1994 JAGUAR XJ6 service

Exhaust System (AJ16)
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Fig. 1 Components of the Exhaust System (AJ16 Normally aspirated)
J?3-Z2l
Heated oxygensensorsarefittedtothedownpipeassembly (1 Fig.l)which isconnectedtothemanifold (2 Fig.1). There
are two sensors for the ROW and Japan (3 Fig.1) and two additional sensors (4 Fig.1) for NAS markets.
The sensors are located upstream and downstream of catalytic converters.
Apart from two heated oxygen sensors, the exhaust system for vehicles destined for the Japanese market are also
fitted with two exhaust gas temperature sensors
(5 Fig.1).
The exhaust system is held in a predetermined position by a fixing arrangement to the manifold by exhaust centre
mountings (6 Fig.l), by rear axis mountings (7 Fig.l), and tail pipe mountings (8 Fig.1).
Clamps (9 Fig.1) used on each slip joint are welded to the pipes and tightened to a higher torque setting than non- welded clamps.
The exhaust system must be free of leaks, binding, grounding and excessive vibrations. These conditions are usually
caused by loose, broken, or misaligned clamps, shields, brackets, or pipes. Should any of these conditions
exist,check the exhaust system components and alignment. Adjust and renew if necessary. Do not attempt to service brackets,
clamps and insulators.
Issue 1 August 1994 2 X300 VSM

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

Exhaust System (V12)
The exhaust system must be free of leaks, binding, grounding and excessive vibrations. These conditions are usually
caused by loose, broken, or misaligned clamps, shields, brackets, or pipes.
Should any
of the above mentioned conditions exist, check the exhaust system components and alignment.
Adjust and renew if necessary.
Do not attempt to service brackets clamps and insulators.
6.2.2 DIAGNOSIS AND TESTING
The standard exhaust system Diagnosis and Testing procedures are given in Section 6.1 (Exhaust System (AJ16)).
X300 VSM 3 Issue 1 August 1994

1. SERVICE TOOLS & EQUIPMENT
Illustration I JaauarNumber I -
18G 1465
Description Notes
Engine lifting brackets
Engine
fl support beam
11. TORQUE TIGHTEN1 NG SPEC1 FICA TIONS
Fixing Tightening Torque
(Nm)
49 - 54
8- 10
22 - 28
22
- 24
23 - 27
7 - 10
95 - 105
23
- 27
15
-18
23
- 27
Bell housing to adaptor plate
Bleed nipple to slave cylinder
Center bearing to body
Center bearing to mounting plate
Clutch cover to flywheel
Clutch damper to mounting bracket
Flywheel to crankshaft
Front cover to transmission
Front pipe to intermediate pipe
Gearshift lever
housing to transmission
Issue 1 August 1994 ii X300 VSM

Manual Transmission & clutch (AJ16)
I Molykote FB 180 grease
Brake (clutch) fluid
- minimum
DOT 4
Dexron IID Transmission oil
Loctite
573
Tivoli Kay Adhesives No. 5696
Withdrawal arm pivots / Gearshift lever ball
Clutch hydraulic system
Front cover securing bolts
Exhaust sealer also used
in
ZF automatic
transmissions
Application
Material removal to clean up clutch face
IU SERVICE DATA
Specification
Up to lmm maximum
X300 VSM iii 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

Manual Transmission & clutch (AJ16)
. Ensure that the draught excluder is not displaced from its
. Remove the mounting rubbers and washers (2 Fig. 1).
. Mount the gear selector remote control assembly (1 Fig.
. Remove the spring ring (2 Fig. 2).
. Remove the gearshift lever (5 Fig. 2).
. Remove the spring retainer (3 Fig. 2) and spring (4 Fig. 2)
. Remove the gearshift lever lower nylon cup (6 Fig. 2) and
. Remove the lever housing assembly from the vice.
. Clean all components thoroughly and examine for wear
. Replace worn or damaged components as necessary.
. Ensure mating faces are clean and grease-free.
. Mount the gear selector remote control assembly (1 Fig.
. Fit and seat the lower nylon cup (6 Fig. 2).
. Grease the gearshift lever ball.
Fit and seat the upper nylon cup (7 Fig. 2).
. Fit the spring (4 Fig. 2) and spring retainer (3 Fig. 2) to the
. Fit and seat the gearshift lever
. Compress the spring (4 Fig. 2).
* Fit and seat the spring ring (2 Fig. 2).
= Remove the gear selector remote control assembly (1 Fig.
Lubricate the gearshift lever to ease fitment through the
Lubricate the lower spacer.
Position the assembly in its mounting location; enter the
. Position the gearshift lever into the selector shaft yoke.
. Fit but do not tighten the selector shaft bolt (3 Fig. 1).
Fit the lower LH mounting rubber and washer.
. Fit the remaining mounting rubbers / washers (2 Fig. 1)
Secure the selector shaft bolt (3 Fig. 1).
. Tighten MS 538 hook nut to raise the transmission into
position.
. Using a jack, fit and seat the rear mounting to the trans- mission / body, ensuring that the spring is seated correctly
in the spring pan.
position.
2) in
a vice.
from the gearshift lever.
upper nylon cup (7
Fig. 2).
and damage.
2) in a vice.
lever.
2) from the vice.
draught excluder.
gearshift lever into the gaiter.
and secure with the bolts
(1 Fig. 1).
. Fit but do not fully tighten the mounting securing bolts.
. Remove the jack and jack channel.
Secure the rear mounting bolts.
. Slacken off MS 538 hook nut.
. Refit the drive (propeller) shaft assembly, see Section 9, SRO 47.15.01.
Remove Service Tool MS 538.
. Refit the gearshift lever knob.
Fin. 1
J37-WB
Fig. 2
Issue 1 August 1994 8 X300 VSM