1994 JAGUAR XJ6 lamps

Manual Transmission & clutch (AJ16)
Fit and tighten transmission to adaptor plate securing
. Slacken chain adjuster.
. Release securing peg from adjuster.
. Displace securing chain from the unit lift.
. Slacken clamp from wing nuts.
. Release clamps from transmission.
. Lower lift and traverse aside.
Refit front clamp to unit lift.
. Connect transmission switch and fit multi-way connector
. Clean and lubricate clutch slave cylinder push rod and fit
. Fit slave cylinder to mounting studs and secure with nuts.
Fit and seat remote control mounting rubbers and
. Align remote control assembly to transmission.
. Fit mounting rubber backing washers.
Refit remote control mounting and secure with bolts (1
. Fit wavy washer to gearshift lever.
. Position selector shaft yoke to gearshift lever.
. Apply lubricant to selector shaft yoke / gearshift lever
. Fit and tighten selector shaft yoke to gearshift lever secur-
. From above: Tighten MS 538 hook nut to raise trans-
. Position the jack beneath the transmission.
bolts
(1 Fig. 1).
into
securing clip.
to slave cylinder.
spacers.
Fig.
2).
assembly.
ing nut
/ bolt (3 Fig. 2).
mission into position (Fig. 3).
. Fit spring to rear mounting assembly.
. Fit upper rubber to mounting spring.
Using a jack, fit and seat the mounting assembly to the body / transmission.
. Fit but do not fully tighten mounting securing bolts.
. Lower and remove jack.
. Remove jack channel.
. From above: Fully undo MS 53B hook nut.
. From below: Final align mounting to transmission / body.
. Final tighten the mounting assembly securing bolts.
. Clamp the front exhaust pipe in a vice.
. Remove and discard the front pipe to manifold sealing
. Clean the faces.
Fit and fully seat new rings to pipe.
. Remove the front pipe from the vice and align to the
. Align retaining rings to the studs and secure with the nuts.
rings.
man
ifold.
Fin. 1
Fig.
2
Fig. 3
Issue 1 August 1994 4 X300 VSM

Automatic Transmission (AJl6)
8.1.6 TRANSMISSION FLUID FILTER, RENEW
SRO 44.24.07
9 Raise the hood and fit a fender cover.
. Raise the vehicle on a ramp.
. Drain the transmission lubrication system, see Sub-sec-
. Removethefluid pan,seeSub-section8.1.7 (4,OL)orSub-
. Release and remove the fluid filter securing screws; dis-
. Remove and discard the filter '0' ring.
. Clean the new filter and mating faces.
. Fit the '0' ring to the new filter; fit and seat the filter assem-
. Fit and torque tighten the filter securing screws.
. Refitthefluidpan,seeSub-section8.1.7 (4,OL)orSub-sec-
. Lower the vehicle on the ramp.
. Refill the transmission unit with fluid, see Subsection
8.1.2.
Remove the fender cover and lower the hood.
(3,2L AND 4,011
tion 8.1.2.
section
8.1.8 (3,2L).
place and remove the fluid filter.
bly to the valve body.
tion 8.1.8
(3,2L).
8.1.7 FLUID PAN, RENEW (4,OL)
SRO 44.24.04
. Raise the hood and fit a fender cover.
. Raise the vehicle on a ramp.
. Drain the transmission lubrication system, see Sub-sec-
tion 8.1.2.
Release and remove the rotary switch protection cover to
fluid pan securing screws; remove the rotary switch
protect ion cover.
Release and remove the fluid pan securing bolts and
clamps
(1 Fig. 1). Displace and remove the fluid pan
(2 Fig. 1).
. Drain the fluid pan. Remove and discard the fluid pan
gasket if the gasket is damaged.
Remove the magnets from the fluid pan and place the fluid
pan aside.
. Clean the gasket faces and magnets.
Fit a serviceable gasket to the new fluid pan.
. Fit the magnets in position in the fluid pan.
Fit and align the fluid pan to the transmission unit; fit and
torque tighten the fluid pan clamps and securing bolts.
. Fit the rotary switch protection cover to the fluid pan
bosses and fit and torque tighten the rotary switch protec-
tion cover securing bolts.
. Lower the vehicle on the ramp.
Refill the transmission unit with fluid, see Subsection
Remove the fender cover and lower the hood.
8.1.2.
Fig. 1
X300 VSM 11 Issue 1 August 1994

Automatic Transmission (AJ16)
8.1.8 FLUID PAN, RENEW (3,2L)
SRO 44.24.04
. Raise the vehicle on a ramp.
. Drain the transmission lubrication system, see Sub-sec-
tion 8.1.2.
Release and remove the fluid pan securing bolts and
clamps
(1 Fig. 1).
. Displace and remove the fluid pan (2 Fig. 1).
= Drain the fluid pan. Remove and discard the fluid pan
. Remove the magnetsfrom the fluid pan and place the fluid
. Clean the gasket faces and magnets.
. Fit a serviceable gasket to the new fluid pan.
. Fit the magnets in position in the fluid pan.
9 Fit and align the fluid pan to the transmission unit.
Fit the fluid pan clamps; fit and torque tighten the fluid pan
. Lower the vehicle on the ramp,
. Raise the hood and fit a fender cover.
. Refill the transmission unit with fluid, see Sub-section
. Remove the fender cover and lower the hood.
gasket
if the
gasket is damaged.
pan aside.
securing bolts.
8.1.2.
8.1.9
SRO 44.24.05
. Raise the hood and fit a fender cover.
. Raise the vehicle on a ramp.
. Drain the transmission lubrication system, see Sub-sec-
FLUID PAN GASKET, RENEW (3,2L)
tion 8.1.2.
. Release and remove the fluid pan securing bolts clamps
. Displace and remove the fluid pan (2 Fig. 1).
(1 Fig. 1).
Remove and discard the fluid pan gasket.
pan aside.
. Removethe magnetsfrom the fluid pan and place thefluid
. Clean the fluid pan, gasket faces and the magnets.
. Fit a new fluid pan gasket.
. Fit the magnets in position in the fluid pan.
9 Fit and align the fluid pan to the transmission unit, fit the
fluid pan clamps,fit and torquetighten the fluid pan secur-
ing bolts.
. Lower the vehicle on the ramp.
. Refill the transmission unit with fluid, see Sub-section
. Remove the fender cover and lower the hood.
8.1.2.
/>U492
Fig. 1
Fig. 1
j
X300 VSM Issue 1 August 1994 12

Automatic Transmission (V12 & AJ16 Supercharged) Powertrain
8.2.6
SRO 44.15.40
. Open the hood and fit a suitable fender cover.
. Raise the vehicle on a ramp.
. Slacken the underfloor catalyst to downpipe clamps se-
. Displace and reposition the olive clamps on the pipes.
INPUT SPEED SENSOR, RENEW (6,OL)
curing bolts.
Slacken the underfloor catalyst
to intermediate silencer
clamps securing bolts.
9 Displace the underfloor catalyst assembly rearwards to
disconnect from the downpipes.
Displace and remove the olives from the downpipes.
Using a wire brush, clean the olives and downpipe joints.
. Place a suitable piece of wood between the underfloor
. Reposition the edge of the transmission tunnel insulation
. Release and remove the input speed sensor securing bolt.
. Reposition the speed sensor protection cover for access,
noting that the cover remains captive on the harness.
Disconnect the speed sensor harness multi
-pin plug.
- Displace and remove the speed sensor from the trans- mission case.
Clean the transmission case area.
. Fit a new ‘0 ring seal to a new input speed sensor.
. Lubricate the ‘0 ring seal.
. Fit and fully seat the speed sensor to the transmission
. Reconnect the harness multi-pin plug.
Reposition and align the protection cover.
. Fit and tighten the speed sensor securing bolt.
Reposition the insulation foam to its original position.
Remove the block of wood from between the underfloor
. Apply sealant to the downpipe joints and olives. See Ser-
Fit and seat the olives to the downpipes.
Reposition the olive clamps.
Tighten the underfloor catalyst to downpipe clamps secur-
Align the intermediate silencers to the underfloor catalyst
. Tighten the clamp securing bolts.
. Lower the vehicle on the ramp.
Remove the fender cover and close the hood.
catalyst
and the body for access.
foam for access.
0
case.
catalyst and the floor.
vice Materials
in the preliminary pages, this Section.
Reconnect the underfloor catalyst to the downpipes.
0
ing bolts.
assembly.
lppl
0
X300 VSM issue 1 August 1994 8

Powertwin Automatic Transmission (V12 & AJ16 Supercharged)
8.2.7
SRO 44.15.41
OUTPUT SPEED SENSOR, RENEW (6,OL)
. Open the hood and fit a suitable fender cover.
. Raise the vehicle on a ramp.
. Slacken the underfloor catalyst to downpipe clamps se-
Displace and reposition the olive clamps on the pipes.
. Slacken the underfloor catalyst to intermediate silencer
. Displace the underfloor catalyst assembly rearwards to
. Displace and remove the olives from the downpipes.
. Using a wire brush, clean the olives and downpipe joints.
Place a suitable piece of wood between the underfloor
catalyst and the body for access.
. Reposition the edge of the transmission tunnel insulation
foam for access.
. Release and remove the output speed sensor securing
bolt.
Reposition the speed sensor protection cover for access,
noting that the cover remains captive on the harness.
. Disconnect the speed sensor harness multi-pin plug.
. Displace and remove the speed sensor from the trans-
. Clean the transmission case sensor area.
. Fit a new '0' ring seal to a new output speed sensor.
. Lubricate the '0' ring seal.
Fit and fully seat the speed sensor to the transmission
. Reconnect the harness multi-pin plug.
Reposition and align the protection cover.
. Fit and tighten the speed sensor securing bolt.
Reposition the insulation foam to its original position.
Remove the block of wood from between the underfloor
catalyst and the floor.
. Apply sealant to the downpipe joints and olives. See Ser- vice Materials in the preliminary pages, this Section.
. Fit and seat the olives to the downpipes.
. Reconnect the underfloor catalyst to the downpipes.
= Reposition the olive clamps.
. Tighten the underfloor catalyst to downpipe clamps secur-
= Align the intermediate silencers to the underfloor catalyst
. Tighten the clamp securing bolts.
Lower the vehicle on the ramp.
. Remove the fender cover and close the hood.
curing
bolts.
cl amps securing bolts.
disconnect from the downpipes.
mission case.
case.
0
ing bolts.
assembly.
Issue 1 August 1994 X300 VSM 9

Pomrtrain Automatic Transmission (V12 & AJ16 Supercharged)
8.2.14 FLUID PAN, RENEW (4,OL SC)
SRO 44.24.04
. Open the hood and fit a suitable fender cover.
. Raise the vehicle on a ramp.
. Drain the transmission lubrication system, see Sukec-
. Slacken the downpipe catalyst to intermediate catalyst
Slacken the intermediate catalyst to intermediate si-
9 Disconnect the intermediate catalyst pipe from the down-
. Clean the downpipe and intermediate pipe joint.
. Release and remove the fluid pan securing bolts.
Remove the fluid pan (1 Fig. 1)) and gasket (2 Fig. 1).
. Drain the residual fluid from the fluid pan.
Remove the fluid pan gasket.
. Clean the fluid pan gasket, which can be re-used if in good
Place the fluid pan gasket aside.
= Remove the magnet (3 Fig. 1) from the fluid pan.
= Clean the magnet and place on a clean surface.
. Clean the transmission fluid pan joint face.
. Clean the fluid pan.
Place the fluid pan aside.
. Attach the magnet to the recess in a new fluid pan.
. Fit and align a serviceable gasket to the fluid pan.
. Fit the fluid pan and gasket to the transmission unit.
. Fit and tighten the fluid pan securing bolts.
. Apply sealant to the intermediate pipe joint. See Service
Materials in the preliminary pages, this Section.
Reconnect the intermediate pipe to the downpipe.
Align the intermediate catalyst assembly.
. Tighten the intermediate pipe to the downpipe securing
. Align the intermediate silencers to the intermediate cata-
. Tighten the intermediate silencer securing clamps.
. Lower the vehicle on the ramp.
Refill the transmission unit with fluid, see Subsection
8.2.13.
. Remove the fender cover and close the hood.
tion 8.2.13.
clamp securing bolts.
lencers clamp securing bolts.
pipe.
condition.
clamp. lyst assembly.
.. rli
i
1
JLL-713
Fig. 1
X300 VSM 15 Issue 1 August 1994

Automatic Transmission (V12 & AJ16 Supercharged) Powertrain
8.2.15 FlUlD PAN, RENEW (6,Ol)
SRO 44.24.04
Open the hood and fit a suitable fender cover.
. Raise the vehicle on a ramp.
. Slacken the underfloor catalyst to downpipe clamps se-
. Displace and reposition the olive clamps on the pipes.
. Slacken the underfloor catalyst to intermediate silencer
Displace the underfloor catalyst assembly rearwards to
. Displace and remove the olives from the downpipes.
. Using a wire brush, clean the olives and downpipe joints.
m Place a suitable piece of wood between the underfloor
Drain the transmission lubrication system, see Sub-sec-
Release and remove the fluid pan securing bolts.
Drain the residual fluid from the fluid pan.
. Remove the fluid pan (1 Fig. 1) and gasket (2 Fig. 1).
. Clean the fluid pan gasket, which can be re-used if in good
. Place the fluid pan gasket aside.
. Remove the magnet (3 Fig. 1) from the fluid pan.
. Clean the magnet and place on a clean surface.
. Clean the transmission fluid pan joint face.
. Clean the fluid pan.
. Place the fluid pan aside.
. Attach the magnet to the recess in a new fluid pan.
. Fit and align a serviceable gasket to the fluid pan.
. Fit the fluid pan and gasket to the transmission unit.
. Fit and tighten the fluid pan securing bolts.
. Remove the block of wood from between the underfloor
catalyst and the floor.
. Apply sealant to the downpipe joints and olives. See Ser- vice Materials in the preliminary pages, this Section.
Fit and seat the olives to the downpipes.
Reconnect the underfloor catalyst to the downpipes.
. Reposition the olive clamps.
. Tighten the underfloor catalyst to downpipe clamps secur-
. Align the intermediate silencers to the underfloor catalyst
. Tighten the clamp securing bolts.
Lower the vehicle on the ramp.
. Refill the transmission unit with fluid, see Sub-section
curing
bolts.
clamps securing bolts.
disconnect from the downpipes.
catalyst and the body for access.
tion 8.2.13.
condition.
ing bolts.
assembly.
8.2.13. Remove the fender cover and close the hood.
JLL-719
Fin. 1 ~
Issue 1 August 1994 X300 VSM 16

Powertrain Automatic Transmission (V12 & AJ16 Supercharged)
8.2.16 FLUID PAN GASKET, RENEW (4,OL SC)
SRO 44.24.05
Open the hood and fit a suitable fender cover.
. Raise the vehicle on a ramp.
Drain the transmission lubrication system, see Sub-sec-
. Slacken the downpipe catalyst to intermediate catalyst
. Slacken the intermediate catalyst to intermediate si-
. Disconnect the intermediate catalyst pipe from the down-
Clean the downpipe and intermediate pipe joint.
. Release and remove the fluid pan securing bolts.
. Remove the fluid pan (1 Fig. 1) and gasket (2 Fig. 1).
. Drain the residual fluid from the fluid pan.
. Remove and discard the fluid pan gasket.
Remove the magnet (3 Fig. 1) from the fluid pan; clean the
. Place the magnet on a clean surface.
. Clean the transmission fluid pan joint face.
. Clean the fluid pan.
. Place the fluid pan aside.
. Attach the magnet to the recess in a new fluid pan.
. Fit and align a new gasket to the fluid pan.
. Fit the fluid pan and gasket to the transmission unit.
. Fit and tighten the fluid pan securing bolts.
. Apply sealant to the intermediate pipe joint. See Service
Materials in the preliminary pages, this Section.
. Reconnect the intermediate pipe to the downpipe.
. Align the intermediate catalyst assembly.
. Tighten the intermediate pipe to downpipe securing
. Align the intermediate silencers to the intermediate cata-
. lighten the intermediate silencer securing clamps.
. Lower the vehicle on the ramp.
tion 8.2.13.
clamp securing bolts.
lencers clamp securing bolts.
pipe.
magnet.
clamp. lyst assembly.
. Refill the transmission unit with fluid, see Subsection
8.2.13.
. Remove the fender cover and close the hood.
1
JLL-713
Fia. 1
X300 VSM 17 Issue 1 August 1994