1994 JAGUAR XJ6 steering

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

SECTION CONTENTS 0
Sub-Section Title SRO Page
i to iii ............ Preliminary Pages ................................................................ i To iv
10.1
............. Steering System Description ........................................................... 1
10.1.1 ............ Steering System Description. Steering Column Major Components ........................... 1
10.1 .2 ............ Steering System Description. Steering Column Operating Principle ........................... 1
10.1.3 ............ Steering System Description. Hydraulic System Major Components .......................... 2
10.1.4
............ Steering System Description. Hydraulic System Features .................................... 2
10.1.5
............ Steering System Description. Hydraulic System Operating Principle .......................... 2
10.2 ............. Service Procedures-Safety Related ...................................................... 5
10.2.1
............ Service ProceduresSafety Related. Airbag ............................................... 5
10.3
............. Service Procedures ................................................................... 5
10.3.1
............ Service Procedures Working Practices ................................................... 5
10.3.2
............ Service Procedures Working Practices. Fluid Level Check & Topup .......................... 5
10.3.3
............ Service Procedures Working Practices. System Bleed ...................................... 5
10.3.4
............ Service Procedures Working Practices. Fluid Reservoir ..................................... 5
10.3.5.
........... Service Procedures Working Practices. Hydraulic Connections .............................. 5
10.4
............. Diagnostic Procedure ................................................................. 6
10.4.1 ............ Diagnostic Procedure. introduction ..................................................... 6
10.4.2. ........... Diagnostic Procedure. Preliminary Action ................................................ 6
10.4.3 ............ Diagnostic Chart 1 ................................................................... 6
10.4.4. ........... Diagnostic Chart 2 ................................................................... 7
10.4.5 ............ Diagnostic Chart3 ................................................................... 8
10.5
............. Outer Track Rod Ball Joint. Renew ................................ 57.55.02 ............. 9
10.6 ............. Front Hub Assembly, Renew ..................................... 60.25.01 ............. 9
10.7
............. Front Hub Bearing End Float. Check & Adjust ...................... 60.25.12 ............. 9
10.8
............. Front Hub Bearing. Renew ...................................... 60.25.16 ............. 9
10.9
............. Front Hub Oil Seal. Renew ...................................... 60.25.17 ............. 9
X300 VSM i Issue 1 August 1994

@ Steering
1. SERVICE TOOLS & EQUIPMENT
I Illustration Jaguar Number
JD 100
18G-134
JD550-5 / 1 & 2
JD-179
Description
Ball joint separator
Handle
Adaptor
Seal
replacer
Not- 0
e
0
0
Issue 1 August 1994 ii X300 VSM

TORQUE TIGHTENING SPECIFICATIONS
Fixing Tightening Torque
(Nm)
Air bag to steering wheel
Blanking plug for rack centralizing pin 4-5
7
- 10
Fluid pipe to pump banjo bolt
Fluid
pipe to cooler sleeve nut X 2 34
- 46
17
- 23
Fluid pressure pipe pump to rack mid connector
Heatshield to rack
(12 cvlinder)
17 - 23
22
- 28
Horn bar (at steering wheel)
Hose from
fluid reservoir (worm drive)
Hose
to pump (worm drive)
Hose to fluid reservoir from cooler (worm drive)
Lower column to steerina rack pinion
5-7
2,5
- 3,5
Retighten to nominal
after 30 minutes
Retighten to nominal
after
30 minutes
Retighten to nominal
after
30 minutes
2,5 - 3,5
2,5
- 3,5
22
- 28
Pressure switch to feed pipe 12 cylinder only 8,5 - 11,5
Road wheel -Alloy 88- 102
Road wheel - Steel 68-82
Steering column outer tube to bodv 17 - 23
Steering column universal joint to lower column
Steering column upper bracket to column outer tube
Steering column upper bracket to plenum stiffener 17 - 23
16
-20
17
-23 ~~
I Steering
column upper COWIS I ~ 2.5-3.5
Steering
rack to crossmember 12 cylinder
Steering rack to crossmember
6 cvlinder
39 - 51
43
- 57
Steering wheel to column 34 - 46
Tie strap plenum 16-20
Track rod end taper ball pin to steering arm
Track rod end lock nut 59-71
51
-69
17
- 23 Tube nut -fluid pipe at steering rack 2 off
X300 VSM iii Issue 1 August 1994

@ Steering
Description
Retinax A grease
Power steering hydraulic
fluid
'11. SERVICE MATERIALS
U- Notes
Front hub bearings and seals
Dexron 2E ATF minimum (or equivalent) See
Sub Section IV Service
Data
See Sub Section
IV Service
Data
Application
Front hub end-float
Front hub bearing grease
- Quantity
Toe
-in 12 cylinder
Toe
-in 6 cylinder
Steering system capacity
Steering system operating pressure
Steering system level checking frequency
Drive belt tension (12 cylinder only)
Steering
rack turns lock to lock
Drive belt tension measuring point
Specification
0,025 to 0,08 mm
4 ml in each race
Oo 5' + or - 10' underside of front crossbeam 143mm
from ground level
Oo 5' + or - 10' underside of front crossbeam 153mm
from ground level
Approx
1 liter from dry
100> 110 bar
16,000
km
2,83
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
Issue 1 August 1994 iv X300 VSM

10.1 STEERING SYSTEM DESCRIPTION
10.1.1 Steering Column Major Components
Integrated column assembly incorporating power, or manual, reach /tilt mechanism and lock.
Ignition switch.
Ignition interlock solenoid.
Key transponder coil.
Body attachment points.
Depending upon model, the steering column may be adjusted for
tilt and reach, either by electrical or manual means.
Power variants may be either automatically or manually adjusted and all types have the entry / exit feature.
10.1.2 Steering Column Operating Principle
Power Adjust: Two independent motor / gearbox assemblies provide infinite adjustment for reach and height within
approximate ranges of 35mm and
13O respectively. Adjustments may be automatically made in conjunction with the
seat memory facility or manually when the adjustment switch is used. It should be noted that selection of 'Off will
disable the automatic entry / exit mode.
Manual Adjust: The cable operated reach adjustment is infinite within a range of 35mm, with the desired position being
fixed
by a rack and wedge. Tilt variations are stepped at approximately 3O intervals with 6 positions being available,
the uppermost being unlatched.
From the uppermost position the column may be pulled down to engage the first detent without using the
tilt lever.
WARNING: MANUAL ADJUST ONLY: TO AVOID PERSONAL INJURY, COLUMN UPWARD TRAVEL SHOULD BE MAN- UALLY RESTRAINED TO CHECK UPWARD SPRING ASSISTANCE. THIS IS ESPECIALLY IMPORTANT IF
THE STEERING WHEEL HAS BEEN REMOVED FOR MAINTENANCE REASONS.
WARNING: ALL TYPES; DO NOT REMOVE THE STEERING COLUMN FROM THE VEHICLE WITH THE STEERING
WHEEL ATTACHED UNLESS THE STEERING
IS CENTERED AND THE COLUMN LOCK IS ENGAGED. IFTHE
SERVE THIS MAY RESULT IN AN INOPERATIVE AIRBAG SYSTEM. SEE LABEL ON STEERING WHEEL
HUB. LOCK IS TO BE RENEWED, 'LOCK-WIRE THE ASSEMBLY TO PREVENT ROTATION. FAILURE TO OB-
0
X300 VSM 1 Issue 1 August 1994
J57-27L
3 Ignition switch 1 1 Tilt motor 2 Tilt motor flexible coupling 4 Reach motor
Fig.
1 Major components Power operated steering column

@ 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