1997 JAGUAR XJ6 air suspension

3261 Jaguar XJ6
11
Chapter 11
Bodywork and fittings
Body - maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Body repair - major damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Body repair - minor damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Bonnet - removal, refitting and adjustment . . . . . . . . . . . . . . . . . . . . 10
Bonnet and boot lid support struts - removal and refitting . . . . . . . . 9
Bonnet release latch and cable - removal and refitting . . . . . . . . . . . 11
Boot lid - removal, refitting and adjustment . . . . . . . . . . . . . . . . . . . 16
Boot lid latch and lock cylinder - removal and refitting . . . . . . . . . . . 17
Bumpers - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Centre console - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . 24
Cowl cover - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Dashboard trim panels - removal and refitting . . . . . . . . . . . . . . . . . 26
Door - removal, refitting and adjustment . . . . . . . . . . . . . . . . . . . . . . 19
Door latch, lock cylinder and handles - removal and refitting . . . . . . 20
Door trim panel - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . 18Door window glass - removal and refitting . . . . . . . . . . . . . . . . . . . . 22
Door window glass regulator - removal and refitting . . . . . . . . . . . . . 21
Front spoiler - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . 13
Front wing - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Hinges and locks - maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Instrument cluster housing - removal and refitting . . . . . . . . . . . . . . 25
Outside mirrors - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . 23
Radiator grille - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 12
Seats - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Steering column cover - removal and refitting . . . . . . . . . . . . . . . . . 27
Upholstery and carpets - maintenance . . . . . . . . . . . . . . . . . . . . . . . 4
Vinyl trim - maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Windscreen and fixed glass - replacement . . . . . . . . . . . . . . . . . . . . 8
11•1
Contents
Easy,suitable for
novice with little
experienceFairly easy,suitable
for beginner with
some experienceFairly difficult,
suitable for competent
DIY mechanic
Difficult,suitable for
experienced DIY
mechanicVery difficult,
suitable for expert DIY
or professional
Degrees of difficulty
54321
1 General information
These models feature a “unibody”
construction, using a floor pan with front and
rear frame side rails which support the body
components, front and rear suspension
systems and other mechanical components.
Certain components are particularly vulnerable
to accident damage and can be unbolted and
repaired or replaced. Among these parts are
the body mouldings, bumpers, front wings,
bonnet and boot lids and all glass.
Only general body maintenance practices
and body panel repair procedures within the
scope of the do-it-yourselfer are included in
this Chapter.
2 Body- maintenance
1
1The condition of your vehicle’s body is very
important, because the resale value depends
a great deal on it. It’s much more difficult to
repair a neglected or damaged body than it is
to repair mechanical components. The hidden
areas of the body, such as the wheel wells,
the frame and the engine compartment, areequally important, although they don’t require
as frequent attention as the rest of the body.
2Once a year, or every 12,000 miles, it’s a
good idea to have the underside of the body
steam cleaned. All traces of dirt and oil will be
removed and the area can then be inspected
carefully for rust, damaged brake lines, frayed
electrical wires, damaged cables and other
problems. The front suspension components
should be greased after completion of this job.
3At the same time, clean the engine and the
engine compartment with a steam cleaner or
water soluble degreaser.
4The wheel wells should be given close
attention, since undercoating can peel away
and stones and dirt thrown up by the tyres
can cause the paint to chip and flake, allowing
rust to set in. If rust is found, clean down to
the bare metal and apply an anti-rust paint.
5The body should be washed about once a
week. Wet the vehicle thoroughly to soften the
dirt, then wash it down with a soft sponge and
plenty of clean soapy water. If the surplus dirt
is not washed off very carefully, it can wear
down the paint.
6Spots of tar or asphalt thrown up from the
road should be removed with a cloth soaked
in solvent.
7Once every six months, wax the body and
chrome trim. If a chrome cleaner is used to
remove rust from any of the vehicle’s plated
parts, remember that the cleaner also removes
part of the chrome, so use it sparingly.
3 Vinyl trim- maintenance
1
Don’t clean vinyl trim with detergents,
caustic soap or petroleum-based cleaners.
Plain soap and water works just fine, with a
soft brush to clean dirt that may be ingrained.
Wash the vinyl as frequently as the rest of the
vehicle.
After cleaning, application of a high quality
rubber and vinyl protectant will help prevent
oxidation and cracks. The protectant can also
be applied to weather-stripping, vacuum lines
and rubber hoses (which often fail as a result
of chemical degradation) and to the tyres.
4 Upholstery and carpets-
maintenance
1
1Every three months remove the carpets or
mats and clean the interior of the vehicle
(more frequently if necessary). Vacuum the
upholstery and carpets to remove loose dirt
and dust.
2Leather upholstery requires special care.
Stains should be removed with warm water
and a very mild soap solution. Use a clean,
damp cloth to remove the soap, then wipe

3261 Jaguar XJ6
REF•10MOT test checks
Exhaust system
MStart the engine. With your assistant
holding a rag over the tailpipe, check the
entire system for leaks. Repair or renew
leaking sections.
Jack up the front and rear of the vehicle,
and securely support it on axle stands.
Position the stands clear of the suspension
assemblies. Ensure that the wheels are
clear of the ground and that the steering
can be turned from lock to lock.
Steering mechanism
MHave your assistant turn the steering from
lock to lock. Check that the steering turns
smoothly, and that no part of the steering
mechanism, including a wheel or tyre, fouls
any brake hose or pipe or any part of the body
structure.
MExamine the steering rack rubber gaiters
for damage or insecurity of the retaining clips.
If power steering is fitted, check for signs of
damage or leakage of the fluid hoses, pipes or
connections. Also check for excessive
stiffness or binding of the steering, a missing
split pin or locking device, or severe corrosion
of the body structure within 30 cm of any
steering component attachment point.
Front and rear suspension and
wheel bearings
MStarting at the front right-hand side, grasp
the roadwheel at the 3 o’clock and 9 o’clock
positions and shake it vigorously. Check for
free play or insecurity at the wheel bearings,
suspension balljoints, or suspension mount-
ings, pivots and attachments.
MNow grasp the wheel at the 12 o’clock and
6 o’clock positions and repeat the previous
inspection. Spin the wheel, and check for
roughness or tightness of the front wheel
bearing.
MIf excess free play is suspected at a
component pivot point, this can be confirmed
by using a large screwdriver or similar tool and
levering between the mounting and the
component attachment. This will confirm
whether the wear is in the pivot bush, its
retaining bolt, or in the mounting itself (the bolt
holes can often become elongated).
MCarry out all the above checks at the other
front wheel, and then at both rear wheels.
Springs and shock absorbers
MExamine the suspension struts (when
applicable) for serious fluid leakage, corrosion,
or damage to the casing. Also check the
security of the mounting points.
MIf coil springs are fitted, check that the
spring ends locate in their seats, and that the
spring is not corroded, cracked or broken.
MIf leaf springs are fitted, check that all
leaves are intact, that the axle is securely
attached to each spring, and that there is no
deterioration of the spring eye mountings,
bushes, and shackles.MThe same general checks apply to vehicles
fitted with other suspension types, such as
torsion bars, hydraulic displacer units, etc.
Ensure that all mountings and attachments are
secure, that there are no signs of excessive
wear, corrosion or damage, and (on hydraulic
types) that there are no fluid leaks or damaged
pipes.
MInspect the shock absorbers for signs of
serious fluid leakage. Check for wear of the
mounting bushes or attachments, or damage
to the body of the unit.
Driveshafts
(fwd vehicles only)
MRotate each front wheel in turn and inspect
the constant velocity joint gaiters for splits or
damage. Also check that each driveshaft is
straight and undamaged.
Braking system
MIf possible without dismantling, check
brake pad wear and disc condition. Ensure
that the friction lining material has not worn
excessively, (A) and that the discs are not
fractured, pitted, scored or badly worn (B).
MExamine all the rigid brake pipes
underneath the vehicle, and the flexible
hose(s) at the rear. Look for corrosion, chafing
or insecurity of the pipes, and for signs of
bulging under pressure, chafing, splits or
deterioration of the flexible hoses.
MLook for signs of fluid leaks at the brake
calipers or on the brake backplates. Repair or
renew leaking components.
MSlowly spin each wheel, while your
assistant depresses and releases the
footbrake. Ensure that each brake is operating
and does not bind when the pedal is released.
3Checks carried out
WITH THE VEHICLE RAISED
AND THE WHEELS FREE TO
TURN

3261 Jaguar XJ6
MOT test checksREF•11
MExamine the handbrake mechanism,
checking for frayed or broken cables,
excessive corrosion, or wear or insecurity of
the linkage. Check that the mechanism works
on each relevant wheel, and releases fully,
without binding.
MIt is not possible to test brake efficiency
without special equipment, but a road test can
be carried out later to check that the vehicle
pulls up in a straight line.
Fuel and exhaust systems
MInspect the fuel tank (including the filler
cap), fuel pipes, hoses and unions. All
components must be secure and free from
leaks.
MExamine the exhaust system over its entire
length, checking for any damaged, broken or
missing mountings, security of the retaining
clamps and rust or corrosion.
Wheels and tyres
MExamine the sidewalls and tread area of
each tyre in turn. Check for cuts, tears, lumps,
bulges, separation of the tread, and exposure
of the ply or cord due to wear or damage.
Check that the tyre bead is correctly seated
on the wheel rim, that the valve is sound andproperly seated, and that the wheel is not
distorted or damaged.
MCheck that the tyres are of the correct size
for the vehicle, that they are of the same size
and type on each axle, and that the pressures
are correct.
MCheck the tyre tread depth. The legal
minimum at the time of writing is 1.6 mm over
at least three-quarters of the tread width.
Abnormal tread wear may indicate incorrect
front wheel alignment.
Body corrosion
MCheck the condition of the entire vehicle
structure for signs of corrosion in load-bearing
areas. (These include chassis box sections,
side sills, cross-members, pillars, and all
suspension, steering, braking system and
seat belt mountings and anchorages.) Any
corrosion which has seriously reduced the
thickness of a load-bearing area is likely to
cause the vehicle to fail. In this case
professional repairs are likely to be needed.
MDamage or corrosion which causes sharp
or otherwise dangerous edges to be exposed
will also cause the vehicle to fail.
Petrol models
MHave the engine at normal operating
temperature, and make sure that it is in good
tune (ignition system in good order, air filter
element clean, etc).
MBefore any measurements are carried out,
raise the engine speed to around 2500 rpm,
and hold it at this speed for 20 seconds. Allowthe engine speed to return to idle, and watch
for smoke emissions from the exhaust
tailpipe. If the idle speed is obviously much
too high, or if dense blue or clearly-visible
black smoke comes from the tailpipe for more
than 5 seconds, the vehicle will fail. As a rule
of thumb, blue smoke signifies oil being burnt
(engine wear) while black smoke signifies
unburnt fuel (dirty air cleaner element, or other
carburettor or fuel system fault).
MAn exhaust gas analyser capable of
measuring carbon monoxide (CO) and
hydrocarbons (HC) is now needed. If such an
instrument cannot be hired or borrowed, a
local garage may agree to perform the check
for a small fee.
CO emissions (mixture)
MAt the time of writing, the maximum CO
level at idle is 3.5% for vehicles first used after
August 1986 and 4.5% for older vehicles.
From January 1996 a much tighter limit
(around 0.5%) applies to catalyst-equipped
vehicles first used from August 1992. If the
CO level cannot be reduced far enough to
pass the test (and the fuel and ignition
systems are otherwise in good condition) then
the carburettor is badly worn, or there is some
problem in the fuel injection system or
catalytic converter (as applicable).
HC emissionsMWith the CO emissions within limits, HC
emissions must be no more than 1200 ppm
(parts per million). If the vehicle fails this test
at idle, it can be re-tested at around 2000 rpm;
if the HC level is then 1200 ppm or less, this
counts as a pass.
MExcessive HC emissions can be caused by
oil being burnt, but they are more likely to be
due to unburnt fuel.
Diesel models
MThe only emission test applicable to Diesel
engines is the measuring of exhaust smoke
density. The test involves accelerating the
engine several times to its maximum
unloaded speed.
Note: It is of the utmost importance that the
engine timing belt is in good condition before
the test is carried out.
M
Excessive smoke can be caused by a dirty
air cleaner element. Otherwise, professional
advice may be needed to find the cause.
4Checks carried out on
YOUR VEHICLE’S EXHAUST
EMISSION SYSTEM

3261 Jaguar XJ6
Fault findingREF•15
4 Automatic transmission
Note:Due to the complexity of the automatic transmission, it is difficult
for the home mechanic to properly diagnose and service this
component. For problems other than the following, the vehicle should
be taken to a dealer or transmission workshop.
Fluid leakage
m mAutomatic transmission fluid is a deep red colour. Fluid leaks
should not be confused with engine oil, which can easily be blown
by air flow to the transmission.
m mTo pinpoint a leak, first remove all built-up dirt and grime from the
transmission housing with degreasing agents and/or steam
cleaning. Then drive the vehicle at low speeds so air flow will not
blow the leak far from its source. Raise the vehicle and determine
where the leak is coming from. Common areas of leakage are:
a) Sump pan (Chapters 1 and 7)
b) Dipstick/filler tube (see below)
c) Transmission fluid cooler lines (Chapter 7)
d) Speedometer sensor (Chapter 7)
m mMake sure the dipstick is a tight fit inside the filler tube. If the seal
at the top of the dipstick is worn or damaged, replace the seal or
the dipstick. If fluid continues to leak from the top of the dipstick
tube, inspect the breather, which is a plastic cap secured by a clip
to the top of the extension housing. This breather can be plugged
by the noise-deadening foam installed in the transmission tunnel,
causing transmission fluid to leak from the top of the dipstick
tube.
Transmission fluid brown or has a burned smell
m mTransmission fluid burned (Chapter 1).
Shift cable problems
m
mChapter 7 deals with adjusting the shift cable. Common problems
which may be attributed to a poorly adjusted shift cable are:
a) Engine starting in gears other than Park or Neutral.
b) Indicator on shift lever pointing to a gear other than the one
actually being used.
c) Vehicle moves when in Park.
m mRefer to Chapter 7 for the shift cable adjustment procedure.
Transmission will not downshift
with accelerator pedal pressed to the floor
m mKickdown cable out of adjustment (Chapter 7).
Engine will start in gears
other than Park or Neutral
m mNeutral start/reversing light switch malfunctioning (Chapter 7).
m mShift cable out of adjustment (Chapter 7).
Transmission slips, shifts roughly, is noisy,
or has no drive in forward or reverse gears
m mThere are many probable causes for the above problems, but the
home mechanic should be concerned with only one possibility -
fluid level. Before taking the vehicle to a dealer service department
or transmission repair workshop, check the level and condition of
the fluid as described in Chapter 1. Correct the fluid level as
necessary or change the fluid if needed. If the problem persists,
have a professional diagnose the probable cause.
5 Brakes
Note:Before assuming that a brake problem exists, make sure that:
a) The tyres are in good condition and properly inflated (Chapter 1).
b) The front end alignment is correct (Chapter 10).
c) The vehicle is not loaded with weight in an unequal manner.
Vehicle pulls to one side during braking
m mIncorrect tyre pressures (Chapter 1).
m mFront end out of line (have the front end aligned).
m mUnmatched tyres on same axle.
m mRestricted brake lines or hoses (Chapter 9).
m mMalfunctioning caliper assembly (Chapter 9).
m mLoose suspension parts (Chapter 10).
m mLoose calipers (Chapter 9).
m mBrake pads contaminated with oil or grease (Chapter 9).
Noise (high-pitched squeal
when the brakes are applied)
m mFront and/or rear disc brake pads worn out. The noise comes from
the wear sensor rubbing against the disc. Replace pads with new
ones immediately (Chapter 9).
Brake roughness or chatter (pedal pulsates)
m mExcessive lateral disc runout (Chapter 9).
m mParallelism not within specifications (Chapter 9).
m mUneven pad wear caused by caliper not sliding due to improper
clearance or dirt (Chapter 9).
m mDefective disc (Chapter 9).
Excessive pedal effort required to stop vehicle
m
mMalfunctioning power brake servo (Chapter 9).
m mPartial system failure (Chapter 9).
m mExcessively worn pads (Chapter 9).
m mPiston in caliper stuck or sluggish (Chapter 9).
m mBrake pads contaminated with oil or grease (Chapter 9).
m mNew pads installed and not yet seated. It will take a while for the
new material to seat against the disc.
m mAccumulator in power hydraulic system defective (see a Jaguar
dealer).
Excessive brake pedal travel
m mPartial brake system failure (Chapter 9).
m mInsufficient fluid in master cylinder (Chapters 1 and 9).
m mAir trapped in system (Chapters 1 and 9).
Dragging brakes
m
mMaster cylinder pistons not returning correctly (Chapter 9).
m mRestricted brakes lines or hoses (Chapters 1 and 9).
m mIncorrect handbrake adjustment (Chapter 9).
Grabbing or uneven braking action
m
mMalfunction of power brake servo unit (Chapter 9).
m mBinding brake pedal mechanism (Chapter 9).
m mBrake pads contaminated with oil or grease (Chapter 9).

3261 Jaguar XJ6
REF•16Fault finding
6 Suspension and steering systems
5 Braking system (continued)
Brake pedal feels spongy when depressed
m mAir in hydraulic lines (Chapter 9).
m mMaster cylinder mounting bolts loose (Chapter 9).
m mMaster cylinder defective (Chapter 9).
Brake pedal travels to the floor - no resistance
m
mLittle or no fluid in the master cylinder reservoir caused by leaking
caliper piston(s), damaged or disconnected brake lines (Chapter 9).
Handbrake does not hold
m mHandbrake cable or handbrake shoes improperly adjusted
(Chapter 9).
m mHandbrake shoes need replacement (Chapter 9).
Note:Before attempting to diagnose the suspension and steering
systems, perform the following preliminary checks:
a) Tyres for wrong pressure and uneven wear.
b) Steering universal joints from the column to the steering gear for
loose connectors or wear.
c) Front and rear suspension and the rack and pinion assembly for
loose or damaged parts.
d) Out-of-round or out-of-balance tyres, bent rims and loose and/or
rough wheel bearings.
Vehicle pulls to one side
m mMismatched or uneven tyres (Chapter 10).
m mBroken or sagging springs (Chapter 10).
m mWheel alignment out of specifications (Chapter 10).
m mFront brakes dragging (Chapter 9).
Abnormal or excessive tyre wear
m
mWheel alignment out of specifications (Chapter 10).
m mSagging or broken springs (Chapter 10).
m mTyre out-of-balance (Chapter 10).
m mWorn shock absorber (Chapter 10).
m mOverloaded vehicle.
m mTyres not rotated regularly.
Wheel makes a “thumping” noise
m
mBlister or bump on tyre (Chapter 10).
m mImproper shock absorber action (Chapter 10).
Shimmy, shake or vibration
m
mTyre or wheel out-of-balance or out-of-round (Chapter 10).
m mLoose, worn or out-of-adjustment wheel bearings (Chapter 1).
m mWorn tie-rod ends (Chapter 10).
m mWorn balljoints (Chapter 10).
m mExcessive wheel runout (Chapter 10).
m mBlister or bump on tyre (Chapter 10).
Hard steering
m
mLack of lubrication at balljoints, tie-rod ends and rack-and-pinion
assembly (Chapter 1).
m mFront wheel alignment (Chapter 10).
m mLow tyre pressure(s) (Chapter 1).
Poor returnability of steering to centre
m
mLack of lubrication at balljoints and tie-rod ends (Chapter 1).
m mBinding in balljoints (Chapter 10).
m mBinding in steering column (Chapter 10).
m mLack of lubricant in rack-and-pinion assembly (Chapter 10).
m mFront wheel alignment (Chapter 10).
Abnormal noise at the front end
m
mLack of lubrication at balljoints and tie-rod ends (Chapter 1).
m mDamaged shock absorber mounting (Chapter 10).m mWorn control arm bushings or tie-rod ends (Chapter 10).
m mLoose stabiliser bar (Chapter 10).
m mLoose wheel nuts (Chapter).
m mLoose suspension bolts (Chapter 10).
Wander or poor steering stability
m
mMismatched or uneven tyres (Chapter 10).
m mLack of lubrication at balljoints and tie-rod ends (Chapter 1).
m mWorn shock absorbers (Chapter 10).
m mLoose stabiliser bar (Chapter 10).
m mBroken or sagging springs (Chapter 10).
m mFront or rear wheel alignment (Chapter 10).
Erratic steering when braking
m
mWheel bearings worn (Chapter 1).
m mBroken or sagging springs (Chapter 10).
m mLeaking wheel cylinder or caliper (Chapter 9).
m mWarped discs (Chapter 9).
Excessive pitching and/or rolling around corners
or during braking
m mLoose stabiliser bar (Chapter 10).
m mWorn shock absorbers or mounts (Chapter 10).
m mBroken or sagging springs (Chapter 10).
m mOverloaded vehicle.
Suspension bottoms
m
mOverloaded vehicle.
m mWorn shock absorbers (Chapter 10).
m mIncorrect, broken or sagging springs (Chapter 10).
m mDefective power hydraulic system or leaking rear shock absorbers
(Chapter 10).
Cupped tyres (wear on both edges)
m mFront wheel or rear wheel alignment (Chapter 10).
m mWorn shock absorbers (Chapter 10).
m mWheel bearings worn (Chapter 10).
m mExcessive tyre or wheel runout (Chapter 10).
m mWorn balljoints (Chapter 10).
Excessive tyre wear on outside edge
m
mInflation pressures incorrect (Chapter 1).
m mExcessive speed in turns.
m mFront end alignment incorrect (excessive toe-in). Have
professionally aligned.
m mSuspension arm bent or twisted (Chapter 10).
Excessive tyre wear on inside edge
m
mInflation pressures incorrect (Chapter 1).
m mFront end alignment incorrect (toe-out). Have professionally
aligned.
m mLoose or damaged steering components (Chapter 10).

3261 Jaguar XJ6
Glossary of technical termsREF•19
Catalytic converterA silencer-like device in
the exhaust system which converts certain
pollutants in the exhaust gases into less
harmful substances.
CirclipA ring-shaped clip used to prevent
endwise movement of cylindrical parts and
shafts. An internal circlip is installed in a
groove in a housing; an external circlip fits into
a groove on the outside of a cylindrical piece
such as a shaft.
ClearanceThe amount of space between
two parts. For example, between a piston and
a cylinder, between a bearing and a journal,
etc.
Coil springA spiral of elastic steel found in
various sizes throughout a vehicle, for
example as a springing medium in the
suspension and in the valve train.
CompressionReduction in volume, and
increase in pressure and temperature, of a
gas, caused by squeezing it into a smaller
space.
Compression ratioThe relationship between
cylinder volume when the piston is at top
dead centre and cylinder volume when the
piston is at bottom dead centre.
Constant velocity (CV) jointA type of
universal joint that cancels out vibrations
caused by driving power being transmitted
through an angle.
Core plugA disc or cup-shaped metal device
inserted in a hole in a casting through which
core was removed when the casting was
formed. Also known as a freeze plug or
expansion plug.
CrankcaseThe lower part of the engine
block in which the crankshaft rotates.
CrankshaftThe main rotating member, or
shaft, running the length of the crankcase,
with offset “throws” to which the connecting
rods are attached.
Crocodile clipSee Alligator clipDDiagnostic codeCode numbers obtained by
accessing the diagnostic mode of an engine
management computer. This code can be
used to determine the area in the system
where a malfunction may be located.
Disc brakeA brake design incorporating a
rotating disc onto which brake pads are
squeezed. The resulting friction converts the
energy of a moving vehicle into heat.
Double-overhead cam (DOHC)An engine
that uses two overhead camshafts, usually
one for the intake valves and one for the
exhaust valves.
Drivebelt(s)The belt(s) used to drive
accessories such as the alternator, water
pump, power steering pump, air conditioning
compressor, etc. off the crankshaft pulley.
DriveshaftAny shaft used to transmit
motion. Commonly used when referring to the
axleshafts on a front wheel drive vehicle.
Drum brakeA type of brake using a drum-
shaped metal cylinder attached to the inner
surface of the wheel. When the brake pedal is
pressed, curved brake shoes with friction
linings press against the inside of the drum to
slow or stop the vehicle.
EEGR valveA valve used to introduce exhaust
gases into the intake air stream.
Electronic control unit (ECU)A computer
which controls (for instance) ignition and fuel
injection systems, or an anti-lock braking
system. For more information refer to the
Haynes Automotive Electrical and Electronic
Systems Manual.
Electronic Fuel Injection (EFI)A computer
controlled fuel system that distributes fuel
through an injector located in each intake port
of the engine.
Emergency brakeA braking system,
independent of the main hydraulic system,
that can be used to slow or stop the vehicle if
the primary brakes fail, or to hold the vehicle
stationary even though the brake pedal isn’t
depressed. It usually consists of a hand lever
that actuates either front or rear brakes
mechanically through a series of cables and
linkages. Also known as a handbrake or
parking brake.EndfloatThe amount of lengthwise
movement between two parts. As applied to a
crankshaft, the distance that the crankshaft
can move forward and back in the cylinder
block.
Engine management system (EMS)A
computer controlled system which manages
the fuel injection and the ignition systems in
an integrated fashion.
Exhaust manifoldA part with several
passages through which exhaust gases leave
the engine combustion chambers and enter
the exhaust pipe.
F
Fan clutchA viscous (fluid) drive coupling
device which permits variable engine fan
speeds in relation to engine speeds.
Feeler bladeA thin strip or blade of hardened
steel, ground to an exact thickness, used to
check or measure clearances between parts.
Firing orderThe order in which the engine
cylinders fire, or deliver their power strokes,
beginning with the number one cylinder.
Flywheel A heavy spinning wheel in which
energy is absorbed and stored by means of
momentum. On cars, the flywheel is attached
to the crankshaft to smooth out firing
impulses.
Free playThe amount of travel before any
action takes place. The “looseness” in a
linkage, or an assembly of parts, between the
initial application of force and actual
movement. For example, the distance the
brake pedal moves before the pistons in the
master cylinder are actuated.
FuseAn electrical device which protects a
circuit against accidental overload. The typical
fuse contains a soft piece of metal which is
calibrated to melt at a predetermined current
flow (expressed as amps) and break the
circuit.
Fusible linkA circuit protection device
consisting of a conductor surrounded by
heat-resistant insulation. The conductor is
smaller than the wire it protects, so it acts as
the weakest link in the circuit. Unlike a blown
fuse, a failed fusible link must frequently be
cut from the wire for replacement.Catalytic converter
Crankshaft assembly
Accessory drivebelts
Feeler blade

3261 Jaguar XJ6
REF•20Glossary of technical terms
GGapThe distance the spark must travel in
jumping from the centre electrode to the side
electrode in a spark plug. Also refers to the
spacing between the points in a contact
breaker assembly in a conventional points-
type ignition, or to the distance between the
reluctor or rotor and the pickup coil in an
electronic ignition.
GasketAny thin, soft material - usually cork,
cardboard, asbestos or soft metal - installed
between two metal surfaces to ensure a good
seal. For instance, the cylinder head gasket
seals the joint between the block and the
cylinder head.
GaugeAn instrument panel display used to
monitor engine conditions. A gauge with a
movable pointer on a dial or a fixed scale is an
analogue gauge. A gauge with a numerical
readout is called a digital gauge.
HHalfshaftA rotating shaft that transmits
power from the final drive unit to a drive
wheel, usually when referring to a live rear
axle.
Harmonic balancerA device designed to
reduce torsion or twisting vibration in the
crankshaft. May be incorporated in the
crankshaft pulley. Also known as a vibration
damper.
HoneAn abrasive tool for correcting small
irregularities or differences in diameter in an
engine cylinder, brake cylinder, etc.
Hydraulic tappetA tappet that utilises
hydraulic pressure from the engine’s
lubrication system to maintain zero clearance
(constant contact with both camshaft and
valve stem). Automatically adjusts to variation
in valve stem length. Hydraulic tappets also
reduce valve noise.
IIgnition timingThe moment at which the
spark plug fires, usually expressed in the
number of crankshaft degrees before the
piston reaches the top of its stroke.
Inlet manifoldA tube or housing with
passages through which flows the air-fuel
mixture (carburettor vehicles and vehicles with
throttle body injection) or air only (port fuel-
injected vehicles) to the port openings in the
cylinder head.
JJump startStarting the engine of a vehicle
with a discharged or weak battery by
attaching jump leads from the weak battery to
a charged or helper battery.
LLoad Sensing Proportioning Valve (LSPV)A
brake hydraulic system control valve that
works like a proportioning valve, but also
takes into consideration the amount of weight
carried by the rear axle.
LocknutA nut used to lock an adjustment
nut, or other threaded component, in place.
For example, a locknut is employed to keep
the adjusting nut on the rocker arm in
position.
LockwasherA form of washer designed to
prevent an attaching nut from working loose.
MMacPherson strutA type of front
suspension system devised by Earle
MacPherson at Ford of England. In its original
form, a simple lateral link with the anti-roll bar
creates the lower control arm. A long strut - an
integral coil spring and shock absorber - is
mounted between the body and the steering
knuckle. Many modern so-called MacPherson
strut systems use a conventional lower A-arm
and don’t rely on the anti-roll bar for location.
MultimeterAn electrical test instrument with
the capability to measure voltage, current and
resistance.
NNOxOxides of Nitrogen. A common toxic
pollutant emitted by petrol and diesel engines
at higher temperatures.
OOhmThe unit of electrical resistance. One
volt applied to a resistance of one ohm will
produce a current of one amp.
OhmmeterAn instrument for measuring
electrical resistance.
O-ringA type of sealing ring made of a
special rubber-like material; in use, the O-ring
is compressed into a groove to provide the
sealing action.
Overhead cam (ohc) engineAn engine with
the camshaft(s) located on top of the cylinder
head(s).Overhead valve (ohv) engineAn engine with
the valves located in the cylinder head, but
with the camshaft located in the engine block.
Oxygen sensorA device installed in the
engine exhaust manifold, which senses the
oxygen content in the exhaust and converts
this information into an electric current. Also
called a Lambda sensor.
PPhillips screwA type of screw head having a
cross instead of a slot for a corresponding
type of screwdriver.
PlastigageA thin strip of plastic thread,
available in different sizes, used for measuring
clearances. For example, a strip of Plastigage
is laid across a bearing journal. The parts are
assembled and dismantled; the width of the
crushed strip indicates the clearance between
journal and bearing.
Propeller shaftThe long hollow tube with
universal joints at both ends that carries
power from the transmission to the differential
on front-engined rear wheel drive vehicles.
Proportioning valveA hydraulic control
valve which limits the amount of pressure to
the rear brakes during panic stops to prevent
wheel lock-up.
RRack-and-pinion steeringA steering system
with a pinion gear on the end of the steering
shaft that mates with a rack (think of a geared
wheel opened up and laid flat). When the
steering wheel is turned, the pinion turns,
moving the rack to the left or right. This
movement is transmitted through the track
rods to the steering arms at the wheels.
RadiatorA liquid-to-air heat transfer device
designed to reduce the temperature of the
coolant in an internal combustion engine
cooling system.
RefrigerantAny substance used as a heat
transfer agent in an air-conditioning system.
R-12 has been the principle refrigerant for
many years; recently, however, manufacturers
have begun using R-134a, a non-CFC
substance that is considered less harmful to
the ozone in the upper atmosphere.
Rocker armA lever arm that rocks on a shaft
or pivots on a stud. In an overhead valve
engine, the rocker arm converts the upward
movement of the pushrod into a downward
movement to open a valve.
Adjusting spark plug gap
Plastigage
Gasket

3261 Jaguar XJ6
IndexREF•23
EEarth check - 12•2
ECU -6•2
EGR gas temperature sensor -6•7
Electric shock -0•5
Electric windows - 12•13
Electrical equipment -1•14, REF•9
Electrical system fault finding - 12•1, REF•17
Electronic control system and ECU -4•9, 6•2
Electronic Fuel Injection (EFI) system -4•9, 4•10
Emissions and engine control systems-6•1et seq
Engine electrical systems-5•1et seq
Engine in-car repair procedures-2A•1et seq
Engine fault finding - ref•13,ref•14
Engine oil -0•11, 0•16, 1•2, 1•6
Engine removal and overhaul procedures-2B•1et seq
Environmental considerations - REF•5
Evaporative Emission Control (EVAP) system -6•10
Evaporator and expansion valve -3•14
Exhaust emission checks - REF•11
Exhaust Gas Recirculation (EGR) system -6•9
Exhaust manifolds -2A•4
Exhaust system -1•11, 4•2, 4•14, REF•10
Expansion tank -3•4, 3•5
FFans -3•3
Fault finding- REF•12et seq
ABS -9•2
automatic transmission - 7•1, REF•15
brakes - REF•15, REF•16
cooling system - REF•14
electrical system - 12•1, REF•17
engine - REF•13, REF•14
fuel system - REF•14
suspension and steering systems - REF•16, REF•17
Filling (bodywork repair) - 11•2
Filters
automatic transmission fluid - 1•19
fuel - 1•15
oil - 1•6
Fire -0•5
Fluids -0•16
Fuel and exhaust systems-4•1et seq, REF•11
Fuel filter -1•15
Fuel gauge - 12•7
Fuel pressure relief -4•2
Fuel system fault finding - REF•14
Fume or gas intoxication -0•5
Fuses -0•15, 12•2
GGaiters - 10•9
Gashes - 11•2
Gaskets - REF•5
Glass - 11•3, 11•10, 11•11, 12•13
Glossary of technical terms- REF•3, REF•18et seq
Glove box - 11•13
Grille - 11•5
HHandbrake -1•12, 1•20, 9•1, 9•10, 9•11, REF•8
Handles - 11•9, 11•10
Hazard flasher - 12•4
HC emissions - REF•11
Headlights -1•18, 12•9, 12•10, 12•11
Heated rear window - 12•8
Heater -3•2, 3•7, 3•9, 3•10, 3•11, 3•12
High-mounted brake light - 12•12
Hinges - 11•3
Horn - 12•11
Hoses -1•10
Hub bearings - 1•17, 10•8
Hydraulic system -0•16
Hydrofluoric acid -0•5
IIdle Speed Control (ISC) motor -4•11
Ignition switch - 12•6
Ignition system -1•15
In-tank fuel pumps -4•4
Indicators - 12•4, 12•11, 12•12
Inertia switch -4•1, 12•12
Information sensors -6•3
Injectors -4•12
Instruments - 1•14, 11•12, 12•6, 12•7, 12•12
Intake Air Temperature (IAT) sensor -6•7
Intake manifold -2A•4
Interior lights - 12•12
Introduction -0•4
JJacking - REF•1
Joint mating faces - REF•5
Jump starting -0•7
KKickdown cable -7•2
Knee bolster - 11•13
LLatch - 11•4, 11•7, 11•9
Leaks -0•9, 1•10, 7•2
Locknuts,locktabs and washers - REF•5
Locks - 11•3, 11•7, 11•9, 12•6
Lubricants -0•16
MMain bearings -2B•13, 2B•16
Manifolds -2A•4
Manual valve -7•7
Mass Airflow (MAF) sensor -6•6
Master cylinder -9•6
Mirrors - 11•11, 12•14, REF•8
MOT test checks- REF•8et seq
Mounts -2A•18, 7•8
Multi Point Fuel Injection (MPFI) system -4•1