1994 JAGUAR XJ6 fuel cap

Introduction
FOREWORD
This Vehicle Service Manual (VSM) is Dart
-
of a
set of service literature which covers -. diagnosis and rectification of problems associated with all areas of the X300 family of vehicles.
It is designed to be read in conjunction with other manuals, namely the various Unit Service Manuals (USM) (as
applicable to the particular vehicle under diagnosis/ repair) and the X300 Electrical Diagnostic Manual (EDM); see list
below.
It should be noted that its scope is limited to those areas that are unique to the family, e.g. Remove & Refit procedures
for Body Components, Engine, Transmission etcetera, Fuel, Emissions & Engine Management systems, and so on.
Fault Diagnosis and repair procedures (together
with Technical Data, Recommended Lubricants, Capacities etcetera) for major assemblies such as engines, automatic and manual transmissions, are covered in the separate Unit Service
Manuals.
The Unit Service Manuals are notvehicle
-specific, but are designed to be read in conjunction with this VSM, and, where so equipped, with other Jaguar Vehicle Service Manuals for new models launched subsequent to the X300 family.
The X300 Electrical Diagnostic Manual is the final part of the 'set' of service documentation. This manual
is
family-specific, and is designed to aid theTechnician to isolate electrical faults and to correct them. It covers all aspects
of electrical fault diagnosis, including:
OBD
II Codes and emission control system related fault diagnosis / rectification.
Circuit Diagrams
Component (Relays, fuse boxes, control modules etcetera) Location
/ Harness Diagrams I Ground Locations
Connector Locations.
Service Manuals Required
The Manuals required to service the X300 family of vehicles are as follows:
X300 Vehicle Service Manual
X300 Electrical Diagnostic Manual
Unit Service Manuals:
AJ16 Engine Service Manual
VI2 Engine Service Manual ZF AutomaticTransmissions Service Manual (ZF supplies transmissions for 3.2 liter and 4.0 liter normally aspirated
versions) Powertrain Automatic Transmissions Service Manual (The Powertrain name succeeds that of Hydra
-Matic.
Powertrain are suppliers of the 4L 80 E transmission as fitted to 4.0 litre supercharged and 6.0 litre versions)
Each
of the X3Okpecific manuals is divided into Sections which adopt the same title and number where relevant, i.e. Section 5.1 of both the VSM and the EDM cover Fuel, Emission Control & Engine Management System (AJ16). An
over
-all contents list showing each section title and number together with its page-edge locator is given in this section
and in the introduction to the EDM.
The VSM (not applicable to the EDM) also contains Appendices which cover specialized areas such as the current
vehicle specification, routine maintenance schedule etc. These are carried at the rear of this Manual, and have their
own contents page within this section.
INDEX
rapid location of information. The entries are set out as per the following example: @ This manual carries a comprehensive index at the rear, which is designed to save the Technician time by permitting
CLIMATE CONTROL SYSTEMS. Section 14.
See also Electrical Diagnostic Manual
Clutch
Description: Sect. 7.7 - 10
Fault diagnosis: Sect 7.1 - 11
In the example the heading in upper case lettering is to a section title, and it refers to the section number, 14, and also to the EDM as electrical diagnostic information will be found in that manual's section 14. The entry for clutch tells us that the relevant description will be found on page 10 of Section 7.1 of this manual, and
that fault diagnosis procedures start on page 11. In this case there is no reference to the EDM as electrical diagnosis does not apply to this area.
GLOSSARY OF TERMS
This Section contains a Glossary of general and emissions-related terminology (commencing on page 5).
X300 VSM 1 Issue 1 August 1994

Introduction
Term(s) Abbreviation Definition
(if applicable) Previously
used term(s) (or Eng-
lish Equivalent)
downshift
draft _.
drivability
driveshaft
driveshaft tunnel
dry sleeve
Dual Overhead Cam
Data
Data Link Connector
Data Output Line
defogger, backlight defogger
degree (angle or temperature)
Department of Transportation
(US)
Department of Transport (UK)
Deutsche lnstitut fur
Normuna
diameter
Diagnostic Module
Diagnostic Test Mode
Diagnostic Trouble Code
differential housing
differentia
I pressure
Differential Pressure Feedback
EGR
dimmer switch DOHC
DLC
DOL
deg, O
DOT
DTP DIN dia
DM
DTM
DTC
DPFE longitudinal
shaft transmitting power from
transmission output to rear axle differential
tunnel
in floor above the driveshaft (propeller
shaft)
cylinder sleeve which is not in contact with
coolant
engine configuration with two camshafts
positioned above the valves
(US) Fact or group of facts.
connector providing access
andlor control of
the vehicle information, operating
conditions, and diagnostic information
circuit that sends certain information from
the PCM to the instrument cluster
German Standards regulation body
Supplemental Restraint System
(non-controlling) module for diagnostics
overview
a level of capability in an OBD system. May
include different functional states
to observe
signals, a base level to read
DTCs, a monitor
level which includes information on signal
levels,
bi-directional control with onloff board aids, and the ability to interface with
remote diagnosis
an
alphahumeric identifier for a fault
condition identified by the On
-Board
Diagnostic
(OBD) system
rotating housing
(in a bevel differential)
attached to the crownwheel, carrying the
final drive pinions
pressure difference between two regions e.g.
between intake manifold and atmospheric
pressures
an EGR system that monitors differential
EGR pressure across a remote orifice
to control EGR flow change
down
draught
driveability
propeller shaft
transmission
tunnel
dry liner
(English) Group
of facts (i.e. plural
of
datum)
HRW, rear screen
heater, demister
Self Test Mode
Self Test Code.
Fuel Fail code
differential cage
dip switch,
dipper switch
Issue 1 August 1994 11 X300 VSM

Introduction c
GLOSSARY OF TERMS
Term(s) Abbreviation Definition Previously used (if applicable) term(s) (or Eng- lish Equivalent)
0
EGRT Sensor
EGR Vacuum Regulator
1 Read-only memory
I Electronic Engine Control
kronic Secondary Air Injection
Engine Control Module
Engine Coolant Level
ECT Sensor
Engine Speed
Engine Speed Sensor
1 Evaporative Emission Control
Va Ive
Exhaust Gas Recirculation
Solenoid Vacuum Valve
Exhaust Gas Recirculation
Temperature Sensor
Exhaust Gas Recirculation Valve
Extreme Pressure EGR
EGRT EVR
EVP
EDM
EEPROM EPROM EEC
EAlR
ECM ECL
ECT
ECTS
RPM
EPA
EVAP
EVAPP EGRS
EGRT Sensor
EGRV EP System
which reduces
NOx emissions by
adding exhaust gases to the incoming
fuel/air charae
Sensing EGR function based on temperature
change.
controls EGR flow by changing vacuum to
the EGR valve
an EGR system that directly monitors EGR
valve position to control EGR flow
Manual which deals with the diagnosis of
electrical faults (see also Vehicle Service
Manual and Unit Service Manual)
a system that provides electronic control of
enaine electronics
a pump
-driven system for providing
secondarv air usina an electric air Dump
thermistor which provides engine coolant
temperature signal to the PCME to trigger
enrichment circuits which increase injector
'on' time for cold start and warm-up
sensor fitted on flywheel of
VI2 engine;
provides engine speed information
system designed to prevent fuel vapor from
escaping into the atmosphere. Typically
includes a charcoal filled canister to absorb
fuel
vaoor
additives to drive axle lubricants. Designed
to protect the spiral bevel gears from wear
induced by their
slidingholling action EGR
EEPROM,
EPPROM
EPROM ECU
engine coolant level indicator
Coolant temp.
sensor, ECT
revlmin. RPM
purge valve
EGR solenoid
valve
EGR temperature
sensor
X300 VSM issue 1 August 1994 13

Fan Control FC
Fascia
farad F
I Federal Motor Vehicle Safetv I FMVSS
Standard (US)
fender
fiber
Figure (illustration) Fig.
firewall
Flash Electrically Erasable Pro- FEEPROM grammable Read-only Memory
Flash Erasable Programmable
FEPROM Read-only Memory
Flywheel Sensor CKFS
fueling Fuel Injectors FI
Fuel Pressure Regulator Control FPRC
Fuel Pump FP
Fuel Pump Monitor FPM
Fuel Pump Relay FPR
fuel
rich/lean
engine cooling fan control
SI unit of electrostatic capacitance; more
usually subdivided to microfarad fascia,
facia
wing,
(also tonneau)
fibre
bulkhead,
dash panel
sensor mounted
so as to be triggered by each flywheel sensor
flywheel ring gear tooth to give an engine
speed signal
fuelling
iniectors
solenoid operated
devices that spray a fuel injectors,
metered auantitv of fuel into the inlet
~0rt.s
Drimarilv to aive extra fuel at cold start-uo used I
controls fuel pressure regulator;
I I
monitors oDeration of fuel DumD I I
qualitative evaluation of airbuel ratio based on a ratio known as stoichiometry, or 14.7:l
(Lambda)
Issue 1 August 1994 14 X300 VSM
0
0

- .. I lish Equivalent)
M
Malfunction Indicator Lamp MIL
Manifold Absolute Pressure MAP
Manifold Absolute Pressure Sen
- MAPS
sor
Manifold Surface Temperature MST
manual transmission,
M/T transmission
Mass Air Flow MAF
Mass Air Flow Sensor MAFS
maximum max.
metal inert gas MIG ~
meters (measurement) m
metric
(screw thread, e.g. M8) M
MFD I Microfarad
millimeters mm
millimeters
of mercury mmHg
minimum min.
minute minute
Model Year MY
Module
M
mold
Motorized In
-Car Aspirator MIA
muffler
multiport fuel injection MFI a required
on
-board indicator to alert the
driver of an emission related malfunction
absolute pressure of the intake manifold air
sensor located in the PCM and ported to the
intake manifold
transmission which is manually, externally
controlled
system which provides information on the
mass flow rate of the intake air to the engine
hot
-wire sensor which monitors air flow into
the intake manifold for fueling and ignition
control
electric welding system in which a stream of
inert gas
shielbs~the electrode, preventing
oxidation
unit of electrical capacitance, one millionth of
a farad
self contained group of electrical/electronic
components which is designed as a single
replaceable unit
device which constantly samples cabin
temperature by passing air over a sensor,
and communicates with the
NCCM to modify
NC system performance to suit
device which causes exhaust gas flow to
expand and thereby reduce its pressure and
hence its noise fuelling failure
gearbox
air flow meter
metres
min.
mould
motorized aspi
-
rator
silencer ~~
X300 VSM 19 Issue 1 August 1994

Engine (AJ16)
3.1.2 ENGlNE/ TRANSMlSSlON UN/& RENEW
SRO 12.41.02/20
The engine/transmission unit on the AJ 16 normally aspirated and supercharged engined vehicles are fitted ontothree
engine mounting/bracket assemblies. The two front engine mountings for the 3.2/4.0 liter normally aspirated and the
4.0 liter supercharged engined vehicles are identical. They are fitted to the front crossmember on either side of the
engine bay. Rubber to metal
engine/transmission rear mounts used for both engine types, are secured to a support
bracket which traverses the two body underframe longitudinal members. For access to remove the engine carry out the following procedures:
WARNING: WHEN WORKING WlTHlN THE ENGINE COMPARTMENT, KEEP CLEAR OF THE RADIATOR COOLING
FANS AS THEY COULD START WITHOUT WARNING EVEN IF THE ENGINE IS NOT RUNNING.
. Remove the hood, see SRO 76.16.01, section 13
. Remove the air cleaner assembly.
. Depressurize the fuel system, see SRO 19.50.02, section 5.1.
Disconnect the battery.
. In line with the relevant SRO's and sections, remove all appropriate obstructing parts, including their fixing and
. Disconnect all mechanical and isolate all electrical linkages leading to and from the engine.
. De-gas the airconditioning system, see section 14, Charge Recovery (System depressurization).
mounting
arrangements.
CAUTION : Do not vent refrigerant directly to the atmosphere and always use Jaguar approved recovery/recycle/re- charge equipment.
. Drain the engine oil, see 3.1.3 this section.
. Drain the coolant, see SRO 26.10.01, section 4.1.
WARNING: DO NOT REMOVE THE HEADER TANK PRESSURE CAP WHILE THE ENGINE IS HOT. IF THE CAP MUST
BE REMOVED, PROTECT THE HANDS AGAINST ESCAPING STEAM AND SLOWLY TURN THE CAP ANTI- CLOCKWISE UNTILTHE EXCESS PRESSURE CAN ESCAPE. LEAVETHE CAP IN THIS POSITION UNTIL ALL
STEAM AND PRESSURE HAS ESCAPED AND THEN REMOVE THE CAP COMPLETELY.
Before lifting the complete engine/transmission unit with an engine hoist from the engine bay, ensure that two engine
lifting brackets (tool 18G. 1465) are secured equally spaced to the inlet manifold studs. The engine lifting brackets
should be positioned towards the front and the rear of the assembly. Ensure the front of the vehicle is jacked
up secure- ly on stands when removing the assembly.
e
0
0
X300 VSM Issue 1 August 1994 2

3.2.2 ENGINE - GEARBOX/ TRANSMISSION
ASSEMBLY, RENEW
SRO 12.37.01/90
The engine /transmission unit on the V12 6.0 liter model is mounted on three engine mounting / bracket assemblies
fitted to the front crossmember on either side of the engine bay. The engine/ transmission rear mount is a mounting
bracket and spring assembly fitted and secured to body underframe longitudinal members. For access to remove the
engine carry
out the following procedures:
WARNING: WHEN WORKING WITHIN THE ENGINE COMPARTMENT, KEEP CLEAR OF THE RADIATOR COOLING
FANS AS THEY COULD START WITHOUT WARNING, EVEN IF THE ENGINE IS NOT RUNNING.
. Remove the hood, see SRO 76.16.01, section 13.
. Remove the two air cleaner assemblies, see SRO’s 19.10.01 & 19.10.02.
. Remove the engine cover, see SRO 12.29.93 (V12 Engine Service Manual).
Depressurize the fuel system, see SRO 19.50.02, section 5.1.
In line with the relevant SRO’s and sections, remove all appropriate obstructing parts, including their fixing and
. Disconnect all mechanical and isolate all electrical linkages leading to and from the engine.
. De-gas the air conditioning system, see section 14, Charge Recovery (System depressurization).
Disconnect
the battery.
mounting arrangements.
CAUTION: Do
not vent refrigerant directly to the atmosphere and always use Jaguar approved recovery/recycle/ra charge equipment.
Drain the engine oil, see 3.2.3 this section.
Drain the coolant, see SRO 26.10.01, section 4.1.
WARNING: DO NOT REMOVE THE HEADER TANK PRESSURE CAP WHILE THE ENGINE IS HOT. IF THE CAP MUST
BE REMOVED, PROTECT THE HANDS AGAINST ESCAPING STEAM AND SLOWLY TURN THE CAP ANTI- CLOCKWISE UNTIL THE EXCESS PRESSURE CAN ESCAPE. LEAVE THE CAP IN THIS POSITION UNTIL ALL
STEAM AND PRESSURE HAS ESCAPED AND THEN REMOVE THE CAP COMPLETELY.
Before
lifting the complete engine/transmission unit with an engine hoist from the engine bay, ensure that two engine
lifting brackets (tool 18G. 1465) are secured equallyspaced to the inlet manifold studs. The four engine lifting brackets
should be positioned towards the front and the rear of the assembly. Ensure the front of thevehicle is jacked
up secure- ly on stands when removing the assembly.
X300 VSM Issue 1 August 1994 2

striker and the-fuel cap stowage magnet.
The fuel bowl, retained around the filler neck by a clip, containing a drain tube filter located over the mating drain tube,
is rubber moulded onto a steel armature and fitted to the BIW decking panel by five M5 nuts.
The fuel lid latching assembly fitted to the metal armature of the fuel bowl by an M5 nut, includes the locking pin and
the operating actuator.
The actuator operates from the central locking system driven by the security and locking control module
(SLCM).
The fuel tank, mounted across thevehicle behind the passenger compartment rear bulkhead, is held in position by two
retaining straps, tightened by two M5 fixing arrangements.
The fuel tank of AJ16 engined vehicles contains one fuel pump, supplying fuel to the normally aspirated engine and
two fuel pumps, supplyingfuel to the supercharged engine. They are regenerative turbine pumps supplied by
Nippon- Denso. Nominal operating pressure is 3 bar (3.7 bar for supercharged engine) above the manifold depression and
pump delivery is 90 litredhour minimum at 13.2 volts, 3 bar outlet pressure. The pump(s) draw a nominal current of 7 amperes at 13 volts, 3 bar outlet pressure, ambient temperatures. Built in to the pump assembly is a over-pressure
relief valve which blows at 4.5 - 8.5 bar.
Fuel is drawn by the pumps from the fuel tank and is then supplied to the fuel rail via a
70 micron filter and the fuel
feed line connected in series by fuel filter.
The amount of fuel being injected into the engine
is controlled by the fuel injectors combined with the engine control module (ECM). - Any excessive fuel flowing through the system, is returned to the fuel tankvia the fuel regulator valve mounted on the
fuel rail, the fuel return line and the check valve also located inside the tank.
The two filters prevent contaminants from entering the fuel rail and possible damage to the fuel injectors, the engine,
the pump and the underfloor filter.
The fuel pumps are switched on and off by relays controlled by the engine control module
(ECM).
The second fuel pump for the supercharged engine operates only in the higher speed range, switching on at 4000rpm and off at 3200rpm.
The fuel lines are made up of an assembly, combining steel under floor pipes and flexible conductive anti-permeation
tubing. In orderto perform speedy remove and refit operations, the underfloor steel lines are linked through the engine
bay bulkhead to the flexible tubing, leading to the fuel rail and the fuel regulator by using positive sealing, quick-fit
type connectors. The same type connectors, are used to connect the fuel feed and return line to the fuel tank.
Connectors used inside the engine bay are of different sizes tocorrespond with the difference in pipe diameter, whereas
the connectors for the feed and return lines at the fuel tank are the same size.
Except for the return line connector at the fuel tank, two release tools, one for each size of connector are required to
release all remaining connectors.
-~
Fuel, Emission Control & Engine Management (AJ16)
5.1.2 GENERAL DESCRIPTION
m: WORKING ON THE FUEL SYSTEM MAY RESULT IN FUEL AND FUEL VAPOUR BEING PRESENT IN THE
ATMOSPHERE. FUEL VAPOUR IS EXTREMELY FLAMMABLE, HENCE GREAT CARE MUST BE TAKEN WHllST WORKING ON THE FUEL SYSTEM. ADHERE STRICTLY TO THE FOLLOWING PRECAUTIONS:
DO NOT
SMOEIN THE WORK AREA.
DISPLAY 'NO SMOKING
' SIGNS AROUND THE AREA.
ENSURE THAT A
CO2 FIRE EXTINGUISHER IS CLOSE AT HAND.
ENSURE THAT DRY SAND
IS AVAILABLE TO SOAK UP ANY FUEL SPILLAGE.
EMPTY FUEL USING SUITABLE FIRE
PROOF EQUIPMENT INTO AN AUTHORIZED EXPLOSIOWROOF
CONTAINER.
DO NOT EMPTY FUEL
INTO A PIT.
ENSURE THAT WORKING AREA
IS WELL VENTILATED.
ENSURE THAT ANY WORK ON THE FUEL SYSTEM
IS ONLY CARRIED OUT BY EXPERIENCED AND WELL
QUALIFIED MAINTENANCE PERSONNEL.
The fuel filler assembly, supplied complete with serviceable lid, hinge and hinge spring, is fixed to the Body-in-White
(BIW) decking panel by two M5 nuts. Additional parts of the assembly comprise a adjustable rubber buffer, a snap-in
X300 VSM 3 Issue 1 August 1994