1994 JAGUAR XJ6 ignition

4.2.5.2 Diagnostic Procedures
1
I Symptom ..
Overheating
herheating at
dle
roo cold ~~~
Possible Cause
Thermostat(s) stuck
closed
Incorrect thermostat rating
Faulty temperature gauge
Faulty temperature transmitter
Radiator core blocked
Radiator grille obstructed
Concentration of anti
-freeze
too high
Drive belt slack
Drive belt broken
Water pump seized
lnsuff icient coolant
Internally collapsed hoses
Incorrect ignition timing
Fuel
/ air mixture too weak
Incorrect valve timing
Cylinder head
gasket(s) leak-
ing
Brakes binding
Electric cooling
fan(s) not op- erating
Thermostat(s) stuck open
Incorrect thermostat rating
Thermostatb) not fitted
Electric cooling
fan(s) operat-
ing continuously
Faulty temperature gauge
Faulty temperature transmitter
Check
Cooling System (V12)
4.2.5 FAULT DIAGNOSIS
4.2.5.1 Introduction
The following diagnostic procedures are provided to assist properly qualified persons to identify and rectify the faults in the system which are most likely to be encountered. Reference is made to the Electrical Diagnostic Manual (EDM), which should be consulted for all electrical faults. When investigating faults relating to temperature, the prevailing
ambient temperature conditions should be taken into account. The climate control system is dealt with in Section 14.
Test thermostat(s)
Check thermostat operating
temperature
Refer to EDM
Refer to EDM
Check for
hotspots in radiator
Check grille for obstruction
Check strength of coolant
Check belt tension
Visual check Slacken drive belt and turn
water pump pulley by hand.
Check belt for damage
Check coolant level
Pressure test system and
check for deformation of hoses
Refer to EDM
Refer to EDM
Check valve timing
Pressure
-test system. (Check
for contamination of coolant in
header tank)
Check brake calipers for stick
- ing pistons and seized brake
pad pins
..
Refer to EDM
Test
thermostat(4
Check thermostat operating
temperature
Remove thermostat housing
and inspect
Refer to EDM
Refer to EDM
Refer to EDM
Remedy
Renew thermostat(s)
Renew thermostat(s1
Renew gauge
Renew transmitter
Flush or renew radiator
Remove obstruction from
grille
Drain and
fill with coolant of
correct concentration
Adjust belt to correct tension
or renew belt
if worn
Renew belt
Renew water pump. Renew
drive belt
if required
Top
-up coolant
Renew hoses as required
Rectify as required
Rectify as required
Correct valve timing
Renew head
gasket(s)
Rectify as required
Rectify as required
Renew
thermostat(s1
Renew thermostatb)
Fit thermostat(s)
Rectify as required
Renew gauge
Renew transmitter
Issue 1 August 1994 X300 VSM 5

Fuel, Emission Control & Engine Management (AJ16)
5.1.3
SRO 19.60.13 FUEL RAIL
SRO 19.45.11 REGULATOR VALVE
SRO 18.10.01 INJECTORS
SRO 18.10.02 INJECTORS (VEHICLE SET)
FUEL
RAIL /PRESSURE REGULATOR VALVE/ INJECTORS (SUPERCHARGED), RENEW
Fig. 1
Remove
. Reposition top edge of trunk front liner for access.
. Disconnect multi-plug from evaporative loss flange inset (Fig. 1 ).
. Switch ignition on.
. Switch ignition off.
. Disconnect earth lead eyelet (1 Fig.1) from inlet manifold stud.
. Disconnect engine harness to oxygen sensor leads multi-plug.
. Disconnect engine harness to starter motor solenoid link lead multi-plug.
. Undo fuel injector multi-plug cover fixings (2 Fig.1).
. Disconnect cover from injectors (3 Fig.1).
Crank engine to depressurize fuel system.
Disconnect
battery,see Section 15.
Undo fuel rail to feed pipe union nut
(4 Fig.1).
X300 VSM 5 Issue 1 August 1994

Fuel, Emission Control & Engine Management (AJ16)
5.1.4
SRO 19.60.13
FUEL RAIL /PRESSURE REGULATOR VALVE/ INJECTORS (NORMALLY ASPIRATED ENGINE),
SRO 19.45.11
SRO 18.10.01 INJECTORS
SRO 18.10.02 INIECTORS (VEHICLE SET)
IB
RENEW
Fig. 1
Remove
. Reposition top edge of trunk front liner for access.
. Disconnect multi-plug from evaporative loss flange inset (Fig.1).
. Switch ignition on.
. Crank engine to depressurize fuel system.
. Switch ignition off.
. Disconnect battery, see Section 15.
. Disconnect earth lead eyelet (1 Fig.1) from inlet manifold stud.
. Disconnect engine harness to oxygen sensor leads multi-plug.
. Disconnect engine harness to starter motor solenoid link lead multi-plug.
. Undo fuel injector multi-plug cover fixings (2 Fig.1).
. Disconnect cover from injectors (3 Fig.1).
. Undo fuel rail to feed pipe union nut (4 Fig.1).
Issue 1 August 1994 X300 VSM 7

Also look for loose and rusted flange connections, loose or damaged exhaust shields
or clamp and loose or broken exhaust outlet pipe brackets.
6.1.2.1 Symptom Chart
I Condition I Possible Cause
Noises and exhaust fumes Exhaust leak.
Misaligned exhaust.
Loose clamps or fasteners.
Restricted exhaust system.
Electronic engine controls.
Fuel System.
Restricted exhaust system.
Engine lacking
power Ignition system.
Exhaust System (AJ16)
6.1.2 DIAGNOSIS AND TESTING
m: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. NEVER ATTEMPT
TO SERVICE ANY PART OF THE SYSTEM UNTIL IT HAS COOLED. EXHAUST GASES CONTAIN CARBON
MONOXIDE WHICH CAN BE HARMFUL TO HEALTH AND ARE POTENTIALLY LETHAL. LEAKS MUST BE
REPAIRED IMMEDIATELY.
NEVER OPERATE THE ENGINE
IN ENCLOSED AREAS.
External leaks in the exhaust system are often accompanied by noises and exhaust fumes, therefore a visual inspection
usually detects the location of the leak. When checking for exhaust leakage or noise, inspect the entire system for
burned
-out holes, loose or corroded clamps, muffler or exhaust inlet pipe.
Examine the under body for greyish
-white or black exhaust soot which indicates the exhaust leakage at that point.
The effect of a small leak can be magnified by holding a rag over the tailpipe outlet while listening to the leak.
If this is carried out, ensure that gases are not inhaled
-see WARNING.
When testing for a rattle or vibration condition it is helpful to use a rubber mallet. Tap on the exhaust components to
simulate the bouncing action of the exhaust while watching for exhaust-to-body /chassis contact.
6.1.2.2 Test A, Exhaust Leakage or Noise
Test Step
Step
1A Clamps and Brackets
Check for broken or loose clamps and/or exhaust
outlet pipe frame brackets.
Are clamps and exhaust outlet pipe frame brackets
OK?
Step 2A System Components
Check catalytic converters, muffler.
Are system components OK?
Step 3A Exhaust Manifold
Inspect exhaust manifold for loose fasteners and
cracks.
Is exhaust manifold OK?
Action
Refer to Test Step 1A.
Go to Test Step IB, Restricted exhaust system test. .-
Go to Test Step 1B
Result Action
yes
1
Go to Step 2A
no Service and renew as necessary.
Restart engine.
If noise still exists
go to Step 2
yes Go to step 3A
no Renew exhaust outlet pipe frame brackets, exhaust
inlet pipe and/ or muffler as necessary.
If noise still persists, go to Step 3
yes
no Go to Test Step 1B Restricted exhaust system test.
Tighten fasteners or renew exhaust manifold.
X300 VSM 5 Issue 1 August 1994

Automatic Transmission (AJ16)
Both types of automatic transmission comprise a hydrodynamic torque converter driving an epicyclic gear train which
provides four forward ratios and reverse. Gearshift selection is made by a hydraulic (or electronichydraulic) trans- mission control unit. Six gearshift positions are provided:
Position
'P' (Park) -the driven wheels are mechanically locked at the transmission.
Position
'R' (Reverse) - reverse gear selected.
Position
'N' (Neutral) - engine disconnected from drive-line and wheels.
Position 'D' (Drive)
- all four speed ranges are selected automatically with lock-up available in top gear only.
Position
'3' - automatic selection of the lowest three speed ranges only.
Position '2'
- automatic selection of the lowest two speed ranges only; the transmission is prevented from shift- ing up to the third and top speed ranges.
Immediate selection of a lower ratio is also available, within mapped limits, by 'kick
-down' (pressing the accelerator
pedal down beyond the normal full throttle position) for example when overtaking.
A brake pedal/gearshift interlock is incorporated in the shift lever mechanism. Theshift lever may only be movedfrom
the 'P' (Park) position if the ignition key switch is in position 'll', and the foot brake is applied. The ignition key cannot
be removed from the ignition switch unless the shift lever is in the 'P' (Park) position. Once the ignition key has been
removed, the shift lever is locked in the Park position. The gearshift interlock may be over-ridden manually in the event
of an electrical failure or when it is required to move the vehicle manually for access, ie for removal of the propeller
shaft.
8.1.1.1
Gearshift selection causes the appropriate gear to be selected through a cable operated shift lever on the side of the
Gear Selection (ZF 4HP 22)
transmission unit. When a gea; is selected, the shift points are determined by accelerator pedal position through a
throttle cable connection and by pressures equivalent to road speed derived from a centrifugal governor on the output
shaft.
Gearshift speed and quality are controlled by the hydraulic control unit located in the lower part of the transmission
housing. The control unit contains selector valve, control pistons and pressure valves.
The hydraulic control unit can be overridden by 'kickdown'. This is actuated by the final travel of the accelerator pedal
and causes the next lower gear to be selected.
8.1.1.2
Gearshift selection causes the appropriate gear to be selected through a cable operated shift lever on the side of the
transmission unit; the shift lever also operates a rotary switch attached to the side of the transmission unit. When a
gear is selected, the rotary switch provides an output or combination of outputs to the TCM, which continuously moni
- tors the gear selected in addition to output shaft speed and transmission oil temperature. Information from the Engine
Control Module (ECM) representing engine speed, load and throttle position is also fed to the TCM to enable the most
suitable gear to be selected.
Gear selection and gearshift speeds are controlled by the manually operated selector valve, a solenoid operated pres
- sure regulator and three solenoid valves. On receipt of signalsfrom the TCM, the three solenoid valves MVI, MV2 and
MV3, in various combinations with the safety valve, determine the appropriate gear range. The TCM, on receipt of
information of engine state and road speed, determines the shift speed.
The Performance Mode switch, located on the shift lever surround, provides two alternative shift speed patterns:
1. 'Normal (Economy) Mode' - designed for everyday use.
2. 'Sport Mode'
- gear shift takes place at higher road speeds to enhance performance.
The 'kick
-down' switch, located beneath the accelerator pedal, is actuated by the final travel of the pedal and signals
to the TCM that the next lower gear is to be selected.
Gear Selection (ZF 4 HP 24 E)
X300 VSM 3 Issue 1 August 1994

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 (V12 & AJl6 Supercharged) Pomrtrain
8.2.1 GENERAL DESCRIPTION
This section provides information relating to the Powertrain 4L80-E transmissions fitted to the 4,O liter supercharged
engine (4,OL SC) and to the 6,O liter engine (6,OL).
The Powertrain 4L80-E is a four-speed, high torque capacity, electronically controlled automatic transmission, which
comprises a torque converter with lock-up direct drive clutch and three planetary gear sets. Five multiple diskclutches,
one intermediate sprag clutch assembly, two roller clutch assemblies and two band assemblies provide the drive el- ements necessary for correct sequential gear engagement and operation.
The torque converter containing
a pump, a turbine (rotor), a stator assembly, and a clutch pressure disksplined to the
turbine, acts as a fluid coupling for smooth torque transmission from the engine. The converter also supplies addi- tional torque multiplication when necessary, and the torque converter clutch (TCC) pressure disk provides a mechan- ical direct drive or 'lock-up' above a certain speed in top gear for greater fuel economy.
Gearshift operations are controlled from the Transmission Control Module (TCM), which governs the electronically
controlled valve body situated within the transmission.
Three planetary gear sets provide reverse and the four forward ratios, the changing of which is fully automatic in rela
- tion to load, vehicle speed and throttle opening. The Transmission Control Module receives and integrates various ve- hicle sensor input signals, and transmits operating signals to the solenoids located in the control valve assembly.
These solenoids govern the transmission operating pressures, up-shift and down-shift gear selection patterns and
also the torque converter clutch operation by pulse width modulated control.
8.2.1.1 Gear Ranges
Selectable gear positions are: P - Park, R - Reverse, N - Neutral, D - Drive, 3, 2.
P - Park position of the shift lever provides a mechanical locking of the output shaft of the transmission, and as such,
must only be engaged when the the vehicle is stationary. In addition, and for
extra safety, the handbrake should also
be applied. It is necessary to have the ignition ON and the footbrake applied to move the shift lever from the Park
position. For ignition key removal the shift lever must be in the Park position. The engine can be started in the Park
position.
R - Reverse enables the vehicle to be operated in a rearwards direction. The engine cannot be started in the Reverse
position.
N
-Neutral position enables the engine to be started and operated without driving the vehicle. It also allows the vehicle
to be moved manually for access, ie for removal of the propeller shaft.
D
-Drive position allows the automatic selection of all four forward gear ratios during normal driving conditions for
maximum efficiency and fuel economy. On acceleration, down-shifts are obtained by depressing the accelerator pedal
or by manual selection. The engine cannot be started in this position.
3
- Manual third position allows automatic operation of the three lower gear ratios but inhibits selection of the fourth
ratio. This position is used for towing a trailer or negotiating hilly terrain when greater engine braking control is re- quired. The engine cannot be started in this position.
2 - Manual second position allows automatic operation of the two lower gear ratios but inhibits selection of the third
and fourth ratios. This position is used for heavy traffic congestion or negotiating hilly terrain when even greater en
- gine braking control is required than is provided by manual third. This ratio may be selected at any vehicle speed - even if the transmission is in third or fourth ratio, the transmission will immediately down-shift to second gear pro- vided the vehicle speed is below 137 km / h (85 mile / h). The engine cannot be started in this position.
N.g!b: With the Performance Mode switch in the NORMAL position, the vehicle will pull away in second gear. How- ever, if more than 75 per cent of throttle is applied when the vehicle speed is between zero and 13 km/ h (8 mile / h), then first gear will be selected. From 13 to 61 km/ h (8 to 38 mile/ h) first gear is obtainable by 'kick-down'.
In 'sport' mode thevehicle pulls away in first gear and the transmission operatesfully in all four forward gears.
X300 VSM 1 Issue 1 August 1994

Automatic Transmission (V12 & AJ16 Supercharged) Powertrain
0
8.2.13 LUBRICATION SYSTEM, DRAIN AND REFILL
(4,OL SC AND 6,OL)
SRO 44.24.02
. Raise the vehicle on a ramp.
. Position a drain tin below the transmission unit.
. Release and remove the fluid pan drain plug.
. Allow the fluid to drain.
Clean the drain plug, including the magnet and the fluid
pan drain plug face.
. Fit and tighten the fluid pan drain plug.
. Remove the drain tin from below the transmission unit.
. Lower the vehicle on the ramp.
Open the hood and fit
a suitable fender cover.
Remove and wipe the dipstick.
. Fit a funnel to the dipstick tube.
. Initially fill the transmission with 4,5 liters of fluid.
. Remove the funnel.
. Open the front door.
. Check that the parking brake is applied.
. Start the engine.
Apply the footbrake.
Run the shift lever through all positions, finally returning
to the Park position.
. Release the footbrake.
. Insert the dipstick, then remove and inspect the level.
. Fit the funnel to the dipstick tube.
. Fill the transmission to the 'COLD' level mark on the dip-
stick with the correct fluid, see the Powertrain Automatic
Transmissions Service Manual, General Data.
CAUTION: On no account should the vehicle be driven un- less the fluid level is at the 'COLD' level and the
system primed.
0
Remove the funnel.
. Replace the dipstick.
. Switch the ignition OFF.
. Remove the fender cover and close the hood.
= Close the door.
J&&Q: 0 After road testing the vehicle, the fluid level on the
dipstick should be between the 'HOT' Min I Max
marks. Check the level with the transmission at nor-
mal operating temperature (90 to 100°C), with the
engine left running and the transmission in the Park
position.
m
0
Issue 1 August 1994 14 X300 VSM ~
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