main casing
securingnut.
. Connect the rotary switch harness multi-pin plug to the
transmission
multi-pin socket.
. Refit the speed sensor, see Sub-section 8.1.10.
Renew the fluid filter, see Sub-section 8.1.6.
. Refit the fluid pan, see Sub-section 8.1.7.
. Lower the vehicle on the ramp.
. Reconnect the battery.
. Refill the transmission unit with fluid, see Sub-section
8.1.2.
. Remove the fender cover and lower the hood.
Raise
the hood and
fit a fender cover.
tion
8.1.2.
Fig. 1
Issue 1 August 1994 14 X300 VSM

Automatic Transmission (AJ16)
8.1.12 VALVE BODY ASSEMBLY, RENEW (4,Ol)
SRO 44.40.01
Raise the hood and fit a fender cover.
. Disconnect the battery.
. Raise the vehicle on a ramp.
. Drain the transmission lubrication system, see Sub-sec-
. Remove the fluid pan, see Subsection 8.1.7.
. Remove the fluid filter, see Sub-section 8.1.6.
. Remove the transmission speed sensor, see Subsection
8.1.10.
. Disconnect the rotary switch harness multi-pin plug from
the transmission multi
-pin socket.
. Release and remove the multi-pin socket to main trans-
mission casing securing nut.
Release and remove the valve body assembly to main cas-
ing securing screws.
. DisDlace and remove the valve body assemblv, ensurina
tion
8.1.2.
that
the multi-pin socket is freed from the main case apery
ture. - . Remove the valve body harness multi-pin socket '0' ring
. Clean the valve body and main case mating faces. Check
. Fit a new '0' ring to the multi-pin socket.
. Fit the valve body assembly to the transmission unit. Dur-
ing valve body fitment, engage the shift lever quadrant
peg into the manual valve and seat the multi
-pin socket
through the main case orifice.
m: Theflat on the side of the multi-pin socket should be
located on the vertical (left-hand) side of the case.
. Fit but do not tighten the valve body assembly securing
screws.
Gently push the valve body assembly forward to assume
this position during the final tightening operation.
Carry out final tightening of the valve body assembly to
main casing securing screws.
. Fit and tighten the harness multi-pin socket to main casing
. Connect the rotary switch harness multi-pin plug to the
. Refit the speed sensor, see Subsection 8.1.10.
. Renew the fluid filter, see Subsection 8.1.6.
Refit the fluid pan, see Sub-section 8.1.7.
* Lower the vehicle on the ramp.
. Reconnect the battery.
. Refill the transmission unit with fluid, see Sub-section
8.1.2.
. Remove the fender cover and lower the hood.
and discard.
for any signs of damage.
securing nut.
transmission multi
-pin socket.
Issue 1 August 1994 X300 VSM 15