1994 JAGUAR XJ6 oil filter

1. SERVICE TOOLS & fQUlPMENT
Illustration
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Jaguar Number
JD 103
JD 161
Description Notes
Throttle valve alignment tool
Rotary switch setting tool
11. TORQUE TIGHTENING SPECIFICATIONS
Fixing Tightening Torque
(Nm)
Dipstick tube union nut 90
Drain plug 15
Fluid filter screws 8
Fluid pan securing bolts 8
Rotary switch to mounting bracket nuts
Transmission oil cooler pipes
20
10- 12
15- 18 Switch guard to sump pan bolts
111. SERVICE MA TERlA L S
Description USeS Notes
To be issued

@ Steering
10.1.3 Steering Hydraulic System Major Components
Engine driven rotary vane pump (belt driven 12 cylinder; direct drive from timing gear 6 cylinder) with falling
flow characteristic (as
pump speed increases fluid flow decreases) and integral pressure relief valve.
Remote fluid reservoir with integral 'return' side filter.
Steering rack (incorporating speed sensitive transducer).
Steering control module
(SCM).
Fluid cooler integral with engine coolant radiator and associated pipe-work.
10.1.4 Hydraulic System Features
The 'Servotronic' system reduces steering input loads during parking and low speed manoeuvres and progressively
increases input loads as vehicle speed rises. This feature enhances steering feel.
10.1.5
Rotary motion of the steering wheel is converted, via the steering gear pinion to lateral motion of the rack. Hydraulic
assistance is provided by pressurized fluid being directed against the rack bar piston in the rack cylinder. The pressure
applied to each side of the rack piston is controlled by the pinion valve which varies the restriction through which the
flow for each side of the rack piston must pass.
Hydraulic System Operating Principle (see illustrations on next three pages)
Section on X X
J57-277
A. Steering rack F. Torsion bar 0 Radial groove B. Driving pinion G. Oil pump 1 Speedometer
C. Power cylinder H Pressure & flow 2 SCM D. Rotary disc valve limiting valve 3 Transducer
E. Control sleeve N Radial groove
Fig.
1 Major components & hydraulic flow - Neutral position ~
Issue 1 August 1994 X300 VSM 2

10.4.3 Diagnostic chart 2
0 Trouble
'lay at steering wheel
ieavy when stationary
Excessively heavy when
hiving, stationary effort
3K
Too easy when driving,
itationary effort OK
fffort not equal side to
;ide from center
dariation from heavy to
?asy when driving
:yclic load variation at steering wheel - 2 per
.evolution
:losely spaced cyclic
oad variation at steering
Nheel
Cause
Rack damper loose
Pinion bearing loose
Worn intermediate shaft joint
Worn suspension joint
Loose lower column 'pinch' bolt
Transducer not closed
Transducer not closed
- ground short
Transducer not closed
- no feed voltage
Transducer not closed
- defective cable
SCM defective
Delivery pressure or flow too low
Internal rack leakage
tire pressures low
Transducer open too early
Transducer open too early, incorrect SCM
h/Pe
Transducer open too early, incorrect
speedometer signal
Rack 'reaction limitation valve' CLOSED
or setting incorrect
Transducer not open (no oil flow)
Transducer not open, SCM faulty
Transducer not open, incorrect speedom
-
eter signal
Rack 'reaction limiting valve' OPEN or
setting incorrect
Low pressure pipe 'flattened' or re
-
stricted
Blocked reservoir filter
tire pressure high
Rack check valve leak
Rotary valve blockage Incorrect lower column assembly, see
'Cyclic load variations'
Incorrect speedometer signal
Transducer cable
/ connection faulty or
grounded
Lower column universal joint fitting error
Rack damper too tight
Remedy
Renew rack
Renew rack
Renew joint
Renew joint
Tighten to specification
Inspect and check for debris
Renew transducer*
Investigate and repair
Renew cable
Renew module*
Renew pump
Renew rack
Set to specification
Renew transducer*
Renew
SCM*
Renew speedometer transmitter*
Renew rack
Inspect and check for debris
Renew
SCM*
Renew speedometer transmitter*
Renew rack
Renew pipe
Renew filter
Set to specification
Renew rack
Renew rack
Rectify as required
Renew speedometer transmitter*
Investigate and repair
Verify that the lower column assembly is
correct for that drive.
RH and LH assem- blies MUST NOT be interchanged due to
joint phase differences
Renew rack
W: Items marked * should be validated using EDM test procedures.
X300 VSM 7 Issue 1 August 1994

Climate Control Systems
Description U-
HFC 134A - ICI Klea or
equivalent
Polyalkyleneglycol (PAG) Compressor lubricant
Refrigerant
111.
Notes
Recyclable. NOT
compatible
with CFC 12
Absorbs water readily. NOT
compatible with mineral based
oils
SERVICE MATERIALS
Standard for Recovery I Recycle 1 Recharge Equipment.
Recovery rate
Cleaning capability
Oil separator
.Moisture indicator
Vacuum pump
Filter Replaceable with moisture indicator
Charge Hoses
Feature Requirement
0,014 - 0,062 m3 / min. (1,36 kg in 20 minutes)
15 parts per million (ppm) moisture; 4000 ppm oil; 330 ppm non condensable gases
in air
With hermetic compressor and automatic oil return
Sight glass type, sensitive to 15 ppm minimum
2 stage 0,07 - 0,127 m3 I min.
Selectable charge weight and automatic delivery
Dedicated HFC 134A port connections.
Iv. SERVICE DATA
Application
Charae weight
Lubricant capacity
Compressor pressure relief valve
Drive belt 12 cylinder
Drive belt tension
All figures apply to a cold belt
Special note
Drive belt tension measuring point
Drive belt 6 cyclinder
Drive belt tension
All figures apply to a cold belt
Drive belt tension measuring point
Specification
160 - 200 ml
Opening point 34 Bar. Closing point 27,6 Bar.
Maximum leakage rate of 113 liters 1 minute @ 41 Bar
7 rib Poly
-vee; 1450 mm long
Burroughs method
- New belt 790 N; If tension falls
below 270 N reset at 630 N
Clavis method
- New belt 114 to 120 Hz; If tension falls
below 70 Hz reset at 87 to 93 Hz
For new belt; rotate engine 3 revolutions minimum and
retension
Mid-way between crankshaft and compressor pulley ~
4
rib Poly-vee X 1010 mm long
Burroughs method
- New belt 556 to 578 N; If tension
falls below 245 N reset at 378 to 400
N
Clavis method - New belt 167 to 173 Hz; If tension falls
below 85 Hz reset at 127 to 133 Hz
Mid
-way between crankshaft and compressor pulley on
the upper run
1 Charge pressure I Heating element to increase pressure
Issue 1 August 1994 X300 VSM iii

Climate Control Systems
lnsufficent Cooling
0 Sluggish blower motor(s).
0 Restricted blower inlet or outlet passage
0 Blocked or partially restricted condenser matrix or fins.
0 Blocked or partially restricted evaporator matrix.
0 Blocked or partially restricted filter in the receiver drier.
0 Blocked or partially restricted expansion valve.
0 Partially collapsed flexible pipe.
0 Expansion valve temperature sensor faulty (this sensor is integral with valve and is not serviceable).
0 Excessive moisture in the system.
0 Air in the system.
0 Low refrigerant charge - possible code 23.
0 Compressor clutch slipping.
0 Blower flaps or distribution vents closed or partially seized - possible codes 41 or 46.
0 Coolant flow valve not closed.
0 Evaporator sensor incorrectly positioned
m: Should a leakor low refrigerant be established as the cause of /NSUff/C/€NTCOOL/NG,followthe procedures
Recovery / Recycle / Recharge, this section, and observe all refrigerant and oil handling instructions.
lntermiffent Cooling
0 Is the electrical circuit to the compressor clutch consistent?
0 Is the electrical circuit to the blower motor(s) consistent?
0 Compressor clutch slipping?
0 Motorized in-car aspirator or evaporator temperature sensor faulty, causing temperature variations - possible
codes 11 or 13.
0 Blocked or partially restricted evaporator or condenser.
Noisy System
0 Loose or damaged compressor drive belt.
0 Loose or damaged compressor mountings.
0 Compressor oil level low, look for evidence of leakage.
0 Compressor damage caused by low oil level or internal debris.
0 Blower motor(s) noisy.
0 Excessive refrigerant charge, witnessed by vibration and 'thumping' in the high pressure line (may be indicated
by high HIGH & high LOW side pressures).
0 Low refrigerant charge causing 'hissing' at the expansion valve (may be indicated by low HIGH side pressure).
0 Excessive moisture in the system causing expansion valve noise.
0 Air-lock in water pump*.
lnsufficent Heating
0 Coolant flow valve stuck in the closed position.
0 Motorized in-car aspirator seized.
0 Cool air by-pass damper stuck or seized - possible code 43.
0 Blocked or restricted blower inlet or outlet.
0 Low coolant level.
0 Blower fan speed low.
0 Coolant thermostat faulty or seized open.
0 Water pump inoperative or blocked
0 Air-lock in matrix*.
m: * Please see Sections 4.1 and 4.2 for specific coolant fill / bleed procedures.
Electrical faults may be more rapidly traced using
(JDE), please refer to the (EDM).
Issue 1 August 1994 16 X300 VSM

Systems Repair Body & Body -
A4.1.3. POTENTIAL RISKS I
A4.1.3. Paint
Organic solvents, found in paints, may cause damage or severe irritation to liver, kidneys, digestive tracts and respira- tory system if inhaled over long periods of time.
Prolonged exposure to isocyanates may cause lung sensitization. Asthma
-like symptoms may develop with subse-
quent exposure to very low concentrations of isocyanates.
Solvent inhalation can cause dizziness or loss of consciousness.
Splashes of solvents, paint activators and additives can cause damage to the eyes and may cause dermatitis. Peroxide
and acid catalysts may cause burns.
Inhalation of
spray dust and sanding debris may cause lung damage.
I
A4.1.3.2 Applied Heat (Welding)
There is considerable risk of damage to eyes and skin when welding or flame cutting.
Fire is a serious danger and many materials or fluids within the vehicle are highly flammable.
Toxic and dangerous fumes may be liberated when any of the following are subjected to heat:
0 Expanded foam
0 Corrosion protection
0 Trim and seat materials
0 Paints which contain isocyanates
0 Adhesive and sealing compounds
When heated to a temperature of 3OO0C, polyurethane based compounds may liberate small quantities of isocyanate.
Many types of nitrogen containing chemicals may be liberated as breakdown products; these chemicals can contain
isocyanates, oxides of nitrogen and hydrogen cyanide.
Potentially toxic or asphyxiant fumes and gases are produced by welding, for example; zinc oxide with zinc coated
panels, and ozone gas from the MIG process.
A4.1.3.3 Metal Repair
There is considerable risk of damage to eyes, ears and skin when metal cutting, forming, or dressing is being carried
out.
Soldering may be hazardous because of heat generated fumes and skin contact with the materials.
A4.1.4. PRECAUTIONS
A4.1.4.1 Paint
The inhalation of sprays, fumes, or dust during paint application or sanding processes should always be avoided. En- sure that there is efficient ventilation / extraction at all times. Paint spraying should be confined as far as possible to
spray booths. Personnel with a history of asthma should not be engaged in any process which involves the use of
isocyanates. Any operator working inside
a spray booth where isocyanate material is present must use air-fed breath- ing equipment. Supplied air to the visor should be fed at the recommended pressure and filtered to remove oil, water,
and fumes. Operators involved in handling mixing or spraying should wear protective clothing - gloves and goggles,
to avoid skin and eye contact.
A particle mask or canister type respirator should be worn when sanding.
A4.1.4.2 Applied Heat
When welding, flame cutting, brazing etc, the operator should use as appropriate, goggles, mask/fume extractor and
flameproof protective clothing. It is especially important when working with polyurethane compounds to use air-fed
breathing equipment.
Ensure that
at all times the appropriate fire fighting equipment is available and that personnel are trained in its use.
A4.1.4.3 Metal Repair
Appropriate eye and hand protection should be worn when sanding, drilling, cutting, chiselling, flatting or welding.
Operators should wear
a face mask or air-fed visor when sanding or flatting either body solder or fillers.
When
a soldering operation has been completed, swarf must be removed from the work area and the operator must
wash his hands thoroughly.
X300 VSM 3 Issue 1 August 1994