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1. X300 VSM 27 Issue 1 August 1994 S Electrical y 15 10 4 Harness Connectors GeneralDescription Fig 1 Harness Connectors Fig 1 shows a planview ofthe harnessconnectorsphysically linking all the harnesses locatedin the trunk the passen ger compartment and the engine bay The illustrationis to be read in conjunction with the following table To avoid any accidents such as electric shocks always disconnectthe battery negative lead from the battery negativeterminal before disconnecting any ofthe listed cables Issue 1 August 1994 28 X300 VSM Y Electrical Key toFig 1 Harness Connectors page 34 X300 VSM From Location In Car Entertainment LH Rear Door Console LH Forward LH Forward RH Forward RH Forward LH Forward LH Front Door Passenger Cabin Engine LH Front Bumper Engine RH Front Bumper Console Engine Fascia Cabin Cabin Door Cabin RH Forwards ICE Fascia Console Cabin RH Rear Door Cabin ICE Cabin Rear Lamp Cabin Boot Boot Number 2 3 3 5 eao S 7 a BL 001 9 BR 001 11 12 13 CA 009 14 RS 003 15 IC 007 16 CC 003 005 17 18 19 20 BT 005 21 Issue 1 August 1994 F Electrical E 15 11 MOTORS amp SOLENOIDS 5 11 1 General Description 37 3635 34 33 3 Jab 1695 Fig 1 Motors amp Solenoids Fig 1 shows a plan view of all
2. Note This note only applies to V12 engines When renewing spark plugs apply silicon grease TBA to the spark plug and coil terminals of the ignition cable This will ensure that the terminal covers remain supple throughout their service life thus maintaining a good contact and preventing HT leakage X300 VSM A2 95MY 5 Issue 1 August 1994 Y e Routine Maintenance Item Service intervals Miles X 1000 7 5 15 22 5 30 37 5 45 52 5 60 32 Check power steering system for leaks and hydraulic X X xX x X xX xX x pipes unions for chafing corrosion 33 Check Cooling heating system for leaks security A X X X x Xx X xX 34 Check visually hydraulic hoses pipes unionsfor X X Xx Xx X x xX X leaks chafing cracks corrosion 35 Check condition of steering rackjoint covers A A A A A X X X 36 Check speed control vacuum hoses for security and X A A A A X X X general condition Grease door check arm side edges X X Xx X Check parking brake cable adjustment X X X X X X X X Clean out radiator ti 1 fitt 1 X Xx Xx xX to remove dirt accumulation Clean t t x X Xx Xx Xx X xX Xx y Oout road il t t xX x A A x X X X issue 1 August 1994 A2 95MY 6 X300 VSM General Fitting Instructions gt S SECTION CONTENTS Subsection Title SRO Page ere rere e rere Preliminary Page see EES e ened eee eee eee NEEN ER EEN NEEN ENEE eee i KAS Safety PIeC
3. normally aspirated fueling system using intake air at atmospheric pressure not supercharged or turbocharged Normally Closed NC Normally Open NO North American Specification NAS vehicles for sale in the USA and Canadian markets numbe No octane number measureofthe anti knockproperties ofafuel Occupational Safety amp Health OSHA Administration US odometer instrument which records the total mileage mileometer covered by a vehicle oil gauge oil gage dipstick oil pan On Board Diagnostic OBD asystemthat monitors some or all computer input and output control signals Signal s outside the pre determined limits imply a fault inthe system or a related system open circuit oriainal equioment manufacturer a circuit which does not provide a complete path for flow of current la outside diameter o dia overhead camshaft OHC engine configuration with single camshaft positioned above the valves Oxidation Catalytic Converter oc catalytic converter system that reduces levels of HC and CO oxides of nitrogen INOx Oxygen Sensor 02s asensor which detects oxygen content inthe EGO 02 EOS exhaust gases EGS OS EGOS Lambda Sensor Issue 1 August 1994 20 X300 VSM paragraph Term s Introduction Previously used term s or Eng lish Equivalent Abbreviation if applicable P para parking brake
4. p D E Ger p A y yyy X SSN SSNS OG 139 045 8 X300 VSM 17 Issue 1 August 1994 2 E Manual Transmission Clutch AJ16 7 1 18 CLUTCHHYDRAULIC SYSTEM BLEED SRO 33 15 01 CAUTION Only use minimum DOT A brake fluid inthe hy draulic system a Removethe reservoir filler cap and top upto the correct level with hydraulic fluid a Attach one end of a bleedtube 1 Fig 1 tothe slave cylin der bleed nipple 2 Fig 1 a Partiallyfillaclean container 3 Fig 1 with hydraulicfluid a Immerse the other end of the bleed tube inthe fluid a Slacken the slave cylinder bleed nipple Pump the clutch pedal slowly up and down pausing be tween each stroke a Top upthe reservoir with fresh hydraulic fluid after every three pedal strokes CAUTION Do not use fluid bledfrom the system for top ping up purposes as this will contain air Ifthe fluid has been in use for some time it should be discarded Fresh fluid bled from the system Fig 1 may be used after it has stood for afew hours allowing allthe air bubbles to disperse 333 070 Pump the clutch pedal until the pedal becomes firm tighten the bleed nipple a Top upthe reservoir refit the filler cap a Apply working pressureto the clutch pedalfortwotothree minutes and examine the system for leaks Issue 1 August 1994 18 X300 VSM Automatic Transmission AJ16 SECTION CONTENTS Sub Section Title SRO Page LOW
5. Instruction Press small button once vehicle locked and zarmed Variant 1 Variant 2 a Variant 3 Check all doors trunk lid and fuel filler cap unlock Checkthat the alarm system dis arms and the interior light illuminatesfor 15seconds Check luggage compartment valet lock out is cancelled if set Ensurethe memory position of the driver s seat steering column and door rear view mirrors is restored Check that two audible signals are heard andthe direction indicator flashes twice during the unlocking disarmina process Japanese Market Only No audible or visual in dication of unlocking dis arming Check luggage compart ment released when but ton pressedwithin 10sec onds of first press Press small button again Check all passenger doors Check luggage compart unlocked ment released when but ton pressed within ten sec onds of first press Press small button again No feature Check luggage compart No feature ment released when but ton pressed within 10 sec onds of second press Check that the sounder gives a short high pitched warble every time a button on the key ring transmitter is pressed whenever one of the following conditions is present Q The trunk lid or hood is not properly closed when an attempt to arm the security system is made o The ignition key is in the ignition switch o If there is a failure within the security system
6. gend Issue 1 August 1994 22 X300 VSM i Automatic Transmission V12 amp AJ16 Supercharged ES Powertrain 8 2 22 MANUAL DETENT SPRING RENEW 4 0L SC AND 6 0L SRO 44 26 10 s Open the hood and fit a suitable fender cover a Raise the vehicle on a ramp a Drain the transmission lubrication system see Sub sec tion 8 2 13 a Removethe fluid pan see Subsection 8 2 14 4 0L SC or Sub section 8 2 15 6 0L a Removethe fluid filter see Subsection 8 2 18 a Select P Park and ensure that the pawl is engaged e Release and remove the manual valve detent spring and roller assembly to valve body securing bolts Removethe detent spring assembly and place aside a Clean the relevant parts e Fita new detent spring assembly to the valve body Fit but do not fully tighten the detent spring assembly to the valve body securing bolts a Align the detent springtocentralizethe roller with the det ent lever inthe H Park position a Check that in N Neutral the shift lever is properly in position It is essential that the detent spring within the transmission unit dictates to the shift lever and not the other way around Finally tighten the detent spring assembly to valve body securing bolts a Refit the fluid filter see Subsection 8 2 18 e Refit the fluid pan see Subsection 8 2 14 4 0L SC or Sub section 8 2 15 6 0L a Lower the vehicle on the ramp a Refill the transmission
7. Trunk lid release Remote panic Large button Small button 1st press N A Locks all doors trunk and fuel filler cap Arms alarm system O ee ee bat Sree Continued hold of N A Locks all doors trunk lid and 1st press for 2 seconds 2nd press 1st press if vehicle is locked and armed DOOR UNLOCKING Retin Deviceoperation incon N A 1st press 2nd press 3rd press press to be within 10 seconds of previous action 3 second press fuel filler cap Arms alarm system Key only closes open windows and sliding roof in 1 5 seconds Switches headlights on for driver convenience Unlocks driver s door and fuel filler cap Disarms alarm system Turns on interior lights for 15 seconds Remote button only cancels trunk valet lock out and recalls memorised driving position Unlocks all other doors key only unlocks trunk lid Trunk lid lock release Unlocks disarms and enters full alarm state ie audible alarm bothsounder and horn and visual alarm flashing lights Issue 1 August 1994 10 X300 VSM Y Security System RESTRICTED ISSUE e A5 4 3 Rest of the World variant 3 DOOR LOCKING Device operation Key Remote signal transmitter Function Large button Small button Lock and arm perimeter inclin
8. p Issue 1 August 1994 44 X300 VSM
9. Description Notes Dewar Handla Pinion flange wrench 18G 1205 Pinion flange wrench Issue 1 August 1994 iii X300 VSM oe Driveshafts amp Final Drive IL TORQUE TIGHTENING SPECIFICATIONS Fixing TighteningTorque Nm A frame to differential 85 115 A frame to wide mountina bracket 727 98 ABS sensor to hub carrier 8 10 Axle shaft hub nut See repair operations47 10 01 and 64 15 14 amp 15this section Axle shaft to output flange 81 99 Bush A frame lower mountingto body 80 100 Centre drive shaft bearing to crossmember 19 27 Crossmemberto bodv 19 27 Differential nose to wide mounting bracket 34 46 Differential strut to bodv 85 95 Drive shaft to auto gearbox flange 337 45 Drive shaft flexible coupling to pinion flange 71 83 Exhaustjoint Olive 14 18 Exhaust joint Torca clamp 60 80 Exhaust mounting to wide mounting bracket 22 88 Final drive unitto wide mounting bracket at differential nose 34 46 Hub carrier fulcrum 80 100 Lower shock absorber bolt 80 100 Mounting bracket A frame to body inner 40 50 Mountina bracket A frame to bodv outer 80 100 Oil drain plug 26 34 Oil filler plua 20 26 Output shaft housing to differential case 52 58 Pendulum assembly to differential 160 200 Pinion drive flange nut See repair operation 5120 01 this section Minimum 135 Rear mounting bracke
10. Torque converter 4 speed gear train Output flange Transmission control unit Oil outlet drain plug SP ens 6 7 8 344 688 Rotary switch positions P Park R Reverse Nr Neutral D Drive Fully automatic control Dipstick oil filler tube Oil cooler connection Fig 2 Z 4 HP 24 E Transmission A SS E e Issue 1 August 1994 X300 VSM z utomatic Transmissio CC Bothtypes of automatic transmission comprise a hydrodynamictorque converter driving anepicyclic gear train which provides four forward ratios and reverse Gearshift selection is made by a hydraulic or electronic hydraulic 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 Neutral engine disconnected from drive line and wheels r Position N Position D Drive all four speed ranges are selected automatically with lock up available intop 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 preventedfrom shift ing upto 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 ov
11. handbrake Park Neutral Position Switch Park Neutral Position PNP Dart number NDS NGS TSN gearbox sensor PNPS indicates the selected non drive modes of the automatic transmission piston pin also wrist pin power steering pressure poWenAansted Steering pin boss piston pin boss boss inthe pistonwall two per piston which is bored to accept one end of the pistonpin ping pinging metallic pingingsound caused by detonation pinking in the combustion chamber usually caused by incorrect grade of fuel too low octane or over advanced ignition timing see also knock pin which connects the connecting rodto the gudgeon pin piston and permits articulation between the power assisted steering two power steering pressure hvdraulic pump assisted steerina svstem Dower steerina powertrain the elements of a vehicle by which motive drive line power is generated and transmitted to the driven axle program sequence of events to be performed by a programme pro programable or Droarammable programed or programmed proaramer or programmer programing or programming Programmable Electronic Control Units System iProgrammable Read Only Mem control modute computer gram PO programmatle Po programmed programmer PECUS process whereby a common ECM is programmed on the p
12. Electrical Oo Mt Universalgarage door opener Roofconsole panel 86 52 01 Security amp Locking Control Module LH side upper wheel arch inside the SLCM trunk below fuel filler pipe Sunroof Roofconsole panel 86 91 83 Mirror memory control Mounted inside driver s amp passenger s seat Seat Mirror Memory Passenger 19 75 21 Speed control Behindpassenger knee bolster 2 RHD 20 LHD 86 80 24 Air conditioning AYCCM RH side of air conditioning unit 1 Transmission control Behind passenger knee bolster 16 RHD 128 6 7 LHD 12 amp 16 Engine Management RH side footwell infront of A post 6 12 amp 16 behind cover BPU Body Processor Unit Behind passenger knee bolster Sup RHD Sup LHD ABS Anti lock Braking System amp Engine compartment below anti lock 18 RHD ee Control wherefitted braking system modulator 4 RHD ABS TC CM Bulbfailure Trunk inside electrical carrier box Rear Engine compartment behind each 22 amp 24 Front headlamp assembly Power steering LH side footwell on A post behind cover Column mirror ECM On the side of steering column i 5 e Reader exciter Around the lock barrel of steering column Airbag SRS diagnostic Behind passenger knee bolster below the 15 RHD airbag module 23 E Cooling fan Striebel unit Behind bumper LHS of vehicle X300 VSM 39 issue 1 August 1994 40 y Specification mm CONTENTS Title y Specification 1995 Mo
13. Remove lower trim pad and place on a clean workbench Removefixings and remove door pocket Fig 1 Door With Full Trim a Removeveneer panel switch assembly loudspeaker and loudspeaker grille To refit carry out reversal of the above procedure X300 VSM 7 Issue 1 August 1994 cr Body Components amp Trim 13 2 18 Fuel Filler Flap Description The fuel filler flap comprises a hinged flap attached to the body decking panel by two M5 nuts the flap incorporates a rubber buffer snap in striker hinge spring and the fuel cap stowage magnet The rubber fuel bowl moulding is at tached via asteel armature to the body reinforcement panel by five M5 nuts and is retained at the filler neck by aclip The mating drain tube is fitted with an internal filter Thefuelfiller flap latch mechanism attachedto the fuel bowlarmature by two M5 nuts includes a locking pin and actua tor which are both serviceable items The latch actuator operates independently from the central locking system it is driven directly by the security and locking control module Locking of the fuel filler flap is achieved only by operation of the key or by the remote rf transmitter 13 2 19 Filler Flap and Hinge Renew a Disconnect vehicle battery ground lead With filler cap open remove hinge securing screws fuel filler cap and remove flap and hinge assembly a To refit carry out reversal of the above procedure 13 2 20 Filler Cap Retention
14. A5 3 GENERAL INFORMATION The following information detailsthe purpose andfunction of the systemcomponentsirrespective of individual variant features A5 3 1 Locking Central locking A traditional central locking application such that when the driver s passenger s door is locked unlocked using the door key all four doors lock unlock simultaneously Note Locking operations will only take place when all doors are completely closed Remote central locking Automatic locking unlocking activated by the larger of the two key fob buttons Note Locking operations will only take place when all doors are completely closed Deadlocking A means of securing door locks so that they cannot be opened using the interior release mechanism and arming the security sensing system using the door key or remotetransmitter Two stage unlocking A key remote operated unlocking procedure which releases driver s door and fuel filler cap locks only initially and then releasesall other doors and the luggage compartment locks Drive away locks Automatic locking of all doors and luggage compartment but not fuel filler cap when gear selector is moved away from Park and the ignition switch is in position Il providing all doors are closed Central lock unlock all close Automatic locking of all doors and luggage compartment by operation of the fascia mounted central locking switch Continuedswitch operation causes closure of sliding r
15. D b D 22 Hitt OOO OOOO ODDO Gas Weld A AL AG AE A IG EG EEE AA AA MIG Plug Weld WWW WWW Fig 1 Keyto symbols AUTION Reference should always be madeto the welding tables and illustrations inthe relevant procedures Observe all safety precautionswith respectto yourself otherpeople your equipment andtheworkplace Issue 1 August 1994 18 X300 VSM y Body Systems amp Body Repair A4 3 1 ADHESIVES SEALERSAND BODY PROTECTION APPROVED SYSTEMS Specifications and recommendations may befound inthe Body Sealing and Preservation Manual which is available inthe following languages Language Dutch English AKM 9137 Italian AKM 9164 French AKM 9162 German AKM 9163 Japanese AKM 9178 Spanish AKM 9166 Cavity wax injection points Underbody amp underhood wax Approved paint refinish pro cesses Health and Safety Legislation applicable U K only general precautions and advice applicable to all Not applicable see A4 3 2 for specific injection points Not applicable Notapplicable see section A4 4 1 1 A4 3 2 CAVITY WAX INJECTION Protective wax should be applied inthe locations as specified inthe following illustrations Please refer to the Body Sealing and Preservation Manual for processes materials and equipment Note Cavity wax processesshould only be applied after ALL other refinishing and protection procedures are com plete X300 VSM 19 Issue 1 Aug
16. a Release and remove the speed sensor securing bolt Reposition the speed sensor protection cover for access noting that the cover remains captive on the harness a Removethe speed sensor fromthe transmission unit and place aside a Cleanthe main case speed sensor area a Fitanew O ring seal to a new output speed sensor a Lubricate the O ring seal a Fit and seat the speed sensor to the main case a Reposition and align the speed sensor protection cover Fit and tighten the speed sensor securing bolt Connect the harness plugto the speed sensor Reposition the edge of the transmission tunnel sound in sulation foam to the original position a Lower the vehicle on the ramp X300 VSM 7 Issue 1 August 1994 Bee z Automatic Transmission V12 AJ16 Supercharged Powertrain 8 2 6 INPUT SPEED SENSOR RENEW 6 0L SRO 44 15 40 a Open the hood and fit a suitable fender cover a Raise the vehicle on a ramp a Slacken the underfloor catalyst to downpipe clamps se curing bolts a Displace and repositionthe olive clamps on the pipes Slacken the underfloor catalyst to intermediate silencer clamps securing bolts s Displace the underfloor catalyst assembly rearwards to disconnect from the downpipes e Displace and remove the olives from the downpipes Using a wire brush clean the olives and downpipe joints a Place a suitable piece of wood between the underfloor catalyst and the body for access
17. 376 1081 Issue 1 August 1994 32 X300 VSM 13 3 31 Steering Column Switchgear Mounting Bracket Renew SRO 76 46 33 Body Components amp Trim Fig 1 J 76 1082 e Removethe steering column lower and upper cowls see subsections 13 3 30 and 13 3 29 a Remove the battery cover and disconnect the battery a Remove the driver airbag module see section 15 1 a Removethe steering wheel see section 10 a Remove the cassette and cancellation module 1 Fig 1 see section 10 a Displacethe audible warning speaker multi plug 2 Fig 1 from the mounting bracket 3Fig 1 a Disconnectthe speaker multi plug a Displace and remove the switch gear mounting bracket 3 Fig 1 a Undo and remove the audible warning speaker securing screws a Undo and remove speaker harness securing P clip nut a Displacethe P clip nut a Removethe audible warning speaker 4 Fig 1 Displacethedimmer modulemulti plug 5 Fig 1 fromthe mounting bracket X300 VSM 33 issue 1 August 1994 Body Components amp Trim 376 1082 Fig 1 a Displace and remove the dimmer module 6 Fig 1 a Discard the foam pads fromthe mounting bracket a Place the mounting bracket aside e Place new mounting bracket to the front a Place newfoam pads to the front a Remove the foam backing paper a Fit and fully seat the pads to the mounting bracket a Fit and align the audible warning speakertothe m
18. Clean the face of the flywheel and dowels ao na Issue 1 August 1994 14 X300 VSM Manual Transmission amp Clutch AJ16 Dee a Check the flywheel face for scoring shouldthis be excess ive skim within tolerance e Fita new spigot bearing to the flywheel 2 Fig 1 a Refitthe flywheel to the crankshaft and tighten the secur ing bolts 1 Fig 1 a Fit the clutch assembly to the flywheel ensuring that the larger rounded boss faces the flywheel a Align the clutch with an input shaft a Fitthe balance weights to the clutch cover and tighten the securing bolts a Remove the input shaft Remove the circlip 1 Fig 2 securing the clutch release armto the pivot and remove the assembly 2 Fig 2 a Slacken and remove the release arm pivot pin a Removethe bearing 3Fig 2 fromthe release arm assem Sl bly 2 Fig 2 grease the bearing seat fit the new bearing to the release arm assembly Re assemble the release arm ensuring that the pivots are greased a Select third forward gear a Move the transmission under the ramp and raise it into position against the adaptor plate and secure with the bolts a Remove the securing chain from the unit lift and fit front clamp a Refit the transmission switch and fit the multi plug into the securing clip a Refitthe clutch slave cylinder see 33 35 01 a Fitthe mounting rubbers and spacers reconnect the re mote control a Refit the selector to
19. Remove and discard the fluid pan gasket Removethe magnet 3 Fig 1 fromthe fluid pan clean the magnet Placethe magnet on a clean surface Clean the fluid pan joint face Cleanthe fluid pan a Placethe fluid pan aside a Attach the magnetto the recess in the fluid pan a Fit and align a new gasketto the fluid pan a Fit the fluid pan and gasket to the transmission unit a Fit and tighten the fluid pan securing bolts a Remove the block of wood from between the under floor catalyst and the floor Apply sealantto the downpipe joints and olives See Ser vice Materials inthe preliminary pages this Section Fit and seat the olives to the downpipes 8 2 a Reconnectthe underfloor catalyst to the downpipes a Reposition the olive clamps a Tighten the underfloorcatalystto downpipe clamps secur ing bolts Alignthe intermediate silencers to the underfloor catalyst assembly a Tighten the clamp securing bolts a Lower the vehicle on the ramp a Refill the transmission unit with fluid see Subsection 8 2 13 Remove the fender cover and close the hood Issue 1 August 1994 18 X300 VSM 4 y Automatic Transmission V12 amp AJ16 Supercharged ines Powertrain 8 2 18 FLUID FILTER RENEW 4 0L SCAND6 0L SRO 44 24 07 e Openthe hood and fit a suitable fender cover a Raise the vehicle on a ramp a Drain the transmission lubrication system see Sub sec tion 8 2 13 s Rem
20. Suspension Bushes Issue 1 August 1994 X300 VSM Suspension Systems 1 SERVICE TOOLS amp EQUIPMENT continued Illustration Jaguar Number Description JD143 4 Adaptor Remover Renewer Suspension Bushes Bottom Front Wishbone Inner Not illustrated JD199 Spring Compressor Rear Suspension JD199 1 Damper Retaining Tie Rear Not illustrated Suspension JD 550 6 Adaptor Replacer Rear Hub Pivot Bearing Cup 18G 134 Driver Handle 18G 284 AAH Adaptor Remover Main Shaft Pilot Bearing Outer Track 18G 284 Impulse Extractor slide Hammer UNF Basic Tool K Fixing Tightening Torque Nm To be issued Description Uses Notes LM Multi purpose grease Lower damper bolt Wishbone to crossmember fulcrum shaft Molib Alloy P1907 No1 Stabilizer mounting bushes amp rear damper top guide bush Molykote 111 Caliperto carrier bolts guide pins X300 VSM iii Issue 1 August 1994 Su Ne Suspension Systems Application Camber angle front suspension Caster angle Same setting each side of vehicle Wheel alignment Specification 0 3 to 08 3 0 to 6 09 5 Toe in 10 Note Geometry isto bechecked set usingthe mid ladensetting links Setting height should correspondtothe fol lowing dimensions Front 153 5mm under front crossbeam AJ16 Front 143 5mm under front crossbeam V12 Rear 160 5mm under rear edge of
21. Washer fluid level warning indicator bulb Orange pe Transmission fault indicator bulb Orange Coolanttemperature gauge illumination bulb Speedometer illumination bulbs upper and lower 12 5V 1 2W Ea 1 2W 13 5V 1 2W 13 5V 1 2W Tachometer illumination bulbs upper and lower 13 5V 1 2W uel gauge illumination bulb White 13 5V 1 2W Battery condition indicator illumination bulb White 13 5V 1 2W Oil pressure gauge illumination bulb White 13 5V 1 2W X300 VSM A1 95MY 13 Issue 1 August 1994 Specification The following tables list all fuses intheir locations used inthe vehicle Engine Bay Fuse Box left hand side Fuse Colour Code amps Value Circuit Clear 25 Heated front screen right hand side where fitted Red 10 Main beam headlamp left hand side Clear 25 Starter solenoid Red 10 Lowered beam headlamp left hand side Red 10 Side light front left hand side Turn indicator front left hand side Side repeater flasher left hand side Light Blue Light Green Light Green 2 Windshield wiper system 0 E AA AN IN mi 30 Cooling fans Series Parallel Not used Horn 2 Heated front screen left hand side where fitted 30 Cooling fans Series Red 10 Front fog lamp left hand side where fitted Iss
22. When handling deployed airbags always wear rubber glovesto BS 1651 grade 2 or equivalent and chemical resistant goggles to BS 2092 grade 2 or equivalent After handlingdeployed airbags immediatelywash hands and exposed skin surface areas with mild soap and water 15 1 5 Safety Procedures For Handling Undeployed Damaged Modules The material insidethe module is hermetically sealed and is completely consumed during deployment No attempt should be made to open the module as this leadsto a risk of exposure to sodium azide Inthe unlikely event of a gas generator being damaged it must be examined by trained personnel before any attempt is madeto remove and or deploy Full protective clothing must be worn when dealing with any spillage Rupturedunits must be stored away from acids halogens heavy metals and metal salts Damagedunits may produce hydrazoic acid if exposedto liquids Failureto comply with these instructions may result in fire noxious fumes and severe personal injury or death X300 VSM 3 Issue 1 August 1994 Wes Electrical 3 15 1 6 Fire Hazard Information Thermaldecompositionor combustion may produce dense smoke and other dangerousfumes which infire situations form a highly toxic explosive Inthe event of fire the surrounding area must be evacuated and all personnel kept well upwind of the area Fullfire fighting protective gear anda self containedbreathing apparatus operating inthe positive pressure mode must be w
23. 2 Not N A S A q E A E Issue 1 August 1994 28 X300 VSM y Security System RESTRICTED ISSUE Saxe A5 9 5 Hood Switch 1 Check continuity between SLCM 22 way connector pin 9 and ground With hood closed open circuit should be recorded with hood open short circuitto ground should be recorded 2 Check wiring continuityfrom pin 9to switch connector pin 1 and from switch connector pin 2 to ground J86 1910 Fia 1 Hood Switch Circuit X300 VSM 29 Issue 1 August 1994 Las Security System RESTRICTED ISSUE y A5 9 6 Horns 1 Check fuses F10 and F14 in LH engine bay fuse box if blown determine reason for rupture and renew 2 Check wiring harness continuityfrom multi plug 26 way connector pin 24 to relay unit connector pin 6 and column switchgear connector pin 16 Ensure secure ground connection from column switchgear connector pin 7 Check wiring harness continuity from fuse connector pins 7 and 8 to LH and RH horn respectively Ensure secure ground connection from both horn units Ensure that 12V nominal is present at the relay connector pin Operate horn switches and check that 12V nominal is present at the two fuse connector pins and at speaker connector pin 44 both units Check resistance across speaker unit pins a value of approximately 2Q should be recorded 2 gt KM o wm mmm em mm mm oe pm oe a H EIER g z 1 i l im on mm wm J86 1911 Fig 1 Horn Unit and Rela
24. A5 7 6 Panic Feature Key ring Transmitter Only Ensure the ignition key is not in position I or Il and check panic alarm as follows To operate the panic alarm o Variants 1 and 3 press and hold the small button for 3 seconds o Variant 2 press and hold either the small or large buttons for 3 seconds Ensure that the panic alarm sounds for five times the normal full alarm period and the alarm can only be stopped by turning the ignition key to position I or Il ie the key ring transmitter can not be used to cancel the panic alarm Check that the alarm unlocks the doors and fuel filler flap Note The panic alarm can be operated at any time during the locking or unlocking procedure regardless of the state of the locking security system A A SS X300 VSM 19 Issue 1 August 1994 e Security System RESTRICTED ISSUE y A5 7 7 Central Locking Note Ensureall doors are fully closed before commencing lock operations With the ignition switch in either position I or Il pressthe central lockingswitch andcheckthat all the doors andthe luggage compartment lock ifthey are unlocked Hold down the switch for 3 seconds and check any open windows or the sliding roof close if open Check that afurther press onthe central lockingswitch after 3 seconds will unlockthe doors andthe luggage compart ment Ifthe switch is pressed when ignition switch is not in position lor Il tilt and intrusion sensing will be disabled u
25. EEEE a a a X300 VSM i Issue 1 August 1994 Security System RESTRICTED ISSUE Sub Section Issue 1 August 1994 Title SRO Page slem Testing vrai A ES ENNEN begeg aE nes 77 LOCKING KO Yi as ave aa nae maya a en epee thin a Sad wea O eat wea 17 Unlocking KEY vg g d Ee e Ze A Sid atte ie ncaa ia aa 17 Locking unlocking key ring transmitter oe eee eee eee eee eee eee eeeeee 18 Locking key ring transmitter E 18 Unlocking key ring transMitler 0 cece eee ne 19 Panic feature key ring transmitter only en 19 CENIANOCKING oia a ENEE EE VE eae EE KENE EEN ye bade EE 20 Paseivearmmummg uk KEE A A 20 TUN TOCA mia a A a A A A al id 20 UNREAL 20 FIUSASIIDUTIONS ee ee NA NEEN ENN ae ee eee en EENS NEEN ME NENNEN 20 Diagnostic SUD ROUtINGS 60 eee eee eee eee eee eee eeneeeeee 21 Pinpoint TOSSES e e hala no ENN weal EEN EEN E EELER ace ae ate EEN KEEN ENEE EN dE NEE a 24 Central locking SWACH e EE EISE EE A 25 Door ajar SWITCHES EE 26 Door e AA O de oe ele ee g 27 Door lock actuators and SWItCH eoooonooeenennnnnnnnn eee eee eee Ei 28 HOO MC aie ieee os e ow cereale a E 29 A EE dE EE EE A dE 30 incli nationsensor A Son Si aiei Sialie wate E ewan we ydiajeceseeeta re Soe wre e eee dye ee ee ace a Ree E 31 Intrusion sengore sence eee eee 32 Key barrel SWITCHES oooononnnoonnnnn eee eee eee eee eee ee eeeees 33 Reader exciter coil ANA module coooconnnnnccnnn eee eee eee eee eee eeeeeeeee 34 Security active Indicato
26. MY APPOINTMENT TO sr IMENT TO BY APPOINTMENT TO HER MAJESTY QUEEN ELIZABETH 1 nen eg EE HIS ROYAL HIGHNESS THE PRINCE OF pase ke MANUFACTURERS OF DAMLER AND JAGUAR CARS MANUFACTURERS OF DAIMLER AND JAGUAR CARS MARUPAC TUNERS OF E JAGUAR CARS LRETED COVENTRY JAGUAR CARS LIMITED COVENTRY JAGUAR CARS LARTED COVENTRY JAGUAR XJ6 XJI2 Vehicle Service Manual Published by Product Development amp Publications Jaguar Cars Limited Publication Part Number JJM 1004 12 50 Q De Introduction FOREWORD KN This Vehicle Service Manual VSM is Dart of a set of service literature which covers procedures for the efficient diagnosis and rectification of problems associated with all areas ofthe X300 family of vehicles It is designed to be read in conjunction with other manuals namely the various Unit Service Manuals USM as applicableto the particular vehicle under diagnosis repair andthe X300 Electrical Diagnostic Manual EDM see list below it should be noted that its scope is limitedtothose areas that are uniquetothe family e g Remove amp Refit procedures for Body Components Engine Transmission etcetera Fuel Emissions amp 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 manualtransmissions are covered inthe separate Unit Service Manuals The UnitService Manu
27. Nm Blower assembly to body 4 7 Condenser to receiver drier tube nut Discharge hose to condenser tube nut 22 28 Heater cooler case to body 5 7 Hoses to compressor 7 10 Hoses to evaporator plate Liquid line to receiver drier tube nut Mountina strut to heater cooler case a EE Issue 1 August 1994 ii X300 VSM 111 SERVICE MATERIALS Description HFC 134A ICI Klea or equivalent Climate Control Systems Refrigerant Recyclable NOT compatible with CFC 12 Polyalkyleneglyco PAG Compressor lubricant Absorbs water readily NOT compatible with mineral based oils IV SERVICE DATA Application Specification Charae weight Lubricant capacity 1100q rt 50g 160 200 mi Compressor pressure relief valve Drive belt 12 cylinder Drive belttension All figures apply to a cold belt Special note Drive belttension measuring point Drive belt 6 cyclinder Drive belttension All figures apply to a cold belt Drive belttension measuring point Opening point 34 Bar Closing point 27 6 Bar Maximum leakage rate of 113 liters minute 41 Bar 1450 mm long 7 rib Poly vee Burroughs method New belt 790 N If tension falls below 270 N reset at 630 N Clavis method New belt 114to 120 Hz Iftension 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 compress
28. Note Term Material Name ABS Acrylonitrile Butadiene Styrene ABS PA Acrylonitrile Butadiene Styrene amp Polyamide nylon blend ABS PC_ Acrylonitrile Butadiene Styrene amp Polycarbonate blend ABS PBT Acrylonitrile Styrene Acrylate Polybutylene Terephthalate l PA Polyamide nylon PC Polycarbonate PE Polyethylene PMMA Polymethyl Methacrylate POM Polyoxymethylene acetal PP Polypropylene PPO Modified Polyphenylene Oxide PUR Polyurethane PVC Polyvinylchloride SMA Styrene Maleic Anhydride Not all plastic components are nominated only those suitable for economic reclamation A 1 6 2 Plastics Handling Notes Note O Q With reference to the following conditions consider the properties of those plastic components which may be affected by a repair or rectification procedure As mentioned elsewhere the exterior panel temperature of the vehicle must not exceed 95 C at any time and may only be held atthis upper limitfor a maximum of 2 two hours Interior vehicle temperature must not exceed 86 C the time limit being 2 two hours Temperatures above those specifiedin 1and 2 may result in distorted or permanently damaged components Ifthere is any doubt whatsoever remove those components which may be affected bythe application of heat Certainitems may be manufacturedfrom blended materials these must NOT be recycled with pure materials For example do not mix PC ABS wheeltrim with ABS B
29. Note Roadspeedsshown above arefor a vehicle with an axle ratio of 3 58 1 and standard tyres 225 65ZR15 For avehicle with optional sports tyres 225 55ZR16 lattice wheels these speeds must be reduced by 2 4 X300 VSM Issue 1 August 1994 8 2 Lightthrottle D4 TCC on Normal 48 55 77 88 sport 51 59 82 94 Upto detent D3 D4 Normal 83 91 133 164 73 79 99 107 117 127 158 172 Maximum shift speeds through detent D2 D3 D3 TCC on Normal Sport 81 89 116 124 130 149 186 198 Zero throttle TCC off in D4 D4 D3 36 40 15 17 58 64 24 27 sport 36 40 18 20 58 64 29 32 Upto detent D4 D3 Normal mile h 67 75 kmih 108 119 84 92 27 29 134 148 43 47 Kick down available throughdetent TCC4 D3 D2 D1 Normal Sport mile h 103 113 67 75 36 40 km h 164 181 108 119 58 64 TCC Torque converter clutch Note Roadspeeds shown above are for avehicle with an axle ratio of 3 58 1 and standardtyres 225 65ZR15 For avehicle with optional sports tyres 225 55ZR16 lattice wheels these speeds must be reduced by 2 4 8 2 Issue 1 August 1994 4 X300 VSM 8 2 2 TRANSMISSIONINTERNAL HARNESS RENEW 4 OL SCAND 6 0L SRO 44 15 35 Open the hood and fit a suitable fender cover a Raisethe vehicle on a ramp a Drain the transmission lubrication system see Sub sec tion 8 2 13 Removethe fluid pan see Sub section 8 2
30. Power unit and Transmission y 76 104 J Label Anti theft 1 Label Replacement part X300 VSM Issue 1 August 1994 30 A 7 L y Body Systems amp Body Repair 2 S Ss A4 4 3 7 Fitting Process Fit and fully secure the replacement panel s if appropriate a Using a suitable solvent clean the area where the anti theft label should be affixed a Peel the backing from the label and position on the panel Carry out ALL refinishing protection processes a Remove the anti theft label protective mask prior to vehicle handover to the customer Note Any attempt to remove an anti theft label will destroy that label Please ensure correct location before affixing CAUTION Itis a requirement of the United States of America federal law that the protective mask is removed from the anti theft label after performing painting and rustproofing operations FAILURE TO COMPLY MAY RENDER BOTH THE MANUFACTURE AND THE DEALER IN VIOLATION OF THE FOLLOWING LAWS Federal Motor Vehicle Theft 51 FR 8831 at 8835 March 14 1986 Prevention Stan dard Motor Vehicle Information 15 U S C 2027 a 4 B and Cost Savings Act 2027 b sections 607 a 4 B and 607 b X300 VSM 31 Issue 1 August 1994 gt a RS Body Systems amp Body Repair d Vt A4 4 4 UNDER HOOD LABELS Headlamp beam setting adjustment Shock absorber fixings Warning Emission control data Power steering Warning Brake fluid type
31. RESTRICTED ISSUE Y Locking unlocking and setting the vehicle alarm system is carried out by key or by radio frequency key ring trans mitter Operation of the system by key or key ring transmitter will be described separately in this sub section Key ringtransmitter functions vary slightly between marketvariants The actionfor each variant is describedseparate ly where appropriate Note Certainfunctions differ due to market variations Differences will be detailed in the the following instruction tables The variants are defined as follows Q Variant 1 European and UK markets o Variant 2 North American markets Q Variant 3 Rest of the World A 5 1 Locking key Instruction Variant 1 rurn key to lock position Lock all doors trunk lid and release fuel filler cap and arm the alarm system perimeter only rurn key to lock position old for 2 seconds andre ease Lock all doors trunk lid fuel filler cap Arm the alarm system perimeter only Close open windows and sliding roof Ock all doors trunk lid uel filler cap and arm the alarm system ock all doors trunk lid uel filler cap Arm the alarm system Close open windows and sliding roof Lock all doors trunk lid fuel filler cap and arm the alarm system perimeter only alarms Lock all doors trunk lid fuel filler cap Arm the alarm system perimeter only Close open windows and sliding roof rurn key to un
32. Renew vacuum booster Renew vacuum hose Check for leaks refill and bleed the system Renew brake pads Examine brake pads and clean or renew as necessary Renew valve block Examinefront brake rotor andservice or renew as necessary Carry out wheel alignment Refer to Section 11 iv Service Data Inflate tire to correct pressure Brakes do not release Excessive pedal travel No brake pedal free play Vacuum booster binding Tandem master cylinder return port faulty Faulty valve in ABS valve block Leak in hydraulic system Air insystem Adjust brake pedal free play Renew vacuum booster Clean return port on tandem master cy linder Renew valve block Repair leak Check all pipework con nections Refilland bleed the system Check the system for leaks and bleed brakes Issue 1 August 1994 16 X300 VSM Brakes e 12 2 Trouble Excessive pedal travel Cont d continued Brakes grab Brakes drag Hard brake pedal when pressed Excessive brake noise Cause Remedy Worn tandem master cylinder piston seals or scored cylinder bore knock back Excessive brake rotor run out or loose wheel bearings Brake pads contaminated by grease or brake fluid Brake pads distorted cracked or loose Loose caliper mounting bolts or guide pins Renew tandem master cylinder Check brake rotor run out and renew as necessary Adjust wheel bearing Renew brake
33. a Reposition the edge of the transmission tunnel insulation foam for access a Releaseand remove the input speed sensor securing bolt Reposition the speed sensor protection cover for access noting that the cover remains captive on the harness Disconnect the speed sensor harness multi pin plug a Displace and remove the speed sensor from the trans mission case e Clean the transmission case area a Fita new ring seal to a new input speed sensor a Lubricate the O ring seal a Fit and fully seat the speed sensor to the transmission case a Reconnect the harness multi pin plug Reposition and align the protection cover a Fit and tighten the speed sensor securing bolt e Repositionthe insulationfoam to its original position e Remove the block of wood from between the underfloor catalyst and the floor a Apply sealantto the downpipe joints and olives See Ser vice Materials inthe preliminary pages this Section e Fit and seat the olives to the downpipes Reconnectthe underfloor catalyst to the downpipes e Repositionthe olive clamps Tightenthe underfloor catalyst to downpipe clamps secur ing bolts e Align the intermediate silencers to the underfloor catalyst assembly a Tighten the clamp securing bolts a Lower the vehicle onthe ramp Removethe fender cover and close the hood issue 1 August 1994 8 X300 VSM a Automatic Transmission V12 amp AJ16 Supercharged ae Powertrai
34. flushed andfilled with fresh coolant Flushing should be carried out thoroughly to remove all the old coolant from the engine and heater matrix Theheatervalve is open with the ignition OFF After filling check the coolant concentration with a hydrometer For specified anti freeze and coolant concentration see in Appendix Al X300 VSM 3 Issue 1 August 1994 ES Cooling System V1 2 4 2 4 DRAIN AND FILL PROCEDURES 4 2 4 1 Radiator Drain a Placea draintray in position underthe radiator drain plug Fig 1 a Removethe headertank pressurecap Releasethecaptive radiator drain plug and drain the coolant e Tighten the radiator drain plug CAUTION This procedure does not drain the heater cir cuit WARNING DO NOT REMOVE THE HEADER TANK PRES SURE 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 Lipp ET N 126 274 LEAVE THE CAP INTHIS POSITION UNTIL ALL THE STEAM AND PRESSURE HAS ESCAPED AND THEN REMOVE THE CAP COMPLETELY WARNING WHEN DRAINING THE COOLANT WITH THE ENGINE HOT PROTECTM EHANDS AGAINST CONTACTWITH HOT COOLANT 4 2 4 2 Radiator Fill a Add coolant until the level inthe header tank is steady at MAX Do not fit the header tank cap a Switch onthe ignition The climate control system must be OFF a Start the engine and add coolant to the header tank if required to en
35. itisimportantthatthe shed der is refitted correctly to maintain the water seal Itis advisable notto disturb the bottom taped portion of the water shedder unless absolutely necessary itis possible to unclip the top of the shedder and bend it over to gain accessto the inner panel If itis necessaryto disturbthe bottom attachment egto removethe water shedder from the door panel the existing water shedder must be discarded and a new onefitted to ensure that the sealis maintained On refitting the new water shedder should be pressedontothe door panel atthe top andthenthe adhes ive tape backing strip peeled off to enable the shedder to be pressed home atthe bottom 13 2 2 front and Rear Door Trim Pad Veneer Panel Renew SRO 76 47 11 76 47 12 a Reposition the inner door handle See Fig 1 e Removethe inner handle escutcheon plate blanking plate Undo and remove the inner handle escutcheon plate se curing screw a Removethe plate and gasket a Carefully Undo and remove the veneer panel Undo and removethe retaining clip securing screws Removethe retaining clip assemblies a Place the veneer panel aside Place the new veneer panelto the front e Fitthe retaining clip assemblies a Fit and tighten the retaining clip securing screws a Fit and fully seat the veneer panel to the door a Reposition the inner door handle a Fitthe gasket and plate over the inner door handle a Fit and tighten the escutcheon plate
36. protruding through the centre hole of the engine side mounting bracket The front of the engine complete with attached mounting bracket assemblies is seated on support brackets welded to the front crossmember and is secured to the brackets by a single fixing arrangement comprising bolts and washers a Jack up the vehicle and secure the engine hoist Service Tool MS53 C to lifting eyes of the front engine lifting brackets Removethe front engine mounting bracket assembly to front crossmemberfixing bolts These can be accessed via two round openings positioned underneath the cross member Removeany obstructing parts preventingthe front end of engine from being lifted from its seating Liftthe front endof the engine transmission unit slightly and detach the front mounting bracket assemblies from the lower engine housing Engine V1 2 Fig 2 X300 VSM y Engine V12 mmg 3 2 7 REARENGINE MOUNTING ASSEMBLY RENEW SRO 12 45 04 The rear engine mounting assembly Fig 1 comprises a mounting bracketand spring assembly securedto body un derframe longitudinal members using nuts and washers Withthe aid of the engine hoist Service Tool MS53 C se curedtothe lifting eyes ofthe rear engine lifting brackets andajack positionedunder the rear mounting brackettake the weight of the engine a Undo and remove the mounting bracket and spring as sembly fixing arrangement Lowerthe jack and remove assemb
37. Automatic Transmission Ratios Powertrain FIGS a il ad ias 2 482 1 Secad ii EE 1 482 1 A deuce oe uahu ie tseiacese iste a Ea seals EEE E E ese 1 000 1 FOURN abris EEN 0 750 1 REVES a Wow AA RC 2 077 1 Final Drive Unit Ratios 3 2 liter Manual Nee ci A a AEN N EC 3 77 1 32 liter Automati erger dg ees Se a as 4 08 1 4 0 liter A tomatiG ees istie Lai al Ate d 3 54 1 40 liter Manual seein egen a a a a NENNEN EN 3 54 1 4 0 liter Supercharged e 3 27 1 B ISE iii dl 3 54 1 Climate Control air conditioning System COMPIESSO ic a la altea biel Nippondenso 10PA17C Compressor lubriCant e ND Oil 8 R frigerant ii A A E EESE R134A Refrigerant Charge Weight E 1100g Issue 1 August 1994 A1 95MY 2 X300 VSM Braking System Front brakes all vehicles a E E Specification Caliper piston diameter EE EE E Rear brakes all vehicles ooooocoooccmmmnnnnnnannnaaanos Caliper piston diameter EE EE EE EE En Parking brake Disc diameter Beat Eege Brake operation Master cvlinder EEN EEN Main brake friction pad material Front REAM TEE a Parking brake friction shoe material Brake servo booster assembly Boost ratio Anti lock braking system ABS Wheel SENSOMS vacia a Di KN EN X300 VSM ABS modulator EE Control moduletvpe EEN A1 95MY 3 Power assisted ventilated discs sliding calipers FN60 single piston Power assisted ventilated discs FN48 single piston sliding calipers Mechanical
38. CARCINOGEN BY THE STATE OF MASSACHUSETTS USA SODIUM AZIDE HAS BEENLISTED ON THE RIGHT TO KNOW HAZARDOUS SUBSTANCE LST BY THE STATE OF NEW JERSEY AND IS ALSO REGARDEDAS A SPECIAL HEALTH HAZARD SUBSTANCE BY THE STATE THE PROPELLANT MIXTURE ISSENSITIVETO PREMATUREIGNITION BY ELECTRICAL SOURCES IF NOT PROPERLY PROTECTED AND ISOLATED 15 1 3 Emergency First Aid Procedures Ifthe airbag is ruptured without deployment and exposure to the propellant mixture occurs observe the following first aid treatments Ingestion Do not induce vomiting and seek prompt medical attention Skin contact Immediately wash skin with soap and water and seek medical attention Eyes Immediately flush eyes with water for at least 20 minutes and seek prompt medical attention Inhalation Immediately move victim to fresh air and seek medical attention Physical trauma eg burns abrasions or impact due to premature ignition or deployment of the inflator assembly Treat symptomatically and seek prompt medical attention 00000 15 1 4 Safety Procedures For HandlingDeployed Fired Modules See Emergency First Aid Procedures above Preventcontact of the inflatorwith liquids combustibles andflammable materials Failureto followthese instructions could result in chemical burns and personal injury Ensure modules are cool before handling After deploymentthe airbag surface contains small deposits of sodium hydroxidewhichcan cause irritationto the skin and eyes
39. HP11 2RX Tel 0494 534801 3b Continental Europe Stain amp Co GmbH Wulfrather Strasse 49 49 D 5620 Velbert Germany 3c UK HOST UK Unit 1 Ranch House Normanton Lane Bottesford Nottingham NG13 OEL Tel 0949 43372 3d Continental Europe Mr Alex de Roeper Sanfresh BV Dotterbloemstraat 1 3053 JV Rotterdam Holland Tel 31 10 422 5455 13 7 6 Repair of Damaged Carpet The most common cause of accidental damage to carpets is cigarette burns especially to polypropylene carpet These can be repaired easily on newcarpets by cutting out the face material inthe affected area and replacing with newface material with a latex locking coat of approximately 100g m dry then incorporating aP S A B pressure sensi tive adhesive backing which would be appliedto rollcarpet inthe form of alaminate film at Firth Furnishings subsidi ary Textile Bonding Higham Ferrers Northampton UK The film has a peelable release paper which meansthat the new material would simply be cutto size the release paper removed and then the new carpet pressed into position The problem inreplacing areas inold or soiledcarpetsisthatthe replacementof damaged areas with newcarpetwould create avisual difference ie un worn pile clean appearance which would then cause the repaired area to stand out from the rest of the carpet The only answer would beto abrade the rest of the newcarpet to the same degree asthe old carpet X300 VSM 47 Issue
40. Issue 1 August 1994 a X300 VSM Brakes el 12 1 7 Parking Brake J70 293 Parking brake lever In line cable connector Front cable Rear cable RH Relay lever Rear cable LH Driveshaft securing bracket Intermediate cable Cable equalizer 4 0 9N 0 Parking brake switch and harness 1 Parking brake warning lamp DIAN Fig 1Parking Brake Layout All vehicles are fitted with identical parking brake systems Whenthe parking brake leverisoperated the cable system applies equalforce to bothRH and LHbrakeshoe expander assemblies The brake shoes expand and press against the hub assembly locking the rear wheels The handbrake lever ratchet assembly and warning lightswitch item 1 are mounted onthe transmission tunnel by means ofthreeflanged screws a blanking plateand gasket Thefront cable item2 isconnectedtothe relay lever item 3 which is mountedonthe driveshaft securing bracket item 4 The relay lever operates the intermediate cable item 1 2 5 which incorporates an adjusting screw to allow cable tension to be adjusted The intermediate cable operates the equalizer which ensuresthatequalforce is appliedto RH and LH parking brakesvia rearcable RH item 8 and rearcable LH item9 The rear cables are adjustable to allow cable tension to be adjusted The park brake switch item 10 latches when the lever is operated and lights the parking brake warning light item 11 mounted inthe instrument panel X300 VSM 9 Is
41. Les Security System RESTRICTED ISSUE y Component Location Diagram Fig 1 Component Location Diagram Issue 1 August 1994 2 X300 VSM Security System RESTRICTED ISSUE Key to Component Locations Description Access details Central locking switch part of clock module Door ajar switches 4 off part of door tatch assembly Door lock actuators 4 off part of door assembly Door lock switches 2 off Hood switch located above siren located on front RH side of engine bay 07 Inclination sensor behind luggage compartment LH liner Intrusion sensor LH located above LH door behind roof linin intrusion sensor RH located above LH door behind roof linin Key barrel switches 2 off part of door latch assembly 11 Key fob transmitter artof keyfob 12 Key transponder artof ke 13 Reader exciter coil art of ignition switch 14 Reader exciter module art of steering column assembl 15 Relays deadlock Relays door lock unlock Rear screen aerial part of rear screen Security active indicator part of central locking switch Security andlocking control module SLCM located in luggage compartment behind LH liner 18 19 20 Sounder located on front RH side of engine bay _ 21 Trunk release actuator located in trunk latch mechanism 22 Trunk release relay Trunk lid release switch external part of trunk lid Trunk lid releas
42. O ring seals to a new pulse width modulator a Lubricate the O ring seals a Fitandseatthe modulator inthe correct orientation tothe valve body using atwisting motion a Fitthe pulse width modulatorto valve body retaining clip a Connectthe internal harness plugto the modulator a Refitthe fluid filter see Subsection 8 2 18 a Refit the fluid pan see Subsection 8 2 14 4 0L SC or Sub section 8 2 15 6 0L a Lower the vehicle on the ramp a Refill the transmission unit with fluid see Subsection 8 2 13 m Remove the fender cover and close the hood X300 VSM 11 Issue 1 August 1994 a j Automatic Transmission V12 amp AJ16 Supercharged Powertrain 8 2 11 A SHIFT SOLENOID RENEW 4 0L SC AND 6 0L SRO 44 15 45 Open the hood and fit a suitable fender cover Raisethe vehicle on a ramp a Drain the transmission lubrication system see Sub sec tion 8 2 13 Removethe fluid pan see Sub section 8 2 14 4 0L SC or Sub section 8 2 15 6 01 a Disconnect the internal harness plug from the A Shift solenoid a Release and remove the A Shift solenoid to valve body securing screw a Remove the solenoid from the valve body Fig 1 s Removeand discard the Or ring sealfromthe valve body a Placethe solenoid aside a Fitanew O ring sealto a new A Shift solenoid a Lubricate the O ring seal e Fitthe solenoid to the valve body using atwisting motion Fia 1 a Fit andtighte
43. Rene EEN 12 45 08 commons 5 X300 VSM i Issue 1 August 1994 a Engine V12 L SERVICE TOOLS EQUIPMENT Quick fit pipe disconnect ngtoo 18G 1465 Engine lifting bracket 3 2 Engine support beam not illustrated Snap On Oil filter canister removal tool IL TORQUE TIGHTENINGSPECIFICATIONS Fixing lightening Torque Nm Oil cooler to body 17 23 Oil cooler hose clamp to radiator cradle 7 10 Oil cooler pipesto engine 17 23 Heat shieldto hydraulic mount 45 Hose clamp hose to air cleaner and induction elbow 34 111 SERVICE MATERIALS Description Uses Notes Hylosil 102 sealant Filler cap Oring Vaseline or Silicon Top of oil filler tube 5000 Tivoli Kay Adhesives Exhaust system joints No 5696 sealant Issue 1 August 1994 ii X300 VSM y Engine V12 eem 3 2 1 ENGINE GENERAL The twelve cylinder vee formation engine has a capacity of 6 0 liters Each cylinder bank has a single overhead camshaftandtwo valves percylinder The engine hasa fully mappedengine managementsystemwith digitalignition and two ignition coils This section describes the service proceduresto be carried out with the engine in situ It also covers the renewal of the engine transmission unit For informationrelatingto strip down inspection fault diagnosis renovationand rebuildwork refer to the V12 Engine Service Manual X300 VSM Issue 1 A
44. Renew ocococcncncnnnnnn HEIEREN 32 y wech Steering Column Switchgear Mounting Bracket Renew HEITE EEN 33 13 3 32 rara aa A Post Lower Trim Pad Heem OAI 20 35 13 3 33 iaa Rear Quarter Upper Trim Pad Renew usssssssssssnsennensnnennnnnsnnennenennennenun 35 JE et ee B Post Upper Trim Pad ReneW ooccconocconncnannnnnnn kepis kinetan nen aein a a aE 35 III ir ee BY Post Lower Trim Rad RCNGW ENEE 35 LEE Handbrake Lever Trim Renew 35 13 337 ii Combined Grab Handle and Coat Hanger Hook Renew ENEE EE 35 LEE Sun Visor Assembly RH or LH Renew ENEE EE 36 13 339 ia Roof Lining Headlining Description oocoocononccncnnnna eeeeeeeeeeeeeeeeaas 37 LEET Roof Lining ReNeW sssssnunnsnnnnasasnunnsnsnasuasasnununnssnnnasasnunusnsnnenenn 37 LIA eege TUN a gege EE NEE eege AR A A a Ee ER 38 E O Trunk DESCIipti0N ooooccccoccnnncnnnnanan eee eee eee eee ee E 38 US AQS uaaa Trunk Side Liner Left Hand Renew En 76 1922 AEN Eer ee 39 13 43 wakaae Trunk Side Liner Right Hand Renew EEN E 70A 92I ia aa 39 Fe EEN Trunk Floor Carpet Renew ENEE ENEE Z0 I 20 39 VIAS aie ca eene Trunk Front LINCE Renew ste kk eine save ies ace sae oie ENEE NEEN E e de EE 39 LIA O ii Trunk Seal Retainer Renew oooccccccccccccncc eeeeeeees 70 19 44 sauunnnnnnen 40 DBT eric ete E Tr nk Lid Striker AQjUSt 4 coos isis a 40 J348 acia Trunk Lid Liner REN W si ec ee deeded eee N NENNEN NS NIE eee eee eee weet eee EN ER 40 LIADO aur bce cases
45. a Displace and remove the window lift assembly end cover trim pad Fig 2 a Undo and removetheveneer panelto switch assembly se curing screw a Displace and remove the veneer panel from the forward securing clip a Place panel aside a Fitand fully seat newveneer paneltotheforward securing clip a Fit and fully tighten the panel securing screw a Fit and fully seat the switch assembly end trim pad 386 tot X300 VSM 3 Issue 1 August 1994 Body Components amp Trim 13 2 6 Rear Door lower Trim Pad Remove For Access And Refit SRO 76 34 06 90 Removethe rear door armrest see sub section 13 2 8 From inside the door pocket release the puddle lamp 1 Fig 1 securing quarter turn fastener a Disconnectthe multi plugs 1 Fig 2 and removethelamp a Carefully displace the trim pad 2 Fig 1 from the door re taining clips a Displace trim pad fromthe upper retaining tang 3 Fig 1 Disconnect the door speaker multi plug 2 Fig 2 andthe window lift switch multi plug 3 Fig 2 a Feedthe lamp harnessthroughthetrim pad and lowerthe trim pad assembly a Position the trim pad to the vehicle a Feed the puddle lamp harness through the trim pad A 165088 Connect the window lift switch and speaker multi plugs a Locate the trim pad upper retaining tang a Fit and fully seat the trim pad retaining clips Fig 1 Place the puddle lampto position a Connect the lamp multi plugs a Fit a
46. causingtotal loss of refrigerant O Leakinsystem causing total loss of refrigerant possible code 23 o Blockedfilter inthe receiver drier o Evaporator sensor disconnected possible code 13 o Pressureswitch faulty possible code 23 X300 VSM 15 Issue 1 August 1994 hw l PE Climate Control Systems Insufficient Cooling Q Sluggish blower motor s Restricted blower inlet or outlet passage Blocked or partially restricted condenser matrix or fins Blocked or partially restricted evaporator matrix Blocked or partially restricted filter inthe receiver drier Blocked or partially restricted expansion valve Partially collapsed flexible pipe Expansion valve temperature sensor faulty this sensor is integral with valve and is not serviceable Excessive moisture in the system Air inthe system Low refrigerant charge possible code 23 Compressor clutch slipping Blower flaps or distribution vents closed or partially seized possible codes 41 or 46 Coolant flow valve not closed Evaporator sensor incorrectly positioned COO OO Oo OO OO 8 8 OG Note Shouldaleak or low refrigerant be established as the cause of INSUFFICIENT COOLING follow the procedures Recovery Recycle Recharge this section and observe all refrigerant and oil handling instructions intermittent Cooling o Isthe electrical circuit to the compressor clutch consistent o Isthe electrical circuit to the blower motor s consistent o Compressor clutch sli
47. checkfor leaks and repeat the bleed procedure a Fillthe reservoir to the max level 12 4 4 System Bleeding After Hydraulic Control Module Renewal Hydraulic control modules are supplied pre filledto enable the brake system to be bled inthe conventional way a Ensure that the vehicle is standing level Switch the igni tion off a Check that the fluid level inthe reservoir is between the min and max marks Connectthe bleeder bottletube to the relevant front cali per see note on previous page bleeder screw 1 Fig 1 and open the screw a Actuate the brake pedal full stroke wait a moment and then release Wait two to three seconds and then actuate the brake pedal full stroke again This allows the TMC to be completely re filledwith fluid a Repeat 20to 30 times until the fluid inthe bleeder tube is clear and bubble free Withthe brake pedal actuated close the bleeder screw Build up fluid pressure by pumpingthe pedal and then open the bleeder screw Repeatthis action three times Note Ifafiller unitis not used observe the fluid level inthe reservoir andtop up if necessary a Repeatthis procedure for the remaining three calipers a With the motor running check brake pedal travel If pedaltravel is excessive checkthe system for leaks and repeat the bleed procedure Fillthe reservoirto the max level 12 4 5 Bleeding After Renewal of Caliper Follow the procedure above but only at the affected caliper
48. enee NNN ed ens te eee tee a NNN EN ANNER EINEN ee ee et ade See eas 44 130 EE Extenor Mirror Glass Renew EE 44 VOL areas NO setae CAMS A A EN tan dE 45 13 7 1 coco Carpets Descriotion ononcennnnnnnnnnne ee eee e eee ene ene eee eee 45 Li feat eatin texte a Removal of Stains General Information ooooocenononrnnnnannnnn eee eens 45 TELS ca aaa Powder Cleaning Removal of Small Spillage StainS ENEE 45 O vss eee Spot Cleaning Localized Stains 46 E EE Carpet Cleaning and Stain Removal MaterialS EE 47 AAA Repair of Damaged Carpet EE 47 13 8 See ia Seating and Seat Belts EE e eee nee e eee 48 TOO irae tai erase setae Seating Description iia a iaa TEE wie wae wees waved 48 AAA Lieler 48 13 8 EE Front Seat Power Operated Renew EE 48 EE Front Seat Head Restraint Power Operated Renew EE 49 13 8 5 conommonuos Front Seat Head Restraint Power Operated Renew EE EE 49 13 8 Gi Rear Seat Cushion Renew ccccccccccccuccceuceceueaceeeaseenasetuasaseesaseesasecens 49 ELA a Rear Seat Squab Renew EE 49 ERA AAA Seat Belts Description d NN NEE A a a 50 LKH Emergency Locking Retractor Automatic Locking Retractor Seat BeltS oooooonnommnmmmanmmo 50 13 8 10 ar Tear loop Seat Belts Description 220 ee ee cece cee eee eee eee eee ee ee eeeeeeee 51 1381 ici Front Seat Belt Buckle Unit Renew oooconononnnnnnnnnnnnann nan 52 138 12 sais Front Seat Belt ReneW smit ss dore ieren e eee eee a a a a a e eens 52 13 813 EE Rear Inertia Seat Belt Re
49. fluid pan and torque tighten the union nut a Lower the vehicle on the ramp a Removethe transmission dipstick a Renewthe transmission fluid filter see Sub section 8 1 6 a Fillthetransmission with the correctfluid seethe ZF Auto matic Transmissions Service Manual General Data ote Itwill not be possibleto get all the initialfill quantity of fluid into the transmission Refitthe dipstick a Start the engine apply all brakes and runthe transmission through all gear positions and select Park With the engine still running remove the dipstick Clean the dipstick and refit Remove the dipstick and check the transmission fluid level 8 1 a Add fluid until the correct level is achieved a Stop the engine and refit the dipstick Removethe fender cover and lower the hood Check fluid level to the HOT marks after a 20 mile road run to ensure accurate results Issue 1 August 1994 6 X300 VSM Zi Automatic Transmission AJ16 E 8 1 3 TRANSMISSION CONTROL MODULE RENEW 4 01 SRO 44 15 32 a Raise the trunk lid and disconnect the battery a Remove the passenger side dash liner for access e Displace and remove the air conditioning footwell outlet duct a Releaseand remove the footwell carpet securing fastener displace and repositionthe carpet for access Releasethe Transmission Control Module TCM bracket to body bracket securing nut 1 Fig 1 a Disptace the TCM mountin
50. hub splines Remedy Renew driven plate rimary pinion bear ng ncorrect fitting nethod Check for wear in bearing Damage may be caused by acci dental loading during fitting Renew as necessary Always support trans mission weight during fitting Check mating components for damage Renew driven plate Excessive lining wear Iverloading vehicle Referto owners handbook for per missible load details Fit replacement clutch as sembly hiving with left foot Check as described under slipping Fit replacement clutch as esting on clutch clutch sembly vedal 3rabbing clutch Jperating mechan Check operating mechanism for Free off bearing Renew as harsh engagement sm faulty wear and binding which usually necessary om standing start ften followed by clutch udder zluteh unit faults indicates a binding withdrawal race thrust bearing Check pedal for sticking parts in cluding return spring Check for oil on friction driven plate Checkclutchplate and flywheel for wear Check flywheel runout Check also for glazing on driven plate linings Free off pedal and check for damaged and distorted parts Renew if necessary Clean off cover Renew faces Rectify oil leak Reclaim or renew as appli cable Check for driven plate hub splines sticking on pinion shaft Check pinion shaft for wear Check for broken or weak pressure springs Check t
51. on the A Post near the Servotronic Steering Module and under the driver s andthe passenger s seats To gain access to relevant relays remove the heel boards or the centre console wood veneer or the seats or the A Post lower trim pad Issue 1 August 1994 34 X300 VSM y SRO 86 55 89 Gear Shift Interlock Relays Keylock Driver s Seat Height Control Upward Electrical Location Below gear selector J gate G t aer Lage Models only Models only Below gear selector VE gate Nal Automatic Automatic Models only Models EE On seat panel below el UK amp ROW driver s seat Manual cl only Driver s Seat Height On seat panel below eg Control Downward driver s seat Manual Seat only Passenger Seat On seat panel below lad UK amp ROW Height Control passenger s seat Manual Seat Upward only Passenger Seat On seat panel below Violet UK amp ROW Height Control passenger s seat Manual Seat Downward Driver s Seat Heater On seat panel below ad UK amp Manual driver s seat Seat only Passenger Seat On seat panel below i UK amp Manual Heater passenger s seat Seat only RH Front Screen Heater front A post behind cover Left hand side footwell on LH Front Screen Heater Ignition Ignition front A post behind cover Left hand side footwell on Air conditioning Isolate LH Blower Behind RH side heelboard RH Blower Behind RH he
52. one LH and one RH Heatingtemperature control is effected by means of a coolant flow valve and circulation pump For models fitted with air conditioning cooling is provide by passing air through the evaporator which is situated im mediately behind the heater cooler case inlet ducts Electric motors with integral potentiometers are usedto position all flaps Note There are no vacuum operated components in the system 14 2 2 Features Q Self diagnostic control system with error codes o Actuator self check o Display element check Note These features will be helpful for initial trouble shooting and where Jaguar Diagnostic Equipment JDE is not available o Soft touch logic controls o Serial link from panelto control module A CCM o LCD display for temperature status and fan speed o Variable fan speed whether in automatic or manual mode Q Manual air flow distribution over rides o Compensated air flow with regard to vehicle speed O Rear footwell outlets o Rear face outlets Q Scavenge system closed circuit temperature control oO Heatedfront screen wherefitted X300 VSM 3 7 st 1994 A Gu Ae Climate Control Systems 14 3 CLIMATE CONTROL PANEL 12 13 14 15 16 17 18 19 20 Fig 1 Control layout see key listing below The following description of the various control panel functions is provided as a brief over view to assist in function checking Further information concernin
53. pillar upper trim Should plastic components become greasy they may be cleaned with an SBP 3 spirit wipe or equivalent A4 1 6 3 Recycled Materials Any of the materials listed inA4 1 6 1 may be recycled provided that they are notcontaminated by other incompatible plastics or metals For instance the air conditioning unitcase manufactured from PP polypropylene must be separ ated from the heater matrix evaporator control devices electronic and mechanical and all fixings before itcan be considered for recycling After disassembly the case must be placed for disposal only with materials of the same generic type Note X300 VSM The bumper cover assemblies have side armatures non serviceable items rivettedto them becausethey are dissimilar materials the armatures and fixings must be removed prior to recycling Inthe bumper cover intake aperture there is a cosmetic black out piece asimilar component may be found onthe fog lamp blanks wherefitted These items should be separated fromthe major componentfor recycl ing 5 Issue 1 August 1994 o D gt Lo O a o YN E YN gt wn gt Lo O a A4 1 6 4 Plastics Component Location amp Type External SIEN pojoAcey a30u 993 paquied j Yd 9g patuolyo H SEV IA en v101 9 1 X300 VSM Issue 1 August 1994 Body Systems amp Body Repair A4 1 6 5 Plastics Componentlocation amp Type Internal S
54. remote diagnosis Diagnostic Trouble Code DTC an alpha numeric identifier for a fault Self Test Code condition identified by the On Board Fuel Fail code Diagnostic OBD system differential housing rotating housing in a bevel differential differential cage attached to the crownwheel carrying the final drive pinions differential pressure pressure difference betweentwo regions e g between intake manifold and atmospheric pressures Differential Pressure Feedback DPFE an EGR system that monitors differential EGR EGR pressure across a remote orifice to dimmer switch dip switch dipper switch X300 VSM 11 Issue 1 August 1994 o Introduction GLOSSARY OF TERMS Abbreviation Definition if applicable Term s Previously used term s or Eng lish Equivalent direct current dc current which flows in one direction only though it may have appreciable pulsations in its magnitude disk disc Distributor Ignition Distributor Ignition Cap Distributor Ignition Carbon Brush DICB distributor distributor cap distributor car bon brush distributor leads distributor rotor arm Distributor Ignition Leads DIL Distributor Ignition Rotor Arm DIRA Issue 1 August 1994 12 X300 VSM Introduction GLOSSARY OF TERMS Term s Abbreviation Definition Previously used if applicab
55. 0L SC and 6 OL seen 44 26 10 cocos 23 X300 VSM i Issue 1 August 1994 daa i Automatic Transmission V12 amp AJ16 Supercharged Powertrain 1 SERVICE TOOLS 8 EQUIPMENT No Jaguar service tools are required for the operations covered by this Sub section Fixing lightening Torque Drain plugto fliud pan Fluid pan to case pp 0324 Nm Pressure control solenoid bracket to valve body 8 Solenoid to valve body 8 Speed sensor and bracket assembly to case 11 Valve body to case lubrication pipe a a Valve bs Valve body to case PSM Description Uses Notes Tivoli Kay Adhesives No 5696 Exhaust system joints sealant Description Data d To be issued Issue 1 August 1994 ii X300 VSM y Automatic Transmission V12 AJ16 Supercharged aa Powertrain 8 2 1 GENERAL DESCRIPTION This section provides information relating to the Powertrain4L80 E transmissionsfitted to the 4 0 liter supercharged engine 4 0L SC and to the 6 0 liter engine 6 0L The Powertrain4L80 E is a four speed high torque capacity electronicallycontrolled automatictransmission which comprises a torque converter with lock updirect drive clutch andthree planetarygear 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
56. 1 August 1994 ini Body Components amp Trim 13 3 18 Fascia Board Remove For Access And Refit SRO 76 46 01 90 a Remove the battery cover Disconnect the battery Remove the drivers side and passenger side underscuttle pads see sub sections 13 3 19 and 13 3 20 a Remove the drivers airbag module see section 15 5 a Remove the steering wheel section 10 Removethe drivers side fascia closing panel seesub sec tion 13 3 22 a Removethe passenger side fascia closing panel see sub section 13 3 21 a Remove the fascia center veneer panel see subsection 13 2 23 a Undo and remove the fascia tie bar securing nuts a Displace the tie bars a Undo and remove the instrument housing fascia switch pack securing screws a Reposition the multi plug mounting bracket a Disconnect the steering column control module multi plugs a Disconnect the fascia switchpack harness multi plugs a Displace and reposition the instrument pack for access a Disconnectthe instrument pack harness multi plugs a Remove the instrument pack fascia switchpack assem bly a Disconnect the right hand fascia harnessto cabin harness multi plug a Disconnect the column switchgear and column motors harness multi plug e Disconnect the ignition switch harness multi plug a Disconnect the exciter coil harness multi plug a Disconnect the speaker tweeter harness multi plug a Disconnect the speed control control module harness multi
57. 10 2 MainHarnesses General Description J86 1720 Fig 1 Main Harnesses Fig 1showsa plan view of the main harness runs insidethe trunk the passengercompartment andthe engine bay The illustration isto be read in conjunction with the following table To avoid any accidents such as electric shocks always disconnectthe battery negative leadfrom the battery negativeterminal before disconnectingany of the listed cables a Issue 1 August 1994 24 X300 VSM y Electrical y Number Rear Lamp 1 LH Rear Door 2 LH Rear Door Passenaer 3 Fascia 4 Enaine Pl 5 Left Forward 6 a 9 RH Front Door 10 Console 11 Cabin 12 RH Rear Door 13 In Car Entertainment 14 Trunk 15 X300 VSM 25 Issue 1 August 1994 E Electrical E 15 10 3 Link Harnesses General Description J86 1756 Fig 1 Link Hamesses Fig 1 shows a plan view of the link harness runs inside the trunk the passenger compartment and the engine bay The illustrationis to be read in conjunctionwith the following table To avoid any accidents such as electric shocks always disconnectthe battery negative lead from the battery negativeterminal before disconnectingany ofthe listed cables Issue 1 August 1994 26 y Electrical Key to Fig 1 Link Hamesses page 32 Alternator Suppression Power steering Speed Sensor Steering Column Memory Seat Driver s Side Marker RH
58. 11 19 60 13 SEENEN 5 O eg EE Purge Control Valve Renew EE 17 15 42 17 15 43 17 15 44 coco 8 A ee EN Idle Speed Control Valve Gaskets Renew 2 1 0 eee eee eee eee 18 30 72 18 30 73 18 30 74 18 30 75 18 30 76 eonoonnonmmss 9 D 2s TO Fuel Cut off Inertia Switch Renew weccccee eee e eee eee eens e ET ii ais 9 X300 VSM i Issue 1 August 1994 Fuel Emission Control amp Engine Management V12 R 5 2 1 FUEL SYSTEM LAYOUT Fig 1 Fuel System Layout The above schematic illustration Fig 1 shows the part and component layout of the fuel system and sto be read with the table on Page 2 X300 VSM 1 Issue 1 August 1994 NM Fuel Emission Control Engine Management V12 Key to Fig 1 Fuel System V12 page 1 SRO Component parts Location Number 19 55 13 Fuel filler assembly 1 195501 Fueltank Behind rearbulkhead 2 19 45 08 Fuel pumps Inside fuel tank Fuel pump filter Inside fuel tank 19 40 97 Fuel pump to fuel filter Above rear axle assembly Fuel filter to fuel rail 19 60 13 Inlet manifold 18 10 02 Inlet manifold fuel rail Mounted onthe fuel rail 10 i control Rochester valve 17 15 41 Tank pressure control Connected between 13 Rochester valve emission vent lines as shown on schematic Emission vent line Rochester valve to primary 4 17 15 13 carbon canister 17 15 13 Primary carbon canister Left side of vehicle in 5 front of the rear axle Emission vent line Primary
59. 20 a Disconnect the battery a Remove inlet manifold rear securing nuts a Fit lifting bracket 18G 1465 and secure with the nuts a Fit Service Tool MS 538 Fig 2 across the wing channels and align to rear lifting bracket Fit and engage retaining hook a Tighten hook nut to take weight of engine Selectthird gear and remove the gearshift lever knob a Disconnect lambda sensor block connectors Remove the exhaust front pipe to the intermediate pipe securing nut bolt a Remove the sealing olive a Take the weight of the rear engine mounting using ajack jack channel and a suitable block a Remove the rear mounting securing bolts a Lower and remove the rear mounting assembly Carefully ease exhaust system down for access Remove the drive propeller shaft assembly see Section 9 SRO 47 15 01 a From above undo retaining hook nut to lower rear of transmission do not allow engine to foul steering rack a From below slacken but do not remove the selector shaft bolt 3 Fig 3 a Removethe gear selector remote control securing bolts 4 Fig 1 and reposition for access e Finally remove the selector shaft bolt 3 Fig 3 a Remove the gear selector remote control assembly from the selector shaft DER Note To aid removal invert the gear selector remote con trol assembly Le gearshift lever pointing down wards X300 VSM 7 Issue 1 August 1994 2 sa Manual Transmission
60. 3 2 Liter and 4 0 Liter normally aspirated Make EE cere EE rr Nippondenso MD o on da L3A H Part Nos Li da A E cand tal AAA ARA da ia DBC 6819 Earth polarity sediya anas aa aa a een yaa Negative Maximum OUTPUT EE 120 Amps Nominal regulated Voltage ooooccocnnoncncnna rn 14 4V at 25 C 6cyl 4 0 Liter supercharged W naaa da tad Aaa NEEN A AA EN Nippondenso O NO L3A H Bart NOs a a a ae LNA 1800BA Earth polarity ENEE ENEE Negative Maximum OUTPUT seriinin N EEN eee 120Amps Nominal regulated Voltage vdre sienne ennei a aa aa 14 4V at 25 C V12 Make saiad nie vice aii NA NN EN NN d EM paa a aa el wa Nippondenso TY Pe dis da L3B H E Part NOs caco da LNA 1800AA Earth polarity invicta irian ene cheer ee bers ictal in Negative Maximum OUtDUE ENEE 120Amps Nominal regulated Voltage ooocococoncnnnann nr 14 4V at 25 C X300 VSM A1 95MY 5 Issue 1 August 1994 mm Specification Electrical Equipment continued Starter 6 cyl Make ind type eege ai di ia Bosch DW 1 7K Freespinspeed NEE aeewreeie eh a NEE ER 3000 RPM Free Spin Current eriden ii A A aa 90A maximum Load FUNNINQCUTONt wee eee sence eee e eee eee eee eee nena eeeeee 420A maximum Deanne eee NEEN NEEN eee a eee 1050A VI Make andty pe ENEE ENEE dare EEN NN ENEE NEE NN e Magneti Marelli M80R Freespin Speed iii a e EES 2650 RPM Free Spin CUIFCN baa asi tee weedeat a 75A maximum Load running rte t 2c cece eects 375A maximum SHAN aie eisai Pena e ENN ad
61. A frame Issue 1 August 1994 iv X300 VSM y 14 Suspension Systems E 11 1 INTRODUCTION This section describes the front and rear suspension systems and also covers diagnostic procedures 360 123 Fig 1 Front Suspension Layout 11 2 FRONT SUSPENSION DESCRIPTION The upper rear wishbone 1 Fig 1 and the upper front wishbone 2 Fig 1 are pivoted on the upperfulcrum bolt 3 Fig 1 passingthroughthe front cross beamassembly They are alsofitted via an upper balljoint assembly 4 Fig 1 to a verti cal linkaccommodatingthe stub axle 5Fig 1 whereasthe vertical linkisfittedvia a lower balljoint assembly 6Fig 1 to the lower wishbone assembly The lower wishbone assembly comprises a lower rear wishbone 7 Fig 1 lower front wishbone 8Fig 1 damper 9 Fig 1 incorporatingdamper bush 10 Fig 1 and spring pan 1 1Fig 1 supportingthe roadspring 12Fig 1 The lower wishbone assembly is pivotedon the bushed lower fulcrum shaft 13Fig 1 which also passesthrough the cross beam assembly Both independentfront suspension assemblies are linked by a stabilizer bar 14 Fig 1 which is secured to the cross member using a fixing arrangement of mounting rubbers 15 Fig 1 clamps 16 Fig 1 nuts bolts washers 17 Fig 1 andtwo link arm assemblies 18Fig 1 Each link arm assembly is fitted to one end of the stabilizer bar andto one end of the lower front wishbone using a fixing arrangement of bolts washers and self locking nuts All
62. A5 9 9 Key barrel switches 1 Check harness wiring continuity as follows SLCM 16 way connector Switch Function Driver s side pin 6 pin 11 unlock signal pin 12 pin 10 lock signal pin 12 ground Passenger sside pin 5 pin 11 unlock signal pin 10 pin 10 lock signal pin 12 ground 2 Check continuity from switch pin 10 to ground with door locked and from switch pin 11to ground with door unlocked J86 1914 Fig 1 Key Barrel Switches II SS X300 VSM 33 Issue 1 August 1994 Sant Security System RESTRICTED ISSUE y A5 9 10 Reader exciter coil and module 1 Check fuse F4 in trunk fuse box if blown determine reasonfor rupture and renew 2 Check harness wiring continuity as follows SLCM connector Module connector Coil connector Function pin 6 16 way pin 19 ground pin 9 12 way pin 06 2 data code pin 11 22 way pin 08 immobilization on pin 1 pin 10 coil terminal 2 ping pin 11 coil terminal 1 pin 10 12V pin 20 ground 3 Measure continuity between coil pins J80 1915 Fig 1 Reader Exciter Coil and Module Circuit Issue 1 August 1994 34 X300 VSM y Security System RESTRICTED ISSUE Las A5 9 11 Security active indicator 1 Check wiring continuity from multi plug 26 way connector pin 19 to central locking switch connector pin 13 Ensure secure ground at switch connector pin 16 Note If indicatoris faulty the whole clock module must be renewed referto sub section 15 9
63. ASSEMBLY RENEW SRO 60 25 01 10 7 FRONT HUB BEARING END FLOAT CHECK AND ADJUST SRO 60 25 12 10 8 FRONT HUB BEARING RENEW SRO 60 25 16 10 9 FRONT HUB OIL SEAL RENEW SRO 60 25 17 Disassemble Disconnect vehicle battery ground lead Support the vehicle atthe front and remove the appropri ate road wheel s a Remove brake caliper and disc assemblies see SRO 70 10 10 section 12for removal method only Note Donotallowthecaliperto hang by either harness or flexible hose WARNING DO NOT INHALE BRAKE PAD DUST IT MAY DAM AGE YOUR HEALTH a Prise of the hub grease cap 1 Fig 3 Remove and discard cotter pin 2 Fig 3 pull off castel lated nut retainer 3 Fig 3 Remove the hub nut and bearing washer Carefully remove the hub assembly 4 Fig 3 fromthe stub axle Huboilseal Prisethe original sealfromthe spigot and dis card Removealltraces of grease anddirtfrom the stub axle and back plate a Lightly lubricate the stub spigot to ease assembly of the seal andassemblethe sealto the spigot usingspecial too JD 179 Fig 4 X300 VSM 9 Issue 1 August 1994 Qu Steering a Pack the annular gaps of the oil seal lips with grease Ensurethat the hub inner seal diameter is free of debris or damage and is lightly lubricated prior to assembly a Bearing Wash the hub assembly thoroughly and drift the affected bearingcup s from the hub Note Only replacecomplete bearings
64. Code Value Circuit amps F1 Not used s OEE F2 Red 10 Heated door mirrors Instrument illumination dimmer F3 Light Blue 15 Seat motors right hand side F4 Light Blue 15 Seat motors right hand side F5 Red 10 Instrument pack F6 Tan 5 Seat control modules SCMs Low power door switch pack Mirror motors F7 Light Green 30 Anti lock braking system pump via ABS TC Control Module F8 Not used F9 Yellow 20 Cigar lighters F10 Tan 5 Speed cruise control where fitted F11 Yellow 20 Air conditioning blower motor left hand F12 Tan 5 Instrument pack F13 Light Blue 15 Steering column electric power tilt axial operation where fitted F14 Red 10 d Automatic transmission ignition supply F15 Light Green 30 Window lift front and rear left handside F16 ez Tan 5 Anti lock braking system ABS ignition supply F17 T 2 Not used F18 Red 10 Air conditioning supply Issue 1 August 1994 A1 95MY 16 X300 VSM Specification mm Rear Compartment Fuse Box right hand side heelboard Fuse No Fuse Colour Code Circuit F1 Light Blue Central door locking Deadlocking wherefitted F2 Tan Transmission interlock relay Key switch solenoid relay Center console switch pack Interior lighting switch F3 Light Blue 15 Seat motors left hand side F4 Light Blue Seat motors left hand side FS Tan Automatic transmission control module TCM F6 Fi Light Green
65. ENEE 43 Body Exterior Clearances amp Alignments Criteria AlIgNnMent ee 43 Body Exterior Clearances amp Alignments Criteria Exterior FitmentS ee EE EE 43 Body Exterior Clearances amp Alignments Illustrations SpecificatiOnS xemooooomemoonmmmozo 43 LD OOPS reg tue ae ar Sac A meee aaa erent ater area ae 47 Doors F QtureS EE 47 Doors ROMOVAl EEN 47 DDO OTS FING ii O cap en eee ew Eiere eed ste ha 47 Doors Alignment EE EE i a ae i aa 47 Door SealS Table siris Ne EE EN KS iaa 48 Door Seals Typical Sections IIUStratiON ocooomneonoonncnnarnnan eee 48 ii Issue 1 August 1994 2 d Body Systems amp Body Repair Y L SERVICE TOOLS EQUIPMENT Notes Locally made Locally made Description Support jig bumper cover Rear strut height setting tool Hlustration Jaguar Number see text not illustrated not illustrated N A Guide block to fender setting tool Locally made not illustrated N A Heated extrusion gun for glazing ad Manufactured by hesive Gurit Essex not illustrated N A Heated cabinet for glazing adhesive Gurit Essex IL TORQUE TIGHTENING SPECIFICATIONS Fixing Tightening Torque Nm Bumper Beam to mounting strut height adjuster 39 50 Bumper Guide block to fender 16 20 Bumper Mounting brkt or strut to body 22 28 Door check arm to A C pillar 8 5 Door hinge locking screw 15 S
66. Engine Management System AJ16 An over all contents listshowing eachsectiontitle and number together with its page edge locator is given inthis section and inthe 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 This manual carries a comprehensive index at the rear which is designed to save the Technician time by permitting rapid location of information The entries are set out as perthe following example CLIMATE CONTROL SYSTEMS Section 14 See also Electrical Diagnostic Manual Clutch Description Seet 7 7 10 Fault diagnosis Sect 7 1 11 Inthe example the heading in upper case lettering isto a section title and it refers to the section number 14 and also tothe EDM as electrical diagnostic information will be found inthat 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 Inthis 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 relatedterminology commencing on page 5 X300 VSM 1 Issue 1 August 1994 Introduction D 1 SE
67. Issue 1 August 1994 i 2 RS Body Systems amp Body Repair y J76 1017 Fig 1 Front bumper Typical components Issue 1 August 1994 36 X300 VSM Body Systems amp Body Repair A4 6 1 3 SERVICE PROCEDURES A4 6 1 4 Fitted Condition Front The following procedures may apply should any part of the bumper mounting system or cover berenewedbutshould not be necessary if the cover is removed for service reasons The front mountings must initially besetfor cross car pitchand center within the clearances aroundthe strut to body fixings a Inorderthatthe bumpertopface headlamp surrounds and grille lower havethe correctrelationshipthe strut height adjusters must be finally see AFTER the cover is fitted a Set the guide blocksto thespecified dimensionto achievethecorrectoumpertofendergap BEFORE fitting the cover because adjustments can only be made with the cover off a With all fixing points set the bumper cover may be fitted and adjusted as necessary to achieve the specified gap conditions a Tighten all fixings to specification J76 1018 Fig 1 Front bumper setting dimensions sec Ss X300 VSM 37 Issue 1 August 1994 GC e l z3 aN Body Systems amp Body Repair y A4 6 1 5 Fitted Condition Rear Thefollowing procedures may apply should any partofthe bumpermountingsystem orcover berenewedbutshould not be necessary if the cover is removedfor service reasons a The rear mountings mustinitiall
68. Issue 1 August 1994 20 X300 VSM 12 5 GENERAL FITTING INSTRUCTIONS 125 1 Brake Fluid WARNING BRAKE FLUID B CORROSIVE EXTREME CARE MUST BETAKENWHEN HANDLING AVOID SKIN OR EYE CONTACT AVOID INGESTION IF SKIN OR EYES ARE ACCIDENTALLY SPLASHED WITH BRAKE FLUID RINSETHE AFFECTED AREA IMMEDIATELY WITH PLENTY OF WATER AND SEEK MEDICALATTENTION IF BRAKE FLUID IS INGESTED SEEK MEDICAL ATTENTION IMMEDIATELY CAUTION Fluid must not be allowedto contact the vehicle paintwork Remove any spilt fluid from the paintwork by rinsing away with runningwater Methylatedspirit denatured alcohol must not be usedto cleanthe contaminatedarea Cleaning Solvents CAUTION Never use methylated spirit denatured alcohol for cleaning purposes Use only a proprietary brake cleaning fluid WARNING THROUGHOUT THE FOLLOWING MAINTENANCE SERVICE OPERATIONS ABSOLUTE CLEANLINESS MUST BE OBSERVED TO PREVENT GRIT OR OTHER FOREIGN MATTER CONTAMINATING THE BRAKE SYSTEM IF THE SYSTEMISTO BE FLUSHED USECLEANBRAKEFLUIDTO MINIMUMDOT 4 SPECIFICA TION TO CLEAN BRAKE SYSTEM COMPONENTS WASH INA PROPRIETARY BRAKE CLEANING FLUID REMOVEALL TRACES OF CLEANING FLUID BEFORE REASSEMBLY ALL BRAKESYSTEM RUBBERCON PONENTS MUST BE DIPPED INCLEAN BRAKE FLUID AND ASSEMBLED USING THE FINGERS ONLY 12 5 2 Hoses Fully releasethe unions 1 Fig 1 securing each end of the hoseto the fluid pipes Withdraw the pipe unions 1 Fig 1 from the hose ends e Plugthe ends of the
69. Magnet Renew Disconnect vehicle battery ground lead a With filler flap open use ablunt flat bladed implement and remove the magnet assembly CAUTION Take care notto damage paintwork a To refit carry out reversal of the above procedure 13 2 21 Filler Flap latching Assembly Renew a Disconnect vehicle battery ground lead a Depress the latching assembly retaining nut and remove the assembly CAUTION Take care notto damage paintwork ener a To refit carry out reversal of the above procedure 3 Hingespring A Stowage magnet 5 Fuel bowl Fig 1 Fuel Filler Flap Issue 1 August 1994 8 X300 VSM Body Components amp Trim se o 13 3 PASSENGER COMPARTMENT 13 3 1 Console Assembly Remove For Access And Refit SRO 76 25 01 90 s Remove the battery cover Disconnect the battery a Remove the drivers side underscuttle pad see sub sec tion 13 3 19 a Remove the passenger side underscuttle pad see sub section 13 3 20 s Removethe console ashtray see sub section 13 3 28 a Remove the console finisher veneer panel see sub sec tion 13 3 24 a Remove the radio console see sub section 13 3 10 a Remove the fascia center veneer panel see sub section 13 3 23 Undo and remove the console upper securing screws a Displace and reposition the rear air distribution outlet box a Disconnectthe cigar lighter multi plug where fitted a Disconnect the security system valet switch harness
70. Protection Agency E Evaporative Emission EVAP Evaporative Emission Control EVAPP Valve Exhaust Gas Recirculation EGRS Solenoid Vacuum Valve Exhaust Gas Recirculation EGRT Sensor EGR temperature Temperature Sensor sensor Exhaust Gas Recirculation Valve POD J Extreme Pressure EP additives to drive axle lubricants Designed to protect the spiral bevel gears from wear induced by their stiding rolling action system to prevent fuel p from escaping 1 the 5 Typi includes a charcoal filled canister to absorb fuel vapor purge valve EGR valve solenoid X300 VSM 13 issue 1 August 1994 Introduction GLOSSARY OF TERMS Term s Abbreviation Definition Previously used if applicable term s or Eng lish Equivalent T Fan Control FC engine cooling fan control Fascia fascia facia farad SI unit of electrostatic capacitance more usually subdivided to microfarad Federal Motor Vehicle Safety Standard US fender wing also tonneau 1 fibre Figure illustration Fig firewall bulkhead dash panel Flash Electrically Erasable Pro FEEPROM grammable Read only Memory Flash Erasable Programmable FEPROM Read only Memory the be Flywheel Sensor CKFS sensor mounted soasto betriggered by each flywheel sensor flywheel ring gear tooth to give an engine speed signal fuel
71. RENEW SRO 18 30 74 VEHICLESET SRO 18 30 73 VALVE RIGHT HAND SRO 18 30 76 GASKET RIGHT HAND SRO 18 30 72 VALVE LEFT HAND SRO 18 30 75 GASKET LEFT HAND Remove a Disconnect battery a Drain coolant from radiator see Section 4 2 a Disconnect idle speed control valve multi plug e Disconnectall hoses linkedto the idle speed control valve a Remove valve a Remove gasket Refit in the reverse order of the removal procedure 5 2 6 FUEL CUT OFF INERTIA SWITCH RENEW SRO 18 30 35 Remove a Disconnect battery a Removethe A post lower trim pad Removethe EMS control module see Section 15 a Disconnect vehicle harness through panel connector a Disconnect inertia switch multi plug Fig 2 s Remove switch Refit in the reverse order of the removal procedure J18 227 Fig 2 X300 VSM 9 Issue 1 August 1994 Exhaust System AJ16 SS SECTION CONTENTS Sub Section Title SRO Page ee PYONMINANY Se ida nta deer Se E ie ENNEN AR RE E EE ege i Gils sentence cave Exhaust System General Description ee eee ee eee e een e ene EEN 1 G12 caracas or Diagnosis amp T StINQ omooccccccnnnnnan eee ee eeeeeeeeeeeeeeeeeeeeeeeeeaae 5 A ascent ce SYVMPIOM CNAME wie einai 9 wala ger ier uA A 5 BTS aca alan scones TestA Exhaust Leakage Or Noise sees ueeeec cece ENEE 5 CARS TestB Restriction in Exhaust System ENEE EE EE EE EEN 6 X300 VSM i Issue 1 August 1994 Exhaust System
72. RESTRICTED ISSUE EC A5 5 5 Unlocking Key ting Transmitter Variant 3 Unlocks all doors trunk lid fuel filler cap Disarms the alarm system and switch on interior light for 15 seconds Cancels luggage compart ment valet lock out if set Recalls the memory posi tion of the driver s seat steeringcolumn and door rear view mirrors Two audible signals will be heard andthe direction indicator will flash twice during the unlocking dis arming process Japanese Market Only No audible or visual in dication of unlocking dis arming Releases luggage com partment Button must be pressed within ten sec onds of first press Variant 2 Unlocks drivers door only trunk lid fuel filler cap Disarmsthe alarm system and switch on interior light for 15 seconds Cancels luggage compart ment valet lock out if set Recalls the memory posi tion of the driver s seat steering column and door rear view mirrors Two audible signals will be heard andthe direction indicator will flash twice during the unlocking dis arming process Variant 1 Unlocks all doors trunk lid fuel filler cap Disarms the alarm system and switch on interior light for 15 seconds Cancels luggage compart ment valet lock out if set Recalls the memory posi tion of the driver s seat steering column and door rear view mirrors Two audible signals
73. TEST 14 11 1 Interrogation Procedure via the Control Panel Action Result Simultaneously hold AUTO and RECIRC Switch Display element check ignitionto ON Press AUTO Any stored fault NUMERIC code IfZERO appears there are no stored codes Press FACE Scroll through stored faults maximum of 5 Simultaneously press FACE and HRW Clear stored fault codes may need to be repeated for each fault Press RECIRC Press FAN to skip actuator check Initiate actuator check Actuator codes 20 through 27 Press FAN Exit error check mode 14 11 2 Control Panel Fault Code Key FaultCode lem Description 0 Normal Operation No fault codes present wait 30 seconds for system self check 11 Motorized In car Aspirator Open short insensor circuit Panel fault codes are not stored for motorized in car aspirator motor failure 12 Ambient Temperature Sensor Open short circuits 13 Evaporator Temperature Sensor Open short circuits 14 Water Temperature Input Instrument pack output 15 Heater Matrix Temperature Sensor Open short circuits 21 Solar Sensor Open short circuits 22 Compressor Lock Signal 12 cylin Open short circuits Low gas charge low compressor oil der and supercharged 6 cylinder loose belt engines only 23 Refrigerant Pressure Switch Open short circuits Low gas charge 24 Face Vent Demand Potentiometer Open short circuits 31 LH Fresh Recirc Potentiometer 32 RH Fresh Recirc
74. Title SRO Page asen Preliminary Pages EE EEN EE EE EEN EE EEN EE EE i TODS pain aci Supplemental Restraint SysteM SRS EE EE EE 1 hdr SRS General Description ee EE ENEE ENEE EE ENEE 1 AL et re pee SRS Handling Undeployed Modules ssusssssunussssnnnnsnnnnunnsnnnunnnnnnnnnnnnnnn 2 ery peer rire cre SRS Emergency First Aid ProcedureS EEN NEE ENEE ENEE EE EE 3 DL Sree eee re SRS Safety Procedures Handling Deployed Modules ee ENEE ENEE ENEE En 3 VS AGS ia SRS Safety Procedures Handling Undeployed Damaged MOQules w eseeeseeeueeeueenuenennes 3 TOO raadiis uana SRS Fire Hazard Information ee eee eeeeeeeeeneeeeneeeee 4 TIA ca SRS Ventilati0N airera unana n AE A a a A a a AA 4 ESA AAA SRS Respiratory PreCautiOns ocnnnnnnnnnnnannnann EE 4 LIL ee eine SRS Eye Protection oonconnonnncnnn eee e eee e eee a E a 4 ISIO conan SAS Protective Clotbimg ee 4 AA SRS Handling amp Storage Precautions ue 4 FE lts SRS Modules Assembly Removal Service INStrUCTIONS EN 4 MSAD a Ka Eug SRS Spillage amp LEAKAGE ee 5 E E rai SRS Scrapping Vehicles With Live Airbags EE EE 5 TAREAS wie na dech SRS Scrapping Vehicles With Deployed AirbagS EE ENEE EE EE EE 6 POTATO NNN eech SRS Disposal of Live Airbag Modules ee EEN ENEE EE EE 6 DOALA ERR SRS Disposal of Deployed Airbag Modules oooccconnconcnnncnnn 7 LID Sees cue one INS TUMENTS coccannnn EEN 8 ON EE eee eh Instruments General Description EE EE 8 T522 ir Instruments Analog DiSPIAY ooo
75. Warning Ei legislation label not all markets Clutch fluid type Warning Rotating components Warning Coolant pressure temperature Warning Vacuum pipe routing X300 VSM Issue 1 August 1994 32 Body Systems amp Body Repair A4 4 5 STONE CHIP PROTECTION APPLICATION The approved material should be applied to the areas indicated 376 1048 X300 VSM 33 Issue 1 August 1994 2 ia Body Systems amp Body Repair De A4 5 GLAZING A4 5 1 Specialnotes In order that the design condition of the vehicle is preservedwhen direct glazing repairs are carried out it is essential that both the applied materials and processes are as stipulated OW A4 5 1 1 Glassand Body Preparation The preparation methods and materials as usedwith the Betaseal HV3 system on previous Jaguar vehicles are fully compatible with the current sedan range Ease of working and extended processtime may be gained by ensuring that the vehicle body and replacement glass are soaked at room temperature a minimum of 20 C prior to adhesive application and fitting Should damage occur to the body flange finish rectify as appropriate with the full paint refinishing process as de scribed in the Paint Refinishing Manual see section 4 4 1 1 A4 5 1 2 Adhesive Application Temperature The specified adhesive has a high viscosity and is not easily applied at room temperature using conventional methods When the adhesiveis applied it
76. a Remove side seat belt buckle and the lower anchorage belt a Move the belt aside and remove the upper spacer e Removethe seat belt bracket bodyfixing andremove reel bracket assembly Remove seat belt reel securing bracket fixings a Remove the reel and belt assembly a To refit carry out reversal of the above procedure Issue 1 August 1994 52 X300 VSM Body Components Trim fpi 13 8 14 Rear Center Static Seat Belt Renew Remove rear seat cushion Remove seat belt buckle bolt and remove buckle Remove washers spacers and side seat belt buckle Removecenter lap strap buckle and seat belt strap secur ing bolt Remove the strap and buckle assembly Remove washers spacers and side seat belt buckle a To refit carry out reversal of the above procedure X300 VSM 53 Issue 1 August 1994 54 yA Du Climate Control Systems YE SECTION CONTENTS Sub Section Title SRO Page LO bl caco Preliminary Pages onccccccnnncnnanan i to iii VAT E E E eia Se Working Drachen ERR RRE E KEREN ERR aaa amine e EEEE rN Aena 1 AAN ti Working Practices General onoonoccccnnnnnanannn eee eee eee eee eee eee eeeeeee 1 Td Working Practices Handling Refrigerant oonocconcccnnncacannnacacna ar 1 VA TB is iin ered Working Practices Handling Lubricating Oil seess EEN EE 2 TATA TE Working Practices System Maintenance ENEE ENEE EE En 2 14 2 ca Climate Control SysteM EEN 3 14 2 1 is Climate Control S
77. a bench a Displace and reposition the solar sensor assembly from the fascia Disconnect the solar sensor harness multi plug Removethe solar sensor assembly Undo and remove the defrost vents securing screws Displace and reposition the defrost vent assemblies a Disconnect the tweeter speaker harness multi plugs a Removethe defrost vent assemblies a Displace the fascia harness grommet from the fascia a Route the harness through the aperture a Removethe fascia harness assembly a Undo and remove passenger airbag deployment door to fascia securing bolts one bolt is removed with the fascia a Displace and remove the deployment door assembly a Undo and remove the passenger airbag module to fascia securing bolts a Displace and removethe airbag module assembly a Undo and remove the airbag module BPU mounting bracket assembly to fascia securing nuts bolts a Displace and remove the mounting bracket assembly a Retrieve the spacing washers a Displace and remove the side vent outlets from the fascia a Displace and removethe side vent ducts securing clips a Displace and remove the side vent ducts a Undo and remove the center vent flap assembly to fascia securing nuts a Displace and remove the center vent flap assembly e Undo and remove fascia location bracket securing nuts 1 3 e Displace and remove the location bracket xsovem OOS Te T August 1994 aa Body Components amp Trim a Und
78. amp clutch AJ16 a Ensurethat the draught excluder is not displaced from its position a Remove the mounting rubbers and washers 2 Fig 1 a Mount the gear selector remote control assembly 1 Fig 2 in a vice a Remove the spring ring 2 Fig 2 a Remove the gearshift lever 5 Fig 2 a Remove the spring retainer 3 Fig 2 and spring 4 Fig 2 from the gearshift lever a Remove the gearshift lever lower nylon cup eo 2 and upper nyloncup 7 Fig 2 a Remove the lever housing assembly from the vice a Clean all components thoroughly and examine for wear and damage a Replace worn or damaged components as necessary a Ensure mating faces are clean and grease free a Mount the gear selector remote control assembly 1 Fig 2 inavice a 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 a Fitthe spring 4 Fig 2 and spring retainer 3 Fig 2 tothe lever a Fit and seat the gearshift lever a Compress the spring 4 Fig 2 Fit and seatthe spring ring 2 Fig 2 Removethe gear selector remote control assembly 1 Fig 2 from the vice Lubricate the gearshift lever to ease fitment through the draught excluder Lubricate the lower spacer Position the assembly in its mounting location enter the gearshift lever into the gaiter a Position the gearshift lever into the selector shaft yoke a Fit but do not tighten th
79. and effort when the system is re charged Moisturecan be highly destructive and may cause internal blockages due to freezing but more importantly water sus pendedin the PAG oil will damage the compressor Once the system has been opened for repairs or the refrigerant charge recovered all traces of moisture MUST be removed before recharging 14 9 4 Adding Lubricating Oil Compressor Related The amount of oil drawn out during a recovery procedure will be dependent on the state of the system and the rate of recovery The quantity will be approximately 30to 40 ml this may vary andthe figure is given only for guidance The oil separatorvessel inthe recovery equipment must beclean and empty atthe start of the processso that the quan tity of oil which is drawn out may be accurately measured Oil may be added by three methods 1 and 2 being direct into the system and 3 with the compressor off the vehicle 1 Viathe recovery recycle recharge station 2 Proprietary oil injector Note Equipment manufacturer s instructions must be adheredto when using direct oil introduction 3 Directly into the original or new unit because of rectification work to the existing compressor or the needto fit a new compressor Original Froman existing compressor drain the oil into a measuringcylinder and recordthe amount Flushthe unit out with fresh PAG oil and drain thoroughly Replenish the compressor with the same amount of PAG oil that was original
80. and remove rear mounting assembly e Removejack and jacking channel a Remove mounting spring and spring mounting rubber a From above undo retaining hook nut to lower rear of 7 1 transmission do not allow engine to foul steering rack a From below removeselectorshaftyoke securing nut bolt 3 Fig 2 a Disconnect selector shaft yoke from lower gearshift lever SEH and remove wavy washer i A 337 095 a Remove gear selector remote control securing bolts 1 Fig 2 a Remove mounting rubbers and washers 2 Fig 2 a Reposition remote control assembly for access a Remove transmission to engine adaptor plate securing bolts 1 Fig 3 Note Leave two opposing bolts in for safety Issue 1 August 1994 2 X300 VSM de Manual Transmission amp Clutch AJ16 EE a Remove front clamp from unit lift a Raise lower unit with jack no stands a Traverse lift under ramp and take weight of transmission a Adjust jacking platform angles to suit transmission a Adjust side and rear clamps to suit transmission and tighten clamp wing nuts a Fitthe safety chain assembly to left hand arm of lift and secure with peg e Pass safety chain over transmission and engage infront arm of lift Tighten the safety chain adjuster a Remove remaining transmission to adaptor plate securing bolts and carefully lower transmission from engine a Removetransmission from ramp area Remove clutch release bearing asse
81. as the examples for the compressor except for the fact that trapped oil within any one of these components cannot normally be drained Therefore a nominal amount of oil should be substituted in addition to that recovered from the recovery station separator Condenser Add 40 mi Evaporator Add 40 ml Receiver drier NO adjustment CAUTION Always decant fresh oil from a sealed container and do not leave oil exposed to the atmosphere PAG oil is very hygroscopic absorbs water and will rapidly attract atmospheric moisture PAG oil must NEVER be mixed with mineral based oils Do not re use oil following a recovery cycle dispose of it safely 14 9 6 Adding Refrigerant In order that the air conditioning system may operate efficiently it must contain a full refrigerant charge The indica tions of some system defects and the results of certain tests will show that a low charge is the most probable cause ofthe fault In such casesthe charge should be recovered from the system the weight noted andthe correct amount installed Should refrigerant be added in liquid form initial engine start up revolutions must NOT exceed 2000 RPM for a period of 2 two minutes Ifthe engine speed is excessive compressor damage may occur due to the lubricating oil and the liquid refrigerant being initiallyforced around the system as a slug thus taking oil awayfromthe compressor These marginal lubrication conditions inthe compressor will cease as the refrigerant beco
82. assembly to the floor a Fit and tighten the extension securing screws a Refitthe rear extension veneer panel Refit the rear extension finisher 13 3 7 Selector Trim Finisher Renew 3 2 Liter SRO 76 25 07 a Carefully displace and removethe gearshift aperture plas tic finisher Fig 2 a Displace and remove the selector trim finisher a Fit and fully seat the new selector trim finisher a Fit and fully seat the gearshift aperture plastic finisher 376 1077 Issue 1 August 1994 14 X300 VSM 13 3 8 Selector Trim Finisher Renew 4 0Liter 4 0 Liter SC And 6 0 Liter SRO 76 25 07 Removethe mode switch Fig 1 Removethe mode switch finisher Fig 2 Displace and remove the selector trim finisher Refit the mode switch finisher Refit the mode switch 13 3 9 Mode Switch Finisher Renew SRO 76 25 09 Removethe mode switch Fig 1 Carefully displace and remove the finisher Fig 2 a Fit and fully seat the new finisher Refit the mode switch X300 VSM 15 Body Components amp Trim as Fig 1 Issue 1 August 1994 Body Components amp Trim 13 3 10 Radio Console Renew SRO 76 25 15 a Removethe battery cover Disconnectthe battery a Removethe console ashtray see subsection 13 3 28 Remove console veneer panel see subsection 13 3 24 a Remove the gear selector ident plate securing screws a Carefully repositi
83. atthe COLD level andthe system primed e Remove the funnel a Replace the dipstick a Switch the ignition OFF a Remove the fender cover and close the hood e a Close the door Note After road testing the vehicle the fluid level onthe dipstick should be between the HOT Min Max marks Checkthe levelwith the transmission at nor mal operating temperature 90to 100 C with the engine left runningandthe transmission inthe Park position Issue 1 August 1994 14 X300 VSM i Automatic Transmission V12 amp AJ16 Supercharged E Powertrain 8 2 14 FLUID PAN RENEW 4 01 SC SRO 44 24 04 Open the hood and fit a suitable fender cover a Raise the vehicle on a ramp a Drain the transmission lubrication system see Sub sec tion 8 2 13 a Slacken the downpipe catalyst to intermediate catalyst clamp securing bolts e Slacken the intermediate catalyst to intermediate si lencers clamp securing bolts s Disconnectthe intermediate catalyst pipe from the down pipe a Clean the downpipe and intermediate pipe joint a Release and remove the fluid pan securing bolts a Removethe fluid pan 1Fig 1 and gasket 2 Fig 1 a Drainthe residual fluid from the fluid pan e Removethe fluid pan gasket Cleanthe fluid pan gasket which can be re usedifingood condition Place the fluid pan gasket aside Removethe magnet 3 Fig 1 from the fluid pan Cleanthe magnet and place on a clean surface a
84. been rectified After the system has been disabled the warning lamps remain on untilthe vehicle has reached a speed of 20 km h during the first igni tion cycle after fault rectification Full diagnostic information for the ABS TC CM is given inthe Electrical Diagnostic Manual EDM Section 12 eege Issue 1 August 1994 2 X300 VSM Brakes 3 12 1 2 Anti lock Braking Traction Control Operation 370 284 Vacuum booster Pressureconscious reduction valve Vacuum hose Ventilated brake rotor Tandem master cylinder Single piston caliper Primary brake circuit 3 way brake pipe connector Secondary brake circuit Wheel speed sensor Hydraulicpump motor unit ABS warning lamp Valve block Brake fluid level warning lamp ABS TC CM ADA wNn Fig 1 ABS Traction Control System The vacuum booster see Fig 1 is mounted on the brake pedal box and secured by three bolts Brake pedal force is increasedby the vacuum booster which activatesthe Tandem Master Cylinder TMC intermediate piston Brakefluid is supplied to the pump inlet ports on two separate circuits The primary circuit supplies the front brakes whilst the secondary circuit supplies the rear brakes The rear wheels are controlled collectively on a select low principle during ABS operation During traction control separate circuits allow individual control of the rear wheels To facilitate this the valve block has four outlet ports The ABS TC CM is
85. bench Place drain tray beneath the transmission assembly Remove the front securing bolts 1 Fig 1 and remove the front cover Note and remove the shims Remove the oil seal from the assembly Clean the front cover and gasket faces s Clean the shims Lubricate the face of the new seal Fit and seat the seal to the assembly Fit the shims to the cover Apply sealant to the front cover Lubricate the seal lip Fit and seat the front cover to the transmission and secure with the bolts a Remove the transmission filler plug Fill the transmission to the correct level and refit the filler plug s Remove the drain tray a Refit the transmission assembly see Sub Section 7 1 2 337 088 X300 VSM 5 Issue 1 August 1994 7 1 d Dee Manual Transmission amp Clutch AJ16 7 1 4 REAR OIL SEAL RENEW SRO 37 23 01 e Remove the drive propeller shaft see Section 9 SRO 47 15 01 a Using asuitable oil seal remover displace and removethe rear oil seal 1 Fig 1 a Clean the seal mounting face a Lubricate the seal lip a Fit and seat the seal to the transmission a Refitthe drive shaft see 47 15 01 7 1 5 GEARSHIFT LEVER RENEW SRO 37 16 04 a Remove and strip down the gear selector remote control assembly as detailed in Sub section 7 1 8 a Rebuild and refit the gear selector remote control assem bly Sub Section 7 1 8 but fit a new replacement gear shift lev
86. carbon canister to 6 purge valve 17 50 30 Purge valve Below the left head lamp 7 module Emission vent line Primary carbon canister to at 18 mosphere ine 5 2 Issue 1 August 1994 2 X300 VSM Fuel Emission Control amp Engine Management V1 2 5 2 2 GENERAL DESCRIPTION WARNING WORKING ON THE FUELSYSTEM RESULTS IN FUEL AND FUEL VAPOUR BEING PRESENT IN THE AT MOSPHERE FUELVAPOUR IS EXTREMELY FLAMMABLE HENCEGREATCARE MUST BETAKENWHILST WORKING ON THE FUELSYSTEM ADHERE STRICTLY TO THE FOLLOWING PRECAUTIONS DO NOT SMOKE INTHE WORK AREA DISPLAY NO SMOKING SIGNS AROUND THE AREA ENSURE THAT A CO 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 EXPLOSION PROOF CONTAINER DO NOT EMPTY FUEL INTO A PIT ENSURETHAT WORKING AREA IS WELL VENTILATED ENSURE THAT ANY WORK ON THE FUEL SYSTEM IS ONLY CARRIED OUT BY EXPERIENCED AND WELL QUALIFIED MAINTENANCE PERSONNEL 5 2 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 asnap in 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 moulde
87. chills rapidly on contact with the body and revertsto the hardcondition thus providing full retention not full strength within minutes Raisingthe temperatureof the adhesivelowers the viscosity and speeds upthe flow Itis recommendedthereforethat the adhesive is pre warmedina heated cabinetfor a minimum of 20 twenty minutes andthe extrusion gun has inte gral heating elements see Preliminary pages for details Applicationtime including positioning Optimumtemperature 60 C 70 C Maximum Temperature 750 Minimumtemperature 35 C Will not bond A4 5 1 3 Adhesive Application CAUTION The glass will not bondto the body ifthe time taken to apply the adhesive AND position the glass exceeds the stated limit E Itis recommendedthat the beadof adhesive conformsto the shape and dimensions as shown in Fig 1 and is positioned 1 E SR along the edge of the rubber Note The depth ofthe glass and thus the thickness of the adhesive is controlled by the screen rubber bot toming on the body flange A4 5 1 4 Adhesive Curing The specified polyurethane adhesive cures by exposure to moisture and NOT by heat Cure times may vary consider ablyand are dependant upon ambient humidity levels how ever the initial chill off will occur within Ito4 minutes after Da which the screen may not be moved thisis entirely depend 2 ant upon the application temperature and rate of cooling 12mm 16mm Smm
88. converter containing a pump a turbine rotor a stator assembly and a clutch pressuredisksplined 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 andthe four forward ratios the changing of which is fully automatic in rela tion to load vehicle speed andthrottle 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 handbrakesh
89. door bracketto door frame assembly 5 7 Issue 1August 1994 y Electrical 15 1 SUPPLEMENTAL RESTRAINT SYSTEMS SRS 15 1 1 SKS Airbags General Description One airbag assembly is fitted on the passenger side into an aperture of the fascia see Fig 1 and the second assembly is fitted to the steering wheel see Fig 1 next page 376 1097 Fig 1 The Passenger side Airbag The following procedures and precautions must be adhered to while handling installing and testing airbag modules Failure to adhere to these procedures could cause the airbag to inadvertently deploy with the potential of personal injury The procedures and precautionary guidelines conform to the Handling amp Storage The Explosives Act of 1875 amp 1923 and to the Health amp Safety at work Act of 1974 or local guidelines as appropriate X300 VSM 1 Issue 1 August 1994 Electrical y 15 1 2 HandlingUndeployed Modules The electrically activated airbag module contains sodium azide and sodium nitrate which are poisonous and extremely flammable substances Their contact with acid water or heavy metals may produce harmful and irritatinggases or combustiblecompounds The airbag module is non serviceable and must not be dismantled punctured incineratedor welded WARNING DO NOT ATTEMPT ANY REPAIRSTO THE AIRBAG MODULE Never measure the resistance of the airbag module as this may cause the airbag to deploy Suspect modules must be
90. e Removethe lower trim pad See Section 13 of the VSM a Using a suitable plastic knife cut through the weather shield to door sealant and pull back the weathershield 1 Fig 1 for accessto the door lock assembly a Disconnect the door handle link rod 2 Fig 1 a Disconnectthe door sill button link rod 3 Fig 1 a Disconnect the key barrel link rod 4 Fig 1 s Displace and reposition the door lock assembly multi plug from the mounting bracket and disconnect e Undo and remove the lower securing bolt 5 Fig 1 from the glass frame a Undo and removethe door lock assembly securing bolts 6Fig 1 a Displace and reposition the glass frame a Displace and reposition the door lock assembly 7 Fig 1 Displace and removethe edge clip from the door handle release cable 8 Fig 1 a Displace and reposition the door handle release cable from the abutments a Displace and removethe door lock assembly Positionthe new door lock assembly to the door a Position and fit door handle release cable to abutments a Fit and fully seat the cable retaining edge clip a Fit and tighten the door lock assembly securing bolts a Reposition glass frame Fit and tighten frame securing bolt a Connect the multi plug and fit to the mounting bracket Connect the key barrel link rod a Connect the door sill button link rod a Connect the door handle link rod a Repositionthe weathershieldto the door Usinga suitable tool app
91. electri cal power to the compressor clutch should the system pres sure not be in a range of 2 bar 1st function to 30 bar 2nd function The switch also provides a ground signal to oper ate the appropriate relay within the Stribel unit to ener gize both engine cooling fans when maximum A Ccooling is required Operation pressure 20 bar input 3rdfunction b Pressure Switch Slow Cooling Fans When the system pressure is 12 bar mediumA Cdemand the operation of this switch connects both engine cooling fans inseriesto op erate at half battery voltage and so half fan speed on 12cyl amp Trinary on 6cyl Fig 1 Issue 1 August 1994 12 X300 VSM La Bos Climate Control Systems Ge 14 9 GENERAL SYSTEM PROCEDURES 149 1 Leak Test Faults associated with low refrigerant charge weight and low pressure may be caused by leakage Leaks traced to mechanicalconnections may be caused by torque relaxationor joint face contamination Evidence of oil around such areas is an indicator of leakage When checkingfor nonvisible leaks use only a dedicatedHFC 134A electronic analyzer and apply the probe all round the joint connection Shoulda leakbe traced to ajoint check that the fixing issecuredtothecorrecttightening torque before any other action is taken Do not forget to check the compressor shaft seal and evaporator CAUTION Never use a dedicated CFC 12 or naked flame type analyzer 14 9 2 Charge Recovery System depressur
92. enters the Expansion Valve where it is meteredthrough a controlled orifice which has the effect of reducing the pressure and temperature The refrigerant now inacold atomized state flows intothe evaporator and cools the air which is passing through the matrix As heat is absorbed by the refrigerant it once again changes state into a vapour and returns to the compressor for the cycle to be repeated Fig 1 There is an automatic safety valve incorporated inthe com pressor which will operate shouldthe system pressure be in excess of 41 bar The valve will reseat when the pressure drops below 27 6 bar SS Oo y SS Note Thedivisionof HIGH and LOW side is simply the sys tem pressure differential created bythe compressor discharge pressure suction inlet ports and the relative inlet and outlet portsofthe expansion valve This differential is criticalto system fault diagnosis and efficiency checks 382 452 Twelve Cylinder Vehiclesonly Dual pressure switch This two function pressure switch cuts electrical power to the compressor clutch if the system pressure is outside of the range of 2 Bar 1st Function to 30 Bar 2nd Function Compressor Condenser 3 Receiver Drier Six Cylinder Vehicles only Expansion Valve e f f Evaporator There aretwo switches incorporated intothe high side ofthe Pressure switch Dual type system which have the following functions a Trinary This three function pressure switch cuts
93. feature X300 VSM Security System RESTRICTED ISSUE A5 5 3 Locking Unlocking Key ring Transmitter Each vehicle is supplied with two radio frequency transmitters designedto be attachedto the drivers key ring Key ringtransmitter 1isdedicatedto driving position memory 1and key ringtransmitter 2 is dedicatedto driving position memory 2 The key ringtransmitter is activated by pointing ittowards the vehicle and pressingone of the two operating buttons the large button locksthe vehicle and arms the alarm system whilst the small button unlocksthe vehicle and disarms the alarm system When either one of the buttons are pressed an indicator light on the key ringtransmitter flashes red for the large button greenfor the small button If the ignition key is left inthe ignition switch the following features will be inhibited Q Alarm system o Remote luggage compartment release Ifthe ignition key is left inthe ignition switch in position 1the remote headlamp conveniencefeature will be inhibited Locking is inhibited if any door is open or ajar Note A5 5 4 Instruction Press large button once Press large button again within 3 seconds of first press Press large button for third time within ten seconds of previous action X300 VSM Locking Key ting Transmitter Lock all doors trunk lid Lock all doors trunk lid Lock all doors trunk lid fuel filler cap andarmthe Fuelfiller cap and armthe fue
94. finisher veneer panel see sub sec tion 13 3 24 a Removethe radio console see sub section 13 3 10 a Remove the fascia center veneer panel see sub section 13 3 23 a Undo and remove the console upper securing screws a Displace and repositionthe rear air distribution outlet box a Disconnect the cigar lighter multi plug where fitted a Disconnect the security system valet switch multi plug a Remove the rear air distribution outlet box a Disconnect the security system valet switch multi plug a Remove the rear air distribution outlet box a Undo andremovethe center console rear mountingsecur ing screw a Remove the console assembly and place on the bench a Displace and remove spire clips from console assembly Open the glove box lid a Removethe glove box lid latch Undo and remove glove box lid rear securing screws Displace and remove glove box lid glove box assembly a Placethe console aside a Placethe new console to the front a Fit and align the glove box lid glove box assembly a Fitbutdo notfully tighten the glove box lid securing screw Close the glove box lid and check the adjustment a Open and adjust the glove box lid a Finally tighten the lid securing screws a Fit and align the glove box lid latch a Close the glove box lid a Fit and align the spire clips to the console a Place the console in position inthe vehicle a Fit and tighten the console front securing screws Fit and tight
95. for the lower pivot and remove the gas strut e To refit carry out reversal of the above procedure 13 5 5 Hood Lock RH or LH Renew Open the hood and disconnect the lock operating cable from the lock a Remove the bolts securing the lock to the body and re move the lock a To refit carry out reversal of the above procedure Align the lock with the striker prior to tightening 13 5 6 Hood Lock Control CableRH or LH Renew Slackenthe clamp boltsecuringthecabletothe lock actua tor a Disconnectthe cable fromthe lock andfromthe mounting clip e Release the cable from the bulkhead mounting clips and remove the tie wraps securing the cable to the pipes and harnesses a Removethe cable fromthe remaining large tie wraps Open the front door a Removethe underscuttle pad a Pullthe release handle and disconnect the cable from the release handle and bracket e Pullthe cable throughthe bulkhead grommet and discard e To refit carry out reversal of the above procedure 13 5 7 Hood Striker Assembly Renew Open the hood slacken the locknut and unscrew the striker a Renew any damaged components and reassemble a A distance of 62mmfromthe end of the striker to the lock nut may be used as an initial setting e Adjust the striker until the hood is flush with the fender 13 5 8 Hood Lock Release Handle Renew a With the hood raised slacken the clamp bolt which se cures the cable to the lock actuator Repea
96. head gasket s Rectify as required X300 VSM Fuel Emission Control amp Engine Management AJ16 EM SECTION CONTENTS Sub Section Title SRO Page Paint PreliMiNarypDaQe eoonoconnncncnnnn eee e eee a ee eee eee eee eee eee eee eee i SI idan eee dee Fuel System lQyQUt EE 7 TD CA E 3 A a Fuel Rail Pressure Regulator Valve Injectors Supercharged Dee wscee eee cece eee eee eee 18 10 01 18 10 02 19 45 11 19 60 13 si sua wi aaa 5 CT E Fuel Rail Pressure Regulator Valve Injectors Normally Aspirated Renew En 18 10 01 18 10 02 19 45 11 UE ORK 7 a Purge Control Valve All Models Renew 17 15 30 EE 9 od Oi ema Throttle Assembly Supercharged Renew oooooooconmomnanananss 18 30 17 19 70 04 19 70 07 commons 10 o TARATA Idle Speed control Valve Gaskets Supercharged Renew o oo o 18 30 74 18 30 77 nertsen 11 SAO ora bs Idle Speed Control Valve Gaskets Normally Aspirated Renew 18 30 74 18 30 77 EE 12 DADS a ais Fuel Cut Off Inertia Switch All Models Renew cocccooosoommoo 18 30 35 E 13 PPP nnn PPP PP a S X300 VSM i Issue 1 August 1994 y Fuel Emission Control amp Engine Management AJ16 5 1 1 FUEL SYSTEM LAYOUT 15 16 17 22 E 319 461 Fig 1 Fuel System Layout The above schematic illustration Fig 1 showsthe part and component layout of the fuel system of 4 0 liter normally aspirated engined vehicles Th
97. hold the small button for 3 seconds Q Variant 2 press and hold either the small or large buttons for 3 seconds Note Thepanicalarmcan be operatedat any time during the locking or unlocking procedure regardlessof the state of the locking security system Issue 1 August 1994 14 X300 VSM y Security System RESTRICTED ISSUE Sant A5 5 7 Central Locking Note The following lock conditions are inhibited when any door is open or ajar The central locking switch is mounted on the facia With the ignition switch in either position I or Ir press the central locking switch to lock all the doors and the luggage compartment if they are unlocked Hold down the switch for 3 seconds to close any open windows or the sliding roof A further press on the central locking switch after 3 seconds will unlock the doors and the luggage compartment If the switch is pressed when ignition switch is not in position or Il tilt and intrusion sensing will be disabled until the next arming action The active indicator mounted in the switch housing will flash to confirm this action A5 5 8 Passive Arming Passive arming is a dealer option on variants 1 and 3 Passive arming of the vehicle If the feature has been activated takes place 30 seconds after the last closure of the doors trunk lid hood or sliding roof For passive arming to take place the ignition switch must be in the OFF position When passive arming occurs the directio
98. hood 8 1 7 FLUID PAN RENEW 4 0L SRO 44 24 04 a Raise the hood and fit a fender cover a Raise the vehicle on a ramp a Drain the transmission lubrication system see Sub sec tion 8 1 2 Release and removethe rotary switch protection cover to fluid pan securing screws remove the rotary switch protection cover Release and remove the fluid pan securing bolts and clamps 1 Fig 1 Displace and remove the fluid pan 2 Fig 1 a Drain the fluid pan Remove and discard the fluid pan gasket if the gasket is damaged Removethe magnetsfromthe fluid panand placethe fluid pan aside a Cleanthe gasket faces and magnets Fit a serviceable gasket to the new fluid pan a Fitthe magnets in position in the fluid pan e Fit and alignthe fluid panto the transmission unit fit and torque tighten the fluid pan clamps and securing bolts a Fit the rotary switch protection cover to the fluid pan bosses and fit andtorque tightenthe rotary switch protec tion cover securing bolts a Lower the vehicle onthe ramp Refill the transmission unit with fluid see Subsection 8 1 2 e Remove the fender cover and lower the hood 146 691 X300 VSM 11 Issue 1 August 1994 Automatic Transmission AJ16 8 1 8 FLUID PAN RENEW 3 21 SRO 44 24 04 a Raise the vehicle on a ramp a Drainthe transmission lubrication system see Sub sec tion 8 1 2 Release and remove the fluid pan securing bolts and c
99. if applicable term s or Eng lish Equivalent shift fork part of the shift mechanism of a manual selectorfork transmission mounted on the shift rail and relaying movement in the shift lever to the sleeve coupling which moves gears in and out of engagement shift rail rail which carries the shift fork selector rod shift solenoid Ss controls shifting in an automatic transmission short block part engine usually the cylinder block short engine crankshaft connecting rod piston assemblv supplied as a reconditioned unit short circuit an undesirable connection between a usually electrical circuit and any other point slant engine in line engine which is mounted in the inclined engine vehicle at an angle fromthe perpendicular as AJ6 sliding roof sun roof sliding roof control module SRCM sun roof control module signal return SIG RTN snap ring circlip snubber buffer block usually of a rubber compound bump stop which fits betweenthe axle andthe body unit and absorbs any excess travel Society of Automotive Engineers SAE solenoid device consisting of an electrical coil which when energized produces a magneticfield in a plunger which is pulled to a central position A solenoid may be used as an actuator in avalve or switch splash guard mud flap speed the magnitude of velocity regardless of direction Speed Control Control Module SCCM Module controlling Speed Control System Cruise Control Module CCM square centimeters em s
100. is closed when the engine is off The purge valve is controlled by the engine control module ECM and is linked to the carbon canister Issue 1 August 1994 4 Fig 1 Quick fit connector and releasetool X300 VSM Fuel Emission Control amp Engine Management AJ16 EM 5 1 3 FUEL RAIL PRESSURE REGULATOR VAL VE INJECTORS SUPERCHARGED RENEW SRO 19 60 13 FUEL RAIL SRO 19 45 11 REGULATOR VALVE SRO 18 10 01 INJECTORS SRO 18 10 02 INJECTORS VEHICLE SET eS on yA ES TN 319 463 Fig 1 Remove a Reposition top edge of trunk front liner for access a Disconnect multi plug from evaporative loss flange inset Fig 1 a Switch ignition on Crank engine to depressurize fuel system a Switch ignition off Disconnect battery see Section 15 a Disconnect earth lead eyelet 1 Fig 1 from inlet manifold stud a Disconnect engine harness to oxygen sensor leads multi plug a Disconnect engine harness to starter motor solenoid link lead multi plug a Undo fuel injector multi plug cover fixings 2Fig 1 a Disconnect cover from injectors 3Fig 1 a Undo fuel rail to feed pipe union nut 4 Fig 1 X300 VSM 5 Issue 1 August 1994 Wi Fuel Emission Control Engine Management AJ16 a Repositionfuel feed pipe from fuel rail union and fit blanking plugs to rail and pipe a Undo and remove regulator mounting bracketto inlet manifold bracket securi
101. it Arrange the wire so that its tension tends to tighten the bolt heads or nuts to which it is fitted A3 2 18 Screw Threads Metricthreads to ISO standards and UNF threads are used See belowforthread identification Fixingswith damaged threads must always be discarded Cleaningthe threads with adie or tap impairsthe strength andcloseness of fit and is not recommended Always ensurethat replacementbolts are of equalstrengthto those removed Do not allow oil grease or jointing compound to enter blind threaded holes because the hydraulic action which would be generated when screwing inthe bolt or stud could split the housing Oilthe thread lightly beforetightening to ensure a free run ning thread except in the case of self locking nuts Always tighten a nut or bolt to the recommended torque figure Damagedor corrodedthreads will affect the torque reading To check or retighten a bolt or screwto aspecifiedtorque figure first slacken by a quarter of aturn then retightento the correct figure A3 2 19 Unified Thread Identification Bolts A circular recess is stamped inthe upper surface of the bolt RES El head 1 Fig 1 A3 2 20 Unified Thread Identification Nuts A continuous line of circles is stampedon one of the flats of the hexagon parallelto the axis of the nut 2 Fig 1 Y E A3 2 2 1 Unified Thread Identification Studs Brake LS y Sg 2 Rods etc 507 011 The component is reducedto the core diameter for a short F
102. lifting amp Vehicle Recovery EZ 2 2 7 Suspended Towing CAUTION Do nottow with sling type equipment as damage to the bodywork may result Do not front suspend tow vehides with automatic transmission 2 2 8 Rear Suspended Tow e Removethe ignition key from the ignition steering lock a Raisethe vehicle using a lifting device with a cradle This should be positioned under each rear wheel as indicated in Fig 1 108 026 Fig 1 X300 VSM 5 Issue 1 August 1994 p Engine AJ16 Lo SECTION CONTENTS Sub Section Title SRO Tholl enn Preliminary PageS 0 2000 cece eee eee a a a a a EE E EE E EE Aa eee TL EENS Engine General EE A a a EE a ILL NEES Engine Transmission Unit ReneW EE 12 41 02 20 An B13 ET Engine Oil Renew EE EE 12 60 00 oonomnnconnors 3 BAA aera eee weit Oil Filter Canister Renew EE a 12 60 04 ee 3 BL rs Front Engine Mounting Bracket Assembly Renew En 12 45 01 LH 12 45 03 RH oooooo 4 FALLO ied ee ware Rear Engine Mounting Assembly Rene eee eee 12 45 04 AAA 4 X300 VSM i Issue 1 August 1994 Ip Engine AJ16 y TOOLS8 EQUIPMENT Illustration Jaguar Number 18G 1433 Notes Camshaft timing tool 18G 1437 Front pulley lock 18G 1465 Emgine lifting bracket MS 53C Emgine support beam not illustrated YA 992 Snap On Oil filter canister removal tool IL TORQUE TIGHTENING SPECIFICATIONS Fixing lightening Torque N
103. motors located insidethe trunk the passenger compartment and the engine bay The motors drive various devices to performcertain functions such wipe wash operations window lift operations seat operations etc In orderto carry out remove and refit operations the annotated illustrationis to be read in conjunctionwith the table shown on the following page This lists all the motors and solenoids Some motors can be accessed by removing the various trims the carpet or carpet sections other can be located through carrying out a visual inspection around the engine bay the cab and the trunk To avoid any accidents such as electric shocks always disconnect the battery negative lead from the battery negative terminal before disconnecting any of the listed cables Issue 1 August 1994 30 X300 VSM Y Electrical Key to Fig 1 Motors amp Solenoids page 36 Motors amp Solenoids Power Wash Power Wash RH Blower AC Steering Tilt Steering Reach Driver s Mirror Ignition Key Solenoid Window Lift Sunshine Roof Memory Seat Rise Fall Rear Memory Seat Rise Fall Front Key Lock Door Memory Seat Recline Lumbar Pump Motor Memory Seat Head Rest Rear Window Lift Rear Door Lock Fuel Pump Double Electrical Aerial Trunk Lock Filler Cap Solenoid Rear Door Lock Window Lift Passenger Seat Recline Passenger Seat Head Rest Lumbar Pump Motor Passenger Memory Seat Fore Aft
104. noting orientation and selected adjustable spacer over the hub a Assemble the inner bearing race and locate the inner seal using service tools JD 550 4 2 4 1 and 18G 134 ensuring that the seal is square and fully seated s Press the ABS rotor into position s Assembly and fitting is the reversal of this procedure taking note of the following Adhesive should be applied to axle shaft splines over a radial area of 30 to 50 For the initial setting position the head of the hub carrier fulcrum to the mark previously made on the wishbone prior to checking and adjusting if required rear wheel toe in Renew all bolts that were originally fitted with thread locking adhesive Replace all locking wire and split pins cotter pins Tighten all fixings to the specified torque Verify operation of brakes Renew all self locking nuts Note The axle shaft nut is a self locking item with a thread insert and must NOT be re used 347 045 Axle shaft 5 Inner seal 8 ABS rotor Bearing spacer 6 Outer bearing 9 Hub Adjustable spacer 7 Outer seal 10 Axle shaft nut Inner bearing 11 Hub carrier Fig 1 Sectional view Hub assembly Issue 1 August 1994 9 X300 VSM Steering SECTION CONTENTS Sub Section Title SRO Page LO bl cacao Preliminary PAGES see ENEE ENEE ENEE EE a a i Toiv TOT iia Steering System Description en 1 lO didas Steering System Description Steering Column Major COMPONENHS ee EE ENEE EE 1 TOA Lia Steering Syst
105. on a ramp Drainthe transmission lubrication system see Su Sec tion 8 1 2 a Remove the fluid pan see Sub section 8 1 8 a Remove the fluid filter see Subsection 8 1 6 a Release and remove the valve body securing screws 1 Fig 1 Displace and remove the valve body assembly Clean the valve body and mating faces Fitthe new valve body to the transmission unit locating the throttle valve behind the throttle valve cam and en gage the selector a Fit but do not tighten the valve body securing screws a Fit and engage Service Tool JD 103 between the valve body and the throttle valve pin Align the valve body assembly a Fully tighten the valve body securing screws Remove Service Tool JD 103 a Fita newfluid filter see Sub section 8 1 6 a Refit the fluid pan see Subsection 8 1 8 a Lower the vehicle onthe ramp a Refill the transmission unit with fluid see Subsection 8 1 2 a Remove the fender cover and lower the hood J44 151 Issue 1 August 1994 16 X300 VSM Automatic Transmission V12 AJ16 Supercharged CC Powertrain SECTION CONTENTS Sub Section Title SRO Page Tonne Preliminary Pages ERKENNEN ENEE EEN EE A Ea EE EEA i OZI iia General Description onnnccnnnncnnnnnnnnnnn eee eee eee eee eee eee A eee eeeeeee 1 822 eege Transmission internal Harness Renew 4 0L SC and 6 OL oooommo E tai wae ex 5 B28 WEE EEN Pressure Switch Manifold Renew 4 0L SC a
106. parts preventingthe front end of 312 844 the enginefrom being lifted from its seating e Liftthe front endof the engine transmission unit slightly and detach the front mounting bracket assemblies from the lower engine housing 3 1 6 REAR ENGINE MOUNTING ASSEMBLY RENEW SRO 12 45 04 The rear engine mounting assembly comprises a rubber to metal engine transmission rear mount 1 Fig 2 securedto a support bracket 2 Fig 2 by asingle fixing arrangement a With the aid of the engine hoist ServiceTool MS53C se cured to the lifting eyes of the rear engine lifting brackets and a jack positioned under the rear mounting bracket take the weight of the engine a Undo and remove the fixing arrangement securing the rear engine mounting bracket assembly a Lower the jack and remove assembly a Dismantlethe assembly clean all components and exam inefor any signs of wear or damage Renew components as necessary J12 845 Issue 1 August 1994 4 X300 VSM y Engine V12 SECTION CONTENTS Sub Section Title SRO Page Itoll caco Preliminary Pages EE i E AA Engine General EE EE EE cn nr rr eee 1 DL EE Engine Transmission Unit Renew EE o 12 37 01 90 sa 2 AS E Engine Oil Renew EE ENEE EE ECO 3 E AAA Oil Filter Canister Renew oooococccccn 12 60 04 NEE 3 TL ee 12 60 68 e 4 I di Front Engine Mounting Bracket Assembly Renew EE 12 45 01 LH 12 45 03 RH 00 omo 4 EISE Rear Engine Mounting Assembly
107. pipes 2 Fig 1 to prevent the loss of fluid andthe ingress of dirt Removethe mounting bracket locknut 3 Fig 1 and re movethe hose 4 Fig 1 Thoroughly clean the hose and examine for any signs of wear or damage Renew the hose if there is any doubt aboutits condition Thoroughly cleanthe bore ofthe hose using compressed air a Removeall blanking plugs andfit the new hoseto the cali per connector Secure the hoseto the mounting bracket a Beforefully tightening the locknut ensure that the hose is neither kinked nor twisted a Bleed the brakes 12 5 3 Pipes a Fully release the pipe unions 1 Fig 1 a Withdraw the pipe 5 Fig 1 from the vehicle Plug the pipes 2 Fig 1 to preventthe loss of fluid or the ingress of dirt Thoroughly clean and examine the pipe for signs of damage or deterioration Renew the pipe if there is any doubt about its condition Thoroughly clean the bore of the pipe using compressed air s Removeall blanking plugs and fit the new pipe to the ve hicle Secure the pipe to the body a Bleed the brakes X300 VSM 21 Issue 1 August 1994 Brakes Es Brakes 12 6 REAR WHEEL SPEED SENSOR RENEW SRO 70 60 04 a Drivethe vehicleonto arampor raisethe backand support ontwo stands a Cut and remove the ratchet strap securing the speed sen sor harness to the brake hose a Undo and remove the speed sensor to hub carrier secur ing bolt Fig 1 Removethe speed sensor
108. re moving the plugs immediately prior to connection Tighten the gland nuts Note Take necessary steps to prevent rotation of the PCRVs when fitting the rear brake pipes a Removethe absorbent material andcleanthe surrounding area a Ensurethat all fixings aretorque tightenedto specifiedtol erances e Release the brake pedal hold downtool and remove a Bleedthe brake system referto sub section 12 4 4 a Examine the hydraulic control module for leaks X300 VSM 25 Issue 1 August 1994 Brakes 12 9 ABS TCCM RENEW SRO 70 60 02 70 60 20 Refer to Section 12 4 Brake System Bleeding before carry ing out this procedure Pay particular attention to the warn ings and cautions relating to brake fluid cleanliness and cleaning materials e Remove the hydraulic control module Refer to sub sec tion 12 7 SROs 70 60 18 amp 19 Disconnectthe pump electric motorto ABS TC CM multi plug 1 Fig 1 Undo and remove two securing screws and remove the ABS TC CM Clean the mating faces of the hydraulic control module and the new ABS TC CM Fit and tighten two securing screws e Re connect the pump electric motorto ABS TC CM multi plug a Refit the hydraulic control module Referto sub section 12 7 SROs 70 60 18 amp 19 Issue 1 August 1994 26 X300 VSM SECTION CONTENTS Sub Section Title SRO Page IR aan Preliminary Pages cecccccccceeeneeeeeeenee eee p eee ee ee ee en eeeeeeeeeeeeeeeen
109. rear section forward to disengage Fig 1 from pinion spigot Note Take account of any shims located between the center bearing and the crossmember a Releasefixings and remove over axle exhaust pipe mounting from wide mounting bracket a Support the rear suspension assembly from below and remove fixings from RH and LH sides inthe following order 1 Shock absorber to body upper fixings 2 Differential strut to body 1 Fig 2 3 A frame bush 2 Fig 2 4 Lower mounting bracket assembly to body 3Fig 2 a Carefully lower the unit clear of the vehicle and place in a safe working location a Release handbrake cable to wide mounting bracket clips a Disconnect RH and LH axle shafts from differential couplings note camber shim and discard fixings a Remove wishbone pivot bolt washers and remove wisbone hub axle shaft assembly RH and LH issue 1 August 1994 6 X300 VSM a Remove upper link assembly from differential and wide mounting bracket A frame Driveshafts amp Final Drive mom a Release fixings A frame to differential A frame to wishbone tie and wide mounting bracketto A frame a Remove wishbone tie assembly rear mounting bracket and pendulum assembly a Release fixings differential nose to wide mounting bracket a Assembly and fitting isthe reversal of this procedure taking note of the following Drive shaft must be aligned in accordance with Sub Section 9 2 Renew all self locking
110. routing based on peratur catalytic converterthat reducesthe levels of HC CO amp NOx catalyticconverter systemthat has both TWC and OC Usually secondary air is introduced Thermal Vacuum Valve TVV Three way Catalytic Converter TWC cat Three way Oxidation Catalytic TWC OC Converter cat dual bed test between the two catalysts 1 procedure whereby the performance of a product is measured under various Throttle conditions a valve for regulating the supply of a fluid S Can Ti toanengine Throttle Body TB Ce Throttle Position TP Throttle Position Sensor TPS interprets throttle position and movementto identify idle acceleration and full power tiometer TPS TP demands tthrow out bearing clutch release bearing tthrow out fork clutch release lever ttie rod steering ttiming relationship between spark plug firing and piston position usually expressed in crankshaft degrees BTDC or ATDC of the compression stroke UA tire tyre DETECTA DS EEN EEN ttorque converter device which by its design multiplies the torque in afluid coupling between an engine and transmission Torque Converter Clutch TCC device which selectively increases or decreases the ratio of relative rotation between its input and output shafts controls the shifting pattern automatic transmission Modifies the operation of elec
111. screw a Displace and remove the latch assembly a Fit and align the new latch assembly to the lid a Fit and tighten the latch securing screw a Fit and align the lid inner to the lid a Fit and tighten the inner lid securing screws a Close the cupholder a Refit the the console glove box lid issue 1 August 1994 20 X300 VSM Body Components amp Trim ge 13 3 17 Fascia Board Renew SRO 76 46 01 a Removethe battery cover and disconnect the battery Removethe drivers side and passenger side underscuttle pads see sub sections 13 3 19 and 13 3 20 a Removethe drivers airbag module see section 15 5 Removethe steering wheel section 10 e Removethe drivers side and passengersidefascia closing panels see sub sections 13 3 22 and 13 3 21 a Remove the fascia center veneer panel see subsection 13 3 23 Remove the fascia board for access see subsection 13 3 17 a Disconnectthe air conditioning differential potentiometer harness multi plug Removethe differential potentiometer assembly a Displace and reposition the through panel connectors from the fascia assembly a Displace the fascia vent motor gearbox assemblies har ness multi plug from the mounting bracket a Disconnect and reposition the fascia harness to console harness multi plug from the mounting bracket a Disconnect the BPU harness multi plugs Removethe tiestraps securing the harness to the fascia a Reposition the fascia on
112. securing screw a Refitthe blanking plate Fig 1 Issue 1 August 1994 2 X300 VSM Body Components amp Trim 13 2 3 Rear Door Upper Trim Pad Remove For Access And Refit SRO 76 34 05 90 a Removethe rear doortrim pad veneer panel see sub sec tion 13 2 2 Undo and remove the upper trim panel securing screws a Lift to release the panel from the door mounting and re move the panel a Fitthe trim pad and fully seat on the door mounting posi tion a Fit and tighten the trim pad securing screws Refit the veneer panel 13 2 4 Rear Door Upper Trim Pad Renew SRO 76 34 05 a Removethe rear door trim padveneer panel see sub sec tion 13 2 2 a Undo and remove the upper trim panel securing screws a Lift the panel to release from the door mounting and re move the panel a Undo and remove the chrome strip securing screws a Removethe chrome strip a Undo and remove the top channel securing nuts Fig 1 a Displace and remove the top channel assembly Placethe trim pad aside a Place newtrim pad to the front st he upper channel to the trim pad a Fit and tighten the channel securing nuts a Fitthe chrome strip a Fit and tighten the chrome strip securing screws a Fitthe trim pad and fully seat onthe door mounting posi tion a Fit and tighten the trim pad securing screws a Refit the veneer panel 13 2 5 Rear Door Window Lift Switch Veneer Panel Renew SRO 76 47 34
113. 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 PROTECTTHE HANDS AGAINST ESCAPINGSTEAM AND SLOWLY TURNTHE CAP ANTI CLOCKWISE UNTILTHE EXCESS PRESSURECAN ESCAPE LEAVE THE CAP INTHIS POSITIONUNTILALL STEAM AND PRESSURE HAS ESCAPED AND THEN REMOVE THE CAP COMPLETELY Before liftingthe complete engine transmission unit with an engine hoistfrom the engine bay ensure that two engine lifting brackets tool 18G 1465 are secured equallyspaced to the inlet manifoldstuds The four engine lifting brackets should be positionedtowards the front andthe rear of the assembly Ensurethe front ofthevehicle isjacked upsecure ly on stands when removing the assembly ae N EEEE S S E Issue 1 August 1994 2 X300 VSM SE Engine V12 Leg 3 2 3 ENGINE OIL RENEW SRO 12 60 00 a Undo and removethe sump plug positionedatthe rear of the sump drain the engine oil into a suitable receptacle and dispose of it in a safe and environmentally friendly manner a Replenishtheengineoiltothecorrectlevel 1 Fig 1 on the dipstick Note Ifthe O ringonthe on the filler cap is damaged re move the O ring and clean the groove Secure a new O ring in position using silicon sealant Treat the screw threads with copper grease and grease the top face of the oil filler with Hylosil lubricant When the oil is renewed start the engine wait for the oil light to extinguish a
114. speed Renew pump Secure connection and bleed air out Renew pump Renew pump Vague feel about center Knocking vibration felt at steering wheel Fluid level low tire pressures high Air in system due to loose connection Stiff or seized steering joint Rack damper too tight Castor or tracking error Lower column over extended Fluid level low Air in system due to loose connection Pump shaft seal faulty fluid loss Rack damper loose Pinion bearing faulty Rack or column fixings loose Rack mounting bracket loose Rack mounting bush loose Free play in column assembly Rectify fluid loss and or top up Set to specification Secure connection and bleed air out Test and renew faulty joint Renew rack Check geometry and rectify if required Set to specification Rectify fluid loss and or top up Secure connection and bleed air out Renewpump Renew rack Renew rack Tighten to specification Renew rack Renew rack Check and rectify as required Issue 1 August 1994 X300 VSM Steering 10 4 3 Diagnosticchart 2 Trouble lay at steering wheel Cause Rack damper loose Pinion bearing loose Worn intermediate shaft joint Worn suspension joint Loose lower column pinch bolt Remedy Renew rack Renew rack Renewjoint Renewjoint Tightento specification deavy when stationary ixcessively heavy when lriving stationary effort aK Too easy when driving itationary effort OK fff
115. switch to ground switch to ground data communications switch to ground Signal Description Comment switch to ground 200mA ns 07 Inclination alarm Hood open ajar Inertia switch Transponder immobilization on 12 Memory seat remote indicator CRT ignition on ignition key in Central locking switch 2 OFP Issue 1 August 1994 06 1 P Trunk valet isolate switch momentary switch to ground 08 1 P Trunklid release internal switch to ground O7P Headlight convenience switeh to ground for 25 seconds E a Ee A A AE OS SA 20 1 P Trunklidajar switch to ground 21 TUE Rear doors ajar switch to ground Unlock relay switch to ground 200mA switch to ground switch to ground data communications switch to ground for 500ms switch to ground switch to ground switch to ground eege X300 VSM Security System RESTRICTED ISSUE A A5 2 13 Siren Located on the RH side at the front of the engine bay to provide audible alarm signals A5 2 14 Trunklid release external Locatedintrunk lidfor conventional key access to luggage compartment A5 2 15 Trunklid release internal Located on fascia switchpack to allow lid release from driving position A5 2 16 Valetswitch Located in the central column compartment to allow securing of luggage compartment independently of other faci lities
116. system Renew ball joints Check and correct tire pressure Renew ball joints Check brakes Check steering system Renew bushing Check tires Renew wheel bearing Renew ball joints Renew stabilizer bar Renew link Renew bracket Tighten connections Renew bushing Renew dampers Renew bushing Issue 1 August 1994 Brakes SECTION CONTENTS Sub Section Title SRO Page Toi ee Preliminary PageS omocoonnnnnnn e ener e eee eee e eee ee ewes eee eeeeeeeae i LOL aii Anti Lock Braking System ABS General Description enee ENEE EE E AEN 12 1 JL ca Anti lock Braking TractionControl Operation EE 12 3 DIS ri a ee tives Anti lock Braking Operation ee 124 TIZIA is Actuation COMPONEN S nnocnnonncnncnnncnna EEN 12 5 AZAD wee been ABS Components EE EE nee een eee 12 6 T216 ri aie wat CALIDOIS es vi a E A EEN oh E A a dE eck EE 12 7 12 17 EE Parking Brake ENEE tiaren ENEE a 12 9 LEE Wheel Speed Gees EE ENEE EEE A EE 12 11 IBM Di Hydraulic Operation ABS CM EE EEN 12 12 12 10 en Hydraulic Operation ABS TC CM weceececeeee teen eee eee eee e eee ee ee eeeeeeeeneeeeee 12 14 J22 cere ERR Fault Diagnosis and Testing suusuuununnsunnunnnnnnnnnnunnnnnnnnnnnnnnnnnnnnnnnn 12 16 J23 eer eem ase Brake Fluid Level Check ee 12 18 IDA wuuneuneunnes Brake System Bleeding ee 12 19 AQF ege System Bleeding General INStruCtiONS ee EE EE EE 12 19 J242 ia System Bleeding After Brake Fluid Renewal een 12 19 LILA EEN
117. tential damage from fire and other matters The conductive anti permeation tubing does not return to its original shape after being deformed Therefore do not clamp eg for sealing purposes prior to disconnection of tubes as this damages the fuel pipes The evaporative loss control system prevents unprocessed vapour emitted from the fuel tank from entering the atmos phere The tank pressure control Rochester valve is installed be tween the fuel tank and the carbon canister It is normally closed but open during engine operation venting the va pours from the fuel tank to the carbon canister The purge valve is controlled by the engine control module ECM and is linked to the carbon canister Fig 1 Quick fit Connector and Release Tool Issue 1 August 1994 4 X300 VSM Fuel Emission Control amp Engine Management V12 NM 5 2 3 FUEL RAIL PRESSURE REGULATOR VALVE INJECTORS RENEW SRO 19 60 13 FUEL RAIL SRO 19 45 11 REGULATOR VALVE SRO 18 10 01 INJECTORS SRO 18 10 02 INJECTORS VEHICLE SET SRO 18 10 04 INJECTOR LEFT HAND BANK SRO 18 10 05 INJECTOR RIGHT HAND BANK A ES E 3 Lx 8 Si y D mo Sh ee ley gt Siz PPD sc RA e z ARA la SH SS a INES Ee gt z uE ue Gry es SS Se JE E y 6 319 471 Remove a Reposition top edge of trunk front liner Disconnect multi plug from evaporative loss flange inset Fig 1 Switch ignition o
118. the gearshift lever a Refit the exhaust front pipes to the manifold a Remove the blanking plug from the rear of the trans mission a Refitthe drive propeller shaft a Refitthe heat shield and reconnect the exhaust system a Lower the ramp a Remove the Service Tool MS 53B a Remove the engine lifting eye 18G 1465 Refit the injector harness mounting bracket and tighten the rear inlet manifold securing nuts 333 074 SE X300 VSM 15 Issue 1 August 1994 di Bee Manual Transmission amp clutch AJ16 7 1 15 CLUTCH MASTER CYLINDER RENEW SRO 33 20 01 a Removethe clutch master cylinder to clutch pedal clevis pin securing clip 1 Fig 1 and remove the clevis pin 2 Fig 1 a Removethe master cylinder securing nuts 3Fig 1 a Disconnect the hydraulic pipe 4 Fig 1 from the master cylinder and fit blanking plugsto the pipe and master cy linder a Remove the master cylinder assembly 5 Fig 1 and the gasket 6 Fig 1 a Fit the new master cylinder to the bench vice and fill the reservoir a Refit the reservoir cap a Removethe blanking plug from the master cylinder a Primethe master cylinder by working the push rod until fluid appears at the hydraulic pipe outlet a Removethe master cylinder from the vice a Place a new gasket 6 Fig 1 over the mounting studs a Fit and align the master cylinder assembly to the studs and secure with the nuts 3 Fig 1 a Remove the blankin
119. the internal working running in surfaces of e g an engine by avoiding excess build up of heat L bottom dead center BDC EE point of piston travel in a reciprocating engine bypass air mechanical control of throttle bypass air bumper guard overrider bushing cylindrical plain bearing bush Issue 1 August 1994 8 X300 VSM Introduction GLOSSARY OF TERMS Term s Abbreviation Definition Previously used if applicable term s or Eng lish Equivalent camshaft l a shaft on which phased cams are mounted Usually usedto regulate opening and closing of engine cylinder head valves Camshaft Position CMP Camshaft Position Sensor CMPS indicates camshaft position CID sensor Hall sensor canister device designed to hold dry material e g evaporative emission canister Canister Purge CANP controls purging of the EVAP canister Carbon Dioxide CO colorless gas with a density of approximately 1 5times that of air Carbon Monoxide CO poisonous gas produced as the result of incomplete combustion Case Ground f CSEGND Control module casing ground camber inclination of the plane of a wheel to the vertical plane of the vehicle May be negative or positive Also convex curvature across road surface Canadian Motor Vehicle Safety CMVSS Standard caster trail built in to the geometry of a steered caster castor roadwheel
120. thread levelina levelling license licence license plate registration plate number plate optical digital display system applied voltage to which varies the way the crystals reflect liaht thereby modifvina the display liquid crystal display Liter louver lowered beam low tension primary circuit of the ignition system linking the battery to the primary winding in the ignition coil a Issue 1 August 1994 18 X300 VSM O Introduction GLOSSARY OF TERMS WW E Term s Abbreviation Definition Previously used if applicable term s or Eng lish Equivalent M Malfunction Indicator Lamp MIL a required on board indicator to alert the fuelling failure driver of an emission related malfunction Manifold Absolute Pressure MAP absolute pressure of the intake manifold air Manifold Absolute Pressure Sen MAPS sensor located inthe PCM and portedto the sor intake manifold Manifold Surface Temperature manual transmission M T transmission Mass Air Flow transmission which is manually externally gearbox 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 ____ Mass Air Flow Sensor maximum metal inert gas electric welding system in w
121. three outlet ports Apart from this the removal procedure isthe same for all vehicles a Raise the vehicle Displacethe bleeder screw dust cap ofthe front LHcaliper The dust cap will remain captive on the bleed screw a Connecta bleeder tube and bottle to the bleeder screw 1 Fig 1 and open the bleeder screw Fita brake pedal hold downtool JDS 9013 betweenthe brake pedal and the steering wheel Adjust the tool to op erate the brake pedal 60mm down This operation is necessaryto preventfluid lossfrom the reservoirthrough disconnected brake pipes a Re tighten the front LH caliper bleeder screw Disconnect the bleeder tube from the bleeder screw and remove the tube and bottle Refit the bleeder screw dust cap s Place absorbent material underneath the hydraulic con trol module to absorb any spillages 3 a Undothe rear brake pipe gland nuts 1 Fig 2 at the pres S 370 288 sure conscious reducingvalves PCRVs 2 Fig 2 Remove the rear brake pipes Note Take necessary steps to prevent rotation of the PCRVs when removing the rear brake pipes Fitplugsimmediatelyto the brake pipes andthe PCRVsto prevent fluid loss Undoand removethe PCRVs Fit plugs immediatelytothe PCRVs and the hydraulic control module a Cleanthe surrounding area a Fit new PCRVsto the hydraulic control module removing plugsimmediatelyprior to connection Tightenthe PCRVs Connect the rear hydraulic brake pipes to the PCRVs
122. to faint yellow resulting from overloador incorrectlubricant As excessive heat can cause softening of tracks and rollers check by drawing afine file over a softened area Iffaulty the file will grab and cut metal If still hard the file will skid over the surface without removing any material Remedy Renewthe bearings and seals if any heat damage is evident Issue 1 August 1994 10 X300 VSM General Fitting Instructions s Fault Seizure Cause Seizure caused by lack of lubrication excessive loads or the ingress of foreign matter Remedy Renew the bearings Checkthe seals for wear and ensure that there is adequate lubrication Fault Etching Cause The bearing surfaces are grey or greyish black with the rollers andtrack material being etched away This is usually related to uneven spacing of the rollers Remedy Renew the bearings Check the seals for wear and ensure that there is adequate lubrication J51 054 Fault Rotating track and inner race material removal Cause Removal of materialdueto slippage This can be caused by poor fit incorrect lubrication overheating overloading and poor assembly Remedy Renewthe bearings andclean all related parts Checkthe fit and ensure the replacement bearings are the correct type Renew the shaft or housing if damaged X300 VSM 11 Issue 1 August 1994 Body Systems Body Repair r SECTION CONTENTS Sub Section Title SRO Page T
123. unit with fluid see Subsection 8 2 13 a Remove the fender cover and close the hood X300 VSM 23 Issue 1 August 1994 24 Driveshafts amp Final Drive Se SECTION CONTENTS Sub Section Title SRO Page O aci Preliminary Pages EE itov BT eee tie Major Component Description EEN 1 A A Drive Shaft AliQn EE 47 15 51 conan 2 OF iia ada Final Drive Unit Output Shaft End Float Check En 51 10 24 AA 4 A ste Final Drive Unit Output Shaft Housing O Ring Renew ooooomomo 512019 ras 4 Dis Final Drive Unit Oil Seal Pinion Flange Renew ee 51 20 01 een 4 QO ica taa iay Final Drive Unit Output Shaft Bearing Renew EE 51 10 22 conan 5 OT EE E Final Drive Unit Output Shaft Oil Seal Renew e 51 20 04 eu 5 DE iaa ob Cie Final Drive Unit Renew EEN XA 6 A ase niin Sines Axle Shaft Assembly Renew ooooocnonnnnncnnnnnnnnnnrn AL AOOL a nen vee 7 Q10 wie leanne Rear Hub Bearing Renew EE 64 15 14 ccoo 8 OAT a Rear Hub Oil Seal Renew EE 64 15 15 cono 8 Issue 1 August 1994 i X300 VSM Ta Driveshafts amp Final Drive Hub remover JD 1D 7 Thread protector Dial test indicator DTI and locator JD 132 1 Hub presstool and button Pinion puller Pinion Oil seal installer Output shaft oilseal remove replace JD 550 4 18 4 2 Adaptor replacer bearing and Bearing replacer Issue 1 August 1994 ii X300 VSM Driveshafts Final Drive en Jaguar Number 18G 134
124. valve and opening the inlet valve and re charging brake pressure During the pressure build up phase the volume required for replenishment is supplied by the TMC and additionally by the pump from the low pressure accumulators Since the delivered flow is generally greater than volume flow drained fromthe brake circuits the low pressure accumulators serve as intermediate accumulators to compensate for temporary volume flow peaks The TMC piston positions andtherefore the brake pedal vary withthe fluid displacement inthe brake caliper As con trolled pressure inthe brake caliper decreases and increasesduring ABS the brake pedal cycles informingthe driver that controlled braking is in progress Actuation ofthe brake pedal causesthe central valve item 5 inthe TMC to close This action prevents damage to the TMC piston seals At the end of a brake application volume is restoredto the TMC at low pressure from the fluid reservoir item 6 i A CS TS ED X300 VSM 13 Issue 1 August 1994 ES Brakes j 9 D 12 1 10 Hydraulic Operation ABS TCCM ABS TC CM hydraulic modules incorporateinlet valves items 16 and 17 and outlet valves items20 and 21 for each driven wheel This enables individual pressuremodulation to the rear brakes under wheel spin conditions i e traction control Increasedwheel spin of a driven wheel under accelerationcauses the NO isolationvalve item 14 to be closedandthe pump item 10 to be switched o
125. vidual control of the driven wheels ABS CM ABS TC CM The ABS CM or ABSTC CM locates beneaththe modulator valve block and is secured by two screws The CM houses the solenoids which operate the inlet and outletvalves of the modulator valve block When fitted the valve stems locate inthe CM mountedsolenoids There is no electrical connec tion betweenthe CM andthe modulator valve block Fig 3 shows an ABS TC CM having nine solenoids The CM functions includethe following Q Providing control signals for the operation of ABS and traction control solenoid valves o Calculating wheel speed from voltage signals trans mitted by the wheel speed sensors o Monitoring of all electrical components o OnBoard Diagnostics OBD storage of possible fail ures ina non volatile memory The signalsfrom the four wheel speed sensors are indepen dently processedby the ABS CM or ABS TC CM calculating numerical values which correspond directly to the wheel speed These values are convertedinto control signals for pressure modulation during ABS control The ABS and traction control are continuously monitored whilst the ignitionison for possiblefaults and interruptions If afault is detected the module deactivates the ABS and indicates this by lighting the ABS warning lamp Ina fault condition conventional braking is unaffected The module stores fault codes in a non volatile memory which can be 1 2 read via the OBD link Note For elec
126. wheel control operates on a select low principle i e lockingin either wheel is sensed and controlled brake pressure is appliedto both wheels For vehicles with traction control the valves operate on four circuits During ABS control the rear wheel are controlled on a select low principle as above but during traction control operationthe rear wheels are controlled individually Note Functionalanddiagnosticinformation for the ABS CM andthe ABS TC CM is contained inthe Electrical Diag nostic Manual EDM Section 12 ABS Warning lamp Traction Control Warninglamp Fluid level indicator The ABS andtraction control warning lamps mounted inthe instrument panel indicatea fault inthe ABS or traction control These systems are inhibited or disabledwhen the lamps are lit although conventional braking is unaffected When the ignition is switched on an ABS self test is initiated During this test the ABS andtraction control warning lampsare litfor approximately 1 7 seconds andthen extinguish A fault is indicatedifthe warning lamps remain lit or come on whilst the vehicle is being driven Note The ABS self test is masked by the 5 second lamp test initiated when the ignition is switched on The fluid level indicator lamp mounted inthe instrument panel is lit when the brake fluid falls below the minimum mark on the brake fluid reservoir ABS Traction Control Inhibit Disable Faultsconditions are detected by the ABS TC CM which disa
127. 1 August 1994 Electrical C 15 7 CLOSURES SWITCHING Informationto be issued with Amendment 1 Issue 1 August 1994 18 X300 VSM y Electrical 15 8 IN CAR ENTERTAINMENT ICE 1 Radio Cassette Unit 3 Door Speakers 2 Auto Changer 4 Tweeters 5 8 1 General Description The plan view inFig 1 showsthe locations of the In Car Entertainment ICE equipment This consists of a radio cas sette playerfitted inside an aperture ofthecentreconsole switch assembly acompactdisc auto changer locatedinside the trunk four speakersfitted to the front and rear doors and four tweeters of whichtwo are located on either side of the crash roll dash below the windscreen andtwo on either side of the rear shelf The vehicle has an electrically operated retractable aerial fitted onthe offside rear fender X300 VSM 19 Issue 1 August 1994 PS Electrical ai 15 9 LAMPS amp LIGHTINGLOGIC 15 9 1 Exterior Lighting General Description Y o gt 1617 1819 2021 22 386 1713 11 12 1314 15 Fig 1 Exterior Lighting Figure 1 indicates all exterior lamps located atthe front the sides and the rear of the vehicle Theexteriorlampsconsistingoftwo headlampassembliescontainingthe inboardand outboardheadlampunitsincor poratingthe pilot bulbs the fog lamps the front direction indicator lamps and side marker lamps fitted through the front bumper the repeater lamps positioned on the fenders t
128. 1 August 1994 ali Body Components amp Trim 13 8 SEATING AND SEAT BELTS 13 8 1 Seating Description The front seats are available in a range of materials consisting of sculptured fabric leather leather sports cloth leather embossed leather leather and autolux Both seats are available as manual ie manually adjustable with elec tric rise and fall manual height adjustment headrests power ie 12 way electric adjustment power with memory ie memory controlled 12 way electric adjustment of seat steeringcolumn and exterior rearview mirrors and heated ie with integral heating Front seats are based on anon handed one piece frame which includes cushion and squab frames and seat adjuster mechanisms The seat switchpacks powerseats arefitted to the outboard side of driver and passenger seats on man ual seats the seat height adjustment switch is similarly located Seat control modulesSCMs are contained within the seat assemblies The seats are secured through four mounting points to the vehicle floor Rear seats are of the bench type with full width removable cushion and individual seat squabs Electrical components installed on the heel board belowthe rear passenger seat are protected by two covers secured by two locating brackets onthe floor and by two latches onthe cover The latches are released by pushing down on the two recesses in the top edge of the cover 13 8 2 Front Manual Seat Renew a Disconnect vehicle
129. 10 J86 1916 Fig 1 Security Active Indicator Circuit X300 VSM 35 issue 1 August 1994 o Security System RESTRICTED ISSUE E A5 9 12 Sounder 1 Check harness wiring continuity from multi plug 26 way connector pins 13 and 26 to sounder connector pins 2 and 1 respectively 2 Measure resistanceacross sounder pins a value of 8 should be recorded J86 1917 Fig 1 Security Sounder Circuit eegend Issue 1 August 1994 36 X300 VSM Security System RESTRICTED ISSUE Las A5 9 13 Trunk lid release actuator and relay Check fuse F8 in trunk fusebox if blown determine reason for rupture and renew Check harness wiring continuity between trunk fuse box connector pin7 and relay pins 1 and 5 3 Check harness wiring continuity to ground from relay connector pin 4 and actuator connector pin 1 4 Check harness wiring from multi plug 26 way connector pin 11 to relay connector pin 2 5 Check harness wiring continuity from relay connector pin3 to actuator connector pin 2 6 Measure resistance across relay connections 1 and 2 a value of 85Q should be recorded 7 Measure resistance across actuator pins a value inthe region of 20 30Q should be recorded 37 J86 1918 Fig 1 Trunk Lid Actuator and Relay Circuit X300 VSM 37 Issue 1 August 1994 Bez Security System RESTRICTED ISSUE A5 9 14 Trunklid release switches Check harness wiring continuity from multi plug 12 w
130. 12 Axle shaft UJs grease 6 Engine coolant refill 13 Door check arm grease 7 Clutch fluid refill Fig 1 Fluids and Lubricants Service Points 6 Cylinder Vehicles X300 VSM A2 95MY 1 Issue 1 August 1994 Routine Maintenance p d J10 055 1 Engine oil refill 7 Final drive oil refill 2 Engine oil drain 8 Final drive oil drain 3 Transmission fluid refill 9 PAS fluid refill 4 Transmission fluid drain 10 Windshield wash reservoir refill 5 Brake fluid refill 11 Axle shaft UJs grease 6 Engine coolant refill 12 Door check arm grease Fig 1 Fluids and Lubricants Service Points 12 Cylinder Vehicles X300 VSM Routine Maintenance y Y SERVICE SCHEDULE UK EUROPE ROW 3 2 Liter 4 0 Liter 4 0 Liter SC and 6 0 Liter Item Service intervals Miles X1000 aa uy 1 Renew engine af and ie x 2 Renew transmission fluid and filter ME aa X 3 Renew manual transmission oil SO RS SE E d Renew brake fluid two years xX x 5 Renew coolant and check specific gravity VE hl E 5 Renew air cleaner element 7s PESA NE 1530 ERA 7 Renew air cleaner element supercharged x 8 Renew fuel filter Des 9 Renew spark plugs see note Ke x he el 10 Renew spark plugs Sweden only see note x 0 xX 11 Renew drive be
131. 127 Hz reset at 132to 138 Hz Drive belt tension measuring point Mid way between crankshaft and air injection pump pulleys ERAEN a ceil Issue 1 August 1994 ii X300 VSM Cooling System V1 2 4 2 1 COOLING SYSTEM DESCRIPTION 4 2 1 1 Major Components Q Engine crossflow radiator incorporating a concentrictube cooler for the power steering fluid mounted in the left hand radiator side tank Vehicles with automatic transmission have a six plate transmission fluid cooler mounted inthe right hand radiator side tank A double action temperature switch for controlling the electric radiator cooling fans is mounted in the left hand radiator side tank Engine driven viscous coupled radiator cooling fan Two electrically operated radiator cooling fans mounted in front of the radiator Coolant circulating pump belt driven from the engine crankshaft Coolant header tank with pressure relief cap and coolant level probe Two engine thermostats one in each cylinder bank o0O0 00 4 2 1 2 Components for Climate Control System o Heater matrix Q Electrically operated coolant circulating pump mounted on the left hand side of the engine bulkhead oO Solenoid operated valve located adjacent to the coolant circulating pump 4 2 1 3 Operation The configuration of the cooling system is shown in Sub section 4 2 2 The cooling system is pressurized which allows the system to operate at a higher temperature without overheating The head
132. 134A Never use a CFC 12 analyzer or naked flame type Q Donot attempt to guess the amount of refrigerant in a system always recover and recharge with the correct charge weight Inthis context do not depress the charge or discharge port valves to check for the presence of refrigerant 14 1 3 Handling Lubricating Oil Q Avoid breathing lubricant mist it may cause irritation to your respiratory system Q Always decant fresh oil from a sealed container and do not leave oil exposedto the atmospherefor any reason other than to fill or empty a system PAG oil is very hygroscopic absorbs water and will rapidly become con taminated by atmospheric moisture PAG oil is NOT compatible with previously used mineral based oils and must NEVER be mixed Fig 1 Do not re use oil when it has been separated from refrigerant following a recovery cycle Dispose of used oil safely 14 1 4 System Maintenance o When depressurizing a system do not vent refrigerantdirectlyto atmosphere always use Jaguar approved recovery equipment Oo Always decant compressor oil from a sealed con tainer anddo not leave oil exposedto the atmosphere for any reason other than to fill or empty a system PAG oil is very hygroscopicand will rapidly become contaminated by atmospheric moisture o Plug pipes and units immediately after disconnection and only unplugimmediately prior to connection Do not leave the system open to atmosphere oO Itis not necessary to renew the r
133. 14 4 0L SC or Sub section 8 2 15 6 0L Note Note the internal harness cable runs for assembly purposes and removethe transmission internal har ness multi pin socket 1 Fig 1 discarding the Or ring seal 2 Fig 1 see Sub section8 2 19 Disconnect the internal harness plug from the A Shift solenoid a Disconnect the internal harness plug from the B Shift solenoid Disconnect the internal harness plug from the pressure switch manifold a Disconnectthe internal harness plugfrom the pulsewidth modulator TCC solenoid a Disconnect the internal harness plug from the variable force motor a Displace the internal harness from the retaining clips a Remove the internal harness from the transmission unit a Placethe harness aside a Clean all relevant parts a Fit the new internal harness to the transmission unit a Secure the internal harness to its retaining clips a Connect the internal harness plug to the variable force motor a Connect the internal harness plug to the pulse width modulator a Connect the internal harness plug to the pressure switch manifold Connectthe internal harness plugto the B Shift solenoid Connectthe internal harness plugtothe A Shift solenoid Fit a new internal harness multi pin socket O ring refit the multi pin socket to the main case and connect the ex ternal harness see Subsection 8 2 19 a Refit the fluid pan see Subsection 8 2 14 4 0L SC or Sub
134. 20 7 1 10 REVERSE LAMP SWITCH RENEW SRO 37 27 01 a Raise the vehicle on a ramp a Note and disconnect reverse lamp switch multi way connector Slacken off and remove the switch e Cleanthe mating face e Fit anew switch Connect the multi way connector a Lower the ramp 7 1 11 LAYSHAFT FRONT SEAL RENEW SRO 37 23 07 s Remove the transmission assembly see Sub Section 7 1 2 a Removethefront oil seal assembly see Sub Section 7 1 3 a Using suitable oil seal remover tool remove and discard layshaft plug seal a Clean the transmission face and the front oil seal assem bly a Fit and fully seat the new seal to the casing s Refitthe transmission front seal assembly a Refit the transmission X300 VSM 9 Issue 1 August 1994 d Bea Manual Transmission amp Clutch AJ16 7 1 12 CLUTCH DESCRIPTION The single plate diaphragm type clutch is operated by the pushrod of the slave cylinder acting on the clutch lever The slavecylinder mountedonthe transmission bell housing is operated hydraulicallyfrom the clutch mastercylinder through a series of hydraulic pipes The piston in the master cylinder is operated by a push rod from the clutch pedal which is fitted to the bulkhead mounted pedal box The clutch pedal is positioned to the left of the brake pedal The engines use a twin mass flywheel configuration with built in springs to provide a smooth take up of dri
135. 205to restrict rotation and JD 156 to remove drive flange a Inspect the drive flange oil seal surface for damage corrosion or grooving and replace as necessary Do not use abrasive cloth or paper to remove imperfections from the seal surface a Remove oil seal from differential case taking care not to damage the machined counterbore a Clean seal counterbore a Using special tool JD 198fit replacement oil seal to differential case ensuring that seal is square fully seated and the lip spring is not dislodged Apply grease to drive flange seal diameter and refit the flange to the pinion in the original position Note Do not hammer the drive flange onto the pinion pull down with the drive flange nut Tighten the drive flange nut to the original noted torque PLUS 10 Check that the pinion spigot radialrun out isto specifica tion Fitting and reassembly isthe reversal of this procedureen suring that drive shaft fixings are renewed and that the shaft is aligned in accordance with Sub Section 9 2 Correct the final drive oil level if required a Tighten all fixings to specification Issue 1 August 1994 4 X300 VSM Driveshafts Final Drive RER 9 6 OUTPUT SHAFT BEARING RENEW SRO 51 10 22 9 7 OUTPUT SHAFT OIL SEAL RENEW SRO 51 20 04 a Disconnect vehicle battery ground lead a Support the vehicle at the rear and remove the rear road wheel or wheels Match mark the axle shaft flange to the out
136. 30 Anti lock braking system traction control control module ABS TC CM F8 Red 10 Interior lamps Luggage compartment lamps F9 Clear 25 Seat heaters where fitted F10 Tan 5 Data link connector Fuel pump relay coil F11 Yellow 20 Air conditioning blower motor right hand F12 Red 10 Air conditioning t Seat control modules SCMs Mirror heaters relay Power assisted steering F13 Not used F14 Red 10 Mirrors Heated rear window Cigar lighter Rear lighting control module High mounted stop lamp where fitted Light Green Window lift front and rear left hand side Windshield wiper system Front screen heaters Front lighting control module left hand Water pump relay Headlamp levelling where fitted Clock Light Blue Airbag F18 Light Blue 15 Sunroof where fitted X300 VSM A1 95MY 17 Issue 1 August 1994 om Specification Luggage Compartment Fuse Box Fuse No Fuse Colour Code Value Circuit amps F1 Clear 25 Power amplifier radio cassette and compact disc player where fitted F2 Tan 5 Tail lamp left hand side Number plate lamp left hand side F3 Light Blue 15 Back up lights Stop lamp left hand side Turn indicator rear left hand side F4 i Red 10 Security system F5 Red 10 Body processor unit BPU F6 Tan 5 Data link connector d Radio telephone where fitted F7 j Light Green 30 Fuel pump F8 Light Blue 15 Luggage compartment remote release
137. 3mm J76 1031 1 Fittedcondition 2 Bead application Fig 1 Issue 1 August 1994 34 X300 VSM Body Systems amp Body Repair 449 A4 6 1 BUMPERS A4 6 1 1 Major Components The sedan range bumper system comprises of Q 00000000 Note Bumper cover Mounting struts Beam Guide blocks Integrated lamps Chromium plated stainless steel upper trim blades Brake ducts Under tray Grille vane See illustration following page A4 6 1 2 Features Q Q oo H OO o O Note X300 VSM One piece moulded bumper spoiler finished in body colour see note sub section A4 1 6 All components and harnesses may be sub assembled on the bench and the complete assembly then fitted to the vehicle Fully height adjustable front and rear strut or mounting and side guide block Energy absorbing struts on North American market vehicles which comply with US and Canadian legislation FMVSS 007 and CMVSS 215 Fixed struts on rest of world vehicles Aluminium beam on North American market vehicles Plastic beam on rest of world vehicles Indicator fog and reflective or illuminated side marker lamps are removable from front and the fog lamps are adjustable from beneath Blanking grilles fitted where fog lamps are not specified The grille vane MUST be removed before the front towing eye may be used Quick release fasteners fix the vane to the cover and are accessed from the front 35
138. 4 10 1 ccoo Fault Diagnosis Introduction uuu ucceeeeee ence eee ee enn c eee ENEE 15 1410 2 ca Fault Diagnosis Functional Check wicccccccceeece eee een n eee n eee en eee eneneneeeee 15 LEINEN Fault Diagnosis System SYMPtOMS EE EE 15 14 11 ic System Sel Ti A A EAR E 17 VAT a nai System Self Test Interrogation Procedure via the Control Panel oonoononcononcnnonnancnns 17 EAR System Self Test Control Panel Fault Code Key ENEE EE E EE 17 1411 a System Self Test Associated FaultS ENEE EE EE EE 18 14 11 4 A System Self Test Panel Communication CHECK oooconnonnnnncnncnnannnnncnna nan 18 14 12 coco Manifold Gauge Set onnccnnnncccnnncn nee een eee nean eee ee eeeeeeeeeeeeeneeee 19 14 13 ccoo System Checking With Manifold Gauge Set ee E 20 14 13 71 weuunuunne System Checking With Manifold Gauge Set Evacuating the Gauge Set EEN ENEE EN 20 14 13 22 common nn System Checking With Manifold Gauge Set Connecting the Manifold Gauge et 20 14 13 39 sasasnnuan System Checking With Manifold Gauge Set Stabilizing the System EEN ENEE EE 20 EE Pressure Temperature Graph High Side Ambient Temperature ee EEN EEN 21 TATI ia a Pressure Temperature Graph Low Side Evaporator Temperature ee EEN 22 14 160 rro System Pressure Fault Classification een 23 X300 VSM i Issue 1 August 1994 Ox LS Climate Control Systems Illustration Jaguar Number Description CAES ee station il TORQUE TIGHTENING SPECIFICATIONS Fixing lightening Torque
139. 4 4 X300 VSM Cooling System AJ16 4 1 4 4 Complete System Fill a Add coolant until the level inthe header tank is steady at MAX Do not fit the header tank cap a Switch on the ignition Theclimate control system must be OFF e Start the engine and wait until the cooling fans operate for the second time The engine speed may be raised to reduce the warm uptime a While the cooling fans are operating raisethe engine speedto 1500RPM for one minute Returnto idle speed a Turn the climate control system ON Setthe temperature to HI Manually select a fan speed of approximately 50 a Runthe enginefor four minutes Ensurethat the climate control system outlet airtemperature ishotto very bot and that there is no noisefrom the heater coolant circulating pump The engine speed may be raised to assist with heat ing Switch off the ignition and wait for one minute Check that the coolant level inthe headertank is between MAX and 10 mm above MAX Add coolant as necessary e Fitthe header tank cap sf X300 VSM Issue 1 August 1994 3 Cooling System AJ16 4 1 5 4 1 5 1 FAULT DIAGNOSIS Introduction The following diagnostic procedures are providedto assist properly qualified personsto identify and rectify the faults inthe system which are most likely to be encountered Reference is madeto the Electrical Diagnostic Manual EDM which should be consulted for all electrical faults When investigating faults
140. 4 X300 VSM Body Components amp Trim efi 13 2 8 Rear Door Armrest Renew SRO 76 34 23 a Displace and remove the armrest securing screw hole plastic finisher covers 1 Fig 1 a Undo and remove the armrest securing screws 2 Fig 1 and remove the armrest assembly a Remove the armrest screw hole plastic finishers 3 Fig 1 a Undo and remove the chrome finisher securing screws a Undo and remove the armrest inner black finisher secur ing screws a Displace and remove the finisher a Place the armrest aside a Place the new armrest to the front a Fit and align the inner trim finisher Fit and tighten the finisher securing screws a Fit and align the armrest chrome finisher SES a Fit and tighten the finisher securing screws a Fit and seat armrest securing screw hole plastic finishers a Positionthe armrest assembly Fitandtightenthe armrest securing screws a Fitand seat the armrest screw hole plastic finisher covers 13 2 9 Rear Door Pocket Renew SRO 76 34 28 a Removethe rear door armrest see sub section 13 2 8 a Removethe lower trim pad see sub section 13 2 6 a Undo and removethe rear door pocket to trim pad secur ing screws Fig 2 Remove the door pocket a Displace and removethe rear window lift switch assembly end cover trim pad Fig 3 a Undoandremovethe veneer panelto switch assembly se curing screw Fig 3 a Displace and remove the veneer panel from the forward securin
141. 46 11 90 Motor the drivers seat fully rearwards Undoand remove the underscuttle padsecuring screws 1 Fig 1 Using special tool JD 188 2 Fig 1 displace securing clip Displace and reposition the underscuttle pad assembly 3 Fig 1 Disconnectthe air conditioning aspirator multi plug Removethe underscuttle pad Place the underscuttle pad assembly in position Connect the air conditioning aspirator multi plug Reposition the underscuttle pad Securethe underscuttle pad with clip and align the secur ing screw holes a Fit and tighten the underscuttle pad securing screws Motor the seat to the original position 376 1083 13 3 20 Underscuttle Pad Passenger Side Remove For Access And Refit SRO 76 46 15 90 Motorthe passenger seat fully rearwards Undo and remove the underscuttle pad securing screws Using special tool JD 188 displace the securing clip Displace and remove the underscuttle pad Place the underscuttle pad assembly in position a Secure the underscuttle pad with clip and align the secur ing screw holes Fit and tighten the underscuttle pad securing screws Motor the seat to the original position Issue 1 August 1994 26 X300 VSM o Body Components amp Trim 13 3 21 Fascia Closing Panel Passenger Side Renew SRO 76 46 27 s Remove for access the passenger side underscuttle pad see sub section 13 3 20 a Undo and remove th
142. 5 6 0L a Lower the vehicle onthe ramp a Refill the transmission unit with fluid see Sub section 8 2 13 Removethe fender cover and close the hood em Issue 1 August 1994 6 X300 VSM a Automatic Transmission V12 AJ16 Supercharged asas Powertrain 8 2 4 INPUT SPEED SENSOR RENEW 4 0L SC SRO 44 15 40 a Raise the vehicle on a ramp Reposition the edge of the transmission tunnel sound in sulation foam for access a Disconnectthe harness plugfrom the input speed sensor Release and remove the speed sensor securing bolt Repositionthe speed sensor protection cover for access the cover remains captive on the harness a Removethe speed sensor from the transmission unit and place aside a Clean the main case speed sensor area a Fit a new O ring seal to a new input speed sensor a Lubricate the O ring seal a Fit and seat the speed sensor to the main case a Reposition and align the speed sensor protection cover a Fit and tighten the speed sensor securing bolt Connect the harness plug to the speed sensor e Reposition the edge of the transmission tunnel sound in sulation foam to the original position a Lower the vehicle on the ramp 8 2 5 OUTPUT SPEED SENSOR RENEW 4 0L SC SRO 44 15 41 a Raise the vehicle on a ramp a Reposition the edge of the transmission tunnel sound in sulation foam for access Disconnect the harness plug from the output speed sen sor
143. 5 7 Closures 2 Examine and repair or renew faulty harness Remedy Fault Door locking unlocking facility inoperative or faulty Possible causes No power supply to lock relays Door lock unlock relays faulty Door actuators faulty Keylock switches faulty Deadlockcircuitry faulty Wiring harness or connectors faulty om Fabi Remedy Check fuse F1 in RH A post base fusebox Renew faulty relay Renew door lock assembly complete Renew door lock assembly complete See Deadlockfault Sub Routine Examine and repair or renew faulty harness NAIP2UWN Fault Deadlocking facility inoperative or faulty not NAS Possible causes 1 No power supply to deadlock relays 2 Deadlock relays faulty 3 Deadlock status micro switch faulty Remedy Check fuse F1 in RH A post base fusebox Renew faulty relay Renew doorlock assembly complete wha n X300 VSM 21 Issue 1 August 1994 Las Security System RESTRICTED ISSUE y Fault Intrusionsensing inoperative Possible causes 1 Faulty sensor 2 Harness wiring or connectors faulty Remedy 1 Renew sensor 2 Examine and repair or renew faulty harness Fault Inclination sensing inoperative Possible causes 1 Faulty sensor 2 Harness wiring or connectors faulty Remedy 1 Renew sensor 2 Examine and repair or renew faulty harness Fault Fuel filler cap locking unlocking faulty Possible causes 1 No power to actuator relay 2 Wiring harness o
144. 5 O P Lock relay switch to ground 200mA 16 17 18 19 Alarm switch to 12V 20m 20 O P Start inhibited coded communication 21 O P Memorv seat 1 switch to 12V for 500ms 22 All close switch to groun 23 O P Interior lights on switch to ground for 80ms 5 24 O P Horn relay switch to ground 200ms 25 I P_ Powerground OV nominal 26 O P Sounder ve Intrusion sensor RH Intrusion sensor RH ground screen Intrusion sensor RH O P I P X300 VSM Intrusion sensor RH Ground RF ground Diagnostic1SO K line E Intrusion sensor LH ground Intrusion sensor LH Intrusion sensor LH Intrusion sensor LH 8V E CI 15 UP RF signal DiaanosticISO L line 40kHz signal diagnostic link input Issue 1 August 1994 Security System RESTRICTED ISSUE y Connector C 12 way Description 1 P Passenger door ajar Trunk lid release external 1 P Gearshift in park signal Lock actuator status RH Passenger door key unlock Driver door key unlock 07 Driver door ajar 08 TUE ignition coil on aux Transponder immobilization Lock actuator status LH Connector D 22 way 11 1 P Passenger door key lock switch to ground 12 1 P Driver door key lock switch to ground Comment switch to ground not in park ground switch to ground switch to ground switch to ground
145. 86 1550 A5 13 HAND TRANSMITTER BATTERY RENEW SRO 86 52 28 a Removethe handtransmitter rear cover 1 Fig 2 e Remove batteries 2 Fig 2 and discard Fittwo new batteries makingsurethe polarity is as shown in Fig 2 Fit and fully seat the transmitter rear cover A5 14 VALET SWITCH RENM SRO 86 52 08 Open the centre console compartment and carefully dis placethe valet switch a Disconnect the harness connector and remove the valet switch Fittinganewvaletswitch isthe reverseofthe removalpro cedure Make sure the switch is fully seated NN AAA Ecce X300 VSM 41 Issue 1 August 1994 Sas Security System RESTRICTED ISSUE y A5 15 SECURITY SIREN 12 CYL RENEW SRO 86 52 03 a Openthe trunk and remove the battery cover Disconnect the battery ground lead s Openthe hood and remove the headlamp relay cover See SRO 76 11 22 Section 13 Remove the RH air cleaner element See SRO 19 10 11 Section 5 2 Remove the RH air cleaner assembly See SRO 19 10 02 Section 5 2 a Identifythe RH forward harness relays 1 Fig 1 for subse quent refitting Remove the relays and relay bases from the mounting bracket a Disconnectthe siren harness multi plug 2 Fig 1 a Repositionthe side harness 3 Fig 1 to gain accesstothe siren securing bolts a Undo the siren securing bolts 1 Fig 2 and remove the siren 2 Fig 2 Note The siren securing bolts remain captive a Rem
146. 9 5 X300 VSM iii Exhaust Manifold Exhaust manifold to cylinder head 44 5 59 5 Heatshieldto exhaust manifold 21 5 28 5 Lifting eye setscrew slave item only 21 5 28 5 Miscellaneous Hoses Hose clamp heater return hoseto throttle body 15 25 Hose clamp hose to cam cover 25 35 Hose clamp water pump 25 735 Oil Cooler 4 0 liter supercharged Hose clamp oil cooler hose to radiator cradle 7 10 Oil cooler clamp screw 5 7 Oil cooler pipe bracket screw 15 25 Oil cooler pipesto engine 14 18 Oil coolerto body 17 23 Tube nut all except those shown below 17 23 Tube nut transmission pipesto transmission 16 20 Oil Pump Filter amp Oil Pan Drain plug 64 8 79 2 Filter headto cylinder block 21 5 28 5 Oil filter cartridge 12 15 Oil panto cylinder block 21 5 285 Oil panto timing cover 21 5 28 5 Oil pump and oil pump carrierto cylinder block 21 5 28 5 Rear cover to body 95 12 5 Relief valve plug 35 7 48 3 Supercharger Adapterto timing cover 22 28 Air duct clamp to intercooler 25 35 Air duct hoses 25 739 Air duct lower to intercooler 25 35 Issue 1 August 1994 3 1 In Engine AJ16 lightening Torque Nm Supercharger continued Air duct upper castingto lower Bypass valve disc to spindle IBypassvaive to throttle body Elbow to intercooler Idler bracket timing cover to cylinder black Idler bracket to water pump dler mounting bracketto thermostat ho
147. A Trunk Seal Retainer Eiere Zseeagie ege naaa aa caian 40 13410 ura TrunkLid Lock Striker Renew enc ENN NNN ENEE VEER ENNEN NEEN di 40 ABS ALD id i Trunk Lid Lock Barrel Here coccccocccconnnannn eee eee eeeneeenae 40 TBAT aiii Trunk Lid Lock Mechanism Renew 0ccc cece cece eee eee eee eee ee eee ee eens 4 LESS aa Trunk Lid Gas Strut Adjust Renew sssssssnnsnnnnnennannnnnnnnnnununnnnnennnnnnnnnn 41 13414 cocos Trunk Lid Hinge RENEW e 41 LALO E acer Tr nk Rear Liner En EE 41 DBD rania eii HOO0 WEE EE EE ER ET eg gece Hood Description eneen 42 E EEN Plenum Chamber Finisher Renew 764001 a 42 ABD E ewan ies FINGO RONEN sin tana ana aon ow E ENEE NEE EEN ANERE EE ege 42 E See ere ae Gas Strut B new soe EE EE NN IN EE ENEE EEN dis 43 LED a a Hood Lock RH or LH ReneWos 2 ve ENER ERENNERT a 43 issue 1 August 1994 ii X300 VSM S Body Components amp Trim SECTION CONTENTS Sub Section Title SRO Page ERSA RA E E Hood lock Control CableRH or LH Renew ooooconcncnnnnn eee eeneeeeeeeneeneae 43 13 576 aiaa Hood Striker Assembly Renew oeonononnnnnnnnnnn eee eee eee eee eee eeeeees 43 13 018 a iran a Hood lock Release Handle Here 43 LEE Glazing Fixed 2 ug A dE KN H Ee ANERER EE REN EC AN 44 ERC REG Glazing Fixed Description EE eee eee eeeneeeeeeeeee 44 TIO Interior Mirror Renewal a 44 ES AAA Sun Visor Mirror Assembly Renew oococooncnnnnnnnn eee ee eee eee eee eeeeeee 44 13 624 caia Exterior Mirror
148. AJ16 Ng rs 6 1 1 EXHAUST SYSTEM GENERAL DESCRIPTION J30 223 Fig 1 Plan View Exhaust System AJ16 Normally Aspirated This section covers the various exhaust systems fitted to AJ16 engined vehicles Always refer to the Parts Catalog for parts usage and interchangeability before replacing a component part of the exhaust system The low loss catalytic converter exhaust system for the AJ16 normally aspirated engine comprises of a catalyst downpipe assembly 1 Fig 1 a underfloor catalytic converter assembly 2 Fig 1 complete with heat shield 3 Fig 1 an intermediate muffler section 4 Fig 1 and a rear muffler section 5 Fig 1 On non catalytic converter systems the downpipe catalyst assembly is fitted with conventional twin branch downpipes hence there are no oxygen sensors or gas temperature sensors Conventional mufflers are fitted in place of the underfloor converters X300 VSM 1 Issue 1 August 1994 s Exhaust System AJ16 y Fig 1 Components of the Exhaust System AJ16 Normally aspirated Heatedoxygensensorsarefittedtothedownpipeassembly 1Fig 1 which isconnectedtothemanifold 2 Fig 1 There are two sensors for the ROW and Japan 3Fig 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
149. ANCE 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 STEERINGISCENTEREDAND THE COLUMN LOCKIS ENGAGED IF THE LOCK IS TO BE RENEWED LOCK WIRE THE ASSEMBLY TO PREVENT ROTATION FAILURE TO OB SERVE THIS MAY RESULT IN AN INOPERATIVE AIRBAG SYSTEM SEE LABEL ON STEERING WHEEL HUB X300 VSM 1 Issue 1 August 1994 Qu Steering 10 1 3 Steering Hydraulic System Major Components Engine driven rotary vane pump beltdriven 12cylinder direct drive fromtiming gear 6 cylinder with falling flow characteristic as pump speed increases fluid flow decreases and integral pressure relief valve Remotefluid 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 Hydraulic System Operating Principle see illustrations on next three pages Rotary motion of the steering wheel is converted via the steering gear pinionto lateral motion ofthe rack Hydraulic assistance is provided by pressurized fluid bei
150. Aerial Radio cassette and compact disc player memory feed F9 Light Blue 15 Rear fog guard lamps Stop lamp right hand side Turn indicator rear right hand side F10 Tan 5 Radio cassette and compact disc player control relay F11 Clear 25 Caravan Trailer module a F12 Tan 5 Accessories and telephone control relay F13 Se Red g 10 Accessories F14 Not used a e F15 Clear 25 Heated rear window Airbag warning Not used F18 Tan 5 Tail lamp right hand side A f l License plate lamp right hand side Issue 1 August 1994 A1 95MY 18 X300 VSM Y Routine Maintenance 2 CONTENTS Title Routine Maintenance 1995 Model Year Vehicles ooooocococncoc ee eee eee eee 7 Fluids amp Lubricants Service Points 6 Cylinder Vehicles ee EE 1 Fluids amp Lubricants Service Points 12 Cylinder Vehicles een 2 Service Schedule U K Europe ROW EE EE 3 Service Schedule USA Canada EE meee 5 X300 VSM A2 95MY i Issue 1 August 1994 A2 95MY ii Y Routine Maintenance gt lt ER ANE a preree SAN 2 SS CTN a aD ne y Jj IN K ni E un i AAN GH RIN 4 E NEO 10 054 1 Engine oil refill 8 Final drive oil refill 2 Engineoil drain 9 Final drive oil drain 3 Transmissionfluid refill 10 PAS fluid refill 4 Transmission fluid drain 11 Windshield wash reservoir refill 5 Brake fluid refill
151. Automatic Transmission AJ16 8 1 1 3 Shift Speeds 3 2 Liter Upshifts Light throttle D1 D2 d D2 D3 D3 D4 D4 TCC on mile h 10 11 16 23 24 29 49 53 km h 16 18 26 37 38 47 79 85 Up to kick down point D1 D2 D2 D3 D3 D4 mile h 32 38 58 64 79 91 km h 51 61 94 104 127 147 Through kick down point D1 D2 D2 D3 D3 D4 mile h 37 43 65 71 90 103 km h 104 114 145 166 Downshifts Zero throttle TCC off in D4 D4 D3 D3 D2 mile h 47 51 16 22 13 14 km h 76 82 24 35 22 23 Upto kick down point D4 D3 D3 D2 D2 D1 a ae mile h 64 71 42 48 22 31 km h 102 114 67 78 36 50 Kick down available D4 D3 D3 D2 D2 D1 Re mile h 86 99 km h 139 160 Manual inhibit Wei D4 D3 available speed mile h NOT INHIBITED 67 76 km h 108 123 TCC Torque converter clutch Issue 1 August 1994 4 X300 VSM 2F Automatic Transmission AJ16 g 4 0 Liter Lightthrottle D1 D2 D2 D3 D3 D4 D4 TCC on Economy mile h 10 12 14 21 20 29 45 55 km h 16 20 23 34 32 47 72 88 sport mile h 10 16 16 24 25 33 49 59 km h 16 26 26 38 40 53 79 95 Economy mile h 34 38 57 64 88 98 88 98 km h 55 61 91 103 141 157 141 157 Sport mile h 43 48 73 81 110 119 110 119 km h 69 77 117 130 176 191 176 191 Through kick dpwn po
152. C brake pipe gland nuts 2 Fig 2 and disconnect the brake pipes a Fit plugs immediatelyto the brake pipes andthe hydraulic control moduleto prevent fluid loss a Undothe rear brake pipe gland nuts 3 Fig 2 at the pres sure conscious reducingvalves PCRVs 4 Fig 2 Remove the rear brake pipes Note Take necessary steps to prevent rotation of the PCRVs when removing the rear brake pipes Fit plugs immediately to the brake pipes andthe PCRVsto prevent fluid loss a Undoand removethe PCRVs Fit plugs immediatelyto the PCRVs andthe hydraulic control module Place PCRVs aside to be fitted later to the new hydraulic control module a Undothe front brake pipe gland nuts 5 Fig 2 and remove the front brake pipes a Fit plugs immediatelyto the brake pipes andthe hydraulic control module to prevent fluid loss a Undo and removethe three securing nuts 6 Fig 2 and re move the hydraulic control module J70 296 X300 VSM 23 Issue 1 August 1994 Brakes Removethe absorbent material and clean the mounting bracket and surrounding area Fit and align anew hydrauliccontrol moduleto the mounting bracket Ensurethat the mounting cup tangs fully en gage the bracket slots s Fit andtighten the securing nuts 6 Fig 1 a Place absorbent material underneath the hydraulic con trol moduleto absorb any spillages Connect the front hydraulic brake pipes 5 Fig 1 to the hy drauliccontrol module removing plug
153. CAUTION Donotvent refrigerant directlyto the atmosphereand always use Jaguar approvedrecovery recycle re charge equipment a Drain the engine oil see 3 1 3 this section a 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 TURNTHE CAP ANTI CLOCKWISE UNTIL THE EXCESS PRESSURE CAN ESCAPE LEAVE THE CAP INTHIS POSITIONUNTIL ALL STEAM AND PRESSURE HAS ESCAPED AND THEN REMOVE THE CAP COMPLETELY Before liftingthe complete engine transmission unit with an engine hoistfrom 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 positionedtowardsthe front andthe rear of the assembly Ensurethe front of the vehicle isjacked upsecure ly on stands when removing the assembly Issue 1 August 1994 2 X300 VSM y Engine AJ16 Iron 3 1 3 ENGINE OIL RENEW SRO 12 60 00 a Undo and remove the sump plug positionedatthe rear of the sump drain the engine oil into a suitable receptacle and dispose of it in a safe and environmentally friendly manner Replenish the engine oil to the correct levelonthe dip stick see Fig 1 When the oil is renewed start the engine wait for the oil light to extinguish and switch off the engine for 30 sec onds a Finally remove and wipe clea
154. CE PERSONNEL The fuel filler assembly supplied complete with serviceable lid hinge and hinge spring isfixed to the Body in White BIW decking panel by two M5 nuts Additional parts of the assembly comprise a adjustable rubber buffer asnap in striker and the fuel cap stowage magnet The fuel bowl retained around the filler neck by aclip 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 includesthe 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 acrossthevehicle behindthe passenger compartment rear bulkhead is held in position bytwo retaining straps tightened by two M5fixing arrangements The fuel tank of AJ16 engined vehicles contains one fuel pump supplying fuel to the normally aspirated engine and two fuel pumps supplyingfuelto 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 litres hour minimum at 13 2 volts 3 bar outlet pressure The pump s draw a nominal current of 7 amperes at 13volts 3 bar outlet pressure ambient temperatures Builtintothe pum
155. Clean the transmission fluid pan joint face a Cleanthe fluid pan Place the fluid pan aside a Attach the magnetto the recess in a new fluid pan a Fit and align a serviceable gasket to the fluid pan a Fit the fluid pan and gasket to the transmission unit a Fit and tighten the fluid pan securing bolts a Apply sealant to the intermediate pipe joint See Service Materials inthe preliminary pages this Section e Reconnect the intermediate pipe to the downpipe Align the intermediate catalyst assembly Tighten the intermediate pipe to the downpipe securing clamp a Align the intermediate silencers to the intermediate cata lyst assembly a Tighten the intermediate silencer securing clamps a Lowerthe vehicle on the ramp Refill the transmission unit with fluid see Subsection 8 2 13 m Removethe fender cover and close the hood Jm X300 VSM 15 Issue 1 August 1994 Wes i Automatic Transmission V12 amp AJ16 Supercharged y Powertrain 8 2 15 FLUID PAN RENEW 6 0L SRO 44 24 04 e Openthe hood and fit a suitable fender cover a Raise the vehicle on a ramp a Slacken the underfloor catalyst to downpipe clamps se curing bolts Displace and repositionthe olive clamps onthe pipes a Slacken the underfloor catalyst to intermediate silencer clamps securing bolts e Displace the underfloor catalyst assembly rearwards to disconnect from the downpipes a Displace and remove the olives fr
156. Cleaning of water based stains from carpets Cleaning of water based stains from carpets Novatreat Genklene Trichloroethane Cleaning of water based stains from carpets Cleaning of grease or oil based stains from carpets Spot Remover X300 VSM Cleaning of grease or oil based stains from carpets Issue 1 August 1994 vi 13 1 Body Components amp Trim GENERAL DESCRIPTION This section covers the following areas of the vehicle body Q 000000000000 Olu Oem Oem Of One Q Referto Appendix A4 Body Systems amp Body Repairfor information relating to crash damagerepairs and to the fol Battery cover Carpets passenger compartment trunk Console including radio glovebox Doors frames sealing locks trim glazing Fascia Fuel filler flap assembly Footrest Hood liners gas strut locking Illuminated sunvisor inc mirror Interior trim trim pads finishers veneers Mirrors internal external Rear parcel tray Roof console Roof lining headlining Seats front rear Seat belts front rear Sliding roof Steering column cowl Underscuttle pad lowing external components exterior trim bumpers windscreen and rear screen closures and sealing Refer to Section 15 Electrical for details of the following motors and solenoids driver s and interior mirrors window lift sunroof seat headrest and locking mechanisms doors trunk and filler cap Referto S
157. Cooling System Layout LIX Issue 1 August 1994 2 X300 VSM Cooling System V12 ES 4 2 3 SERVICE PROCEDURES 4 2 3 1 Safety Precautions The anti freeze specified in Appendix At must be used wherever possible It is designedto afford the maximum cor rosion protection to all metals found inthe engine cooling system as well as having the frost protection properties necessary during the winter months Should it not be available then anti freeze conforming to Ford Motor Company specification ESD M97B49 A may be used To provide optimum temperature and corrosion protection the specified anti freezeconcentration must always be used Once coolant has been drainedfrom the system it must be discarded and not reused Anti freeze is harmful to the environment Always dispose of used coolant safely and never pour it down a drain connected to the public sewer CAUTION Never fill or top up the system with water only CAUTION Anti freeze is harmfulto paintwork Coolant spillages must be wiped up immediately andthe affected area washed to remove all traces of coolant CAUTION To preventthe possibility of damage to the heater circuit pump the pumpshould be electrically isolated 4 2 ifthe ignition has to be turned ON while the cooling system is drained WARNING DO NOT REMOVE THE HEADER TANK PRESSURE CAP WHILE THE ENGINE IS HOT IF THE CAP MUST BE REMOVED PROTECT THE HANDS AGAINST ESCAPINGSTEAM AND SLOWLY TURN THE CAP ANTI CLOCKWIS
158. Drain and Fill Procedures Radiator Fill 4243 cute wea BOA AN E AE EERE AE ET Fault DIAgnoS S En ALA ie Fault Diagnosis introduction ALDO AS Fault Diagnosis Diagnostic Procedures X300 VSM i Issue 1 August 1994 ES N ES Cooling System V12 L SERVICE TOOLS amp EQUIPMENT NoJaguar servicetools are requiredfor working onthe cooling system Some normalworkshop itemswill berequired including a pressure tester hydrometer and thermometer ll TORQUE TIGHTENING SPECIFICATIONS Fixing Tightening Torque Nm Electric fan assembly to body 7 10 Headertank bracketto body 7 10 Header tankto body 2 5 3 5 Hose clip all main hoses 2 5 3 5 Hose clip bleed hoses except those shown below 1 5 2 5 4 A 2 Hose clip bleed hoses to header tank 2535 Locator fan cowl to radiator top panel 8 5 11 5 Lower radiator cradle to body 7 10 Radiator drain plug 1 5 2 5 Radiator temperature switch 13 17 Receiver drier to cooling fan assembly 2 5 3 5 Top radiator panel to body mn SERVICE MATERIALS Description Uses Notes to be issued IV SERVICE DATA Application Specification Engine thermostat temperature rating 88 C Coolant header cap pressure rating 12 bar Water pump air injection pump drive belttension Burroughs method new belt 650 N In service if tension falls below 320 N reset at 400 N Clavis method new belt 169to 175 Hz In service if tension falls below
159. E RE SSE X300 VSM A2 95MY 3 Issue 1 August 1994 Y lt gt Routine Maintenance Service intervals Miles X1000 10 30 40 50 60 35 Check power steering system for leaks and hydraulic x xX xX XxX pipes unions for chafing corrosion Check Cooling heating system for leaks security 4 xX x XxX Check visually hydraulic hoses pipes unions for leaks Xx Xx XxX X chafing cracks corrosion A x Check speed control vacuum hoses for security and gen Xx x eral condition Grease door check arm side edges Xx x Check parking brake cable adjustment A xX X Clean out radiator matrix and condenser where fitted to remove dirt accumulation x lt x lt Clean antenna mast X X Carry out road roller test X X Issue 1 August 1994 A2 95MY 4 X300 VSM Y Routine Maintenance SERVICE SCHEDULE USA CANADA 4 0 Liter 4 0 Liter SC and 6 0 Liter i z S E es E 75 15 225 30 375 45 525 1 Renew engine oil and filter Xx X X X X Xx 2 Renew transmission fluid and filter ES A a 3 Renew brake fluid two years T xi f A Renew coolant four years and check specific gravity EA AA ee 5 Renew air cleaner element s EXI Se ee 6 Renew air cleaner element s SC only T X CG Jx IX 7 Renew SC unit drive belt SC only x 0 f 8 Check Adjust SC unit drive belt tension
160. E UNTIL THE EXCESS PRESSURE CAN ESCAPE LEAVE THE CAP IN THIS POSITION UNTIL ALL THE STEAM AND PRESSURE HAS ESCAPED AND THEN REMOVE THE CAP COMPLETELY WARNING WHEN DRAINING THE COOLANT WITH THE ENGINE HOT PROTECT THE HANDS AGAINST CONTACT WITH HOT COOLANT WARNING WHEN WORKING WITHIN THE ENGINE COMPARTMENT KEEP CLEAR OF THE ENGINE DRIVENRADI ATOR COOLING FAN WHEN THE ENGINE IS RUNNING 4 2 3 2 Working Practices Whenfilling thesystem with coolant ensure that the vehicle isstanding on a level surfaceandthatthecoolantis poured in slowly so that airlocks are not introduced into the system Airlocks can seriously affectthe operation of the climate control system and can cause damage to the heater circuit pump Hose clips should always be positioned so that there is proper access for tightening andthat the clip does not foul or interfere with the operation of any components The drive belt must always be tensioned to the specified value and the tension checkedatthe correct point onthe belt This information is given in Sub section IV inthe preliminary pages When tightening components the torque figures given in Sub section Il inthe preliminary pages should always be used for the fastenings listed When fitting a replacementthermostat ensure that the jiggle pin is to the top of the thermostat housing 4 2 3 3 Coolant Change The coolant must be changed at intervals of four years The system should be drained from the radiator drain plug
161. EDICAL ATTENTION IF BRAKE FLUID IS INGESTED SEEK MEDICAL ATTENTION IMMEDIATELY CAUTION Fluid must not be allowed to contact the vehicle paintwork Remove any spilt fluid from the paintwork by rinsing away with runningwater Methylated spirit denaturedalcohol must not be usedto cleanthe contaminated area CAUTION Neveruse methylatedspirit denaturedalcohol for componentcleaningpurposes Useonly a proprietary brake cleaning fluid WARNING THROUGHOUT THE FOLLOWING MAINTENANCE SERVICE OPERATIONS ABSOLUTE CLEANLINESS MUST BE OBSERVED TO PREVENT FOREIGN MATTER CONTAMINATING THE BRAKE SYSTEM 12 4 1 System Bleeding General Instructions Use a brake bleeder bottle with aclear bleeder tube Also recommended is afiller unitwith afill pressure of 1 0 bar If afiller unit is not used ensure that their is sufficient brake fluid inthe reservoir throughout the bleeding procedure Note Always bleedthe caliper furthest away from the actuation unit first On right hand drive vehicles bleed inthe following order front left FL front right FR rear left RL and rear right RR Onleft hand drive vehicles bleed inthe following order FR FL RR and RL 12 4 2 System Bleeding After Brake Fluid Renewal a Ensurethat the vehicle is standing level Switch the igni tion off Check that the fluid level inthe reservoir is between the min and max marks Connectthe bleeder bottle tube to the relevant front cali per see note above bleed
162. Fig 1 a Fit Service Tool JD161 Fig 2 to the rotary switch to align the switch rotor with the switch body CAUTION Service Tool JD161 is a precision tool and 1 2 344 689 should be treated as such Fig 1 a Evenly torque tighten the rotary switch to mounting 9 bracket securing nuts a Disengageand removeService Tool JD161 fromthe rotary switch a Fully seat the rubber blanking plug into the rotary switch center boss a Fit the rotary switch protection cover and align with the fluid pan bosses a Fitandtorquetighten the rotary switch protection coverto fluid pan securing bolts e Lower the vehicle on the ramp a Check for correct operation of start inhibit and gear selec tion JA do 612 Issue 1 August 1994 8 X300 VSM X300 VSM 8 1 5 TRANSMISSION ROTARY SWITCH RENEW 4 0L SRO 44 15 36 a Check the shift cable adjustment Switchthe ignition ON apply the footbrake and movethe shift lever to N Switch the ignition OFF and disconnect the battery Open the armrest lid a Release and remove the ashtray securing screws a Displacethe ashtray assembly for access a Disconnect the cigar lighter illumination harness con nectors a Placethe ashtray assembly aside a Displace and remove the console veneer panel rear fin isher Carefully displace the Performance Mode switch from the gear surround finisher a Disconnect the Performance Mode switch from the ha
163. GH NEVER ATTEMPT TO SERVICE ANY PART OF THE SYSTEM UNTIL IT HAS COOLED EXHAUST GASES CONTAIN CARBON MONOXIDE WHICH CAN BE HARMFULTO HEALTHAND ARE POTENTIALLY LETHAL LEAKSMUST BE REPAIRED IMMEDIATELY NEVER OPERATE THE ENGINE IN ENCLOSED AREAS External leaks inthe exhaust system are often accompanied by noises and exhaust fumes therefore avisual 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 helpfulto 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 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 Condition Possible Cause Noises and exhaust fumes Exhaust leak Referto Test Step 1A Misaligned exhaust Loose clamps or fasteners Restricted exhaust system Goto Test Step 1B Restricted exhaust system test Engine
164. IL J76 1037 1 Section roof 2 Drip rail finisher assembly 3 Assembled condition Fig 2 42 X300 VSM Issue 1 August 1994 Body Systems amp Body Repair e A4 7 1 BODY EXTERIOR CLEARANCES AND ALIGNMENTS A4 7 1 1 introduction Wherever a panel closure or component is renewed refitted or reset the factory specifications for clearance gap and alignment profile MUST be attained There is no distinction betweenthe importance of visual and operational characteristics all conditions must be satis fied so that the vehicle looks and operates to the satisfaction of both design intent and the customer A4 7 1 2 Criteria Clearances Oo Gaps should be uniform around body panel contours Q Gaps must be parallel to within Imm in a 400mm linear measurement Q Panelswhich arecentered between 2 two adjacent panels must have equal gaps either side there are excep tions to this please refer to the appropriate specification O Gaps between adjacent panels or components must not expose harnesses labels brackets or visually poor joint or assembly conditions Particular areas of concern Fuel filler flap Trunk lid to fenders and saddle Hood to fenders grille and headlamps Sliding roof panelto the main roof panel Door gaps at fender B C pillar roof drip rail and rocker panel Bumper cover to fender and cross car assemblies see section A4 6 1 4 amp A4 6 1 5 Note Pleasenotethat the sliding roof pa
165. Introduction There are two types of moulding fitted to the standard wheelbase sedan The lower moulding is self locating on the body door lower feature line and therefore provides a fixed datum for the location of the upper moulding wherefitted Replacementlower mouldings will be suppliedina primedcondition and therefore must be finished in accordance with 44 63 this section Location Finish Application Fixing method Upper Polished stainless steel Daimler VDP Adhesive tape Lower Body color All models Adhesive tape A4 6 6 2 Body side Moulding Fitted Condition 2 0mm nominal 1 Adhesive tape 2 Moulding Daimler VDP 3 Moulding All models Fig 1 A4 6 6 3 Fitting process a Spirit wipe appropriate body panel and where appropriate protect against damage a Gently warm body panel and moulding using infa red lamp or similar a Lower moulding align to body feature and other mouldings if appropriate and secure into position a Upper moulding align to lower moulding for distance Fig 1 and parallelism and other mouldings if appropriate and secure into position a Apply an even pressure along the mouldingto fully secure to the panel X300 VSM 41 issue 1 August 1994 Hi 4 mS Body Systems amp Body Repair A4 6 7 FINISHER DOOR FRAME 1 Section door frame 2 Compression cord 3 Frame finisher Fig 1 A4 6 8 FINISHER ROOF DRIP RA
166. Issue 1 August 1994 ZE CT Automatic Transmission AJ16 a Ensurethe shift lever is in N a Fit and fully seat a new rotary switch to the transmission unit Fit but do notfully tighten the rotary switch securing nuts a Fit and align Service Tool JD161 Fig 1 to the rotaryswitch to alignthe switch rotor to the switch body a Finally torque tighten the rotary switch securing nuts e Displace and remove Service Tool JD161 a Reposition and fit the rubber sealing plug to the switch a Reconnect the transmission unit multi pin plug a Reposition the harness and feed the multi pin plugs and grommet through the tunnel aperture From below the vehicle reposition the harness P clip to 7 Ant its mounting stud a Fit and tighten the P clip securing nut Fia 1 a Align the harness P clip to transmission shift abutment bracket e Fit and tighten the P clip securing screw a Fit and align the rotary switch protection cover fit and torque tighten the securing bolts a From inside the vehicle fit the grommet in the correct orientation and reposition the harness inthe correct posi tion a Reconnectthe rotary switch harness multi pin plugs a From below the vehicle ensure that there is no excess slack inthe switch harness that could foul the propshaft a Lower the vehicle onthe ramp Reposition and fit the tunnel carpet Usingsuitable tie straps secure the harnesstotheconsole harness Fit an
167. Kay Adhesives No 5696 Exhaust sealer Reeg IV SERVICE DATA Application Specification Material removal to clean up clutch face Upto Im m maximum EE X300 VSM iii Issue 1 August 1994 Manual Transmission amp Clutch AJ16 Bea 7 1 1 MANUAL TRANSMISSION DESCRIPTION The Getrag 290 5 speed manual transmission Fig 1 fitted to this vehicle incorporates synchromesh on all forward gears Gear selection is by acentrally mounted lever connected to the transmission selector shaft via a pivoting joint All gears are engaged by asingle selector shaft operating three rods which move the selector forks The drive pinion is supported at the rear by aduplex ball bearing situated inthe front casing and atthe front aspigot engages in a needle roller bearing in the flywheel The mainshaft issupported atthe front by acaged roller bearing situated inthe drive pinioncounterbore inthe centre by a roller bearing supported by the intermediate casing and at the rear by a duplex bearing inthe transmission rear casing Each of the forward speed mainshaft gears incorporates an integral synchromesh mechanism with the clutch hubs splined to the mainshaft and situated between each pair of gears Thecountershaft issupportedat the front bya roller bearing situated inthe front casing inthecentre byaroller bearing inthe intermediate casing and at the rear by a roller bearing situated in the tail housing The reverse idle
168. Locatedon the steering column to receive signals from the reader exciter coil and disarmthe engine immobilization system on correct demand A5 2 11 Security active indicator An LED built into the central locking switch to indicate when security system is armed A5 2 12 Security and locking control module Locatedinthe luggagecompartmentbelow the LHside liner Controlssystem operation and interfacewith associated modulesto achieve correct responseto input signals 16 91112 7 A B C D Fig 1 Control Module Connector Pins Issue 1 August 1994 4 X300 VSM y Connectionsto the SLCM are detailed inthe following table Security System RESTRICTED ISSUE ConnectorA 26 way ConnectorB 16 way Pin No Signal Description Comment 01 O P Deadlock front right rear left switch to ground 200mA 02 O P Unlockdriver s door switch to ground 200mA 03 04 05 I P_ Vehiclespeed 7600 pulses mile 06 O P Inclination alarm 07 Intelligent sounder serial communications 08 O P Memory seat 2 switch to 12V for 500ms 09 O P Visual warning switch to ground 10 O P Secure mode status arm 200Hz square wave 5 disarm 400Hz square wave 5 duration 64ms 11 O P Trunk lid release relay switch to ground 12 UP Power 12V battery 12V power supply 13 O P Sounder ve half of push pull network 14 O P Deadlock front left rear right switch to ground 200mA 1
169. MD ii Fault Diagnosis Diagnostic Procedures ooocnoconccnnnnnncnnnnnncnanan 6 X300 VSM i Issue 1 August 1994 ES Cooling System AJ16 1 SERVICE TOOLS amp EQUIPMENT NoJaguar servicetools are requiredfor working onthe cooling system Somenormalworkshop itemswill berequired including a pressure tester hydrometer and thermometer Fixing TighteningTorque Nm Fan cowl assembly to radiator Header tank bracketto body 7 10 Headertankto body 2 5 3 5 Hose clip all exceptthose shown below 2 5 3 5 Hose clip bleed hoseto radiator Lower radiator cradle to body Radiator drain plug Radiator temperature switch Supercharger pump mounting Supercharger pump to instrumounts 5 7 Supercharger radiator to body 7 10 Top radiator panelto body 7 10 111 SERVICE MATERIALS Description Uses Notes To be issued IV SERVICE DATA Application Engine thermostat temperature rating Coolantheader cap pressure rating Generator water pump drive belt tension new belt Setto Burroughsmethod 556 to 578 N Clavismethod 174to 180 Hz Run for one minute and allow belt to cool Resetto Burroughs method 511 to 534 N Clavis method 167to 173Hz Generator water pump drive belt tension service Burroughs method 511to 534 N tension Clavis method 167to 173 Hz Generator water pump drive belt tension measuring Mid way between crankshaft and generator pulleys point I
170. Motor the column fully upwards a Fit and tighten the cowl securing screws s Fita new ignition lock rubber gaiter and position the lower cowl to the steering column a Fit and tighten the cowl securing screws a Motor the column to the original position 13 3 30 Steering Column Lower Cowl Renew SRO 76 46 03 s Motor the drivers seat fully rearwards a Undo and removethe lower column cowl securing screws 1 Fig 1 a Displace and reposition the lower cowl 2 Fig 1 a Disconnect the rheostat multi plug 5 Fig 1 a Disconnectthe tilt column harness multi plugfrom the tilt Fig 1 column switch 6Fig 1 Removethe cowl and place to the front remove the igni tion lock rubber gaiter and discard 3 Fig 1 Displaceand removethe rheostat adjusting knob 7 Fig 1 a Undo and remove the rheostat securing screws 8 Fig 1 a Displace the tilt column switch retaining tangs and re move the switch a Place the cowl aside a Place the new lower cowl to the front a Fit and fully seat the column switch a Fit and align the rheostat Fit and tighten the rheostat se curing screws a Fit and fully seat the rheostat knob Fit new ignition switch rubber gaiter and reposition the lower cowl Connect the rheostat harness multi plug a Connect the column switch harness multi plug a Positionthe cowl to the steering column a Fit and tighten the cowl securing screws a Motor the seat to the original position
171. NEE EE u 22 A434 conan Insulation Pads LOCATION assi siani naai eee eee eee eee eee eens eee mara da 23 MIS ee Foam Injection wvcccuccccueucueeeeeeueeeeee eee eee eee eee E Ea AEE AE aa EA 24 A4 4 1 cono Paint Systems Approved Table ooccnconncncnnanannna EE EE 25 A4 4 1 1 wuneunnnen General Recommendations Paint Refinishing Manual ee EE EEN nana 25 GEAR Paint Refinishing Manual Section Relevance ee ENEE EE EE 25 A4 4 2 cana Black Out Areas lllustration EEN 26 MAS een Anti theft laDe S ee EEN EEN EE EEN EE EE ENEE EE EE EE Eu 27 A44 3 1 aannnnennn Anti theft labels Original Components ee EE EE ENEE EE EE 27 A4 4 3 2 ee Anti theft Labels Replacement COMPONENTS ENEE 27 MAS e Anti theft Labels Procurement ENEE EEN EEN 27 MASA NEE Anti theft Labels Location Front oconocnnncnnncnnnnnnccn 28 A44 3 5 e Anti theft Labels Location Pear onccnnnconnccnancnnnnnnnn 29 MAS e Anti theft Labels Location Power Unit amp Transmission ee ENEE ENEE EE EE E En 30 A4 4 3 7 nono Anti theft Labels Fitting Dees ooononoonocnnananncanannn anne 31 X300 VSM i Issue 1 August 1994 X300 VSM Body Systems amp Body Repair Title SRO Page Underhood Labels Location amp Type EE EEN EEN EE EEN 32 Stonechip Protection Area ENEE ENEE EE EE EE ENEE EE 33 Glazing WEE 34 Glazing Special Notes ENEE ENEE ENEE EE EE EEN a a EEN ENEE E EN 34 Glass And Body Preparation ooooononnnnncnncnnann eee eee e eee eee eeeeeeeeeeeees 34 Glazing Ad
172. O Preliminary Pages ENEE ENEE EE EE EEN EE EEN i Tout ALT er Body Repair Introduction oooconnnnonnnncnnnn anaapa uag a KA i a a 1 EAR Health And Gatti EE 1 A412 enen Notification Of Hasan 2 MALAS caco Potential RISKS lt i Eu uua k iiaa E cece a 3 ATIT sannnnnene Potential Risks Paint e ENEE EE EEN ENEE ENEE a aA 3 A4132 coo Potential Risks Applied Heat WeldinQ oocncconccnncnnncnnnnn 3 A4 1 3 3 ccoo Potential Risks Metal Repair ENEE ENEE ENEE ENEE EE ENEE EE 3 MATA ccoo PreCauliOns 2 A a E 3 A4 1 4 1 ccoo Precautions Paint EEN EEE EE E EEN a 3 A4 1 4 2 ccoo Precautions Applied Heat ooocononnnnnnnnnncn eee a e eee eee ena ee eens 3 MITAD timimi Precautions Metal Repaif s sssunnssnnnnunnannnnnnnnnnnnnnnnnnnnnnnnunnnnnnnnnnnnnnn 3 ALND ic otawen eee General Repair Notes NN 4 E uea Welding amp Gas Processes Special Notes enen 4 AGG NEES Plastics Explanatory Notes e 5 GEAR ANEN Plastic Component amp Trim Materials Table een 5 EAR Plastics Handling Notes ene tania EEN ENEE ENEE EE 5 A4 T oriire Recycled MaterialS ane EEN 5 A4 1 6 4 coco Plastics Component Location amp Type External Illustration ee 6 A41 6 5 ceccecenes Plastics Component Location amp Type Internal IUStratiON EEN 7 A4 1 6 6 Plastics Component Location amp Type Underhood Illustration ENEE 8 Ad Body SITUCIUTS nonnanononnnrarononra rana SEENA KAA SRIENE ENa NA Maa KT A 9 A421 en Body Structure Introduction ee EE 9 A4 2 1 1 A Body Struct
173. Passenger Door Lock Passenger Memory Seat Rise Fall Front Passenger Memory Seat Rise Fall Rear Passenger Window Lift Mirror LH Blower AC ABS Pump Motor Unit Traction Control Actuator A C Water Pump amp Water Valve Solenoid Cruise Control Pump Starter Solenoid Starter Wiper Alternator A C Compressor Clutch SCM Steering Control Module Transducer Number Memory Seat Fore Aft N N zech WI gt HX a a o Ki N p gt X300 VSM 31 Issue 1 August 1994 s Electrical y 15 12 RELAYS 15 12 1 Engine Compartment Relays General Description Fig 1 Engine Compartment Relays In order to locate individual relays Fig 1 showing all relay locations within the engine compartment is to be read in conjunctionwith the followingtable The numbers indicatingthe relays onthe illustrationcorrespondto the numbers inthe right handcolumn To remove and refit individual relays open the bonnet locatethe faulty relay unplug and renew Issue 1 August 1994 32 X300 VSM y Electrical Key to Fig 1 Engine CompartmentRelays page 14 SRO Relays Location VG uge B6 55 04 Horn Engine All Models All Models 1 compartment inside the left hand side fuse box Starter Motor Engine Al
174. Potentiometer Open short circuit in potentiometer feed 33 S Note Incertain circumstances the motor can over travel Cool Air by pass Potentiometer and log further faults Cycling the ignition two or three times 34 Defrost Vent Potentiometer after rectification of the fault will cure this 35 Centre Vent Potentiometer 36 Foot Vent Potentiometer LH Fresh Recirc Motor 42 RH Fresh Recirc Motor 43 Cool Air by pass Motor Checktor short open circuits in motor drive lines Motor flap 44 Defrost Vent Motor sticking jammed 45 Centre Vent Motor 46 Foot Vent Motor Note Inambienttemperatures below0 G the system may logfault code 23 becausethe low ambient causesatem porary low gas pressure Where the ambient temperature rise above 40 C and if the engine isclose to over heating feed to the compressor clutch may be cut and code 23 registered X300 VSM 17 Issue 1 August 1994 4 Gu YE Climate Control Systems 14 11 3 Associated Faults Other symptoms that may exist without storing fault codes No heat Airlock in system Electric water pump inoperative Coolant flow valve stuck closed Faulty engine coolant thermostat One vent failing to open close Broken linkage Poor airflow Blower motors incorrect operation 14 11 4 Panel Communication Check SCREEN amp FOOT DEFROST RECIRC lines checked State lamps will illuminate if all is OK Unlit state lamp means continuity fault for that specific link S
175. RVICE REPAIR OPERATION SRO NUMBERING A master index of numbered operations has bee compiled for universal application to all vehicles manufactured by Jaguar Cars Ltd Each operation described inthis manual is allocated a numberfromthe masterindex and cross referswith an identical number inthe Service Repair Operation Times Manual The number consists of six digits arranged inthree pairs Each operation is described inthe sequence necessaryto complete the operation inthe minimumtime as specified inthe Manual of Repair Operation Times SERVICE TOOLS Where non standard service tools i e tools which are not generally available handtools are requiredto complete an operation the number and an illustration of that tool is given inthe preliminary pages of the Section concerned TORQUE TIGHTENING SPECIFICATIONS Torque tightening specifications are given intabular form inthe preliminary pages of the relevant Section REPAIRS AND REPLACEMENTS When service parts are required it is essential that only genuine Jaguar Daimler replacements are used Attention is drawn to the following points concerning repairs and the fitting of replacement parts and accessories Q Safety features embodied in the vehicle may be impaired if other than genuine parts are fitted In certain territories legislation prohibits the fitting of parts which are not produced to the vehicle manufacturer s specification o Torque wrench setting figures given inthis Manual must be
176. Renew balljoints Dog Tracking ump steer ua side te side Sawteeth pattern er exeessive tire Wear Damaged tires unbalanced or damaged wheels Incorrectwheel alignment Steering system malfunction Front damper malfunction Loose front damper mounting Damaged front suspension upper or lower ball joints Damaged or worn sub frameto body mounting Damaged or worn stabilizer bar insulators Damaged or worn stabilizer bar link Damaaed or worn wheel bearina Uneven tire wear outer or inner shoulder Front rear suspension noises Issue 1 August 1994 Rear suspension damage Worn steering gear mounting bracket housing insulators Excessive toe in high edges inboard or toe out high edges outboard Incorrecttire pressure Excessivetoe Excessive positive or negative camber Brake pull Unequaltire pressure Inflate the tires to correct and uniform pressure Brake system fault s Check the brakes Shimmy Wheelftire imbalance or runout Check wheels and tires Check the tires and renew if necessary Balancethe wheels if necessary Adjust wheel alignment Check steering system Renewfront damper if necessary Tighten front damper mounting Renew upper and lower ball joint Renew rear suspension bushing Renew insulators Renew link Renew adjust wheel bearing Ifthe caster is uniform check and compare the wheelbase at the right and left sides If different inspect the
177. SC only x xIx x xXx i xi 9 Renew ietekiegg O 10 Check adjust drive belt tensions not SC eel esi 11 Renew fuel filter 12 Renew spark plugs see note Xx 13 Renew wiper blade and clean windshield with Jaguar X x X xX Xx x A Screen Clean Paste 14 Check adjust parking brake shoes 15 Inspect brake pads for wear rotor condition on pad Xx xX Xx x Xx change 16 Grease axle shaft universal joints Xx Xx Xx Xx A 17 Check front hub end float 13 Clean and adjust front hub bearings 19 Check tire pressures tread depth general condition signs of uneven wear and suitability including spare 20 Check top up automatic transmission fluid 21 Check top up brake fluid reservoir 22 Check top up cooling system and check specific grav ity 23 Check top up windshield power wash reservoir 24 Check top up final drive oil 25 Check top up PAS fluid 26 Check exhaust system for leakage and security 27 Check for oil leaks engine 28 Check for oil leaks automatic transmission 29 Check for oil leaks final drive x Xx Xx Xx Xx Xx Xx Xx 30 Check for fuel leaks Xx Xx Xx Xx Xx Xx Xx Xx 31 Check all suspension dampers for fluid leaks X X X X X x x x ppp Dx B gt gt gt x lt x lt x lt x x lt x x Xx x lt x lt xj x lt x x x x x x x x lt gt lt X lt gt lt gt lt Xx gt lt gt lt gt lt x x lt
178. Seal Renew EE EE ENEE En GU 28 TZ 9 X300 VSM i Issue 1 August 1994 L SERVICE TOOLS EQUIPMENT Jaguar Number Steering Description JD 100 18G 134 Ball joint separator Handle 4D550 5 18 2 Issue 1 August 1994 Seal replacer X300 VSM Steering il TORQUE TIGHTENINGSPECIFICATIONS Fixing Tightening Torque Nm Air bag to steering wheel 4 5 Blanking plug for rack centralizing pin 7 10 Fluid pipe to pump banjo bolt 34 46 Fluid pipe to cooler sleeve nut X 2 17 23 Fluid pressure pipe pump to rack mid connector 17 23 Heatshield to rack 12 cylinder 22 28 Horn bar at steering wheel 5 7 Hose from fluid reservoir worm drive 25 35 Retighten to nominal after 30 minutes Hose to pump worm drive 25 Retightento nominal after 30 minutes Hoseto fluid reservoir from cooler worm drive 25 35 Retighten to nominal after 30 minutes Lower column to steerina rack pinion 22 28 Pressure switch to feed pipe 12 cylinder only 85 11 5 Road wheel Alloy 88 102 Road wheel Steel 68 82 Steering column outer tube to body 17 23 Steering column universal joint to lower column 17 23 Steering column upper bracketto column outer tube 16 20 Steering column upper bracket to plenum stiffener 17 23 Steering column upper cowls 25 35 Steering rackto crossmember 12 cylinder 39 51 Steering rackto crossmember 6 cvlinder 43 57 Steering wheel to column 34 46 Tie strap plenu
179. System Bleeding After Tandem Master Cylinder Renewal EE EEN EEN EEN 12 19 LL AA iia a KR System Bleeding After Hydraulic Control Module Renewal ee ENEE ENEE En 12 20 EE Reg E Ae Bleeding After Renewal Of Caliper ee EEN 12 20 J23 ic ew steven General Fitting INStrUCTIONS een EEN ENEE EE EE ENEE EE ENEE Eu 12 21 DDO ii aa General Fitting Instructions Brake Fluid een 12 21 DQ DE Hace vain NN CN General Fitting Instructions HOSES Eu 12 21 1253 seaddauesnes General Fitting Instructions Des aen 12 21 126 easeeee ee Rear WheelSpeed Sensor Renew REENEN 70 60 04 sauss 12 22 DR Aa Hydraulic Control Module Renew EE 70 60 18 19 sa 12 23 LES iea a Pressure Conscious Reducing ValveS neen 70 60 21 enen 12 25 129 ithe a ABS TC CM RON W ENEE 70 60 02 20 saves 12 26 X300 VSM i Issue 1 August 1994 Brakes SERVICE TOOLS amp EQUIPMENT Parking brake cable remover Replacer disc brake pistom seal me 6947017 Brake hose clamp Girling not illustrated JDS 9013 Brake pedal hold down too A Ml TORQUE TIGHTENING SPECIFICATIONS Fixing Tightening Torque Nm Vacuum booster to pedal box 21 29 Tandem master cylinder to booster 21 29 Hydraulic module to module bracket 18 26 Caliper guide pins 25 35 Caliper to vertical link 120 160 Caliper to hub carrier 54 66 Pipe connectors to hydraulic module M12 15 19 M10 12 16 111 SERVICE MATERIALS Description Uses Notes Molyk
180. Vehicle Recovery Suspended TOWING EEN EE Vehicle Recovery Rear Suspended Tou X300 VSM i Issue 1 August 1994 a Jacking Lifting amp Vehicle Recovery EZ 2 1 JACKINGAND LIFTING 2 1 1 Safety Precautions The following safety precautions must be observed when raising the vehicle to perform service operations o Whenever possible use a ramp or a pit in preference to ajack when working beneatha vehicle O Never rely on a jack to support a vehicle use axle stands or blocks under the vehicle jacking points to provide rigid support o Whenworking beneath avehicle chockthe wheels in addition to applying the handbrake o Ensure that the vehicle is standing on firm level ground before using the jack Q Check that any lifting equipment used has adequate capacity for the load being lifted and is infull working order 2 1 2 JackingPoints The jack provided inthe vehicle toolkit engages with jacking points situated belowthe body side members infront of the rear wheels Fig 1 and behind the front wheels Fig 2 Fig 2 2 1 3 Wheel Free Lift Use of a wheel free lift is recommendedfor maintenanceoperations Supportthe vehicle using lifting pads at the four jacking points Fig 3 eegend X300 VSM 1 issue 1 August 1994 EZ Jacking Lifting amp Vehicle Recovery 2 1 4 Workshop tacks 2 1 4 1 Front One Wheel Positionthejack underthe lower spring support pan Fig 1 using awooden bloc
181. a Connectthe 10 meter 33ft link harness to the airbag wires a Ensurethat no personnel are inthe vicinity of the cabinet Move back 10 meters 33ft and connect the link harness crocodile clips to the battery the airbag will immediately deploy e Allow the unitto cool for at least 20 minutes Open guard and remove deployed module e Seal deployed module in plastic bag ready for disposal a Inthe event of any problems or queries contact Jaguar Cars Ltd or the importer 15 1 17 Disposal Of Deployed Airbag Modules Deployed airbag modules are to be disposed of as special waste and must comply with local environmentalrequire ments If in any doubt contact local authority for disposal instructions Note The storage transportation disposal and or recycling of airbag module components must be preformedin accordancewith all applicable federal state andlocalregulationsincluding but not limitedto those governing building and fire codes environmental protection occupational health and safety and transportation Modules removed and deployed by Jaguar Service are to be returnedto the importer for disposal X300 VSM 7 Issue 1 August 1994 Electrical y 15 2 INSTRUMENTS 15 21 General Description The instruments measure monitor and display data relevant to the vehicle s performance Data is received from sensors positioned at various locations around the vehicle via two multi pin sockets located at the rear of the instrument pan
182. a cae eae gen ewe NENNEN NEEN E 1000A Windshield Wiper Motor ELE Trico Light running speed after 60 seconds from cold Slows peed EE 40 48 cycles Fast epeed cccococcnncccrcn rr 57 67 cycles Light running current ee EE EG 2 54 max FastSpeed ene 5A max eegend issue 1 August 1994 A1 95MY 6 X300 VSM Specification _mm LUBRICANTSAND FLUIDS Engine Oil SpecifiCatiOn ii gas KENE E he ENN NN NN Cer API SG CD or AP SH when available SAE Viscosity Range 5w 20 20w 50 dependent onambienttemperature Capacities evt 32L and 4 Oli ara dt cnc 8 liters Y ai Sats 10 liters Manual Transmission 3 21 4 01 Fluid SPECIFICATION 228 dica a A a NEE EEN Dexron D Dexron lE Capacitan 14 liters Rear Axle Fluid EELER ee eats ii A P L GL5 SAE ViscOSity RATING su Sue ENEE NEEN eaten cere ee eee ele EP 90 Fluid Make amp TYPO en Shell Spirax Super 90 oil alternative brands may be used for top up only when ShellSpirax is not available Capacity allvehicleS cccee cece eee eee eee eee eens 2 1 liters Power Assisted Steering Preferred fd unicidad wig datas eae DexronllE Alternative Huel ds a Cea ve is DexronlID use only when Dexron IIE is not available Spe ee asar al das cli is 10 liter approximately Cooling System Coolant Mixture Specification 2c cceceeee cence ee een ene no 50 plain water 50 Jaguar Anti freeze Coolant and Corrosion Inhibitor conforming to specification ESD M97B49A for
183. a clockwise direction Oto 1000 mbar 0 to 30 inHg FSD negative pressure in a counter clockwise direction High Side Pressure Gauge This pressure gauge may betypicallycalibrated from 0to30 bar 0to 500 Ibf in2 FSDinaclockwise direction Depend ing onthe manufacturer this gauge may also be of the compound type X300 VSM 19 Issue 1 August 1994 EA Se Climate Control Systems 14 13 SYSTEM CHECKING WITH MANIFOLD GAUGE SET 14 13 1 Evacuating the Manifold Gauge Set Attach the centre service hoseto a vacuum pump and startthe pump Open fully both highand low valves and allow the vacuum to remove air and moisture from the manifold set for at least five minutes Turn the vacuum pump off and isolate it from the centre service hose but do not open the hoseto atmosphere CAUTION Itisimperativethat the vacuum pump is not subjectedto a positive pressure of any degree Therefore the pump must be fitted with an isolationvalve at the centre service hose connection and this valve must be closed beforethe pump is switched off This operation replaces the purge procedure used on previous systems Observe the manufacturers recommendation with regard to vacuum pump oil changes 14 13 2 Connecting the Manifold Gauge Set CAUTION Only use hoseswith connectors which are dedicatedto HFC 134Acharge ports Attachment of the hose quick release connectors to the high and low side system ports is straightfotward provided that the high and low valv
184. above procedure noting that seat belt fixings must be tightened to the specified torque 13 3 34 RI Post Upper Trim Pad Renew a Position front seat and squab fully forward a Remove seat belt lower anchorage and feed the belt through the lower trim aperture a Remove seat belt upper anchorage a Remove trim finisher upper seat belt aperture and door aperture edge trim a Release upper trim padfrom its fixings by exerting down ward pressure a To refit carry out reversal of the above procedure WARNING ENSURE THAT THE SEAT BELT IS CORRECTLY ASSEMBLED AND FIXINGS TORQUE TIGH TENED 13 3 35 B Post lower Trim Pad Renew a Position front seat and squab fully forward Remove seat belt lower anchorage and feed the belt through the lower trim aperture a Release trim pad quarter turn fasteners and remove trim pad Remove fasteners from trim pad as required To refit carry out reversal of the above procedure WARNING ENSURE THAT THE SEAT BELT IS CORRECTLY ASSEMBLED AND FIXINGS TORQUE TIGH TENED X300 VSM 35 Issue 1 August 1994 A Body Components amp Trim 13 3 36 Handbrake Lever Trim Renew a Release the trim assembly upper clip and remove trim from handbrake lever a To refit carry out reversal of the above procedure 13 3 37 Combined Grab Handle and Coat Hanger Hook Renew Carefully prise out and remove screw cover Remove screws and handle coat hook a To refit carry out
185. age Io cacao Preliminary Pages ococcnonncnnnancnnanccannn eee eee eee eee eee eee eee eeeeeeee LUT apd Qian ane areata INTOUCUON iw ee edn ae Eer wie A a NEE Bac 1 TAS Sass wee ee Front Suspension DeSCripti0N en 1 TB eww tors Soest Rear Suspension Description ee EE EE EE EE EE ENEE EEN 2 VIA EEE T Diagnosis amp Testing enee EEN NEE EE EE EE EEN EEN 3 ILAN iere waters Diagnosis amp Testing Tire Wear ee EEN 3 ITA T Diagnosis Testing Vibration amp ROUGHNESS ENEE EEN EEN EEN EEN 3 TAS iii Diagnosis Testing Front End INSPECTION nee ENEE EE 4 114 4 ccoo Diagnosis amp Testing Upper Lower Ball Joint Inspection ee ENEE EE EE ENEE EE 4 114 5 ras Diagnosis Testing Damper Inspection eseu 4 ITA Diagnosis amp Testing Rear Suspension INSPECTION ee ENEE EE EE naa 5 V A id Diagnosis amp Testing Vehicle Inspection onocconnoncnonannccnn 5 RE EE Diagnosis amp Testing Diagnostic Procedure Chart ee EE D Ee oe X300 VSM i Issue 1 August 1994 Su Ne Suspension Systems 1 SERVICE TOOLS amp EQUIPMENT A Waste Jaguar Number Description IHub Remover Rear Suspension Remover Steering Arm and Swivel Hub Ball Pins Spring Compressor Front Suspension Camber Tie Down Link Front JD135 Remover Renewer Front Damper Lower Bush JD143 Remover Renewer Suspension IBushes Main Tool JD143 1 Adaptor Ring Front Sub Frame Rear Bushes 3D143 2 Anvil adapter JD143 3 Adaptor Remover Renewer
186. ained from the system it must be discarded and not re used Anti freezeis harmful to the environment Used coolant must be disposed of safely and never poureddown a drain connectedto the public sewer CAUTION Neverfill or top up the system with water only 4 1 e AUTION Anti freeze is harmfulto paintwork Coolantspillages must be wiped up immediately and the affected area washed to remove all traces of coolant CAUTION To preventthe possibility of damage to the heater circuit pump and supercharger pump where fitted the pumps should be electrically isolatedif the ignition hasto be turned ON while the cooling system is drained WARNING DO NOT REMOVE THE HEADER TANK PRESSURE CAP WHILE THE ENGINE IS HOT IF THE CAP MUST BE REMOVED PROTECTTHE HANDS AGAINST ESCAPINGSTEAM AND SLOWLY TURN THE CAP ANTI CLOCKWISE UNTIL THE EXCESS PRESSURE CAN ESCAPE LEAVE THE CAP IN THIS POSITION UNTIL ALL THE STEAM AND PRESSURE HAS ESCAPED AND THEN REMOVE THE CAP COMPLETELY WARNING WHEN DRAINING THE COOLANT WITH THE ENGINE HOT PROTECT THE HANDS AGAINST CONTACT WITH HOT COOLANT WARNING WHEN WORKING WITHIN THE ENGINE COMPARTMENT KEEP CLEAR OF THE RADIATOR COOLING FANS THE FANS COULD START WITHOUT WARNING EVEN IF THE ENGINE IS NOT RUNNING 4 1 3 2 Working Practices Whenfilling thesystem with coolant ensure that the vehicle isstanding onalevelsurfaceandthatthecoolant is poured inslowly so that airlocks are not introducedinto the system Airlocks ca
187. ainer because it will absorb water Fluidinthis condition would be dan gerous to use due to a lowering of its boiling point Do not allow hydraulicfluid to be contaminatedwith mineral oil or use a container which has previously contained mineral oil Do not re use fluid bled from the system Always use clean brake fluid ora recommended alternative to clean the hydraulic components Fit a blanking cap to the hydraulic union and a plug to its mating socket after removal from the vehicle to prevent ingress of dirt Absolute cleanliness must be observed with hydraulic components at all times After any work has been performedon hydraulicsystems inspectcarefullyfor leaks underneaththe car while a second operator applies maximum pressureto the brakes withthe engine running and operates the steering A3 2 9 Metric Bolt Identification An ISO metric bolt or screw made of steel and larger than 6mm in diameter can be identified by the symbolsiSOM or M embossed ontop ofthe head Fig 1 In addition to marks to identify the manufacturer the head is also marked with symbols to indicatethe strength grade eg 8 8 10 9 12 9 or 14 9 The first figure givesthe minimum strength of the bolt material in tens of kgf mm Zinc platedISO metric bolts and nuts are chromate passivated and coloured greenish khaki to gold bronze A3 2 10 Metric Nut Identification A nutwith anISO metricthread is markedon one face 1 Fig 2 or on one of the flats 2 Fig 2 of
188. alet switch to the glove box a Align and affix a security sticker to the glove box Align and affix a cassette storage foam pad e Placethe glove box assembly into position a Reconnect the valet switch harness multi plug a Fit and fully seat the glove box assembly a Fit and align the lid latch a Reposition and fit the ashtray a Fit and tighten the ashtray securing screws a Refit the glove box lid X300 VSM 17 Issue 1 August 1994 Rf Body Components amp Trim 13 3 12 Console Glove Box Lid Renew SRO 76 25 18 Open the console glove box lid Undo and remove the glove box lid checkarm to lid secur ing screw Reposition the checkarm Undo and remove the glove box lid to console securing screws Displace and remove the glove box lid assembly s Place the lid assembly to the front a Undo and remove the lid inner securing screws a Displace and remove the lid inner s Displace and remove the lid latch release lever Undo and remove the lid hinge securing screw Displace and remove the hinge s Undo and remove the lid latch securing screw Displace and remove the lid latch Displace and remove the lid latch return spring Place the lid aside a Place the new lid to the front a Fit and align the latch return spring to the lid s Fit and align the lid latch ensuring that the latch leg lo cates behind the spring s Fit and tighten the latch securing screw s Fit and a
189. aliperface by acopper gasket Fig 2B IA Pipe sizes outside diameter for UNF are 3 16 in 1 4 in and y ya 5 16 in Metric pipe sizes are 4 75 mm 6mm and 8 mm The 5 E D 4 75 mm pipe is exactly the same diameter as 3 16 in pipe 2 C U KC ee The 6 mm pipe is 0 014 in smaller than 1 4 in pipe The 8 mm pipe is 0 002 in larger than 5 16 in pipe Convex flares for metric brake pipes have a different form thanthoseon UNF brake pipes When making pipesfor met ric equipment metric pipe flaring tools must be used The greatest danger lies with the confusion of 10 mm and 3 8 in UNF pipe nuts used for 3 16 in or 4 75 mm pipe The 3 8 in UNF pipe nut or hose can be screwed into a10 mm port but is very slack and easily stripped The thread en gagement is very weak and cannot provide an adequate seal The opposite condition a 10 mm nut in a3 8 in port will cause difficulty during fitting The 10 mm nutwill screw infor oneortwoturns andthen seize lthasacrossedthread feel and it is impossible to force the nutfar enough to seal the pipe Withfemale pipenutsthe position is reversed The other combinations are so different that there is no danger of confusion A3 2 12 Keys And Keyways Remove burrsfromthe edges of keyways with afinefile and clean thoroughly before attempting to refit the key Clean and inspect the key closely Keys are suitable for refitting only if no indentations exist whichwould indicate the onset of
190. als are notvehicle specific butare designedto be read inconjunctionwiththis 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 aidthe Technician to isolate electrical faults andto correct them Itcovers 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 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 V12 Engine Service Manual ZF Automatic Transmissions Service Manual ZF suppliestransmissions for 3 2 literand 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 Etransmission as fitted to 4 0 litre supercharged and 6 0 litre versions Each of the X300 specific 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 amp
191. amp LOCKING CONTROL MODULE SLCM RENEW SRO 86 52 01 Open the trunk and removethe battery cover a Disconnectthe battery ground lead Removethe trunk floor carpet a Removethe trunk front liner e Removethe trunk seal retainer See SRO 76 19 44 Section 13 a Removethe trunk side liner a Undo and removethe inclination sensor securing nuts 2 Fig 1 and displace the sensor 3 Fig 1 to gain accessto the SLCM 1 Fig 2 a Undo and removethe SLOM securing nuts 5 Fig 1 a Displacethe SLOM Identify the SLCM multi plugs 2 Fig 2 for subsequent reconnection Disconnect the mult plugs and removethe SLCM Fitting a new SLOM is the reverse of the removal pro cedure Make sure that the multi plugs are reconnectedas Fig 2 removed from the old SLCM 9 J86 1981 Note Thearrows on Fig 2show the position of the mount ing bolts and mounting holes Issue 1 August 1994 X300 VSM y Security System RESTRICTED ISSUE A5 12 INTRUSION SENSOR RENEW SRO 86 52 20 Carefully displace the intrusion sensor from the headlin ing Note View 1 Fig 1 shows a vehicle fitted with a sliding roof View 2 Fig 1 showsa vehicle without a sliding roof a Disconnect the multi plug and removethe intrusion sen sor Reconnect multi plug to a new intrusion sensor a Locate the intrusion sensor securing studs and carefully push into the headlining Make sure the intrusion sensor is fully seated 3
192. amps Coolant Temperature Direction Indicator Left GREEN Odometer Trip Computer Display Traction Control Off GREEN Primary Warning Indicators RED Transmission Sport Mode GREEN Exhaust Temperature Charging Fault RED Low Oil Pressure Check Engine AMBER Seat Belt Not Fastened Low Fuel Level AMBER Boot Open Anti Lock Fault AMBER Door Open Traction Control Fail AMBER Coolant Level Bulb Fail AMBER Air Bag Fault Washer Fluid Level AMBER Status Warning Lamps Transmission Fault AMBER STEET Fig 1 Instrument Panel Front Mew Note The Premium Unleaded Fuel Only caution is added to the Federal Market vehicles also PARK BRAKE and BRAKE replace international symbols used in all other markets Note Six cylinder vehicle version shown the tachometer red line on 12 cylinder vehicles starts at 6000 RPM The front of the PECUS programmable instrument panel features 6 analog gauges 22 warning lamps tell tales and a Liquid Crystal Display LCD the rear of the panel accommodates two PCB mounted connectors one 24 way connector one 48 way connector one instrument panel identification label and 14 light bulbs arranged in groups of seven on either side Three power inputs and two ground inputs are provided for POWER UP and POWER DOWN sequence the three power inputs comprising battery ignition and auxiliary The instruments are protected by a housing lens assembly 1527 Gau
193. and disconnect connector 6 Fig 1 from purge valve 7 Fig 1 a Disconnect hose 8Fig 1 from purge valve a Disconnect elbow 9 Fig 1 from front of purge valve e Remove purge valve from mounting bracket 10 Fig 1 Refit in the reverse order of the removal procedure AE X300 VSM 9 Issue 1 August 1994 Fuel Emission Control amp Engine Management AJ16 5 1 6 THROTTLEASSEMBLY SUPERCHARGED RENEW SRO 18 30 17 THROTTLE POTENTIOMETER SRO 19 70 07 THROTTLE HOUSING GASKET SRO 19 70 04 THROTTLE HOUSING NZ Jl2 822 Remove a Disconnect battery a Removethe intercooler intake elbow a Raise vehicle on a four post ramp a Removethe rear air duct to throttle body connecting hose a Removethe oil filter cartridge and gasket e Undo and remove bolts securing EGR supply pipe to manifold e Remove EGR supply pipe gasket Reposition EGR sensor harness multi plug from mounting bracket a Release throttle outer cable abutment from abutment bracket a Disconnectthrottle inner cable from throttle linkage Remove speed control speed control bracketto throttle lever clevis pin and pin circlip a Disconnect and remove return spring a Disconnect speed control actuator vacuum hose a Release cooling system pressure by slowly undoing the tank cap Tighten cap after pressure release a Remove abutment bracket assembly Disconnect idle speed actuator harness multi plug a Disconnect throttle potentiometer harne
194. and isthen secured by a nut and washerfixing arrangementtothependulumassembly 8Fig 1 and the wishbonetie assembly 9 Fig 1 The differential strut 10 Fig 1 isfastenedto the wishbonetie assemblv andto a bracket weldedto the vehicle bodv Both the pendu lum andthe wishbone tie assembly are fitted to the differential unit which is mounted onto a mounting frame anda rear frame carrier The superchargedvehicle manualonly the XJ12 andthe sport versions are equipped with a rearstabilizer bar a dif ferential monostrut instead of two single struts a modified wishbone tie andtwo stabilizer bar drop links which are seated on the lower wishbone cast bosses Issue 1 August 1994 2 X300 VSM S y Suspension Systems Ne 11 4 DIAGNOSIS AND TESTING 11 4 1 Tire Wear Tires should be inspected as abnormal or excessive wear may be caused by incorrect wheel alignment wheel tire im balance or incorrecttire pressure 1142 vibrationand Roughness Vibration roughness and shimmy conditions may be caused by excessivetire or wheel runout worn or cuppedtires or wheel and tire unbalance Most of these conditions are due to irregularities inthe road surface hence driving the vehicle on different types of road surface will often indicate the cause of the condition Do not automatically suspect the tires when attempting to diagnose avibration concern as other sources of vibration may include Loose or worn wheel bearings Loose or worn sus
195. ar 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 Whena 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 andtransmission oiltemperature Informationfrom the Engine Control Module ECM representing engine speed load and throttle position is also fed to the TCMto enable the most suitable gear to be selected Gear selection and gearshift speeds are controlled by the manually operated selector valve asolenoid operated pres sure regulator andthree solenoid valves On receipt of signalsfromthe TCM the three solenoid valves MV1 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 X300 VSM 3 Issue 1 August 1994 8 1 ZF CT
196. arm up period Usually located in or near the exhaust manifold watts Ww Sl unit of power 1 hp 745 7 watts wet sleeve thin walled hard metal cylinder supported at wet liner cylinder head andcrankshaftends in contact with coolant wheelslip wheelspin Wide Open Throttle WOT full throttle position windshield windscreen wrist pin also piston pin pin which connects the connecting rodto the gudgeon pin piston and permits articulation betweenthe two XYZ Issue 1 August 1994 28 X300 VSM Jacking Lifting amp Vehicle Recovery SECTION CONTENTS Sub Section Title P Gate eee att Preliminary Page ENEE ENEE nn a DE JackingAnd Lifting EE EEN E E JackingAnd Lifting Safety Precautions ee EE EEN E EE JackingAnd Lifting Jacking POINTS ee E e E JackingAnd Lifting Wheel Free Lift een QV O JackingAnd Lifting WorkShOpJackS ee ENEE ENEE EEN EE NEE JackingAnd Lifting WorkshopJacks Front One Wheel 21 42 aa JackingAnd Lifting Workshoplacks Front Both Wheels 214A coco JackingAnd Lifting WorkshopJacks Rear Both Wheels 22 ee SE Vehicle Recovery EE EE EE 22s EE Vehicle Recovery General 22A Suid ed Vehicle Recovery Gear shift Interlock EE 22 8 eet paste wats Vehicle Recovery Gear shift Interlock Manual Override 2 2 4 veces ea Vehicle Recovery Transporting ee EEN ENEE E DN EE Vehicle Recovery TOWING Recovery EE EEN 220 AO Vehicle Recovery Vehicles With Defective Automatic Transmission 22S ee ee
197. arometric Absolute Pressure BARO sensor measuring the pressure oi BARO APS Sensor surrounding air at any given temperature and altitude base Idle Idle rpm determined by the throttle lever being hard set on the throttle body with the IAC solenoid disconnected base timing Spark advance in degrees before top dead center of the base engine without any control fromthe PCM battery Electrical storage device producing DC Voltage by means of electrochemical reaction before bottom dead center BBDC event occurring before BDC blower BLR Device which supplies a current of air at moderate pressure e g heater or A C blower Body Processor Module BPM Control module for body electrical systems CCM Central e g interior lamps windshield wash wipe Control Module control etc CPU BS British Standards standard specification issued by the British Standards Institution before top dead center BTDC event usually ignition occurring before TDC L British Standards Automotive BSAu brake horsepower bhp effective horsepower developed by an engine or motor as measured by a brake applied to its output shaft brake mean effective pressure BMEP that part of the effective pressure developed in a cylinder that would result in a cylinder output equal to the bhp of the engine brake on off BOO indicates the position of the brake pedal brake rotor brake disc break in breaking in wearing in process of bedding in
198. as of the carpet The solvent loosens the grease from the fibre and the powder then absorbs the grease carrying solvent a Allow the solvent to evaporate and remove the powder containing the grease by using a vacuum cleaner or brush Note Neatsolvent eg dry cleaning fluid may be used but should be used sparingly from aclean white cloth CAUTION Solvents must only be used in well ventilated areas where naked lights and smoking are prohibited To removestains which are a combination of oil and water based contamination usually resulting from food or drink a Treat combination stains as for water based stains a Allow to dry out a Treat as for grease based stains Issue 1August 1994 46 X300 VSM Body Components amp Trim ams 13 7 5 Carpet Cleaningand Stain Removal Materials The carpet cleaning and stain removal materials listed in the table below must be used according to manufacturer s instructions la Fibrefresh Servicemaster 308 Melton Road Leicester LE4 7SL Tel 0533 6107610 Ib 1001 Foam Shampoo PC Products Swinton Manchester Tel 061 792 6111 Ic Novatreat British Nova Works 57 61 Lea Road Southall Middx Tel 081 574 6531 2a Trichloroethane Genklene IC 2b Spot Remover RPM Marketing Sussex 11 Chaucer Industrial Estate i Dittons Road Polegate East Sussex BN26 6JF Tel 0424 211427 3a UK SEBO UK Ltd Baker Street High Wycombe
199. ash and one for headlamp power wash are externally fitted to the reservoir located at the front right hand side of the engine compartment Containedwithinthe reservoirs pull upneck is a serviceable filter The screen wash jets with independently adjustable eyeballs are mounted onthe plenum chamber finisher and the temperature of the fluid passing through the jets is controlled from an ambient temperature sensor fitted near the inlet of the right hand side air duct The fluid temperature for each of the headlamp wipe wash operation is controlled by self regulating heated power wash jets mountedon to either side of the bumper Each powerwashjet is protectedby a cover suppliedwith an integralcover to bumperseal The cover snap fixes into the bumper 15 6 2 windscreen Wiper and Washer Switch This switch only operates with the ignition switch in position II and has the following functions Position O The wind screen wiper is switched OFF and parked Position 1 Normal speed wiper operation is obtained by pushingthe switch lever up one position Position2 Highspeed wiper operation is obtained by pushing the switch lever fully up Position D To obtain intermittent wiper operationthe switch lever is pushed down and released The delay period will vary with vehicle speed To cancel the function repeat the procedure 15 6 2 1 Single Wipe Operation To obtain a single sweep of the wiper blade the lever is pulledtowards the steering wheel and r
200. ategories are the only conditions which may be repaired Category Cosmetic Abrasion to surface paint finish only Substrate surface Deep scratches gouges or localized radial stress cracks Substrate penetration Splits not exceeding 100mm Splits radiating from a gouge and accompanied by lo calized stress cracks CAUTION Cosmetic appearance must not override safety Damage beyond category three will compromise the protective performanceof the unit should repairs be effected the cover MUST be renewed Dueto the thermo setting nature of the cover material itis NOT possible to repairsplits by heator weld ing A4 6 2 2 Repair Materials Repair of accepted damage for categories 2 and 3 may be carried out using products from 3M 5900 FPRM Flexible part repair material Kent Industries Urepatch Itis essential that the repair product manufacturer s recommendations and procedures are followed carefully X300 VSM 39 Issue 1 August 1994 zz 2 Body Systems Body Repair A4 6 3 REFINISHING The paint refinishing system must be approved by Jaguar Cars Lid and be appropriate for polyurethane substrate application Itis importantthat the finishing clear lacquer includes a plasticising ingredient mixedto the manufac turer s recommendation to reflect the semi flex condition of the factory finished item The effect of heat decreases the cover rigidity to the point that paint cure temperatures require that the
201. ation intrusion Turn to lock position and release 1st press Locks all doors trunk and fuel filler cap Arms alarm system Lock arm perimeter inclination intrusion and all close Headlamps ON for 25 seconds Turn to lock position and hold for 2 seconds Continued hold of N A 1st press for 2 seconds 2nd press within 10 seconds of first with vehicle unlocked disarmed 1st press if vehicle is locked and armed DOOR UNLOCKING Action Unlock Trunk lid release Remote panic Device operation Function Turn to unlock position and release Locks all doors trunk lid and fuel filler cap Arms alarm system Key only closes open windows and sliding roof in 1 5 seconds Switches headlights on for driver convenience ist press 2nd press pressto be within 10 seconds of previous action 3 second press Unlocks all doors trunk lid key only and fuel filler cap Disarms alarm system Turns on interior lights for 15 seconds Remote button only cancels trunk valet lock out and recalls memorised driving position Trunk lid lock release Unlocks disarms and enters full alarm state ie audible alarm both sounder and horn and visual alarm flashing lights X300 VSM 11 Issue 1 August 1994 a A5 5 HOW TO OPERATE THE SYSTEM Security System
202. auli0NS wawan tan unana aa a ai aa a a a aa wa 1 AS cana Safety Precautions Used Engine OIlS EE ne 1 ABLE sima Safety Precautions Health Protection PreC UtionS 1 ASA a a Safety Precautions Environmental Protection Precautions En 1 KEEN General Fitting INStrUCTIONS ee EEN 2 A32 connnnnnoco General Fitting Instructions Precautions Against Damage To The Vehicle aaen 2 KEREN General Fitting Instructions Preparation ee 2 AB23 gratisi iia General Fitting Instructions Dismantling ee EE ENEE ENEE 2 KEREN General Fitting Instructions INSPECTION een EE EE EE EN 2 KEE General Fitting Instructions Ball And Roller BearingS ENEE ENEE EEN 3 AB 2 6 eru General Fitting Instructions Oil Seals ENEE EE EE 3 KK General Fitting Instructions Joints And Joint FACES aaen 4 AB 2 8 ee General Fitting instructions Hydraulic Flexible Pipes And HOSES ee EE ENEE 4 A329 ee General Fitting Instructions Metric Bolt identification EE EEN 4 A3 2 10 connnnnnco General Fitting instructions Metric Nut Identification EE EEN EE 4 A3211 wuuuunnnen General Fitting Instructions Hydraulic Fittings Metrification E EE EE ENEE 5 KETTER General Fitting Instructions Keys And KeywayS EE EE 6 AB 2 13 wuunennnns General Fitting Instructions Split PINS ee ENEE EEN 6 A3 2 14 cono General Fitting instructions Tab WaSherS e ENEE Eu 6 KAS General Fitting instructions Special FIXINGS e EE EE 6 AB 2 16 EEN General Fitting Instructions NUtS sssssusunnunsunnnnnnnnnnnnnnnnunnnnn
203. ay connector pin 2 to external trunk release switch connector pin 10 Ensure secure ground connection from switch pin 5 2 Check harness wiring continuity from multi plug 22 way connector pin 8to internal trunk release switch connector pin 1 Ensure secure ground connection from switch pin 2 3 Test continuity across switch pins operate switch and ensure short circuit occurs J86 1919 Fig 1 Trunk Lid Release Switches Issue 1 August 1994 38 X300 VSM Security System RESTRICTED ISSUE A5 9 15 Valetswitch 1 Check harness wiring continuity from multi plug 22 way connector pin 6 to valet switch connector pin 1 2 Test continuity across switch connections operate switch and ensure short circuit occurs Fia 1 Valet Switch Circuit X300 VSM 39 issue 1 August 1994 Saxe Security System RESTRICTED ISSUE y AS 10 INCLINATION SENSOR RENEW SRO 86 52 21 Removethe trunk floor carpet a Removethe trunk front liner a Removethe trunk seal retainer See SRO 76 19 44 Section a Removethe trunk side liner a Disconnectthe inclination sensor multiplug 1 Fig 1 a Undo and remove the sensor mounting bracket securing nuts 2 Fig 1 Removethe sensor 3 Fig 1 completewith mounting bracket 4 Fig 1 a Displacethe mounting bracket retainingtang and remove the sensor a Fitting a new inclination sensor is the reverse of the re moval procedure J86 1882 Fig 1 A5 11 SECURITY
204. b sec tion 13 3 24 a Remove the radio console see sub section 13 3 10 Remove the fascia center veneer panel see sub section 13 3 23 Undo and remove the console upper securing screws a Displace and reposition the rear air distribution outlet box a Disconnect the cigar lighter multi plug where fitted a Disconnect the security system valet switch harness multi plug a Removethe air distribution outlet box s Undoandremovethe center console rear mounting secur ing screw a Displace and remove the console assembly and place on the bench a Displace and remove the spire clips from the console as sembly a Open the glove box lid a Remove the glove box lid latch a Undo and remove the glove box lid rear securing screws a Displace and remove the glove box lid glove box assem bly a Placethe console aside a Placethe new console to the front a Fit and align the glove box lid glove box assembly a Fitbutdo notfully tighten the glove box lid securing screw a Close the glove box lid and check the adjustment a Open and adjust the lid a Finally tighten the securing screws a Fit and align the glove box lid latch a Close the glove box lid a Fit and align the spire clips to the console Issue 1 August 1994 10 X300 VSM Body Components amp Trim eise a Placethe console in position inthe vehicle a Fit and tighten the front securing screws a Fit and tighten the rear securing screw a R
205. battery ground lead a Disconnect electrical connections as required a Removethe seat forward fixings Movethe seat fully forward a Remove the rear fixing slide covers a Remove the seat rear fixings a Reposition seat for access and remove seat from vehicle a To refit seat carry out reversal of above procedure 13 8 3 Front Seat Power Operated Squab Back Cover Renew a Disconnect vehicle battery ground lead a Move the seat fully forward to gain access to squab back cover outer fixings e Remove squab side fixings disconnect lamp harness and remove squab back cover a To refit carry out reversal of the above procedure 13 8 4 Front Seat Power Operated Renew a Position seat as required for access a Disconnect vehicle battery ground lead a Release sound insulation retainers and displace insula tion a Remove SCM cover move SCM aside and remove seat switch multi plug from its mounting bracket a Remove the seat forward fixings and move the seat fully forward a Remove the seat rearward fixing covers and remove the seat rearward fixings a Disconnect multi plugs seat switch and motor harnessto SCM a Release harnesstie strap and remove seat assembly from vehicle a To refit carry out reversal of the above procedure ensur ing that fixings are tightened to the correct torque issue 1 August 1994 48 X300 VSM Body Components amp Trim si 13 8 5 Front Seaf Head Restraint Power Operate
206. ble 0 001 to 0 003 in endfloat 1144 Upper Lower Ball JointInspection a Check the wheel bearings a Inspectthe front suspension upper joint and renew front suspension lower wishbone ifneeded Raise vehicle and position floor jacks beneaththe front suspension lower wishbone Grasp the lower edge of the tire and move the wheel in and out While moving the wheel observe the upper and lower wishbone a Movement between the vertical links and the wishbones indicates abnormal ball joint wear a Renew ball joints a Check the front wheel bearings a Check for excessive play and wear 11 4 5 Damper Inspection Note The gas pressurized hydraulic front dampers are not serviceable adjustable or refillable Verify that all attachments of the suspensioncomponentsandthe front dampers are tight Renew any front damper that has a damaged integral lower mounting bushing a Check front dampers for external damage a Check for oil leakage and vehicle sag o Oil Leak Leakage is the condition in which the entire damper body is covered with oil and from where it will drip onto the pavement Dueto correct damper lubrication alightfilm of oil weepage can usually be seen onthe upper portion of the damper Should there be any leakage ensure that the fluid does not originate from sources other than the front damper Renew worn or damaged dampers Q Vehicle Sag Renewingfront damperswill not correctthe problem of vehicle sag as basicall
207. ble ink etc These stains adhere readily to the pile and do not respond to vacuum cleaning They are best removed immediately using the procedure detailed below Q Oil grease based stains caused by spillage or other contamination by butter grease hand cream ball point pen ink crayon lipstick etc o Acombination of boththese types To remove water based stains a Blot up liquids and or scrape off semi solids using a spatula Sponge the affected area with clean luke warm water Use a clean damp undyed cotton clothto absorb as much of the moisture as possible working from the edge to the centre of the stain a Ifthe stain persists apply a suitable carpet shampoo solution made uptothe manufacturers instructions again work ing from the edge to the centre of the stain Rinse with clean warm water taking care notto over wet the carpet Absorb excess moisture by laying dry undyed cloths or white paper towels over the moist carpet under light pres sure replace when necessary a When the carpet is thoroughly dry vacuum clean the area to lift the carpet pile CAUTION When liquids are appliedto the pile use only a clean cloth or sponge Do not apply liquidsdirectly to the carpet when attemptingto removestains blotthe pile as heavy rubbingcan destroy the yarn structure of the carpet To remove oil grease based stains a Using a suitable aerosol containing solvent loaded with absorbent powder spray the affected are
208. ble sig nal is heard side lights flash once and security active indicator flashes when vehicle secured Check that headlamps are illuminated for 25 seconds if vehicle was previously locked and armed Check headlamps illumi nate for 25 seconds Check all doors trunk lid and fuel filler cap lock and the alarm system per imeter only arms Ensure direction indicators flash once and security active indicator flashes when vehicle secured Check that headlamps are illuminated for 25 seconds if vehicle was previously locked and armed Japanese Market Only Check all doors trunk lid and fuel filler cap lock and the alarmsystem arms Check that headlamps il luminate for 25 seconds if vehicle was previously locked and armed Check all doors are dead locked andthe alarm sys tem perimeter inclination and intrusion is armed Japanese Marked Only Check headlamps illumi nate for 25 seconds Press large button for third ime within ten seconds of revious action Check headlamps illumi nate for 25 seconds Note The headlamps will also il luminate if the large but ton is pressed whenever the vehicle is locked or deadlocked No Feature Check headlamps illumi nate for 25 seconds Japanese Marked Only No Feature issue 1 August 1994 18 X300 VSM Security System RESTRICTED ISSUE all AS 2 5 Unlocking Key ring Transmitter
209. blesthe ABS andtraction control untilthe fault is rectified The ABS andtraction control warning lights on the instrument pack remains lit whilst a fault exists The system will be disabledwhen the following conditions occur Valve failure Sensor failure Main driver failure internal ABS TC CM fault Redundancy error internal ABS TC CM fault Overvoltage undervoltage Pump motor failure 1 2 Throttle valve actuator motor failure traction control vehicles only Throttle valve actuator potentiometer failure traction control warning light only 00000000 X300 VSM 1 Issue 1 August 1994 Brakes The input frequency from each wheel speed sensor signalistranslated by the ABS TC CM into acomparable wheel speed The ABS TC CM continually monitors the system False wheel speed information such as sudden speed changes in excess of 20 km h or excessive speeds are detected as a sensor malfunction The ABS TC CM reacts to fault conditions inthe following ways inhibit ABS traction control is inhibited until the sensedspeed returnsto within an acceptable limit whereupon ABS traction control is restored Conventional brakingis unaffected Dependingon vehicle speedthe ABS traction control warning lights may come on Disable ABS traction control is Disabled switched off andthe ABS traction control warning lights come on The systemwill not be restored untilthe engine is switchedoff and restartedor the fault has
210. c Manual EDM but may be mentioned herefor reference 10 4 2 Preliminary Action Before any problem solving is undertaken it is essential that the fluid level and where applicable belt tension is checked and if required corrected CAUTION Itis imperativethat the power steering system does not become contaminatedin any way Alwaysde cantfluid from afresh sealed containerand cleanthe area aroundthe reservoirneck bothbeforeand after topping up Never return drained fluid to the system 10 4 2 Diagnostic Chart 1 Trouble Heavy on both sides Heavy on one side Heavy when steering rapidly Fluid level low Drive belt slack V12 Pump drive loose 6cyl center pressures low Air in system due to loose connection Pump shaft seal faulty fluid loss Delivery pressure or flow too low Return flow restricted by blocked reser voir filter Both check valves blocked Rack damper too tight Lower column incorrectly set Excessive upper column friction Faulty rotary valve or seal Drive belt slack V12 Engine idle speed too low Pump drive loose 6cyl Air in system due to loose connection Pump shaft seal faulty fluid loss Delivery pressure or flow too low Rectify fluid loss and or top up Re tension belt Renew pump Set to specification Secure connection and bleed air out Renew pump Renew pump Renew reservoir Renew rack Renew rack Setto specification Renew upper column Renew rack Retension belt Reset idle
211. ccordingly Always work from the edge to the centre of the stain to prevent spreading Do not rub or agitate too vigorously as this action could distort or damage the pile Do not over wet the carpet Do not over apply cleaning solvent to foam backed carpets as this could cause damage to the latex backing compounds When using more than one treatment on the same stain allow adequate drying time between applications To remove excess moisture cover the affected area with dry undyed cloths white paper towels etc and weight down moisture removal is then effected by capillary action oO000 oo 13 7 3 Powder Cleaning Removal of Small Spillage Stains Note Powder cleaners are absorbent particles carrying a solvent detergent liquor this type of cleaner is suitable for quick effective cleaning of all the carpet or of small areas without using chemicals As the carpet is never more than damp no drying time is necessary on completion of the cleaning cycle To clean carpets using powder cleaners o Brush powder onto carpet allow to dry for 30 minutes and follow the cleaner manufacturers instructions O Remove powder and stain by normal vacuum cleaner action X300 VSM 45 Issue 1 August 1994 aii Body Components amp Trim 1374 Spot Cleaning Localized Stains Localized stains caused by accidental spillage may be one of three types o Water basedstainscausedby foodstuffs starches sugars soft drinks fruit stains washa
212. ch IFSS shuts down fuel and ignition systems in the inertia switch event of a vehicle impact intake inlet Intake Air air drawn through a cleaner and distributed to each cylinder for use in combustion Intake Air Temperature IAT temperature of intake air Intake Air Temperature Sensor IATS device usedto measure IAT ACT air tempera ture sensor MAT ATSD VAT TBT Intake Air Temperature Sensor IATSI thermistor which signals the ECM to retard Ignition the ignition timing in response to high inlet air temperatures Intake Air Temperature Sensor ATSF thermistor which inputs air density Injection information to the ECM internal diameter i dia International Standards Organiz ISO interrupter J X300 VSM 17 interruptor Issue 1 August 1994 e Introduction GLOSSARY OF TERMS Abbreviation Definition Previously used if applicable term s or Eng lish Equivalent Term s g K kilogrammes mass kilogrammes force kilogrammes force per square centimeter kilometers kilometers per hour kilopascals kilovolt knock the sharp metallic produced sound whentwo pressure fronts collide in a combustion d _ chamber see also ping knock sensor KS sensor which detectsthe onset of detonation and signals the ECMto retard the ignition free play end float left hand left hand drive vehicle left hand
213. ch andthe green headedvalet key can be usedto park and lockthe vehicle but does not unlockthe luggage compartment A5 7 11 Flush Sill Buttons Variants 1 and 3 except Japanese market are fitted with flush sill buttons mounted inthe doortrim panel Check but ton operation as follows To lockthe door fromthe interior pressthe sill button down flush with the doortrim panel To unlockthe door pullthe door lever out Issue 1 August 1994 20 X300 VSM y Security System RESTRICTED ISSUE as A5 8 DIAGNOSTIC SUB ROUTINES The following information details possible remedies to faults identified in the system during the system test For de tailed testing of individual components refer to section A5 9 Pin Point Tests Fault System will not lock and arm Possible causes Transmitter battery faulty remote operation only Rear screen aerial cable damaged disconnected remote operation only No power supply to SLCM Wiring harness or connectors faulty PON gt Renew battery refer to section A58 Identify and repair aerial cable fault Check fuse F4 in trunk fuse box Check harness and connectors from SLCM Repair or renew as necessary Remedy PONS Fault All Close facility only inoperative or faulty Possible causes 1 Faulty components in sliding roof or window systems 2 Damaged harness wiring between SLCM and Sliding Roof Control Module SRCM and Body Processor Unit BPU Refer to Section 1
214. control system which is described in Section 14 X300 VSM 1 Issue 1 August 1994 EQ Cooling System AJ16 4 1 2 COOLING SYSTEM CONFIGURATION The configuration ofthe cooling system for normally aspirated and supercharged engines is shown in Fig 1 and Fig 2 The main coolant flows with the system at normal operating temperature e with the engine thermostat open are indicated by arrows 1 Header Tank 4 Thermostat 7 Heater 2 Radiator 5 Throttle Body 8 Heater Pump 3 Water Pump 6 Engine 9 Heater Valve Fig 1 Cooling System Normally Aspirated Engine Header Tank Water Pump 9 Engine 5 Supercharger Pump 6 Thermostat 10 Heater a Supercharger Radiator Throttle Body 11 Heater Pump Main Radiator 8 Intercooler 12 Heater Valve Fig 2 Cooling System Supercharged Engine Issue 1 August 1994 2 X300 VSM 4 1 3 SERVICE PROCEDURES Cooling System AJ16 ES 4 1 3 1 Safety Precautions The anti freeze specified in Appendix A must be used wherever possible It is designedto afford the maximum cor rosion protectionto all metals found inthe engine cooling system as well as havingthe frost protection properties necessary during the winter months Should it not be available then anti freezeconforming to Ford Motor Company specificationESD M97B49 A may be used To provide optimumtemperatureand corrosion protection the specified anti freezeconcentrationmust always be used Once coolant has been dr
215. correct before any other cross ar dimen sions are checked Note The right handside is always looking towards the front from the rear of the vehicle All dimensions are derivedfrom asingle ZERO datum point for all three axes X for length Z for height and V cross Car X300 VSM 9 Issue 1 August 1994 ZA Body Systems amp Body Repair E A4 2 2 1 Datum location Example The FRONT MASTER DATUM frontcrossmember rear mountingatthe innerface of the mainfloor RH longitudi nal is nominally 359 5mm to the right handside of the body center line The LH side front datum is measured 717 0 721 0mm from the RH Please refer to the illustration on the following page 114 Expressed as a true position inthree planes the front master datum is Datum Location Position Front Master Datum Centre line of the front crossmember rear mounting at the X 300 0 Plan mainfloor RH longitudinal Y 3595 Z 500 A4 2 2 2 Key Plan View Please referto the illustration on the opposite page Location Frontface body bumper strut mounting point Rearmost hole Vee mount to crush tube Front Master Datum Plan centre line of the front crossmember rear mounting at the main floor RH longi tudinal Rearmost hole transmission mounting at the mainfloor RH longitudinal Driveshaftcentre bearing fixings 6 Rear Master Datum Plan rear longitudinal Tapped boss rear suspension A frame mounting bush 8 Rear suspension spring pa
216. cover must be supportedto prevent distortion and sagging these comments apply to off car repairs A4 6 3 1 Original On an original unit where damage has been repaired the beam will provide sufficient support for the forward part of the unit It is recommendedthat the side armatures are supported as they would be on the vehicle A4 6 3 2 New Where a new cover is required the beam may be temporarilyfitted prior to paintingto provide the necessary support A4 6 3 3 All Asimple jig Fig 1 should be made to holdthe unit inthecorrectworking attitudefor both damage repair andrefinish ing CAUTION During heat cure the effective panel temperature must not exceed 95 C d Ai A4 6 4 REPLACEMENT COVERS Replacement covers will be supplied in a primedcondition and therefore must be finished in accordance with A4 6 3 this page Bumpercovers and replacementfixings such as bumper beam adjusters and guide blocks must be fitted and adjusted as detailed in A4 6 1 4 and A4 6 1 5 this section A4 6 5 RECYCLED MATERIALS GENERAL NOTE The aluminium bumper beam as fittedto North American specificationvehicles should not be over lookedas a com ponentfor recycling Side armatures will be fully assembled in replacement bumper covers please see note Recycled materials this sec tion for important information Issue 1 August 1994 40 X300 VSM Body Systems amp Body Repair Z A4 6 6 BODY SIDE MOULDINGS A4 6 6 1
217. ction 7 1 16 and secure the slave cylinder to one side a Disconnectthe transmission switch connectors a Removethe rear mounting assembly see Section3 1 SRO 12 45 04 a Undo the hook nut of Service Tool MS 53B to lower the rear of the transmission engine assembly Disconnectthe gearshift selector shaft universaljoint se curing nut bolt removethe wavy washer from the selec tor and remove the bolts securing the remote control Removethe mounting rubbers and washers e Remove the transmission switch for access to the upper right hand transmission bell housing securing bolt a Remove the transmission to engine adaptor plate secur ing bolts 1 Fig 2 Note Leavetwo opposing bolts in place for safety a Fit a suitable hoist securely to the transmission a Take the weight of the transmission and remove the re maining two securing bolts a Remove the transmission from the rear of the engine a Lower the transmission and remove from the rear of the engine a Holdthe flywheel in one position and remove the bolts se curing the clutch cover to the flywheel CAUTION Make a note of the position of any balance weights relativeto the clutch cover a Remove the balance weights Removethe clutch cover drive plate assembly a Removethe eight securing bolts 1 Fig 3 and remove the flywheel 2 Fig 3 WARNING THE TWIN MASS FLYWHEEL B EXTREMELY HEAVY ASSISTANCE MAY BE REQUIREDDUR ING REMOVAL
218. curing screws a Displace and reposition the rear air distribution outlet box a Disconnect the cigar lighter multi plug where fitted a Disconnect the security system valet switch harness multi plug a Remove the air distribution outlet box a Undoandremovethe center console rear mountingsecur ing screw a Displace and remove the console assembly and place on the bench a Placethe console in position inthe vehicle a Fit and tighten the front securing screws a Fit and tighten the rear securing screw a Reconnectthe security system valet switch multi plug Placethe air distribution outlet in position a Connect the rear cigar lighter harness multi plug where fitted a Fit and fully seat the air distribution outlet Refit the center vent veneer panel assembly Refit the radio console a Refit the console veneer panel a Refit the console ashtray a Refit the console finisher a Refit the underscuttle pads a Refit the console extension a Refitthe console extension veneer panel a Refit the console rear finishe a Reconnect the battery Refit the battery cover Issue 1 August 1994 12 X300 VSM Body Components amp Trim 13 3 4 Console Assembly Renew SRO 76 25 01 a Remove the battery cover Disconnectthe battery a Removethe drivers side and passenger side underscuttle pads see subsections 13 3 19and 13 3 20 a Removethe console ashtray see sub section 13 3 28 Remove the console
219. d Renew a Recline the seat to give access to the head restraint from the rear a Disengage the head restraint from its retainers with a sharp upward pull To refit carry out reversal of the above procedure ensur ing that the restraint is fully locked in position 13 8 6 Rear Seaf Cushion Renew a Release the seat cushion quick release fittings a Removethe seat cushion from the vehicle To refit carry out reversal of the above procedure 13 8 7 Rear Seat Squab Renew a Releasethe rear seat cushion quick release fittings and re move the cushion a Release the rear squab fixings and remove the squab a Move the rear seat belts aside and remove the squab as sembly from the vehicle a Remove the armrest from the squab assembly a Remove the seat belt stowage pocket a To refit carry out reversal of the above procedure X300 VSM 49 Issue 1 August 1994 Pe Body Components amp Trim 13 8 8 Seat Belts Description Three types ofseat beltare used tear loopinertia seat belts usedonfrontseats inassociation with driver and passenger airbags standard inertia types fitted to the outer rear seats and static belts fitted to the center rear seat Front passenger seat belts are fitted with tear loop buckles while drivers seat belts havethe tear loop fittedtothe out board anchorage The front seat belts are provided with height adjuster units which are attached one to each of the B posts 13 8 9 Emergenc
220. d purging of the system takes place automatically as follows The air entrained by the coolant risesto the top ofthe radiator andto the highest point on each side ofthe engine the thermostat housings While the thermostats are closed the radiator is under reduced pressure due to the pump suc tion and air is bledthrough the jiggle pins ineachthermostat Purgedair is returnedvia the bleed systemto the header tank When normal operating temperature is reached the thermostats open and the system operates normally Issue 1 August 1994 4 X300 VSM Cooling System V12 ES 4 2 5 FAULT DIAGNOSIS 4 2 5 1 Introduction The following diagnostic procedures are providedto assist properly qualified personsto identify and rectify the faults inthe 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 4 2 5 2 Diagnostic Procedures Symptom Possible Cause Check Remedy Overheating Thermostat s stuck closed Test thermostat s Renew thermostat s Incorrect thermostat rating Check thermostat operating Renew thermostat s temperature Faulty temperature gauge Referto EDM Renew gauge Faulty temperature transmitter Referto EDM Renew transmitter Rad
221. d fully seat the veneer panel to the console fit and tighten the wing nuts Fit and fully seat the shift lever surround Connect the Performance Mode switch to the harness multi pin plug and fully seat the switch Fit and align the console veneer panel rear finisher Placethe ashtray assembly in position Reconnect the cigar lighter illumination harness con nectors Reposition and fit the ashtray assembly fit andtighten the securing screws a Close the armrest lid Reconnect the battery Issue 1 August 1994 10 X300 VSM ZE Automatic Transmission AJ16 a 8 1 6 TRANSMISSION FLUID FILTER RENEW 3 2L AND 4 0L SRO 44 24 07 Raise the hood and fit a fender cover a Raise the vehicle on a ramp a Drain the transmission lubrication system see Sub sec tion 8 1 2 a Removethefluidpan see Sub section 8 1 7 4 0L or Sub section 8 1 8 3 2L a Release and remove the fluid filter securing screws dis place and remove the fluid filter a Remove and discard the filter O ring a Clean the new filter and mating faces a Fitthe O ringto the newfilter fit and seatthe filter assem bly to the valve body a Fit and torque tighten the filter securing screws a Refit the fluid pan see Sub section 8 1 7 4 0L or Sub sec tion 8 1 8 3 2L a Lower the vehicle onthe ramp a Refill the transmission unit with fluid see Subsection 8 1 2 Remove the fender cover and lower the
222. d 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 includesthe 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 acrossthe vehicle behindthe passenger compartment rear bulkhead is held in position bytwo retaining straps tightened by two M5 fixing arrangements V12 engined vehicles are equipped with two fuel pumps located inside the tank They are regenerative turbine pumps supplied by Nippon Denso Nominal operating pressure is 3 bar above the manifold depression and pump delivery is 90 litres hour minimum at 13 2volts 3 bar outlet pressure The pump draws a nominal current of 7 amperes at 13 volts 3 bar outlet pressure ambient temperatures Builtintothe pump assembly is aover 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 excessivefuel flowing through the system is returned to the fuel tank via the fuel regulator valve mounted onthe fuel rail the fuel return line and the check valve also located in
223. d processes Heat especially excessive heat will reduce the strength of steels o Repairsmay only becarried out successfully and any warranties protected if genuine Jaguar replacement parts and Jaguar approved materials are used o Tools procedures and facilities must be rightfor the job Donotcompromise the quality of the work by using inappropriate methods o All trim and electrical components inthe locality ofthe repair must be removed or disconnected priorto panel removal replacement this is especially important where hollow sections may contain harnesses tubes or foam see section A4 3 5 Q The welding and gas processes detailed in the following sections are the only ones recommended by Jaguar Cars Ltd Q Ensurethat you have read and understood the safety related procedures inthis and other relevant sections E WARNING DO NOTWORK INTHE VICINITY OF A LIVE AIR BAG REMOVEIT COMPLETELY READ WORKING PRAC TICES AIR BAG SECTION 15 ANY SEAT BELTWHICH HAS BEENWORN INAN ACCIDENT MUST BE RENEWED PLEASE SEE SECTION 13 FOR IMPORTANT INFORMATION REGARDING TEAR LOOP SEAT BELTS BUCKLES AND ANCHOR AGE LOCATIONS CAUTION Electricarc welding should not be used on Jaguar vehicles The highvoltages produced by this process will cause irreparable damage to the electricalcontrol and microprocessor systems A4 1 5 1 Welding and Gas Processes Special Notes Resistancespot welding MIG welding and all gas processes may only be carri
224. d upshifts occur at 4800 RPM X300 VSM 15 Issue 1 August 1994 Lei Brakes 12 2 FAULT DIAGNOSIS AND TESTING Trouble Cause Remedy Long brake pedal Vibration during braking Poor braking performance Brakes pullto one side Brake caliper piston or caliper guide pins sticking Worn damaged brake pads Worn damaged brake pads Loose caliper mounting bolts Insufficient grease on sliding parts Foreign material or scratches on brake rotor contact surface Damaged brake rotor contact surface Leak i hydraulic system Air in system Worn damaged brake pads Foreign material on brake pads Brake caliper piston malfunction Tandem master cylinder malfunction Vacuum booster fault Disconnected or damaged vacuum hose Low brake fluid level Worn damaged brake pads Foreign material on brake pad Failing valves in ABS valve block Abnormal wear or distortion on front brake rotor Incorrect wheel alignment Incorrect tire pressure Service or renew caliper or caliper guide pins Renew brake pads Renew brake pads Tighten caliper mounting bolts Apply grease where necessary Clean brake rotor contact surface Renew brake rotor Repair leak Check all pipework con nections Refilland bleedthe system Check the system for leaks and bleed brakes Renew brake pads Examine brake pads and clean or renew as necessary Renew faulty brake caliper piston Service or renew tandem master cyl inder
225. d wear protectiveclothing gloves and goggles to avoid skin and eye contact A particle mask or canister type respirator should be worn when sanding A4 1 4 2 Applied Heat When welding flame cutting brazing etc the operator should use as appropriate goggles mask fume extractor and flameproof protectiveclothing Itis especially important when working with polyurethanecompoundsto use air fed breathing equipment Ensure that at all times the appropriate fire fighting equipment is available and that personnel are trained in its use A4 1 4 3 Metal Repair Appropriate eye and hand protection should be worn when sanding drilling cutting chiselling flatting or welding Operators should wear a face mask or air fed visor when sanding or flatting either body solder or fillers When a soldering operation has been completed swarf must be removedfrom the work area andthe operator must wash his hands thoroughly X300 VSM 3 Issue 1 August 1994 Gd S 2 PS Body Systems Body Repair y A4 1 5 GENERAL REPAIR NOTES The following advice should be noted before ANY repair work is carried out Q Disconnectthe vehicle battery ground lead disconnect the alternator where electric welding is used and take note ofthe reconnection procedures as detailed in Section 15 o Where structural parts are straightened or renewed a body alignment straightening jig must be used o Where appropriate structural sections should be straightened by col
226. del Year Vehicles oooooocnnoncccnnnnn en eee ee eee eee eeeeeeeeeeeeeees Engine Management System NEE e EE ENEE EE E COOLING A ie Fuel System PUMP EE EE ENEE EE EE EE EE EE EE o ea ana UE ee eege serge ee A AE ERE AAA A ee Manual Transmission Ratos EE ee ee ee eee a i a Automatic Transmission RatioS EE Final Drive Unit RatioS EE EEEE eee ence cece nnn E ence EE E cee ERR EEE EE E E E EE EE ENEE EE KN Climate Control SysteM EE Braking System v riere ae aa eee eee eee eee eee eee eee eee eee aa a E ae Steering amp SUSPENSION snnannnnnnncn eee ene Electrical Equipment ed EN eine sale te de RE eee eae Gan Cee ae E REN NENNEN REN dE Ee wae eee Lubricants GI eines eee done ne ea eS Vehicle WEIGHTS ooooooocccccnnnnnnnc eee eee eee eee e eee ee eee eeeeeeee EES EE E de ede Sw ae ala ele aie ee ate ele re wee ee ayaa wale eee eee eee de ae eae eae o GW zl D bk ahaha on NNa Te EE 1 BUIDS EL O e A ES A A A AA e Bee USO a a ENEE 14 N X300 VSM A1 95MY i issue 1 August 1994 A1 95MY ii NEP Specification Lem SPECIFICATION 1995MODEL YEAR VEHICLES Engine See relevant engine service manual Engine Management System MA A e dE ee ENEE SEN dE Nippondenso ESA AA A A AAA eee Lucas GEMS Cooling System Water pump PO ii e A da leida Centrifugal QV O a a la a e dee a Wid wie Belt Cooling fans 6Cyl ees goeien aea E E a Two electric fans controlled by temperature sensor in radiator Cooling fans V12 cece cece eee eee e ee
227. dicator Light X300 VSM 5 Issue 1 August 1994 Brakes 12 1 5 ABS Components Hydraulic Module The hydraulic module is located underthe bonnet adjacent to the engine compartment firewall It is secured within a steel mounting bracket at three securing points All elec tronic and power connections are made through one cable loom connection The hydraulic pump 1 Fig 1 is a reciprocatingtwo circuit pump in which one brake circuit is assignedto each pump circuit The pump supplies adequate pressure and volume supply to the brake circuits under anti lock braking condi tions The pump isdriven by and electric motor 2 Fig 1 The pump housingincorporatestwo low pressureaccumulators and damping chambers for each brake circuit A modulatorvalve block 3Fig 1 incorporatesthe ABS CM or ABS TC CM 4 Fig 1 Vehicles with traction control are fitted with a throttle position actuator 5 Fig 1 which is an electrical device controlled by the ABS TC CM Valve blocks on vehicles without traction control comprise six solenoid valves three normally open NO inlet valves and three normally closed NC outlet valves These valve blocks havethree outlet ports Valve blocks on vehicles with traction control compriseninesolenoidvalves four NO inlet valves four NC outlet valves andone specialisolatingvalve Fig 2 shows a hydraulic module for vehicles with traction control The valve block 2 Fig 2 hasfour outlet ports Indi
228. dy Fig 1 Seat Belt Location and Anchorages Issue 1 August 1994 50 X300 VSM Body Components amp Trim mauler 13 8 10 Tearloop Seat Belts Description The tear loop seat belt Fig 1 is usedto control the rate of forward travel of the occupanttowards the deployed airbag the airbag iscovered in Section 15 Electrical The tear loop assembly is designedto release additional webbing when the stitching which retains the webbing loops breaks under a predetermined load The wires 1 Fig 1 within the as sembly have the following functions Q To protect the stitching from normal loads such as heavy braking or cornering o To control the rate of deployment Q To support the extended head following deployment When the passenger unit has been activated the buckle will extendfromthe shroud and reveala warning label 2 Fig 1 the extent of deployment will depend upon the severity of the load WARNING IF THE LABEL IS VISIBLE AT ALL 3 FIG 3 THE COMPLETE ASSEMBLY MUST BE RENEWED AS MUST ANY SEAT BELT WHICH HAS BEEN WORN IN AN ACCIDENT WARNING ATTENTION BUCKLE MUST BE REPLACED SEE DRIVERS HANDBOOK BOUCLE DOIT ETRE REPLACER VOIR GUIDE Fia 1 Tear Loon Seat Belt X300 VSM 51 Issue 1 August 1994 aio Body Components amp Trim 13 8 11 Front Seat Belt Buckle Unit Renew a Disconnect vehicle battery ground lead a Removethe front seat cushion a Disconnect cable connector and remove cable
229. e Always fit covers to protect the wings before commencing work in the engine compartment Cover the seats and carpets wear clean overalls and wash hands or wear gloves before working inside the car Avoid spilling hydraulic fluid anti freeze or battery acid onthe paintwork Inthe event of spillage wash off with water immediately Use poly thene sheets inthe boot to protect carpets Always use the recommended service tool or a satisfactory equivalent where specified Protecttemporarily exposed screw threads by replacing nuts or fitting caps A3 2 2 Preparation Before disassembly clean the surrounding area as thoroughly as possible When components have been removed blank off any exposed openings using greaseproof paper and masking tape Immediately seal fuel oil and hydraulic lines when separated using plastic caps or plugs to prevent loss of fluid and the entry of dirt Close the open ends of oilways exposed by component removal with tapered hardwood plugs or readily visible plastic plugs Immediately a component is removed place it in a suitable container use a separate container for each component and its asso ciated parts Before dismantling acomponent clean itthoroughly with a recommended cleaning agent check that the agent will not damage any ofthe materials withinthe component Cleanthe bench and obtain marking materials la bels containers and locking wire before dismantling a component A3 2 3 Dismantling Observe scrup
230. e and gradually increase speed to 2000rpm with transmission in neutral Is neutral vacuum above 53 8kPa 16 in Hg Yes Refer to EDM No Goto Step 3 Step 3B Vacuum Test Exhaust Disconnected Turn engine OFF Disconnect exhaust system atthe exhaust mani fold Repeat vacuum test Is the manifold vacuum above 53 8kPa 16 in Hg Yes Goto Test Step 4B No Reconnect exhaust system atthe exhaust manifold Disconnect muffler Repeat vacuum test Is the manifold vacuum above 53 8kPa 16in Hg Yes Renew muffler and re test No Renew catalytic converter issue 1 August 1994 6 X300 VSM Exhaust System V12 bet SECTION CONTENTS Sub Section Title SRO Page ARIAS EOS Preliminary Page oooononnnnnnccnnnan EE a i OR General DESCHDLION Ge Vie ENNEN NEEN NEE NEE e Ee 7 OA E DiaQnOSiS amp TeStiQ coooooonnnonccnnnncannn eee EE Ni 3 X300 VSM i Issue 1 August 1994 Exhaust System V12 eg 6 2 1 GENERAL DESCRIPTION 430 234 Fig 1 Plan View of Exhaust system he low loss catalytic converter exhaust system for the V12 engine comprises catalyst downpipe assembly with addi tional secondary catalytic converters 1 Fig 1 a underfloor catalytic converter assembly 2 Fig 1 complete with heat shield 3Fig 1 an intermediate muffler section 4 Fig 1 and a rear muffler section 5Fig 1 On non catalytic converter systems the downpipe catalyst assembly is fitted with conventi
231. e and remove the left and right hand tail light covers a Undo and remove the trunk seal retainer securing bolts arrowed on Fig 1 a Displace and remove the trunk seal retainer a Fit and fully seat the new trunk seal retainer Fit and fully tighten the trunkseal retainer securing bolts a Fit and fully seat the tail light covers a Refit the trunk floor carpet 13 4 7 Trunk Lid Striker Adjust a Disconnect vehicle battery ground lead a Removethe rear finisher a Slacken the striker plate securing bolts and adjust the striker to ensure that the luggage compartment lid aligns om 376 1074 Fig 1 Body Components A Trim falso 13 4 12 Trunk Lid Lock Mechanism Renew Open the trunk and remove the mechanism cover a Disconnect the operating rod from the remote linkage e Removethetwo lock assembly securing bolts removethe lockfrom the trunk lidand removethe assembly from the vehicle a To refit carry out reversal of the above procedure 13 4 13 Trunk Lid Gas Strut Adjust Renew Open the trunk a Insert a screwdriver and remove the strut from the top pivot and repeat the operation for the lower pivot a Fitthe strut to the lower pivot first to aid re assembly a To refit carry out reversal of the above procedure chang ing one strut at atime 13 4 14 Trunk Lid Hinge Renew Open the trunk a Remove the hinge cover Cut and remove th
232. e closing panel to fascia support bracket fir tree fixing Fig 1 a Displace and remove the closing panel a Removethe draught welt a Place the panel to the front a Displace and remove the end panel securing clip a Place new closing panel to the front a Fit and fully seat the end panel securing clip Fit and fully seat the end panelto the vehicle a Fit andtighten the end panelto fascia support bracket clip Refit the underscuttle pad 13 3 22 Fascia Closing Panel Drivers Side Renew SRO 76 46 28 Removefor access the drivers side underscuttle pad see sub section 13 2 19 a Undo and remove the closing panel to fascia support bracket securing nut Fig 1 a Displace and remove the closing panel Place the panel to the front a Displace and remove the end panel securing clip a Place new closing panelto the front Fit and fully seat the end panel securing clip e Fit and fully seat the end panel to the vehicle e Fit and tighten the end panel to fascia support bracket se curing nut a Refit the underscuttle pad X300 VSM 27 Fig 1 Issue 1 August 1994 Body Components amp Trim 13 3 23 fasciaCenter Veneer Panel Renew SRO 76 47 06 a Fit and align the special tool JD 202 to the center vent as sembly See Fig 1 a Displace and repositionthe center vent assembly a Removethe special tool from the vent a Displace and remove the center vent assembly from the variable d
233. e cornerthrough the driver side rear door a Positionthe roof lining acrossthe car with the roof console cut out straddling B C post a Tip the roof lining forward against bottom of fascia with rear edge of roof lining diagonally across door aperture a Carefully feed the roof lining out of the passenger side front door easing the edge cut outs over the door aper ture and any other obstruction To refit carry out reversal of the above procedure 000000000 X300 VSM 37 Issue 1 August 1994 ec Body Components amp Trim 13 4 TRUNK 13 4 1 Trunk Description The trunk houses the spare wheel the battery an electrical carrier containing electrical fuses relays and modules and a compact disc auto changer attached to body bracketry The trunk is fitted with push fit velour finish liners 1 Fig 1 to the sides and front inner panel the trunk floor is covered with carpet attached to a removable floor board 2 Fig 1 and a battery cover 3 Fig 1 one covering the spare wheel and wheel changing equipment the other covering the battery and electrical carrier The floor board rests onthe spare wheel the front and rear edges of the floor board locating in blocks onthe fuel tank backboard and onthe rear of the body The blocks accommodate the two possible height settings caused by the differ ence inthickness between the space saver and full sized spare wheels A tread plate 4 Fig 1 is attached to the trunk sill and a li
234. e eee eee eee eee eee ee eee One engine driven fan and two electric fans controlled by temperature sensor in radiator Cooling system CONTIG resser eter a Thermostat two on V12 Thermostat opening temperature cee cece cece eee eee ee ee eeeeeeee 88 C FUlly OPEN Atsina dente a en nee eR 93 5 to 96 C Filler cap pressure rating ooccooccnccnnnncnnrn 12 bar Fuel System Pump one fitted on 6 cyl 3 2 Liter and 4 0 Liter normally aspirated two fitted on 6cyl 4 0 Liter supercharged and V12 Electrical module type fitted inthe tank Integral 70 micron filter MAK Cha iaa ican a ear ae ener aca AAA wok re nea AA E Nippondenso PUMPAY it A A a Regenerative turbine Fuel pressure nominal e 3 0 bar Fuel pressure Supercharged e 37 bar max Second pump switches at 4 0 Liter SUPercharged 8 gege dest ra in at 4000 RPM out at 3200 RPM VIZ A A Ee Ee eege EE load sensitiveswitching Clutch Plate diameter ua E ENEE EE ni kirpimo rra 280mm single plate LUK Clutch hydraulic fluid e DOT 4 Manual Transmission Ratios Getrag FUSE QCA vrai aia ai Mwah daa 3 553 1 Second GEA idad da a a 2 041 1 elle Be E ir oa 1 400 1 lit De ri AAA eee A a a Oa 1 000 1 Fifthgear ii a ala erg deg 0 755 1 REVerse ita idas ada 3 553 1 X300 VSM A1 95MY 1 Issue 1 August 1994 A Lem Specification EISE ai ia A a a la 2 48 1 Second masias aaa 148 1 THIKA iaa AAA E 1 00 1 EQUINA AAA 0 73 1 Reverse d da in cae ener A A sears the 2 09 1
235. e harness straps from the RH hinge and move the harness away Note Ensurethatthe lid is adequatelysupported and that paint damage cannot occur a Removethe upper hinge securing bolts a Remove the lower hinge fixings a To refit carry out reversal of the above procedure ensur ingthat the alignment of the trunk buffers is set relative to the fenders 13 4 15 Trunk Rear Liner Renew a Disconnect vehicle battery ground lead a Peelback the floor carpet and sound insulationfor access a Remove the tread plate a Remove the trunk rear liner a To refit carry out reversal of the above procedure X300 VSM 41 Issue 1 August 1994 Body Components Trim 13 5 HOOD 13 5 1 Hood Description The hood is fitted with black moulded covers over the inner fenders and behind the headlamp units the right hand fender cover incorporates compartments for spare fuses and tool kit where fitted Two gas struts attached by press on fittings on the body and hood support the hood cover 13 5 2 Plenum Chamber Finisher Renew SRO 76 10 01 s Openthe hood and fit suitable fender cover a Remove the wiper arm see section 15 6 a Undo and remove the plenum chamber finisher securing screws 1 Fig 1 a Displace and repositionthe plenum chamber a Disconnect the washer jet tubes a Disconnect the washer jet multi plugs a Displace the washer jet securing tangs a Displace and remove the washer jets 2 Fig 1 a Placethe finisher as
236. e inset view shows the differences in the component layout for NAS market vehicles only This illustration is to be read with the table on Page 2 Note The layout of the superchargedvehicle is as shown inthis illustration apart from the routing of the fuel feed line X300 VSM 1 Issue 1 August 1994 NY Fuel Emission Control amp Engine Management AJ16 Key to Fig 1 Fuel System Aj16 page 1 SRO Component Parts Location Number 195513 Fuel filler assembly 19 55 0 1 Fuel tank Behind rear bulkhead 19 45 08 Fuel pump s Inside fuel tank Fuel pump filter Inside fuel tank 4 19 40 97 Fuel feed line Fuel pump to fuel filter 5 19 25 02 Fuel filter Above rear axle assembly 6 19 40 60 Fuel feed line Fuel filter to fuel rail 7 19 60 13 Fuel rail Inlet manifold 8 18 10 02 Fuel injectors Inlet manifold fuel rail 9 19 45 11 Fuel regulator valve Mounted onthe fuel rail 10 19 40 85 Fuel return line Fuel regulator to fuel tank 11 Emission vent line Fueltankto running loss 2 control valve NAS 4 0L normally aspirated engine only Emission vent line Runningloss control valve to primary carbon canister NAS 4 0L normally aspirated engine only Running loss control valve Left side of the fuel tank NAS only Emission vent line Fuel tank to tank pressure 15 control Rochester valve 17 15 41 Tank pressure control Connected between 16 Rochester valve emission vent lines as shown on sc
237. e lubrication pipe clamp a Fitandtightenthe lubrication pipeclamptovalve body se curing bolt a Fit the lubrication pipe retainer a Refit the fluid pan see Sub section 8 2 14 4 0L SC or Subsection 8 2 15 6 0L a Lowerthe vehicle onthe ramp e Refill the transmission unit with fluid see Sub section 8 2 13 Removethe fender cover and close the hood X300 VSM 21 Issue 1 August 1994 fg Automatic Transmission V12 amp AJ16 Supercharged Powertrain 8 2 21 INTERNAL DIPSTICK STOP RENEW 4 0L SC AND 6 0L SRO 44 24 22 Open the hood and fit a suitable fender cover Raise the vehicle on a ramp Drain the transmission lubrication system see Sub sec tion 8 2 13 Remove the fluid pan see Sub section 8 2 14 4 0L SC or Sub section 8 2 15 6 0L Release and remove the dipstick stop to valve body secur ing bolts Reposition the internal harness securing clip Remove the dipstick stop Clean all relevant parts Place the dipstick stop aside Fit a new dipstick stop to the valve body Reposition and align the internal harness securing clip Fit and tighten the dipstick stop to valve body securing bolts Refit the fluid pan see Sub section 8 2 14 4 0L SC or Sub section 8 2 15 6 0L Refit the downpipe to underfloor catalyst olives Lower the vehicle on the ramp Refill the transmission unit with fluid see Sub section 8 2 13 Remove the fender cover and close the hood
238. e or disengage as indicated by the state lamp the refrigeration system compressor The state lamp is also used as acompressor speedfault indicator see System protection this section 11 AUTO push on button and state lamp When selected and the state lamp lit the A C mode is selected and control of demand temperature fans speed and air distribution is automatic AUTO is cancelled by selection of any dis tribution button A C off or manual FANS SPEED 12 DEFROST push on push off button and state lamp When engaged air is distributedto the screen at maximum fans speed andthe heatedfront screen elements wherefitted are energized The heatedfront screen is automati cally timed for asix 6 minute cycle but may be cancelled by pressingthe HEATED FRONT SCREEN button Auto matic temperature control is retained and the fans speed may be manually reduced Deselection will returnthe system to the previous state and selection of AUTO will resume automatic system control 13 The push on push off E button with state lamp manually controls the HEATED FRONT SCREEN where fitted This facility allows rapid screen de icing using laminated electrical heating elements to supplement the hot air defrost 14 The push on push off R button with state lamp manually controls the HEATED REAR SCREEN and door mirror glass heating elements for a timed cycle of screen twenty 20 minutes and mirrors eleven 11 minutes Note The state lamp will remain
239. e pressureto the rear brake circuit item 20 via valves items 14 and 17 on a select low principle it Sidd edd SE E Ge AEN 20 21 22 1 TMC 1 primary circuit 9 Low pressure accumulator 17 Outlet valve NC 2 TMC 2 secondarycircuit 10 Electric pump motor 18 Outlet valve NC 3 Tandem master cylinder 11 Two circuit hydraulic pump 19 Outletvalve NC 4 Vacuum booster 12 Dampingchamber 20 Rear brake circuit 5 Centralvalve 13 Valve block 21 Front brake circuit left 6 Fluid reservoir 14 Inlet valve NO 22 Front brake circuit right 7 Fluid level indicator 15 Inlet valve NO 8 Pump motor unit 16 Inlet valve NO Fig 1 Shouldthe ABS be initiated by a locking tendency of any wheel during braking the pump unit item8 is started and the appropriate NO inlet valve item 14 15 or 16 closes in response to signals from the control module This action prevents further increase of brake pressure by blockingthe supply of brake fluid from the TMC item 3 If excessive deceleration continues the appropriate NC outlet valves item 17 18 or 19 opens releasing brake pressureto the low pressure accumulators item9 until the wheel accelerates again Issue 1 August 1994 12 X300 VSM Brakes Fromthe low pressure accumulators volume is pumped back into the TMC forcing the brake pedal back To optimize the friction coefficient betweentire and road brake pressure is increased insmall steps by closing the outlet
240. e selector shaft bolt 3 Fig 1 e Fit the lower LH mounting rubber and washer a Fit the remaining mounting rubbers washers 2 Fig 1 and secure with the bolts 1 Fig 1 Secure the selector shaft bolt 3 Fig 1 a Tighten MS 538 hook nut to raise the transmission into position a Using a jack fit and seat the rear mounting to the trans mission body ensuring thatthe spring is seatedcorrectly inthe spring pan a Fit but do not fully tighten the mounting securing bolts a Remove the jack and jack channel Secure the rear mounting bolts a Slacken off MS 538 hook nut a Refit the drive propeller shaft assembly see Section 9 SRO 47 15 01 a Remove Service Tool MS 538 a Refit the gearshift lever knob Issue 1 August 1994 8 X300 VSM P4 Manual Transmission amp Clutch AJ16 Bee 7 1 9 GEAR SELECTOR SHAFT REAR OVERHAUL SRO 37 16 41 a Remove the gear selector remote control assembly see 37 16 20 e Displace the selector shaft cover 1 Fig 1 a Removethe selector shaft to selector shaft yoke retaining pin 2 Fig 1 and remove the yoke 3 Fig 1 a Clean all components thoroughly and check for wear and damage a Replace worn or damaged components as necessary a Lubricate and fit the selector shaft yoke to the selector shaft and secure with the retaining pin a Reposition the selector shaft cover a Refit the gear selector remote control assembly see 37 16
241. e switch internal part of fascia switchpack 25 Valet switch incentre console compartment A5 2 COMPONENT DESCRIPTIONS A5 2 1 Central locking switch The central locking switch is located onthe driver sfascia switchpack and allows locking unlocking and all closefrom inside the vehicle when all doors are closed A5 2 2 Door ajar switches Locatedin each front door lock mechanismto indicate door not closed correctly A5 2 3 Door lock actuator and switch Located within each front door panel assemblyto provide automatic lock unlock operation A5 2 4 Door lock switch Locatedin each front door lock mechanismto indicate door lock unlock state A5 2 5 Hood switch Located underhood adjacentto the hornto give indication of hood not closed correctly A5 2 6 Horns Located adjacent to each headlight unit and utilized as part of the full alarm application X300 VSM 3 Issue 1 August 1994 Las Security System RESTRICTED ISSUE A5 2 7 Inclination sensor Locatedadjacentto the SLCM under the luggage compartment LH sideliner to give indication of unauthorizedjacking lifting of the vehicle A5 2 8 Intrusion sensors Located above each front door to give indication of unauthorized entry into the vehicle passenger compartment A5 2 9 Reader exciter coil Forms an integral part of the ignition switch to prove correct key insertion by communicating key transponder signal to control module A5 2 10 Reader exciter module
242. e with all local state and federal regulations 15 1 12 Driver And Passenger Airbag Modules Assembly Removal Service Instructions Note Before starting work ensure ignition switch is in lock position key is removed and negativeterminal cable is disconnectedfrom the battery As the airbag is equipped with a back up power source and due to the risk of airbag being inadvertently deployed wait one minute or longer before starting work O Disconnectingthe battery cancelsthe memory for clock radio seats mirrors steering column and any other components using battery power Reset memory after work is completed Never use airbags from other vehicles always use new parts After work is completed reconnect battery and perform warning light check see diagnostic manual Never use electrical probes to check voltage or electrical resistance Disconnectthe airbag before carrying out any work on or inthe vicinity of module or when using electricweld ing equipment Always ensure that battery negative has been disconnectedfor one minute or longer before commencingany removal procedure 0000 Gi Issue 1 August 1994 4 X300 VSM y Electrical 15 1 13 Spillage and Leakage If material isspilled or released contact Jaguar Servicefor clean up procedures All other personnel must be keptaway from contaminated area Do not dispose contaminated propellant or water into storm or sanitary sewers ground water or soil Spills may be
243. ear Pin21 22 way Pin 05 Pin 06 Fig 1 Door Ajar Switches Circuit Issue 1 August 1994 26 X300 VSM y Security System RESTRICTED ISSUE A5 9 3 Door locks 1 Check harness wiring continuity between multi plug 12 way connector pins 10 driver s side and 4 passenger s side to respective door lock connector pin 8 Ensure secure ground connection from each lock connector pin 9 2 Test continuity across switch pins reading should be open circuit with door unlocked short circuit with door locked Fig 1 Door Locks Circuit X300 VSM 27 Issue 1 August 1994 Bez Security System RESTRICTED ISSUE A5 9 4 Door lock actuators and switch 1 Examinefuse F1 in right hand A post base fusebox if blown determine reasonfor rupture and renew 2 Check continuity of harness wiring as shown on Fig 1 below Ensure secure ground connection from lock unlock and deadlock not N A S relay pins 4 and 9 3 Removethe left hand rear seat hell board gaining accessto lock unlock and deadlock not N A S relays Operate lock unlock and deadlock checking for audible relay operation renew suspect relays Release door lock and measure resistance between actuator unit pins 2 and 3 a value of approximately 8Q should be recorded Operate door lock and check that circuit between pins 2 and 3 is opened Resistance across pins 1 and 3 should now be approximately 88 Fig 1 Door Lock Actuator Circuit 1 NA S only
244. eceiver drier when ever the system has been opene as previously ad vised see note this page However if a unit or part of the system is left open for morethan five minutes it may be advisableto renew the receiver drier This guidance is based on U K average humidity levels therefore locations with lower humidity will be less criticalto moisturecontaminationof the unit It must be stressedthat there is nota safe periodfor work to be carried out in ALWAYS plug pipes and units im mediatelyafter disconnectionand only remove plugs immediately prior to connection Note The receiver drier MUST be renewed if the compressor has failed or if it is suspected that debris may be in the system o If replacement parts are supplied without transit plugs and seals DO NOT use the parts Returnthemto your supplier o Diagnostic equipmentfor pressure mass and volume should be calibrated regularly and certified by a third party organization OQ Use extreme care when handling and securing aluminium fittings always use a backing spanner and take special care when handling the evaporator o Use only the correct or recommendedtools for the job and apply the manufacturer s torque specifications Issue 1 August 1994 2 X300 VSM L Ban Climate Control Systems Wer 14 2 CLIMATE CONTROL SYSTEM 14 2 1 Description The climate control system in the 1995 model year saloon has a centre mounted heater cooler unit with separate blower assemblies
245. ecessary precau tions and remove the brake dust from around the caliper area After renewal pump the brake pedal several times to centralize the new brake pads E eng Note If both front and rear calipers have been removed A from the vehicle take care not to mix up left and Fig 1 right hand caliper bodies Removeall brake dust from the caliper carrier and brake rotor Thoroughly clean the pad abutment areas avoid dam aging the piston and dust cover CAUTION When cleaning brake components only use a proprietary fluid Never use petrol Use of petrol paraffin or other mineral based fluids can prove dangerous Examineallthe components for signs of wear damage andcorrosion Pay particular attentiontothe piston and piston bore Removecaliper body corrosion with awire brush or wire wool No attempt should be madeto clean a badly corroded or scored piston bore The caliper must be renewed CAUTION No attempt should be made to clean corroded bo ts Inspectthe caliper guide pins ensure that they are not corrodedor seized andthatthe caliper movesfreely Ifthey are difficult to remove or corroded in any way they must be replacedtogether with new dust covers CAUTION Ensurethat working surfacesandhandsareclean Useonly brakefluid of the correctspecificationto lubri cate the new seals when fitting When reassembling always renew piston seals Lubricatethe new piston seal and fit carefully to the inner groove of the piston bore
246. econnect the security system valet switch multi plug s Placethe air distribution outlet in position a Connect the rear cigar lighter harness multi plug where fitted s Fit and fully seat the air distribution outlet e Refitthe fascia center veneer panel a Refit the radio console a Refit the console veneer panel a Refit the console ashtray a Refit the console finisher Refit the underscuttle pads a Refit the console extension a Refit the console extension veneer panel a Refit the console rear extension finishe a Reconnect the battery Refit the battery cover X300 VSM 11 Issue 1 August 1994 piee Body Components amp Trim 13 3 3 Console Assembly Remove For Access And Refit Daimler VDP SRO 76 25 01 91 a Remove the battery cover Disconnect the battery a Remove the console rear extension finisher see sub sec tion 13 3 5 a Removethe console rearextensionveneer panel see sub section 13 3 27 a Remove the console rear extension see sub section 13 3 6 a Remove the drivers side underscuttle pad see sub sec tion 13 3 19 a Remove the passenger side underscuttle pad see sub section 13 3 20 Remove the console ashtray see sub section 13 3 28 a Remove the console finisher veneer panel see sub sec tion 13 3 24 a Remove the radio console see sub section 13 3 10 a Remove the fascia center veneer panel see sub section 13 2 23 Undo and remove the console upper se
247. ection 15 Electrical and Electrical Diagnostic Manual EDM for details of the passenger and driver airbags X300 VSM Issue 1 August 1994 ali Body Components amp Trim 13 2 DOORS AND FUEL FILLER FLAP 13 2 1 Doors Description Doors are of welded mild steel frames welded to the door panels sponge rubber primary and secondary seals are mounted onthe doors Internal insulation is provided by afoam water shedder attached to the door by press fitting and double sided adhesive tape Front and rear door armrests are attached to supports riveted to each door frame the attaching screws are fitted with access covers Upper and lower trim pads and a door pocket are attached to each of the doors by clips and screws multi plug connectors are usedto provide a means of connecting the guard lamps window lift switches and loud speakers external mirror and regulator front doors only which are housed within the doors Central locking is provided subject to market variations Dead Locking for UK Europe and Driver only unlock for N America Door locks are eight disc bayonet fixing barrels with integral lock unlock switches Keys include in key transponders which are programmedtothe vehicle viathe Jaguar Diagnostic System also operatethe engine immobi lisation system CAUTION Whenremovingthe door panel water shedder afoam membrane attachedto each door panel by acom bination of pressfitting upper area and bydouble sidedtape bottomarea
248. ed out on bare unpainted or unplated metal The flanges of panels which are to be welded together must be clean corrosion free and treated as appropriate with either weld through primer or inter weldsealer useonly materials and processesinaccordancewith the Body Seal ing and Preservation Manual and relevant application areas in section A4 3 1 1 Note See Zinc Coated Panels section A4 2 Generally the resistance spot welding equipment used inthe motor vehicle repair industry does not produce a weld of equivalent strength to that of the manufacturer Therefore the expression single row of resistance spot welds means that the spots should be spacedon a pitch of 19mm to 25mm This will usually result in more spot welds than found inthe original factory joint To remove resistance spot welds a resistance spot weld cutter should be used Ifthe new joint isto be MIG plug welded the old resistance spot welds should be cut from the panel which isto be retained and those holes used for plug welding Suitable holes may also be drilled or punched 8 0 mm dia for sections up to 1 6 mm and 10 0 mm dia for thicker sec tions Issue 1 August 1994 4 X300 VSM Y Body Systems amp Body Repair A4 1 6 PLASTICS EXPLANATORY NOTES A 1 6 1 Plastic componentand trim materials This table in conjunction with the illustrations onthe following pages will enable rapid identification ofthe particular material of any major plastic part
249. ed when volatile degreasing agents are being used WARNING FUME EXTRACTION EQUIPMENT MUST BE IN OPERATION WHEN SOLVENTS ARE USED E G TRICHLOROETHANE WHITE SPIRIT SBP3 METHYLENE CHLORIDE PERCHLORETHYLENE DO NOT SMOKE INTHE VICINITY OF VOLATILE DEGREASING AGENTS Adhere strictly to handling and safety instructions given on containersand labels Keep oils and solvents away from nakedflames and other sources of ignition Do not apply heat in an attemptto free seized nuts or fittings as well as causing damage to protective coatings there is a risk of damage from stray heat to electronic equipment and brake lines Do not leave tools equipment spilt oil etc around or on work area Wear protective overalls and use barrier cream when necessary A3 1 1 Used Engine Oils Prolonged and repeatedcontact with mineral oil will result in the removal of natural oils from the skin leadingto dry ness irritation anddermatitis In addition used engine oil contains potentially harmful contaminantswhich may cause skin cancer Washing facilities and adequate means of skin protection should be provided A3 1 2 Health Protection Precautions Avoid prolonged and repeatedcontact with oil particularly used engine oils Wear protective clothing including impervious gloves where practicable Do not put oily rags in pockets Avoid contaminating clothes particularly underwear with oil Overalls must be cleaned regularly Discard unwashable clothing and
250. ee Recycled Materials wo Gi o i Ka e EN X300 VSM 7 Issue 1 August 1994 Body Systems amp Body Repair y A4 1 6 6 Plastics Component Location amp Type Under hood wo es o i i issue 1 August 1994 8 X300 VSM E Body Systems amp Body Repair Z A4 2 BODY STRUCTURE A4 2 1 Introduction The Jaguar sedan range with standard wheelbase has a unit construction monocoque body structure with bolt on front fenders and welded rear fenders The doors feature lift off hinges and welded drop glass frames A4 2 1 1 ConstructionalSteel Classification High strength low alloy HLSA Impact prone areas ie seat frame and bumper mount ings Exterior body panels subject to severe conditions such as stone chipping and weather exposure excluding roof panel Internal brackets fillets and strengtheners Double sided zinc plated mild steel Boron steel Mild steel A4 2 2 BODY ALIGNMENT The illustrations on pages 11 Body Dimensions PLAN and 13 Body DimensionsSIDE VIEW provide specifications for damage assessmentand location of replacement parts These dimensions must bestrictly appliedwhether they are usedfor damage assessment componentlocation or post repair verification The plan view MASTER datums are nominated on the right hand side of the body with the left handdatums dimen sionedfrom them Therefore the right handdatums must be knownto be
251. ee EDM for full check Issue 1 August 1994 18 X300 VSM La e Climate Control Systems S Ae 14 12 MANIFOLDGAUGE SET The manifold gauge set is a most importanttool fortracing faults and system efficiency assessment The relationship to each other of HIGH and LOW pressures and their correlation to AMBIENT and EVAPORATORtemperatures must be comparedto determine system status see Pressure Temperature graphs in Sub Sections 14 14 amp 14 15 Because ofthe heavy reliance uponthis piece of equipmentfor service diagnosis ensure thatthe gauges arecalibrated regularly andthe equipment is treated with care AA 382 389 Low side service hose BLUE 5 Highside hand valve RED Low side hand valve BLUE 6 High side service hose RED Low pressure compound gauge BLUE 7 System service hose NEUTRAL High pressure gauge RED COLOUR commonly yellow Fig 1 Manifold gauge set Manifold The manifoldis designedto control refrigerant flow When connected intothe system pressure is registeredon both gauges at all times During system tests both the high and low side hand valves should be closed rotate clockwise to seat the valves The hand valves isolate the low and the high sides from the centre service hose Low Side pressure Gauge This compound gauge is designed to register positive and negative pressure and may be typically calibrated Full Scale Deflection Oto 10 bar 0 to 150 Ibf in pressure in
252. el and isthan presented using three different visual display methods described as follows 15 2 2 Analog Display This is usedto display road speed engine speed oil pressure battery condition fuel level and coolant temperature 15 2 3 Indicator Lamps These indicate the presence of any hazard fault conditions or operational actions 15 2 4 LCD Liquid Crystal Display This single line six digit seven segment display is normally used to display the odometer reading butcan also be used to display vehicle condition messages associated with particular warning lamps andtrip computer information 15 2 5 Transducers These devices listed as follows transmit vehicle conditionto the instruments Q Engine Coolant Temperature Transmitter Q Low Coolant Level Probe o Oil Pressure Transmitter AJ16 V12 o Fuel Gauge Tank Unit AJ16 V12 Note Faultconditions andtheir causesdisplayed bythe instruments and warning lamps are covered in more detail by further information contained within the Electrical Diagnostic Manual 15 26 Instrument Panel General 24 Way Connector 3 Identification Label 4 Way Connector 4 Bulb Holder Fig 1 Instrument Panel Rear View Issue 1 August 1994 8 X300 VSM y Electrical 26 24 21 23 22 20 19 16 18 17 Tachometer 17 Hand Brake On RED Speedometer 18 Brake System Fault RED Battery Condition Main Beam On BLUE Fuel Gauge Direction Indicator Right GREEN Oil Pressure Status Warning L
253. el filler manual release cable through the liner a Fitandalignthe newtrunk side liner passing the fuel filler manual release cable through the liner a Refit the trunk seal retainer a Refit the trunk front liner a Refit the trunk floor carpet 316 1073 13 4 3 Trunk Side liner Right Hand Renew Fig 1 SRO 76 19 23 Raise the trunk lid a Remove the trunk floor carpet 1 Fig 1 see subsection 13 4 4 Remove the trunk front liner 2 Fig 1 see subsection 13 4 5 a Removethe trunk seal retainer 5 Fig 1 see subsection 13 4 6 a Displace and remove the literature pack from the trunk side liner a Displace and remove the trunk side liner 4 Fig 1 s Fit and align new side liner a Fit and alignthe literature pack to the trunk side liner a Refit the trunk seal retainer a Refit the trunk front liner a Refit the trunk floor carpet 13 4 4 Trunk Floor Carpet Renew SRO 76 19 30 e Displace and remove the trunk floor carpet assembly a Fit align and seat new trunk floor carpet assembly 13 4 5 Trunk Front Liner Renew SRO 76 19 31 a Removethe battery cover Removethe trunk floor carpet see subsection 13 4 4 a Displace and remove the trunk floor liner a Fit align and seat new trunk front liner Refit the trunk floor carpet a Refit the battery cover X300 VSM 39 Issue 1 August 1994 g s a Removethe trunk floor carpet see sub section 13 4 4 a Displac
254. elboard LH Blower high speed RH Blower high speed Deadlockfront left rear right Deadlock front right rear left Fuse box assembly Blue All Models RH side heelboard Fuse box assembly Blue All Models All Models LH side heelboard Behind RH side heelboard Beal All Models All Models All Models All Models All Models All Models Behind RH side heelboar Blue All Models All Models Behind RH side heelboard Blue All Models All Models Behind LH side ard Violet Not NAS or Not NAS or 30 Japan Japan Behind LH side heelboard Violet UK amp Europe UK amp Europe 31 only only Door Lock Behind LH side heelboard All Models All Models 28 Door Unlock Behind LH side heelboard All Models All Models SEE Driver s Door Unlock Mirror Heater Puddle Lamps 86 55 78 Cigar Lighter 86 55 74 Fuel Flap Lock Behind LH side heelboard Violet USA USA amp Canada only Canada only Behind RH side heelboard Violet All Models All Models 24 Behind LH side heelboard Blue All Models All Models 33 Behind RH side heelboard Blue All Models All Models 22 Behind LH side heelboard Violet All Models All Models 32 X300 VSM 35 Issue 1 August 1994 ES Electrical y 15 12 3 TrunkRelays GeneralDescription mb ae Yak Fa d Ez gt J86 1694 Fig 1 Trunk Relays Fig 1 shows all relays located inside t
255. eleased Note The intermittent flick wipe operations are both at slow speed and they are controlled by a Central Control Module CCM which also controls the headlamp power wash operation Issue 1 August 1994 16 X300 VSM p Electrical 15 6 2 2 Programmed Wash Wipe Operation The end of the switch lever must be pressed inwards for the windscreen wash and wipe operation Wash wipe con tinues for as long as the lever is pressed When released the windscreen wiper stops immediately and the wiper blades sweep for a further three wipes On pressingthe endoftheswitch leverinwardandthen releasing it the windscreen washers operatefor approximately two seconds before stopping whilst the wiper blade continues for a further three wipes Note Ifthe end of the switch lever is pressed while the washer fluid warning light is illuminated the windscreen washers but notthe wiper blade continuesto operate 15 6 2 3 Headlamp Power Wash Operation where fitted The headlamp power wash operates only when the programmedwasher wipe function is selectedandthe side lights are ON The headlamp power wash does not operate if the windscreen washer reservoir fluid lever is low This is indicated by the washer fluid level warning light illuminating Note The headlamp power wash only operates onthe 1stand every 6th succeeding cycle of the programmewash wipe switch after the ignition switch has beenturned to position Il X300 VSM 17 Issue
256. ely to one side The towing shackle may now be secured to the towing eye When thevehicle is beingtowed see Towing Recovery the gear lever must be set to neutral N see Gear shift Inter lock andthe ignition key turned to position Il to releasethe steeringlock and renderthe indicators horn andbrake lights operational 2 2 2 Gear shift Interlock The gear selector lever may only be movedfrom the park P position by turning the ignition keyto position Il on the key switch and applying pressureto the footbrake pedal To remove the ignition key from the key switch the gear selector lever must be movedto park P With the key removed the gear selector lever will be locked in park P 2 2 3 Gear shift Interlock Manual Override Inthe event of electrical failure or when moving the vehicle without power the gear selector lever can be manually unlocked from park P Below the left hand side of the J gate Fig 2 is the gear shift interlock manual release catch With a flat bladed screwdriver remove the plug arrowed Fig 2 Insert ignition key and press down catch whilst simultaneously moving the gear shift lever from P position Note Gear shift levercan only be moved approximately 25mm with the key still inserted Remove key and replace plug X300 VSM 3 Issue 1 August 1994 EZ Jacking lifting amp Vehicle Recovery y 2 2 4 Transporting Ifthevehicle is beingtransported on atrail
257. em Description Steering Column Operating Principle ENEE EEN 1 UO Steering System Description Hydraulic System Major COMPONENHS ee EEN EEN EEN 2 TO LA ica Steering System Description Hydraulic System Features ENEE ENEE EN 2 TO dra Steering System Description Hydraulic System Operating Principle EE EEN 2 Ola Service Procedures Safety Related ENEE EEN 5 10 2 1 en Service Procedures Safety Related Airbag EEN 5 OB Service Procedures oe cece cece eee eee eee EEN 5 TOT areca aces Stee Service Procedures Working Practices EE 5 UK Service Procedures Working Practices Fluid Level Check amp Top UP ENEE 5 103I iia Service Procedures Working Practices System Bleed ee ENEE EEN 5 UK Service Procedures Working Practices Fluid Reservoit EEN 5 UE Service Procedures Working Practices Hydraulic Connections ee ENEE EE 5 OA ed Serge Diagnostic PrOCCQUIE ee eee eee een eeeeeeeeeeeeeeneeee 6 104 Ti Diagnostic Procedure introduction een 6 1042 anani aasa Diagnostic Procedure Preliminary ACtiON EE EE EE EE Eu 6 1043 EEEE TA Diagnostic Gart aca a a ech ha ae ele dale ca EE aoe D E eee 6 10d NEEN Diagnostic Chart D ooenncennennncnnannn eee e eee eee eeeeee 7 10 4 5 enn Diagnostic Chart ee 8 0D eii e Outer Track Rod Ball Joint Renew ee ENEE EE ENEE 57 55 02 nu 9 10 6 e Front Hub Assembly Renew ee 60 25 01 eu 9 UE Front Hub Bearing End Float Check amp AQUUSt ee ENEE NN 60 25 12 coco 9 108 eu Front Hub Bearing Renew EE EE EEN EN 60 25 16 Eu 9 10 9 ii Front Hub Oil
258. emove a Open the trunk lid Removethe battery cover e Disconnect and insulatethe battery negative lead 1 Fig 1 Disconnectand insulatethe positive lead 2 Fig 1 e Removethe battery 3 Fig 1 Refit Refitting is a reversal of the removal procedure SPP X300 VSM 15 Issue 1 August 1994 Electrical Cl 15 6 POWER WASH SCREEN WASH WIPE 15 6 1 Windscreen Washers amp Wipers General Description The single windscreen wiper blade is controlledby a windscreen wiper washer switch locatedonthe right handside of the steering column switchgear see Fig The windscreen wiper motor part of the wiper motor assembly operates at slow or fast speeds and drives the lever assembly a single arm and blade via a crank On V12 engined vehicles the wiper motor assembly is mounted to the front of the bulkhead with the motor protruding into the plenum chamber whilst on AJ16 engined vehicles the wiper motor assembly is mountedinto the same position but with the motor protruding into the engine compartment For wipe and wash operation a mixture of water and special Jaguar Windscreen Fluid is drawn from the PVC reservoir assembly by two electrically controlled pumps and is then distributed via flexible feeder hoses interconnected using TEE pieces to the screen wash jets and to heated power wash jets wherefitted The ends of powerwash hoses are fitted with quick fit fluid connectors The two pumps one for screen w
259. emove amp Refit en 86 15 07 conan 15 X300 VSM i Issue 1 August 1994 ES Electrical y SECTION CONTENTS Sub Section Title SRO Page 15 6 een Power Wash amp Screen Wash Wine ee NEEN ENEE ENEE EE EE ENEE ENEE En 16 15 6 1 AP Windscreen Wipers and Washers General Description eene ENEE EEN EE 16 15 6 2 conan Windscreen Wipers and Washers Switch ee ENEE EEN EEN EE 16 15 6 2 1 NEE Windscreen Wipers and Washers Single Wipe Operation ee ENEE EE EEN EEN EN 16 TSG Windscreen Wipers and Washers Programmed Wash Wipe Operation eene EEN ENEE 77 15 6 2 3 coo Windscreen Wipers and Washers Headlamp Power Wash Operation ee ENEE 17 LS iii Closures Switching ee ENEE EE EE ENEE EE 18 De caia In Car Entertainment bb AER EE RENE EE RENE EE ENEE E ENEE E KEE E EEN EE ENEE E ENEE r 19 15 9 aaa Lampe amp Lighting LOQ C umama i wa araa e eee ee eee seen enna eens 20 LE EE Lamps amp Lighting Logic Exterior Lighting General Descripton een 20 CEET Lamps amp Lighting Logic Interior Lighting General Description ee EE ENEE EE 21 ZS TO io Hamesses amp CADICS e 22 LEINER Hamesses amp Cables Battery Power Distribution Cables General use SEENEN EEN 22 15 10 2 cono Hamesses amp Cables Main Hamesses General Description ENEE EEN 24 LEO LEE Hamesses amp Cables Link Hamesses General Description EE EE ENEE 26 15 10 4 coco Hamesses amp Cables Hamess Connectors General Description ee EEN ENEE 28 VAT ica ie gek Motors and SoOlend dS ee 30 E AA Motors a
260. en plate for frac tures and distortion Damage may be caused by acci dental loading during assembly of transmissionto engine Always support transmission weight during refitting essure D Clean off metal faces Renew driven plate Rectify oil leaks Renew ove as necessary Reclaimor renewclutch plate as applicable Renew driven plate and check mating components for damage Check for primary pinion bearing Rectify or renew as necess slutch seized ary Check clutch driven hub for bind Renew as necessary ing on primary pinion splines Check for too thick friction linings Ensure linings are good Check for foreign matter in clutch Clean and renew compo unit nents as necessary X300 VSM 13 Issue 1 August 1994 ETA Manual Transmission Clutch AJ16 7 1 14 CLUTCH ASSEMBLY RENEW SRO 33 10 01 a Remove the rear inlet manifold securing nuts and theinjector harness mounting bracket a Fit lifting eye 18G 1465to rear inlet manifold studs and tighten securing nuts Fit Service Tool MS 53B Fig 1 and take the weight of the engine with the hook a Disconnect the exhaust system from the front pipe a Ease the exhaust system down for access and remove heatshield a Remove the drive propeller shaft assembly and fit a blanking plug to the rear of the transmission a Remove the exhaust front pipe assembly a Removethe clutch slave cylinder see Sub Se
261. en the console rear securing screw a Reconnect the security system valet switch multi plug a Placethe air distribution outlet in position e Connect rear cigar lighter harness multi plug iffitted a Fit and fully seat the air distribution outlet a Refit fascia center veneer panel Refit the radio console a Refit the console finisher veneer panel a Refit the console ashtray s Refit underscuttles a Reconnectthe battery a Refitthe battery cover X300 VSM 13 Issue 1 August 1994 fal Body Components Trim 13 3 5 Console Rear Extension Finisher Renew SRO 76 25 04 a Carefully displace and remove the motif from the exten sion finisher Fig 1 a Undo and remove the finisher securing screw a Displace and remove the finisher Fit and seat the newfinisher to the extension a Fit and tighten the finisher securing screw a Apply suitable adhesive to the back of the motif a Fit and seat the motifto the finisher 13 3 6 Console Rear Extension Renew SRO 76 25 05 Removethe console rear extension finisher see sub sec tion 13 3 5 above and Fig 1 Removethe console rear extensionveneer panel see sub section 13 3 27 a Undo and remove the extension securing screws a Displace and remove the extension assembly s Remove the screw and peg inserts a Place the extension aside a Place the new extensionto the front a Fitthe screw and peg inserts a Fit and align the extension
262. enewed by Jaguar Service are to be returnedto the importerfor deployment and disposal CAUTION Neveruse acustomer s vehicle to deploy airbags Equipment required Deployment Cage IDC link harness see 15 1 14 for details of components required Battery Safety Goggles to BS 2092 grade2 or equivalent Rubber Glovesto PREN 374 class 2 or equivalent Ear Protectorsto BS EN 24869 or equivalent ParticulateRespiratorto EN 149 grade FFP 25 or equivalent The deployment procedure should be performedoutdoors away from other personnel Remove any loose debris from around airbag and ensure no flammable liquids are present Assemble the disposal cabinet as shown in Fig 1 in line with the following procedures a Remove mesh guard from rig frame Attach guardto frame by bolting hinges to the frame continuednextpage Issue 1 August 1994 6 X300 VSM y Electrical continued from previous page a Ensure relevant plate is fitted and rotate into position 376 105 Fit and secure airbag module on to plate a Clamp plate down using the two toggle clamps WARNING ALWAYS CONNECTTO AIRBAG FIRST AS THE BAG WILL DEPLOY IMMEDIATELY ON CONNECTIONTO THE BATTERY Note The harnessconnectedbetweenthe driver s airbag andthe yellowconnector has one red purple feed wire and one pink brown returnwire The harness connected between the passenger s airbag and the yellow connector has two red purple feed wires and one pink purple return wire
263. ennen Preliminary Pages oooccoonnnnnnnn EE i ct Ee TEE General Description sarta iea eee eee eee eee eee eee eee eee eeeeeeeeeenes 1 EAR Transmission Fluid Renew 3 2L and 4 0L see EE EEN 44 24 02 enee 6 ELO ia sea al Transmission Control Module Renew 4 0L eene 44 15 32 ccoo 7 ELA a Transmission Rotary Switch Adjust 4 0L eene EC WEIER 8 BIS ewer rere Transmission Rotary Switch Renew 4 0L E 44 15 36 coco 9 81 een Transmission Fluid Filter Renew 3 2L and 4 0L eene A4 407 11 Elan le Fluid Pan Renew 4 0L eneen ENEE EE En 44 24 04 ee 11 B18 ur enan Fluid Pan Renew 3 2L weceueeeeeeeeee eens ne 44 24 04 ooo 12 B19 A seat Fluid Pan Gasket Renew 3 2L een A4 2405 i aa 12 8 1 10 ierg KE e Transmission Speed Sensor Renew 4 0L eene 44 15 34 ccoo 13 ELA Transmission Internal Harness Multi pin Socket O ring Renew 4 0L 44 24 20 ooooooo 14 112 iaia es Valve Body Assembly Renew 4 0L ene E 44 40 00 ene 15 Edd Valve Body Assembly Renew 3 2L ENEE 44 40 01 oonnconncoros 16 X300 VSM i Issue 1 August 1994 ZF Automatic Transmission AJ16 1 SERVICE TOOLS amp EQUIPMENT C usvaion Jaguar Number JD 103 JD 161 il TORQUE TIGHTENINGSPECIFICATIONS Fixing Tightening Torque Nm Throttle valve alignment tool Rotary switch setting tool De Dipsticktube union nut 0 Drain plug 5 uid pan securing bolts 9 Rotary switch to mounting bracket nuts Switch guard t
264. er and discard the original lever 7 1 6 GEARSHIFT LEVER DRAUGHT EXCLUDER RENEW SRO 37 16 05 a Remove the gearshift lever knob 1 Fig 2 see Sub Sec tion 7 1 7 a Open the centre console storage compartment Remove the centre console securing screws disconnect the block connectors and remove the console Remove the foam sealing ring a Remove the draught excluder securing screws 2 Fig 2 and ring 3 Fig 2 and remove the draught excluder 4 Fig 2 a Fitthe new draught excluder over the gearshift lever and secure with the ring 3 Fig 2 and screws 2 Fig 2 a Refit the foam sealing ring Refit the centre console and reconnect the block connectors and secure with the screws Close the centre console storage compartment a Fitthe gearshift lever knob lock nut and align the knobto its final position Tighten the lock nut and reposition the gearshift lever gaiter issue 1 August 1994 6 337 924 Fin 1 X300 VSM d De Manual Transmission amp Clutch AJ16 Be 7 1 7 GEARSHIFT LEVER KNOB RENEW SRO 37 16 11 a 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 a Tighten the lock nut and reposition the gearshift lever gaiter 7 1 8 GEARSHIFT LEVER REMOTE CONTROL ASSEMBLY RENEW SRO 37 16
265. er or flatbed transporter Fig 1 the handbrake must be applied the wheels chocked and iffitted with an automatic transmission the gear selector lever moved to neutral N see Gear shift Interlock 408 031 Fig 1 CAUTION Donotselect P becausethe parkinglock mechanism may be damaged bythe continuous slightforward and backward movementof the vehicle on the transporter There are four tie down brackets onthe vehicle underbody Do notattach the tie down hooks of the transporter to the towing eyes of the vehicle 2 2 5 Towing Recovery Adhere to local regulationsforthetowing ofvehicles Incertaincountriesthe registration number ofthetowingvehicle and an ON TOW sign or warning triangle must be displayed ina prominent position atthe rear of the vehicle which is being towed WARNING WHEN THE ENGINE IS NOT RUNNING THE STEERING AND BRAKES WILL NO LONGER BE POWER ASSISTED APPLICATIONS OF THE BRAKE PEDAL WiLL GRADUALLY DEPRESSURIZE THE ACCUMULATOR THEREFORE BE PREPARED FOR HEAVY STEERING AND THE NEED FOR GREATLY INCREASED BRAKE PEDAL PRESSURE The vehicle may be towed by another for a SHORT DISTANCE ONLY maximum0 8km 0 5mile with the gear lever in neutral N provided that a speed of 48 km h 30 mile h is not exceeded 2 2 6 Vehicles with Defective Automatic Transmission The vehicle must be towed with the rear wheels clear of the ground see suspended towing issue 1 August 1994 4 X300 VSM Jacking
266. er screw 1 Fig 1 andopenthe screw s Bleed until new clear bubble free fluid is observed inthe tube and then close the bleeder screw a Repeatthis procedure at each remaining caliper s Withthe motorrunning checkbrake pedaltravel Ifexcess ive check for leaks and repeat the bleed procedure e Fillthe reservoirto the max level 370 288 12 43 System Bleeding After Tandem Master Cylinder Renewal Ensure that the vehicle is standing level Switch the igni tion off Check that the fluid level inthe reservoir is between the minand max marks Connectthe bleeder bottle tube to the relevant front cali per see note above bleeder screw 1 Fig 1 andopenthe screw X300 VSM 19 Issue 1 August 1994 ES Brakes a Actuate the brake pedal to the floor holdfor approximately two seconds and then releasethe pedal Wait another twoseconds and actuatethe brake pedal againfor afurthertwo seconds Repeatthis action 20to 30times untilclear bubble free brake fluid streams out a With the brake pedal actuated close the bleeder screw Build upfluid pressure by pumpingthe pedalandthen open the bleeder screw Repeatthis action three to five times Note Ifafiller unitis not used observe the fluid level inthe reservoir and top up if necessary a Repeatthis procedure for the remaining three calipers 1 Fig 1 shows the bleeder screw of the rear left caliper a Withthe motor runningcheck brake pedaltravel If excess ive
267. er tank is fitted with a pressure relief cap to protectthe system against overpressure Under cold start conditions coolant is forced by the engine driven water pump through each cylinder block and cylin der headto the thermostat housings The thermostats are closed to give rapid engine warm up hence the coolant is returned via the engine cross pipe to the water pump inlet When normal engine operating temperature is reached the thermostats open and coolant is diverted through the radiator before returning to the water pump inlet Ifthe engine drivenfan is unableto provide sufficient cooling the electrically operatedfans operateinseries and paral lelunder the control of the radiator mountedtemperature switch Under hot operatingconditions the electricfans may continue to operate after the engine has been switched off The fans stop automaticallywhen the coolanttemperature has been reduced sufficiently The system also provides the coolant supply for the climate control system which is described in Section 14 X300 VSM 1 Issue 1 August 1994 4 2 ES Cooling System V12 4 2 2 COOLING SYSTEM CONFIGURATION Theconfigurationofthecooling systemis shown in Fig 1 The main coolant flows with the system at normaloperating temperature i e with the engine thermostats open are indicated by arrows 426 267 1 Header Tank 3 Water Pump 5 Engine 7 Heater Pump 2 Radiator 4 Thermostat 6 Heater 8 Heater Valve Fig 1
268. erial atthe same time as a magnetic field Produces a Ra small voltage in the semi conductor hard fault headlamp Heated Oxygen Sensor afault currently present inthe system Lambda sensor HEGO HOS HO2S electrically heated oxygen sensor which induces fueling corrections heavy duty HD Hertz frequency Hz frequency one cycle per second High Mounted Stoplamp HMSL high tension electrical ht 5 hood bonnet hose clamp hose clip hour hour h hr hydrocarbon HC hydroplaning B aquaplaning Issue 1 August 1994 16 X300 VSM Introduction Abbreviation if applicable Term s Definition Previously used term s or Eng lish Equivalent j Idle Air Control ation IAC electrical control of throttle bypass air Idle Air Control Valve ACV stepper motor driven device which varies the idle speed con volume of air by passing the throttle to trol actuator idle maintain the programmed idle speed air bypass con trol idle speec control valve ignition amplifier IA device which amplifies the ignition system output ignition ground IGN GND Inertia Fuel Shut off IFS an inertia system that shuts off the fuel supply when activated by pre determined force limits brought about by e g collision Inertia Fuel Shut off Swit
269. ertaking A brake pedal gearshift interlock is incorporated inthe shift lever mechanism The shift lever may only be movedfrom the P Park position if the ignition key switch is in position Il and the foot brake is applied The ignition key cannot be removedfrom the ignition switch unless the shift lever is inthe P Park position Once the ignition key has been removed the shift lever is locked inthe Park position The gearshift interlock may be over ridden manually inthe 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 Gear Selection ZF 4HP 22 Gearshift selection causes the appropriate gear to be selected through acable operated shift lever on the side of the transmission unit When a gear is selected the shift points are determined by accelerator pedal position through a throttle cable connection and by pressures equivalentto road speed derived from acentrifugal governor onthe output shaft Gearshift speed and quality are controlled by the hydraulic control unit located inthe 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 bythe final travel of the accelerator pedal and causes the next lower gear to be selected 8 1 1 2 Gear Selection ZF 4HP 24 E Gearshift selection causes the appropriate ge
270. es 9 12 7 HYDRAULICCONTROLMODULE RENEW SRO 70 60 18 70 60 19 Referto Section 12 4 Brake System Bleeding before carrying outthis procedure Pay particular attention to the warn ings and cautions relatingto brake fluid cleanliness and cleaning materials Note The illustration showsthe hydrauliccontrol module of a 6eyl vehicle with traction control Hydrauliccontrol modules on non traction control vehicles have only three outlet ports Apart from this the removal procedure is the same for all vehicles a Raise the vehicle Displacethe bleederscrew dust cap of the front LH caliper The dust cap will remain captive on the bleed screw a Connect a bleeder tube and bottle to the bleeder screw 1 Fig 1 and openthe bleeder screw a Fit a brake pedal hold down tool JDS 9013 between the brake pedal and the steering wheel Adjust the tool to op erate the brake pedal 60mm down This operation is necessaryto preventfluid lossfrom the reservoirthrough disconnected brake pipes a Re tightenthe front LH caliper bleeder screw Disconnect the bleeder tube from the bleeder screw and remove the tube and bottle Refitthe bleeder screw dust cap Undothe securing bolt of the multi plug connector 1 Fig 2 The bolt will remaincaptive Disconnectthe multi plug connector and reposition safely y a Place absorbent material underneath the hydraulic con 370 288 trol moduleto absorb any spillages Undothe tandem master cylinder TM
271. es with coil springs and separate dampers and anti roll bar Rue CEET Telescopic gas pressurised Castril a di 3 0 to 6 0 and with opposing wheels within 1 of each other Camb rangl iii da as 0 39 to 0 8 Front wheel alignMent occcconccocccn eee eee eeeeeneenneeenaee Totaltoe 5minutesin 10 minutes Rear Suspension TYPE NNN de ENKEN AS A a AAA Ad Fully independent rear suspension of double wishbone principle with axle shaft operating as upper wishbone incorporating coaxial springs and dampers with optional rear anti roll bar Camber angle at design ride height all vehicles except supercharged enne ENEE ENEE 0 759 0 40 Supercharged only EEN EE ENEE EE 1 6 0 42 Rear wheel align Ment EEN ENEE EE Total toe 15 minutes in 20 minutes Dampers ra A AAA Telescopic gas pressurised Power Assisted Steering Ke a A A A A AAA ee eke ZF Servotronicspeed sensitive rack and pinion Number of turns locktoO lOCK occccccccccncc ene eeeeeeeneeeee 2 768 Turning circle WalItO Wall seres rinsi a e a E a a 12 9m 42ft 4in CUID TO CUD isa aa Deis tele 12 4m 40ft Sin Issue 1 August 1994 A1 95MY 4 X300 VSM Specification Lem _ Electrical Equipment Battery UK and Europe MakB cis a il aa dida os Varta Nominal Capacity EE 72Ah Earth polarity coccccccnnccccnn e a a a a Negative All Other Markets Make serani dess o a Varta Nominal Capacity EE EE 92Ah Earth polarity EE EE Negative Generator 6cyl
272. es are closed and the system is NOT operational Assessment of system operating efficiency and fault classification may be achieved by using the facilities on your Re covery Recharging Recyclingstation follow the manufacturers instructions implicitly and observe all safety con siderations WARNING UNDER NO CIRCUMSTANCES SHOULD THE CONNECTIONS BE MADE WITH THE SYSTEM IN OPERATION OR THE VALVES OPEN SHOULD THE VALVES BE OPEN AND A VACUUM PUMP OR REFRIGERANT CONTAINER ATTACHED AN EXPLOSION COULD OCCUR AS A RESULT OF HIGH PRESSURE REFRIGERANT BEING FORCED BACK INTO THE VACUUM PUMP OR CONTAINER 14 13 3 Stabilizing the System Accurate test gauge data will only be attained if the system temperatures and pressures are stabilized Ensure that equipment and hoses cannot come into contact with engine moving parts or sources of heat It is recommendedthat a free standing air mover is placed infront of the vehicle to provide air flow through the con denser cooling system see illustration below Start the engine allow it to attain normal working temperature and set at fast idle typically 1200to 1500rpm Select full air conditioning performance With all temperatures and pressuresstable or displaying symptoms of faults begin relevant test procedures 582 490 Issue 1 August 1994 20 X300 VSM de 17 hy 2x Climate Control Systems Vek 14 14 PRESSURE TEMPERATURE GRAPH HIGH SIDE AMBIENT TEMPERATURE To obtain Ibf in f
273. essary Check for seizing on primary shaft or in flywheel renew as dibrating clutch or Clutch unit faults slutch judder often pre szeded by clutch grab Check the clutch driven plate for distortion and damage and for loose or broken torque damper springs Check for oil and other foreign Renewdriven plate andclean matter onthe clutchfriction linings related parts Check for incorrectly fitted clutch Dismantle from clutch and pressure plate refit where applicable Check that contact witness on fric Renew driven plate as tion linings is evenlv distributed necessary Renew driven plate Defects other than in clutch unit stiff clutch operation Operating linkage fault Check for loose flywheel fixings Tighten to correct torque loading and flywheel run out Check for loose engine mountings Tighten mounting nuts and bolts Check for worn drive propeller Renew if necessary shaft universaljoints Check for bent primary pinion Renew as necessary shaft Check for damaged moving parts Renew as necessary in operating linkage Check for seized linkage recheck Lubricate linkage as necess operation after remedv ary X300 VSM Issue 1 August 1994 2 Wee Clutch Fault Diagnosis Symptom lutch knocks ractured clutch late Manual Transmission amp Clutch ossible Cause lutch Fault 6 Check Check for worn clutch driven plate
274. f brakes Renew all self locking nuts Note Theaxleshaftnutisaself lockingitemwith athread insert and must NOT be re used Issue 1 August 1994 7 364 O71 X300 VSM IO Driveshafts amp Final Drive 9 10 REAR HUB BEARING RENEW SRO 64 15 14 9 11 REAR HUB OIL SEAL RENEW SRO 64 15 15 Removal Disconnect vehicle battery ground lead Slacken appropriate axle shaft hub nut a Support the vehicle at the rear and remove rear road wheel Note Toaidassembly markthe position ofthe headofthe hub carrier fulcrum relative tothe wishbone slot a Disconnect handbrake cable inner and outer a Remove brake caliper in accordance with Section 12 but do not disconnect hydraulics a Slacken hub carrier fulcrum and remove ABS sensor from hub carrier a Remove axle shaft hub nut and discard collar and hub carrier fulcrum a Using service tools JD 1D 7 and JD D Fig 1 push shaft through hub and pullthe hubcarrier assembly clear a Using Hubtool JD 132 1 1 Fig 2 and a suitable press alignthe hubassemblytothetoolensuringthe hand brake expander locates intothe too cut out a Locate button JD 132 2 and press the hub from the carrier a Remove the outer bearing race and seal from either the hub or the carrier and placethe ABS rotor to one side a Remove from the carrier bearing spacer adjustable spacer inner race and seal Renew Bearings Seal s a Using a suitable drift remove the inner a
275. fluid level warning lamp ABS CM 1 2 3 4 5 6 7 8 Fig 1 Brake System non Traction Control The rear brakes see Fig 1 are controlled collectively on a select low principle Under ABS braking conditions equal brake pressure is applied to both rear calipers although only one wheel may have atendency to lock The valve block has three outlet ports Brake fluid volume is supplied equally to the rear brakes via the 3 way brake pipe connector eege Issue 1 August 1994 4 X300 VSM Brakes 12 1 4 Actuation Components The vacuum booster 1 Fig 1 is mounted on the brake pedal box and secured by three bolts The TMC locates on two studs on the vacuum booster Two lugs locate the fluid reser voir on the TMC and is secured by a split pin The vacuum is drawn from the inlet manifold At the vacuum booster the vacuum hose is connected to the vacuum chamber via an elbow connector At the inlet manifold the vacuum hose connector is of the push on quick release type Applied pedal force is increased by the vacuum booster which actuates the intermediate piston of the TMC 2 Fig 1 The boost ratio supplied by the vacuum booster is 6 5 1 Note The vacuum booster and the TMC are supplied as a o 370 300 unit but are individually serviceable The brake fluid reservoir 3 Fig 1 is fitted with a fluid level indicator switch which opens when fluid level is low and lights the fluid level in
276. footwear which is oil impregnated First Aid treatment should be obtained immediately for open cuts or wounds Use barrier creams applying before each work period to enable easier removal of dirty oil grease from the skin Wash with soap and water to ensure that all oil is removed skin cleaner and a nail brushwill help The use of preparationscontaining lanolin will help to replace the natural skin oils which have been removed Do not use petrol kerosene gas oil thinners or solvents for washing skin If skin disorders develop obtain medical advice immediately Where practicable degrease components prior to handling Where there is a risk of fluids coming into contact with the eyes eye protection should be worn for example goggles or a face shield An eye wash facility should be provided O98 0000 0 O 0000 A3 1 3 Environmental Protection Precautions Itis illegalto pour usedoil onto the ground down sewers or drains or into water courses The burning of usedengine oil in small space heaters or boilers is not recommended unless emission control equipment isfitted Disposeof used oilthrough authorized waste disposal contractors to licensedwaste disposal sites ortothe waste oil reclamationtrade If in doubt contact the Local Authority for advice on disposal facilities X300 VSM 1 Issue 1 August 1994 gt General Fitting Instructions A3 2 GENERAL FITTING INSTRUCTIONS A3 2 1 Precautions Against Damage To The Vehicl
277. fromthe hub carrier and allow itto hang free forward of the A frame Open both rear doors and displace the rear seat cushion from the seat pan brackets Reposition the rear seat cushion forwards Pushthe seatbelts bucklesthroughthe seat cushion slots and remove the rear seat cushion from the vehicle a Displacethe RH side of the seat pan sound proofing 1 Fig 2 to gain access to the speed sensor harness 2 Fig 2 Displace the speed sensor harness grommet 3Fig 2 from the seat pan aperture Feedthe speed sensor harnessthrough the seat pan aper ture and disconnect the multi plug 4 Fig 2 s Position the new speed sensor harness and connect the multi plug a Feedthe speed sensor harness through the seat pan aper ture to hang free below the vehicle a Refit and fully seat the speed sensor harness grommetto the seat pan aperture Repositionthe seat pansound proofingto its original posi tion Position the rear seat cushion and feed the seat belt buckles through the slots Locate the rear seat cushion into the seat pan brackets 5 Fig 2 a Stow the seat belts buckles a Position the speed sensor harness rearwards over the A frame and locate into the hub carrier Fit and tighten the speed sensor to hub carrier securing bolt Securethe speed sensor harness to the brake hose using a ratchet strap Trim the ratchet strap E gt SE E Een 370 294 Issue 1 August 1994 22 X300 VSM Brak
278. frost protection down to 36 C 33 F Capacities 6 cyl 3 2L and 4 0L normally aspirated Lite FAN essere oes Se oe O A 12 liters drain and WEE 77 liters 6eyl 4 0L SC italia whee ale a 13 5 liters draimand refill ii EE 9 25 liters v12 tad A AA A eee ee 19 2 liters drain and retill iria ad 14 5 liters X300 VSM A1 95MY 7 Issue 1 August 1994 q Lem Specification Braking System and Clutch System Fluid Specification ccc cece eee e cette eee eee E AAE Dot 4 Make amp TY Pei vacio das ee ae ea ere Ba Ree ee ten ee die ee Jaguar Brake Fluid Grease Points Grease Specification N L G I Consistency No 2 Grease Type cira Poesi iia dead cai ee eter ea ea tee Multipurpose Lithium Grease Fuel Tank Capacity Leg UN UNE 81 liters indicated refill Capacity 75 liters EI to F on fuel gauge Issue 1 August 1994 A1 95MY 8 X300 VSM q Specification mm VEHICLE WEIGHTS Note Gross combination weight is the gross vehicle weight plus recommended trailer weight All weights approximate 4 0L normally aspirated O u w 12 Kerb weight 1800 1800 IS EE a EE we ow EE vo wor Gross combination weight SSS A SSS Shh Se SS ssi SS SS X300 VSM A1 95MY 9 Issue 1 August 1994 Lem Specification TIRES Tire Replacement And Wheel Interchanging WARNING UNDER NO CIRCUMSTANCES SHOULD CROSS PLY TIRES BE FITTED When renewal of tires is necessary i
279. g brackettang 2 Fig 1 fromthe body bracket and mounting stud a Reposition the TCM release the TCM multi pin plug lever lock and disconnect the multi pin plug 3Fig 1 a Release and remove the TCM mounting bracket securing bolts and remove the TCM a Fit and align the new TCM to the mounting bracket a Fit and tighten the TCM securing bolts a Connect the TCM harness multi pin plug and secure the multi pin plug lever lock e Positionthe TCMto body mounting bracket ensuringthat the tang locates in the bracket slot and stud Fit andtighten the TCM securing nut a Position the footwell carpet and fit the carpet fastener a Fit and align the footwell outlet duct to air conditioning unit a Position and fit the duct fastener to the blower motor slot Fig 1 Refit the dash liner a Reconnect the battery J44 703 X300 VSM 7 Issue 1 August 1994 2F De Automatic Transmission AJ16 8 1 4 TRANSMISSION ROTARY SWITCH ADJUST 4 0L SRO 44 15 37 a Raise the vehicle on a ramp a Positionthe shift leverto N ensuring that the stalk enters the gate N notch centrally nun Release and remove the transmission unit rotary switch y II protection cover 1 Fig 1 to fluid pan bolts a Removethe rotary switch protection cover from the fluid pan bosses a Slacken the rotary switch to mounting bracket securing nuts Displace the rubber blanking plug from the rotary switch center boss 2
280. g clip Fig 3 a Undo and remove the switch assembly securing screws nuts Fig 3 a Displace and remove the switch assembly a Undo and remove the speaker securing screws and re move the speaker a Displace and remove the speaker grille a Place the door pocket aside a Place new rear door pocket to the front a Fit and fully seat the speaker grille a Position the speaker and fit the speaker securing screws a Fit and align the window lift switch assembly a Fitandtightenthe switch assembly securingscrews nuts a Fitandfully seatthe veneer paneltothe front securing clip a Fit and tighten the veneer panel securing screw a Fit and fully seat the switch end cover trim pad s Position the door pocket to lower trim pad and fit and tighten the door pocket securing screws a Refit the door lower trim pad Refit the rear door armrest J86 Wi X300 VSM 5 Issue 1 August 1994 fm Body Components amp Trim 13 2 10 Front Door Upper Trim Pad Renew a Disconnect vehicle battery ground lead a Remove the front door veneer panel a Remove the upper trim pad securing clip and screws a Liftthe trim padto release itfrom the door and removethe inner waist rail seal To refit carry out reversal of the above procedure 13 2 11 Front Door lower Trim Pad Renew a Disconnect vehicle battery ground lead e Remove armrest a From inside door pocket release guard retainer discon nect mult
281. g plug from the hydraulic pipe 4 Fig 1 a Ensurethatthe union is clean and noforeign matter enters the system 333 072 WARNING USE ONLY CLEAN BRAKE FLUID OR DENA TURED ALCOHOL METHYLATEDSPIRITS FOR CLEANING ALL TRACES OF CLEANING FLUID MUST BE REMOVED BEFORE RE ASSEMBLY ALL COMPONENTS MUST BE LUBRICATED WITH CLEAN BRAKE FLUID AND ASSEMBLED USING THE FINGERS ONLY Reconnect the pipe 4 Fig 1 to the master cylinder 5 Fig 1 and tighten the union nut a Align the push rod to the pedal a Clean and grease the clevis pin 2 Fig 1 a Align amd fit the clevis pin to the pedal and push rod a Fitthe securing clip 1 Fig 1 a Bleed the clutch hydraulic system see Sub Section 7 1 18 issue 1 August 1994 16 X300 VSM Manual Transmission amp Clutch AJ16 7 1 16 CLUTCH SLAVE CYLINDER RENEW SRO 33 35 01 a Disconnectthe pipe from the clutch slave cylinder plug or tape the pipe to prevent the ingress of any dirt a Remove the nuts 1 Fig 1 and spring washers securing the slave cylinder to the transmission Removethe hose clip bracket 4 Fig 1 complete with the hydraulic hose pipe 5 Fig 1 and slide the slave cylinder 2 Fig 1 off the mounting studs a Slide the rubber boot along the push rod 3Fig 1 and withdraw the push rodfrom the cylinder a To refitthe new clutch slave cylinder reversethe removal operations a Bleed the clutch hydraulic system see Sub Sectio
282. g sequence completed Remote trunk lid release Automatic release of the trunk lid lock on operation of the smaller key fob button after door unlocking Trunk valet isolate Independent locking of the trunk lid to eliminate unauthorized entry to the luggage compartment Driver seat memory select Automatic recallof a memorized driving position on operation of the smaller key fob button Intrusionsensing override Allows intrusion sensing to be disabled until the next disarm action A5 3 4 Alarms There are eight possible alarm activation modes driver s door hood ignition key in ignition auxiliary position ignition ON inclination inner door handle action causingactuator status switches to operate intrusion passengerdoor and trunk Any of the above conditions occurring after the vehicle is fully armed will cause full alarm state Any of the above conditions except door opening occurring after the vehicle is fully armed and active disarming is selected will cause full alarm state Door opening after active disarming selection will give a 30 second audible tick period beforefull alarm is entered Any of the above conditions occurring after the vehicle has been passively armed will give a 30 second audible tick period before full alarm is entered Activation of full alarm state causes sidelights direction indicators interior lights or headlampsto flash dependant upon market variations the security sounder to operate andthe vehic
283. g the control panelto component interface may be found inthe fault finding procedures thissection or the Electronic Diagnostic Manual EDM Note Thesystem may be activated by any one offour commands a AUTO button item 11 b DEFROSTbuttonitem 12 c A C button item 10 d OFF switch item 1 1 Combined push for OFF and rotary FAN SPEED control The speed of the two fans is changed by clockwise to increase or anti clockwise rotation of the knob Operation of the control push OFF or rotate FAN over rides the AUTO selection and cancels the AUTO display 2 RECIRCULATE AIR push on push off button and state lamp used to prevent outside air being drawn into the cabin There are two modes a Press and immediate release provides timed recirculation of five 5 minutes b Press and hold for two 2 seconds latches the mode until operator over ride 3 Temperature scale SELECTOR for Celsius or Fahrenheit 4 FANS SPEED display bar graph 5 TEMPERATURE numeric display for demand and exterior 6 Selected temperature SCALE temperature numeric display 7 EXTERIOR temperature option display Issue 1 August 1994 4 X300 VSM 8 AUTO selection display 9 EXTERIOR temperature selection button There are two modes a Press and immediate release provides timed display of four 4 seconds b Press and hold for two 2 seconds latches the mode until operator over ride 10 A C push on push off button will either engag
284. g the gauge faces and ensure cleanliness when handling the panel o To minimizethe risk of damage and contaminationto the instrument panel all repairs must be carried out in a non static and dust free environment Avoid touching connector pins and pcb componentsto minimize risk of static damage o The instrument panel has two different types of bulb holders each of which must be located correctly when changing the bulbs Issue 1 August 1994 10 X300 VSM y Electrical 15 3 SPEED CONTROL Informationto be issued with Amendment 1 X300 VSM 11 Issue 1 August 1994 Electrical y 15 4 DRIVER ERGONOMICS Information to be issued with Amendment 1 Issue 1 August 1994 12 X300 VSM TU art Bet zwet Battery Capacity 72A 20hr 92A 20hr Rapid discharge current 590A at 18 C 700A at 18 C Rapid discharge voltage 7 5V at 18 C 7 5V at 18 C Reserve capacity duration 25A at 135 minutes 25A at 170 minutes Open circuit voltage 12 70V 12 37V 12 11V 11 74V 11 30V Specific gravity voltage temperature 1 280 1 225 1 180 1 120 1 050 compensated hydrometer Charged 100 75 50 25 0 Battery Condition Charge Rates Specific gravity State of charge Maximum Slow temp compensated charge rate times charge rate times hydrometer 50 10 75 20A 120 min 253610 50 30A 120 min Oto 20 40A 120 min Test Load Electrolyte Temperature C Min Voltage Under 15sec Load Load to half batter
285. ges The two major gauges are tachometer and speedometer and the four minor gauges indicate battery condition fuel level oil pressure and coolant temperature Each gauge is contained in a sealed non serviceable can and must be renewed as a complete unit in case of any damage CAUTION Extremecare should beexercised when renewing instrumentpanel components to avoiddamage to the delicate indicator needles X300 VSM 9 Issue 1 August 1994 s Electrical EC 15 2 8 Odometer With the ignition OFF the odometer is permanently dis played but not illuminated With the ignition ON the odo meter is displayed and also illuminated Trip informationor driver informationmessagesmay bedis played instead of the ODO By pressingthe ODO button once or twice the trip and driver information messages can be deleted andthe ODO re displayed Note The odometer value is not stored within the LCD module 15 2 9 TripComputer This provides informationon the vehicle s speed fuel usage and distance traveled all of which are calculated by a micro processor The controls part of the fascia switch assembly are located onthe right handside pod positionedto the right handside of the steeringcolumn 386 1926 15 2 10 Driver Information Messages Two fault messages FLUID AIRBAG are displayed via the LCD in conjunction with relevant warning lamps Ifan airbag fault exists or the brakefluid is low a message will automaticall
286. gine speed with the transmission in NEUTRAL or by stall testing with the engine in gear Ifthe condition is engine sensitive the condition is not relatedto tires Ifthe roadtests indicates that the vibration is relatedto the tires or wheels use a Tire Wear Diagnosis Chart to investigatethe cause of concern Shouldthe roadtest indicatethat there istire whine butno shake or vibration 1 1 the noise originates from the contact between the tire and the road surface X300 VSM 3 Issue 1 August 1994 Xu Sa Suspension Systems 11 43 Front End Inspection Do notcheck and adjust front wheel alignment without carrying outthe following inspectionfor front enddamageand wear a Check for specified air pressure in all four tires Raisefront of vehicle off the floor grasping upper and lower surface of the tire shake each front wheel to check for worn bearings a Check front suspension lower arm ball joint and mounts for looseness wear and damage Check brake caliper mountings Check steering gear mountings and all steering linkages for looseness a Renew parts if necessary a Grasp upper and lower surface of tire and shake each wheel to check wheel bearing end play a Check the action of the front dampers and the condition of their attachments as sticking or binding front dampers may not allow the vehicle to settle into a normal level position possibly affecting the front wheel alignment Note Frontwheel bearings are adjusta
287. gn the stud plates a Fit and fully seat the veneer panel to the console a Fully seat the rear of the veneer panel a Fit and tighten the wing nuts a Fit and align the veneer panel rear finisher a Fit and fully seat the gear lever surround a Fit and fully seat the mode switch surround Connect the mode switch to harness multi plug a Fully seat the mode switch a Refit the ashtray SE a Place the gear selector in P X300 VSM 29 Issue 1 August 1994 aiy Body Components amp Trim 13 3 25 ConsoleAshtray Lid Veneer Panel Renew SRO 76 47 27 Removethe console ashtray see subsection 13 3 28 and Fig 1 Open the ashtray lid Displace and remove the veneer panel securing spire clips a Displace and remove the veneer panel Fit and seat the new veneer panel to ashtray lid a Fitthe veneer panel securing spire clips a Close the ashtray a Refit the ashtray 13 3 26 ConsoleAshtray Surround Veneer Panel Renew SRO 76 47 28 s Remove the console ashtray see sub section 13 3 28 and Fig 1 Fig 1 a Displace and remove the surround veneer panel securing spire clips Open the ashtray a Displace and remove the veneer panel from the ashtray a Fit and seat the new veneer panel to the ashtray Secure the veneer panel with spire clips a Close the ashtray 376 802 13 3 27 Console Rear Extension Veneer Panel Renew SRO 76 47 30 a Removethe console
288. gs 1 8 Sunblind to parcel shelf Tighten to prevailingtorque Sunblind bezel assembly T 1 0 Coat hook 3 0 Issue 1 August 1994 iv X300 VSM eje S Body Components amp Trim Fixing Tightening Torque Nm Seat belts Fronttear loop belt buckle to bracket fixing 30 40 Front belt buckle to bracket fixing 30 40 Front belt reel bracket to body fixing 30 40 Front belt anchor fixing 30 40 Front belt upper guide fixing 7 10 Height adjuster to B post screws 23 27 Height adjuster to seat belt anchor retaining nut 30 40 Rear inertia belt anchor fixing 30 40 Rear inertia belt bracket to body fixing 30 40 Rear inertia belt reel securing bracket to body fixing 30 40 Rear inertia static belt buckle bracket to body fixing 30 40 Rear static belt inertia buckle bracket to body fixing 30 40 Sunroof Sunroof frame to roof 4 5 Sunroof to frame 4 5 Trunk Compact disc autochanger bracket to body 9 11 Battery clamp to tray 7 10 iWarning triangle lower bracket to trunk lid inner panel 1 5 Trunk lock barrel to lid 4 5 i Trunk latch to lid and striker to body 7 10 t Trunk latch actuator to bracket Trunk latch actuator mountingto lid Electrical carrier box to body 5 7 Load floor support blockto body 9 11 7 10 7 10 Trunk seal retainer to body 9 11 111 SERVICEMATERIALS Description Uses Notes Fibrefresh Carpet Shampoo 1001 Foam Shampoo
289. gust 1994 63 Brakes 12 3 BRAKE FLUID LEVEL CHECK WARNING AVOID SKIN EYE CONTACT OR INGESTION OF BRAKE FLUID IF SKIN OR EYES ARE ACCIDENTALLY SPLASHED WITH BRAKE FLUID RINSE THE AFFECTED AREA IMMEDIATELY WITH PLENTY OF WATER AND SEEK MEDICALATTENTION IMMEDIATELY Checkingthe fluid level CAUTION Fluid must not be allowed to contact the vehicle paintwork Remove any spilt fluid from the paintwork by rinsing away with runningwater Methylated spirit denatured alcohol must not be usedto cleanthe contaminated area Correct brake fluid level is essential for the efficient oper ation of the brake system Check that the fluid level is be tween the MAX and MIN markson the fluid reservoir Fig 1 Top up if necessary with recommended brake fluid Note Theefficiency of the brakes may be impaired iffluid is used which does not meet specifications Use ONLY brake andclutchfluid that conformsto a mini mum DOT 4 specification Also do not use brake fluid that has been exposed to atmosphere for any length of time Moisture absorbed from the atmos phere impairs the efficiency of the brake fluid Issue 1 August 1994 18 X300 VSM Brakes 12 4 BRAKE SYSTEM BLEEDING WARNING GREAT CARE MUST BE EXERCISED WHEN SERVICING OR REPAIRING THE SYSTEM AVOID SKIN EYE CONTACT OR INGESTION OF BRAKE FLUID IF SKIN OR EYES ARE ACCIDENTALLY SPLASHED WITH BRAKEFLUID RINSE THE AFFECTED AREA IMMEDIATELYWITH PLENTY OF WATER AND SEEK M
290. hape JO7 006 Note Inthe illustrations on this page A indicates the metrictype and B the UNF type The metricfemale nutis always usedwith atrumpet flared pipeandthe metric male nut is always used with aconvex flared pipe Fig 1 Metric portsin brakecylinders andcalipers have nocounter bores however afew cylinders with UNF threads also have no counterbore Therefore all ports with counterboresare UNF but ports not counterboredare most likelyto be metric Fig 2 The colour of the protective plugs fitted to cylinder ports indicatethe size andthe type of the threads but the primary function of the plugsisto protectthecylinder from contami nation and is not intendedas a positive means of identifica tion As anindication the plug colours andthread sizes are JO7 007 Colour Size Colour Size Red 3 8 in x 24 UNF Black 10 x 1 0 mm Green 7 16 in x 20 UNF Grey 12x 10 mm Yellow 1 2 in x 20 UNF Brown 14x 15 mm Pink 5 8 in x 18 UNF X300 VSM 5 Issue 1 August 1994 gt 3 General Fitting Instructions Note InFig 1and Fig 2 this page A indicatesthe metric type and D the UNF type Hose ends differ slightly between metric and UNF Fig 1 Gaskets are not used with metric hoses the metric hose fit ting seals against the bottom of the port and consequently there is a gap betweenthe hexagonal face of the hosefitting andthe cylinder Fig 2A The UNF hosefitting is sealed on CTE AS the brakecylinder or c
291. harness multi pin socket to the transmission casing a Fitandtighten the internal harness multi pin sockettothe transmission casing securing nut e Connect the external harness multi pin plug to the inter nal harness multi pin socket the plug is secured by its captive locking ring Refit the fluid pan see Sub section 8 2 14 4 0L SC or Sub section 8 2 15 6 0L a Lower the vehicle onthe ramp a Refill the transmission unit with fluid see Sub section 8 2 13 a Remove the fender cover and close the hood Issue 1 August 1994 20 X300 VSM i Automatic Transmission V12 amp AJ16 Supercharged ie Powertrain 8 2 20 INTERNAL LUBRICATION PIPE RENEW 4 0L SCAND 6 0L SRO 44 24 21 Open the hood and fit a suitable fender cover a Raisethe vehicle on a ramp a Drainthe transmission lubrication system see Sub sec tion 8 2 13 Removethe fluid pan see Subsection 8 2 14 4 0L SC or Sub section 8 2 15 6 0L Release and remove the internal lubrication pipe retainer to valve body securing bolt a Remove the lubrication pipe retainer a Release and remove the lubrication pipe clamp to valve body securing nut a Removethe lubrication pipe clamp a Displace and remove the lubrication pipe from the trans mission unit a Drainany residualfluidfromthe lubrication pipe and place the pipe aside a Clean the relevant parts e Fitandfullyseata newlubricationpipetothetransmission unit a Fitth
292. he motor 3Fig 1 from the valve body and place aside e Fitanewvariable force motor to the valve body CAUTION Do not adjust the motor screw and ensure that the motor filter is not damaged a Align the motor a Fitthe motor to the valve body retaining clamp a Fit and tighten the motor retaining clamp securing screw s Connectthe internal harness plugto the motor a Refit the fluid filter see Sub section 8 2 18 a Refit the fluid pan see Subsection 8 2 14 4 0L SC or Sub section 8 2 15 6 0L a Lower the vehicle onthe ramp a Refill the transmission unit with fluid see Subsection 8 2 13 e Remove the fender cover and close the hood Issue 1 August 1994 10 X300 VSM i Automatic Transmission V12 amp AJ16 Supercharged eo Powertrain 8 2 10 PULSE WIDTH MODULATOR TCC SOLENOID RENEW 4 0L SC AND 6 0L SRO 44 15 44 a Open the hood and fit a suitable fender cover a Raise the vehicle on a ramp e Drainthe transmission lubrication system see Sub se tion 8 2 13 a Removethe fluid pan see Subsection 8 2 14 4 0L SC or Subsection 8 2 15 6 0L a Remove the fluid filter see Subsection 8 2 18 a Disconnectthe internal harness plugfrom the pulse width modulator a Remove the modulator to valve body retaining clip a Displace and remove the modulator from the valve body noting the orientation a Removeanddiscardthe O ring sealsfrom the modulator e Placethe modulator aside e Fit new
293. he ae ee Raa Dunlop SP Sport 2000 255 NADAR EE Pirelli P Zero 115185 RAS iii rie diated teste Saanaa Pirelli Recommended Winter Snow Tires Tire designation 225 60 E EE Goodyear Eagle GW M S O EE EE Pirelli Winter 210 M S 225 E TEE a a tnt Michelin 330 M S Only use winter tires in complete sets ofthe same type size CAUTION Tire directional indicators must rotate in a clockwise direction when viewed from the right hand side of the vehicle and in an anti clockwise direction when viewed from the left hand side The recommended pressures for winter tires are shown inthe table of inflation pressures on the following page Issue 1 August 1994 A1 95MY 10 X300 VSM Specification Lem Table ofinflation pressures cold Recommended tires must be inflated to the following pressures Comfort Setting Normal Setting Speeds up to 160 km h 100 mph Bar nis Bar TH 225 60 ZR16 plus winter tires 3 2 Liter and 4 0 Liter Normally Aspirated Front 17 z DERRE 7 ea a DOE AAA A 225 55 ZR16 plus winter tires 3 2 Liter and 4 0 Liter Normally Aspirated EE A ARA AA RA AO E 225 60 ZR16 plus winter tires 6 0 Liter Pet LH EE EE EE 34 225 55 ZR16 plus winter tires 6 0 Liter Front 1 9 28 2 3 34 Rear 1 9 255 45 ZR17 4 0 Liter SC Front 1 9 115 85 R18 space saver wheel all vehicles where fitted Front not applicable not applicable 4 1 60 Rear n
294. he number plate lamps andthe rear lights incorporating tail stop flasher and fog lamps Issue 1 August 1994 20 X300 VSM y Electrical 15 9 2 Interior Lighting General Description Fig 1 Interior Lighting The interior lamps consist of E Post lamps with or without map lights a map lightcombined with switch fitted to the roof console sun visor lamps door courtesy hazard lamps and a trunk lamp Other interior illumination bulbs are fitted within the various switch assemblies X300 VSM 21 issue 1 August 1994 Electrical E 15 10 HARNESSES amp CABLES 15 10 1 Battery Power DistributionCables General Description e SS e AA AAA Mo L 3 7 386 1755 Fig 1 Battery Power Distribution Cables Figure 1 shows a plan view of the battery power distributioncables and their distribution points This illustrationis to be readin conjunctionwith the following table To avoid any accidents such as electric shocks always disconnect the battery negative leadfrom the battery negative terminal before disconnecting any of the listed cables Issue 1 August 1994 22 X300 VSM Electrical Key to Fig 1 Battery Power Distribution Cables page 22 ty Power Distribution Cable Number Terminato terminal postlinklead Engine bay fuse box power cable HO Starter cable Battery negative cable Trunk fuse box power cable X300 VSM 23 Issue 1 August 1994 Electrical y 15
295. he trunk To locate and renew relays open the trunk lid removethe wheel floor carpet board followed by the carpeted battery fuse cover and the back panel carpet board Issue 1 August 1994 36 X300 VSM Y Key to Fig 1 Trunk Relays page 18 18 30 70 Trunk inside electrical carrier Fuel Pump Single Fuel Pump Rear Screen Heater 86 55 73 Trunk Lid Release Accessory Socket Les Color 7 Trunk inside Violet electrical carrier Trunk inside Blue electrical carrier Biue Electrical Blue Trunk inside electrical carrier Trunk inside Blue electrical carrier All Models Supercharged only All Models All Models All Models All Models All Models All Models Secondary Fuel Pump All Models 86 86 10 High Meunt Step Trunk inside Where fitted Where fitted Lamp electrical carrier 66 56 11 Fuse box Assembly Trunk inside Blue All Models All Models Aux Positive electrical carrier X300 VSM 37 Issue 1 August 1994 E Electrical y 15 13 CONTROL MODULES CM 2019 18 17 Fig 1 Control Module Locations 15 13 1 General Description Fig 1 shows a plan view of the control module locations for the vehicle In orderto locate and renew modules the illustrationshould be read in conjunction with the followingtable indicating each module s location Issue 1 August 1994 38 X300 VSM
296. hematic Emission vent line Rochester valve to primary 17 carbon canister Emission vent line Primary carbon canister to 18 secondary carbon canister NAS4 0L normally aspirated engine only Emission vent line Primary carbon canister to 18 atmosphere 17 15 13 Primary carbon canister Left side of vehicle in 19 front ofthe rear axle 17 15 13 Secondary carbon canister To the right of the primary 20 carbon canister on the other side of the vehicle NAS 4 0L normally aspirated engine only Emission vent line Primary carbon canister to 21 purgevalve 17 50 30 Purge valve Belowthe left head lamp 22 module Issue 1 August 1994 2 X300 VSM Fuel Emission Control amp Engine Management AJ16 5 1 2 GENERAL DESCRIPTION WARNING 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 WHILST WORKING ON THE FUEL SYSTEM ADHERE STRICTLY TO THE FOLLOWING PRECAUTIONS DO NOT SMOKE IN THE WORK AREA DISPLAY NO SMOKING SIGNS AROUND THE AREA ENSURE THAT A CO FIRE EXTINGUISHERIS CLOSE AT HAND ENSURETHAT DRY SAND IS AVAILABLE TO SOAK UP ANY FUEL SPILLAGE EMPTY FUEL USING SUITABLE FIRE PROOF EQUIPMENT INTO AN AUTHORIZED EXPLOSION PROOF 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 EXPERIENCEDAND WELL 1 QUALIFIED MAINTENAN
297. hesive Application Temperature eceeeceeee eee e eee eee eeeee eee eeeeeeenaee 34 Glazing Adhesive Application eau 34 Glazing Adhesive Curing een 34 50 11 e ENEE EE 35 Bumpers Major COMPONENTS EE EE EE EE EE 35 Bumpers Features EEN ENEE ENEE EEN EE 35 Bumpers Service Procedures ooocconnnnnnnnnnnnnn nee n eee nen UAE 37 Bumpers Fitted Condition Front EE 37 Bumpers Fitted Condition Rear EE 38 Bumpers Cover DaMag EE EE ENEE EE EE EEN 39 Bumpers Damage Assessment EEN ENEE EEN EE 39 Bumpers Repair MaterlalS oooonnnonnnnonanncnnnncnan een eee ee eeee enna eneeeeeaeee 39 Bumpers RefiniShing bb E EE EE EE EE E ENEE EE EE E EE ERR E EE EE EE EE KEE EELER E EE 40 Bumpers Refinishing Original oeooenoonoenonncenaanaanennann 40 Bumpers Refinishing NeW a asnunannunonnanannanannsnnnasnnnasnnnannasannannunannan 40 Bumpers Refinishing All ee EE 40 Bumpers Replacement Covers en 40 Recycled Materials General Note een 40 Boch aide Moulding ocooooconnnncnnnn ee eee eee eee eee ee eee eeeeeeeeeeeee 41 Body side Moulding Introduction e EE 41 Body side Moulding Fitted Condition Illustration e 41 Body side Moulding Fitting PrOCESS ee EEN ENEE EE 41 Finisher Door Frame Fitted Condition 42 Finisher Roof Drip Rail Fitted Condition 42 Body Exterior Clearances amp AliQNMents een 43 Body Exterior Clearances amp Alignments Introduction EE ENEE 43 Body Exterior Clearances amp Alignments Criteria Clearances ee
298. hich a stream of inert gas shields the electrode preventing oxidation meters measurement metric screwthread e g M8 M E Microfarad MFD millimeters mm millimeters of mercury PET ACA A o Model Year Module minimum min MY M self contained group of electrical electronic components which is designed as a single replaceable unit mold Motorized In Car Aspirator MIA motorized aspi rator device which constantly samples cabin temperature by passing air over a sensor andcommunicates with the A CCM to modify A C system performance to suit muffler device which causes exhaust gas flow to silencer expand and thereby reduce its pressure and hence its noise multiport fuel injection MEI X300 VSM 19 Issue 1 August 1994 GLOSSARY OF TERMS Term s Abbreviation if applicable N Introduction Definition Previously used term s or Eng lish Equivalent National Institute of Occupational NIOSH Safety amp Health US Newton N Sl unit of force 1N 0 2248 pounds force Newton meters Nm Nitrous Oxides NOx Sl unit of torque Must not be confused with nm nanometer compounds of nitrogen and oxygen formed at high temperatures Major source of exhaust gas air pollution Non Volatile Random Access NVRAM Memory RAM which retains memory even if power supply is interrupted
299. hten the checkarm securing screw Close the glove box lid 13 3 14 Cupholder Trim Panel Renew SRO 76 25 21 Open the cupholder a Undo and remove the cupholder trim panel securing screws a Displaceand removethetrim panel assembly by releasing the lower edge and then displacing upwards e Carefully fit and fully seat the new trim panel a Ensurethe panel is correctly seated to the base a Fit and tighten the trim panel securing screws a Close the cupholder X300 VSM 19 Issue 1 August 1994 Body Components amp Trim 13 3 15 Cupholder Renew SRO 76 25 22 Remove the cupholder trim panel see sub section 13 3 4 a Displace and reposition the cupholder assembly from base cupholder remains captive by spring a Using a suitable hook disconnectthespringfromthe base and remove the cupholder a Disconnectthe return spring from the cupholder a Placethe cupholder aside a Placethe new cupholder to the front a Connectthe return spring to the cupholder a Place the cupholder into position a Using asuitable hooktool connect the returnspringtothe base a Reposition and fit the cupholder assembly to the base a Refit the cupholder trim panel 13 3 16 Cupholder Latch Renew SRO 76 25 23 a Remove the console glove box lid see sub section 13 3 12 e Undo and remove the inner lid securing screws e Displace and remove the inner lid Open the cupholder a Undo and remove the cupholder latch securing
300. i plug and remove lamp a Carefully prise the trim pad away from the door and re lease from the upper retainer With the trim pad moved for access disconnect loud speaker and window lift switch multi plugs 376 1053 1 Water shedder f 2 Multi connector a Feed guard lamp harnessthrough aperture and place trim 3 Armrest support pad on a clean workbench a Remove front door pocket and trim pad retainers a To refit carry out reversal of the above procedure Check the trim pad retainers for damage before refitting Fig 1 Door Interior Components 13 2 12 Door lock Barrel Renew a Disconnect vehicle battery ground lead a Remove the door trim veneer door upper trim pad door lower trim pad and door handle a Removethe handle assembly to a clean workbench a Remove the lock barrel from its bayonet type mounting a Carefully remove the barrel components noting the order and position if reassembly is required a TO refit carry out reversal of the above procedure ensur ingthat the components are lightly greased 13 2 13 Front or Rear Door Lock Striker Renew a Note position of striker before removal a Remove two screws attaching striker to pillar Remove striker from pillar a To refit carry out reversal of the above procedure ensur ing that the striker is correctly aligned with the door lock before final torque tightening 13 2 14 Front or Rear Door Outer Handle Operating Rod Renew a Disc
301. iated by following the instruction in Self Test System Diagnosis this section Note Displayed error codes are NOT directly relatedto Jaguar Diagnostic Equipment JDE but more detailed fault related information may be accessed using Portable Diagnostic Unit PDU 14 6 2 System Protection Power to the compressor clutch may be cut should either the engine management or air conditioning control systems detect certain conditions these conditions may be caused by Faultor Demandand can be classified thus Fault Engine coolant overheat Refrigerant excessive pressure Refrigerant insufficient pressure or low charge weight Speed differential between compressor and crankshaft caused by belt slippage or compressor seizure indi cated by A C state lampflashing once per second 12 cylinder engine only This feature lock sensing is fully explained inthe EDM o0o00 Demand o Engine maximum power requirement o Electrical system drain at engine idle X300 VSM 9 Issue 1 August 1994 La EA YE Climate Control Systems 14 7 AIR DISTRIBUTION Refer to illustrations on this and next page Air is drawn fromthe plenum chamber into the heater cooler case at the lower front right and left hand sides All air must first pass through the evaporator not fitted to heater only cars and then through the heater matrix for in car distribution When cooler air than that available from the other outlets is desired at the FACE vents ai
302. iator core blocked Check for hotspots in radiator Flush or renew radiator Radiator grille obstructed Check grille for obstruction Remove obstruction from grille Concentration of anti freeze Check strength of coolant Drain and fill with coolant of too high correct concentration Drive belt slack Check belt tension Adjust belt to correct tension or renew belt if worn Drive belt broken Visual check Renew belt Water pump seized Slacken drive belt and turn Renew water pump Renew water pump pulley by hand drive belt if required Check belt for damage Insufficient coolant Check coolant level Top up coolant Internally collapsed hoses Pressuretest system and Renew hoses as required check for deformation of hoses Incorrect ignition timing Referto EDM Rectify as required Fuel air mixture too weak Referto EDM Rectify as required Incorrect valve timing Check valve timing Correct valve timing Cylinder head gasket s leak Pressure test system Check Renew head gasket s ing for contamination of coolant in header tank Brakes binding Check brake calipers for stick Rectify as required ing pistons and seized brake pad pins verheating at Electric cooling fan s notop Referto EDM Rectify as required dle erating loo cold Thermostat s stuck open Test thermostat s Renewthermostat s Incorrect thermostat rating Check thermostat operating Renewthermostat s temperature Thermostat s not fitted Remove thermostat housing Fit thermostat s and inspect Elect
303. icle on the ramp e Refill the transmission unit with fluid see Subsection 8 2 13 Remove the fender cover and close the hood X300 VSM 13 Issue 1August 1994 ees f Automatic Transmission V12 amp AJ16 Supercharged Powertrain 8 2 13 LUBRICATION SYSTEM DRAIN AND REFILL 4 0L SC AND 6 0L SRO 44 24 02 a Raisethe vehicle on a ramp a Position a drain tin below the transmission unit a Release and remove the fluid pan drain plug a Allow the fluid to drain e Clean the drain plug including the magnet and the fluid pan drain plug face a Fit and tighten the fluid pan drain plug a Remove the drain tin from below the transmission unit a Lower the vehicle onthe ramp Openthe hood and fit a suitable fender cover Remove and wipe the dipstick a Fit a funnel to the dipstick tube a Initially fill the transmission with 45 liters of fluid a Remove the funnel a Open the front door a Check that the parking brake is applied a Start the engine e Apply the footbrake Run the shift lever through all positions finally returning to the Park position a Releasethe footbrake a Insert the dipstick then remove and inspect the level a Fit the funnel to the dipstick tube a 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
304. ide a Fit and fully seat the washer jets to the new plenum chamber finisher a Connect the washer jet multi plugs gt ed EE a Reconnectthe washer jet tubes a Position the plenum chamber finisher a Fit and tighten the finisher securing screws a Refitthe wiper arm Remove the fender cover and close the hood 13 5 3 Hinge Renew a Disconnect vehicle battery ground lead Open hood and fit fender protectors a Remove radiator grille a 12cylinder only a Removefan cowlto top panel clips and movethe cowl as sembly clear a Move water bleed pipe from top panel clips a Releasefixings and remove radiator top mounting panel a Remove hinge securing nuts RH or LH ground lead onthe left hand side CAUTION Ensure that the hood cover is adequately sup ported and that paint damage cannot occur a Remove hinge bolts RH or LH noting the position of the ground lead on the left hand side a To refit carry out reversal of the above procedure ensur ing that the hood should be fully aligned before finally torque tightening the fixings Issue 1 August 1994 42 X300 VSM Body Components amp Trim ali 13 5 4 Gas Strut Renew a Disconnect vehicle battery ground lead Openthe hood and fit fender protectors CAUTION Ensure that the hood cover is adequately sup ported and that paint damage cannot occur a Release upper strut pivot retaining clip and detach the strut from the pivot a Repeat
305. ience not operated within the last 4 seconds Note fkey isturnedto lock position with vehicle already locked deadlocked all close will be activated 2OOR UNLOCKING Action Device operation Function Jnlock Turn to unlock N A 1st press Unlocks doors trunk lid key position and release only and fuel filler cap Disarms alarm system except for 30 second audible tick Turns on interior lights for 15seconds Remote button only cancelstrunk valet lock out and recalls memorised driving position Trunk lid release N A N A 2nd press Trunk lid release within10 seconds of previous action Remote panic N A N A 3 second press Unlocks disarms and enters full alarm state ie audible alarm both sounder and horn and visual alarm flashing lights X300 VSM 9 Issue 1 August 1994 Sec ose tem STRIC JE A5 4 2 North American markets variant 2 Action Device operation DOOR LOCKING Key Remote signal transmitter Function Lock and arm perimeter only Turn to lock position and release Turn to lock position and hold for 2 seconds Lock arm perimeter only and alt close Headlamps ON for 25 seconds Turn to unlock position and release Unlock driver s door only Eitherturn to unlock and holdfor 2 seconds or perform a second unlock action Unlock all doors
306. 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 Rectify as required Iverheating at dle Too cold Issue 1 August 1994 Cooling fan s not operating Thermostat stuck open Incorrectthermostat rating Thermostat not fitted Cooling fan s operating con tinuously Faulty temperature gauge Faulty temperature transmitter Referto EDM Test thermostat Checkthermostat operating temperature Removethermostat housing and inspect Referto EDM Referto EDM Referto EDM Rectify as required Renewthermostat Renewthermostat Fitthermostat Rectify as required Renew gauge Renewtransmitter X300 VSM Cooling System AJ16 Diagnostic Procedures continued Symptom Possible Cause Loss of cool Loose clips on hoses Check clips for correct tight Tighten clips as required ant ness Hoses perished Visual check Renew hoses as required Radiator core leaking Pressure testsystem Repair or renew radiator Water pump seal leaking Pressure testsystem Renew water pump Thermostat gasket leaking Pressure testsystem Check Renew gasket Renew hous for distortion of thermostat ing if required housing Header tank cap defective Inspectcap or test cap spring Renewcap pressure Porosity in castings Pressure testsystem Rectify as required Corrosion caused by con Pre
307. ifferent sizestocorrespond with the difference in pipe diameter whereas the connectors for the feed and return lines at the fuel tank are the same size Exceptfor the return line connector at the fuel tank two release tools one for each size of connector are required to release all remaining connectors X300 VSM 3 Issue 1 August 1994 EE Fuel Emission Control amp Engine Management AJ16 The connectors are releasedby pushingthe tool into the female half oftheconnector and atthe same time disengaging the latches Viton hosing surrounds the tubing thus preventing any po tential damage from fire and other matters The conductive anti permeation tubing does not returnto its original shape after being deformed Therefore do not clamp eg for sealing purposes prior to disconnection of tubes as this damages the fuel pipes The evaporative loss control system prevents unprocessed vapour emitted from the fuel tank from entering the atmos phere A running loss control valve 4 0 liter NAS markets only or atank pressure control Rochester valve wherefitted is in stalled between the fuel tank and the carbon canister Both valves are normally closed but open during engine operation They vent vapours from the fuel tank to the car bon canister s Onfilling up the tank the fuel produces positive pressure in side the tank which causes only the running loss valve to close blocking off the vent line The Rochester valve
308. ifferential control potentiometer a Place the center vent assembly on a bench covered with a suitable cloth a Remove and discard the veneer panel to center vent as sembly securing clips a Displace and remove the veneer panel from the center vent a Fit and align the new veneer panel to the center vent a Fit and fully seat the veneer panel securing clips a Place the center vent assembly to the vehicle Fit and fully seat the vent assembly to differential control Fig 1 potentiometer a Fit and fully seat the center vent assembly to the fascia Issue 1 August 1994 28 X300 VSM Body Components amp Trim dll 13 3 24 Console Finisher Veneer Panel Renew SRO 76 47 26 Apply the handbrake a Turnthe ignition ON a Press the brake pedal and positionthe gear selector in N Turnthe ignition OFF a Removethe console ashtray see sub section 13 3 28 Carefully displace the mode switch from the gear sur round finisher See Fig 1 a Disconnectthe mode switch from the harness multi plug See Fig 1 a Displace and remove the switch surround finisher a Displace and remove the gear lever surround finisher a Displace and remove the veneer panel rear finisher a Undo and remove the veneer panel wing nuts See Fig 2 a Displace and remove the console finisher veneer panel See Fig 3 a Remove the stud plates a Place the veneer panel aside a Place the new panel to the front a Fit and ali
309. ig 1 length at its extremity 3 Fig 1 i X300 VSM 7 Issue 1 August 1994 gt S General Fitting Instructions A3 3 TAPER ROLLER BEARINGS FAULT DIAGNOSIS Fault Bent cage Cause Improper handling or use of tool Remedy Renew the bearing Fault Bent cage Cause Improper handling or use of tool Remedy Renew the bearing Fault Galling Cause Marks on roller ends dueto overheating lubricant failure or overloading Remedy Renew the bearing Check the seals and ensure that the J51 052 bearing is properly lubricated Fault Step wear Cause Wear onthe roller ends caused by fine abrasives Remedy Clean all components and housings Check the seals and bearings and renew if leaking rough or noisy Fault Fretting Cause Corrosion caused by small movement of components with no lubrication Remedy Renewthe bearing Checkthe seals for leakage and ensure that there is adequate lubrication Issue 1 August 1994 8 X300 VSM General Fitting Instructions gt 3 Fault Misalignment Cause Outer track misalignment usually due to a foreign body underthe track Remedy Clean allcomponents and replace or renewthe bearing and ensure that the newtrack is correctly seated Fault Indentations Cause Surfaces are depressed onthe race andthe trackcaused by hard particles of foreign material Remedy Clean all components and housings Check the seals a
310. in socket O ring and discard a Clean the valve body and main case mating faces Check for any signs of damage a Fit a new O ring to the multi pin socket a Fitthe valve body assembly to the transmission unit Dur ing valve body fitment engage the shift lever quadrant peg into the manual valve and seat the multi pin socket through the main case orifice Note Theflat onthe side ofthe multi pin socketshould be located on the vertical left hand side of the case a Fit but do not tighten the valve body assembly securing screws Gently push the valve body assembly forward to assume this position during the final tightening operation s Carry out final tightening of the valve body assembly to main casing securing screws a Fitandtightenthe harness multi pin socket to maincasing securing nut a Connect the rotary switch harness multi pin plug to the transmission multi pin socket a Refitthe speed sensor see Subsection 8 1 10 a Renew the fluid filter see Subsection 8 1 6 Refitthe fluid pan see Sub section 8 1 7 Lower the vehicle on the ramp a Reconnectthe battery a Refill the transmission unit with fluid see Sub section 8 1 2 Remove the fender cover and lower the hood X300 VSM 15 Issue 1 August 1994 2F We Automatic Transmission AJ16 8 1 13 VALVE BODY ASSEMBLY RENEW 3 21 SRO 44 40 01 a Raise the hood and fit a fender cover e Disconnect the battery a Raise the vehicle
311. incorporating power or manual reach tilt mechanism and lock Ignition switch Ignition interlock solenoid Key transponder coil Body attachment points Dependingupon 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 13 respectively Adjustments may be automatically made in conjunctionwith 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 ManualAdjust The cable operated reach adjustment is infinite within a range of 35mm with the desired positionbeing fixed by a rack and wedge Tilt variations are stepped at approximately 3 intervals with 6 positions being available the uppermost being unlatched Fromthe uppermost positionthe column may be pulled downto engage the first detent without using the tilt lever J57 27L 1 1 Tilt motor 3 Ignition switch 2 Tilt motor flexible coupling 4 Reach motor Fig 1 Major components Power operated steering column WARNING MANUAL ADJUST ONLY TO AVOID PERSONALINJURY COLUMN UPWARDTRAVEL SHOULD BE MAN UALLY RESTRAINED TO CHECK UPWARD SPRING ASSIST
312. ined group of electrical electronic components designed as a single replaceable unit and controlling one or more processes as above flexible usually fabric roof of an open convertible vehicle hood convertible hood countershaft shaft carrying pinions running parallel to the mainshaft in a transmission unit layshaft split pin which is used as a locking device for a castellated nut etc split pin cotter pin Crankshaft Position Crankshaft Position Sensor Crankshaft PositionTiming Ring generates crankshaft position information in conjunction with the CKPTR also generates speed information in certain applications toothed ring which triggers the CKPS Crankcase Ventilation System system which scavenges camshaft cover and crankcase emissions and feeds them intothe inlet manifold cubic centimeters curb weight weight of vehicle with fuel lubricants and coolant but excluding driver passengers or payload cubic centimetres kerb weight cylinder sleeve sleeve Issue 1 August 1994 thin walled hard metalcylinder inserted into the cylinder block of an engine andin which the piston runs cylinder liner 10 X300 VSM Y e Introduction Term s Abbreviation if applicable Definition Previously used term s or Eng lish Equivalent transmis
313. ing fuelling Fuel Injectors Fl solenoid operated devices that spray a fuel injectors metered auantitv of fuel intothe inlet ports iniectors Fuel Pressure Regulator Control FPRC controls fuel pressure regulator used primarily to aive extra fuel at cold start up monitors operation of fuel pump Fuel Pump Relay FPR fuel rich lean qualitative evaluation of air fuel ratio based on a ratio known as stoichiometry or 14 7 1 Lambda Issue 1 August 1994 14 X300 VSM a Ge Introduction GLOSSARY TERMS Term s Abbreviation Definition Previously used if applicable term s or Eng lish Equivalent gauge gage also used but not preferred gasoline gas tank gear cluster layshaft gearshift lever shift lever gear lever generator GEN rotating machinewhich converts mechanical alternator energy into electrical energy petroleum spirit petrol tank fuel Gramme centimeter E A A ee Grammes force gt OA Grammes mass AA AAA APA EA ground GND electrical conductor used as a common re earth turn for an electrical circuit or circuits and with a relative zero potential X300 VSM 15 Issue 1 August 1994 Introduction GLOSSARY OF TERMS Term s Abbreviation Definition Previously used if applicable term s or Eng lish Equivalent H Hall Effect T process where current is passed through a small slice of semi conductor mat
314. int Economy mile h 43 48 73 81 110 119 110 119 sport km h 69 77 117 130 176 191 176 191 Zero throttle D2 D1 D3 D2 D4 D3 D4 TCC on Economy mile h NOT AVAILABLE 12 10 15 13 49 39 km h 20 16 24 21 79 63 sport mile h 10 8 12 10 15 13 52 39 km h 16 13 20 16 24 21 83 63 Upto kick down point Economy mile h 21 19 52 47 86 77 86 77 km h 34 31 83 75 138 123 138 123 sport mile h 72 65 109 99 109 99 km h 115 104 175 159 176 159 Kick down available Economy mile h 41 35 73 64 107 95 107 95 sport km h 66 56 117 103 171 152 171 152 Zero throttle DG B2 ws Economy mile h 41 35 73 64 107 94 km h 66 56 117 103 171 152 8 1 sport mile h 50 44 85 75 130 114 kW km h 80 71 136 120 208 182 X300 VSM 5 Issue 1 August 1994 d Automatic Transmission AJ16 8 1 2 TRANSMISSION FLUID RENEW 3 2L AND 4 0L SRO 44 24 02 Raisethe hood and fit a fender cover a Raise the vehicle on a ramp a Placea draintin in position beneaththe transmission drain plug e Release and remove the transmission drain plug allow the fluid to drain a Fitthe drain plug with a new washer and torque tighten Reposition the drain tin beneath the dipstick tube union a Remove the screw securing the dipstick tube bracket a Release the dipstick tube union nut and disconnect the tube from the fluid pan a Drain the transmission fluid e Clean the tube unions reconnectthe dipstick tube to the
315. integratedwith the valve block The pump motor valve block and control module are supplied as a unit and are non sewiceable Faulty units must be renewedas a whole Both front and rear brakes on all vehicles are fitted with single piston caliper assemblies Ventilated brake rotors with provision for parking brake shoes at the rear are fitted all round X300 VSM 3 Issue 1 August 1994 Brakes Pressure conscious reduction valves PCRVs are fitted between the outlet of the valve block andthe rear brake circuit to optimize The valves are fitted to prevent over braking due to the increased size of the rear brake calipers which are required for traction control Upto a threshold of 15 bar brake pressure to the front and rear brakes is equal Above 15 bar the PCRVs reduce pressure to the rear brakesto provide acloser balance between front and rear brakes and optimize road adhesion Wheel speed sensors are fitted to all wheels to transmit wheel speed information to the control module The module uses this information to modulate brake pressure during anti lock braking or traction control 1213 Anti lock Braking Operation Vacuum booster 9 Pressureconscious reduction valve Vacuum hose 10 Ventilated brake rotor Tandem master cylinder 11 Single piston caliper Primary brake circuit 12 3 way brake pipe connector Secondary brake circuit 13 Wheel speed sensor Hydraulic pump motor unit 14 ABS warning lamp Valve block 15 Brake
316. into seat frame a Remove securing bolt buckle unit and wavy washer a To refit carry out reversal of the above procedure 13 8 12 Front Seat Belt Renew a Position the front seat for access a Disconnect vehicle battery ground lead a Release D post upper trim and belt aperture cover a Remove cover from seat belt upper fixing a Removeseatbelt upper fixing and releaseseat belt anchor from height adjuster remove wavy washer a Lower the upper trim pad with seat belt onto the seat Remove B post lower trim a Remove seat belt lower fixing disconnect anchor plate and remove wavy washer a Release upper trim pad from seat belt Remove upper guide fixings at B post a Removeseat belt reelfixings and remove reel and belt as sembly a Refit seat cushion Secure seat belt reel to the specified torque Fit and secure upper guide plateto B post Pass the seat belt through the upper trim pad a Fitwavy washer to loweranchor fit lower anchor plate and nut tighten to specified torque a Refit lower H posttrim panel a Refit upper B post trim panel Place wavy washer on height adjuster stud fit belt upper anchor and nut tighten to specified torque a Fit plastic cover and split finisher 13 8 13 Rear Inertia Seat Belt Renew 2 Removeseatcushion rearseat squab and rear parceltray a Remove foam pad from rear shelf and remove seat belt buckle bolt a Remove buckle assembly washers and spacers
317. is renovation and rebuild work refer to the AJ16 Engine Service Manual x300 VSM 1 Issue 1 August 1994 XXXI Engine AJ16 3 1 2 ENGINE TRANSMISSION UNIT RENEW SRO 12 41 02 20 The engine transmission unitonthe AJ 16normally aspirated and supercharged engined vehicles arefitted ontothree engine mounting bracket assemblies The twofront engine mountings for the 3 2 4 0 liter normally aspirated andthe 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 at 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 a Removethe hood see SRO 76 16 01 section 13 a Remove the air cleaner assembly a Depressurizethe fuel system see SRO 19 50 02 section 5 1 e Disconnect the battery a In line with the relevant SRO s and sections remove all appropriate obstructing parts including their fixing and mounting arrangements a 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
318. itthe originalshims and using hand pressure only to seatthe assembly checkthat theclearance betweenthe output shaft housing and differential case is inthe range 0 05 to 0 13 mm Shim to suit if not inthis range a Using a new Or ring and sealant on the mating faces assemble the output shaft assembly to the differential case See Sub Section 9 3 Output Shaft End Float Check a Fitting and reassembly is the reversal of this procedure ensuring that all fixings are tightened to specification and new locking nuts are used Correct the final drive oil level if required Issue August 1994 5 X300 VSM IWER Driveshafts amp Final Drive 9 8 FINAL DRIVE UNIT RENEW SRO 51 25 13 a Disconnect vehicle battery ground lead a Support the vehicle at the rear and remove the rear road wheels e Disconnect brake pad wear sensor multi plug at RH hub carrier and remove tie straps from wishbone Release ABS speed sensors at RH and LH hubcarriers and remove tie straps from wishbones a Remove rear brake calipers see Section 12 and support at bump stop Disconnect main handbrake cable at com pensator short cables at joining piece and remove com pensator a Remove fixings FLEXIBLE coupling to differential DRIVE FLANGE CAUTION Under no circumstances must the flexible coupling oritsfixings be loosened or removed from the drive shaft flange a Remove fixings center bearing to crossmember 1 Fig 1 and push drive shaft
319. ization The process of HFC 134A recovery will depend onthe basic characteristics of your chosen recovery recycle recharge equipment therefore follow the manufacturer s instructions carefully Remember that compressor oil may be drawn at of the system by this process take note of the quantity recovered so that it may be replaced CAUTION Observe all relevant safety requirements Wear suitable eye and skin protection Do not mix HFC 134A with CFC 12 Do not vent refrigerantdirectly to atmosphere and always use Jaguar approved recovery recycle re charge equipment Take note of the amount of recovered refrigerant it will indicatethe state of the system 14 9 3 Evacuating the System This process the removal of unwantedair and moisture is critical to the correct operation of the air conditioning sys tem The specific procedures will vary depending on the individual characteristics of your chosen recovery recycle recharge equipment and must be carried out exactly in accordance with the manufacturers instructions However it is recommendedihat the initially only the HIGHside valve be opened at the start of the procedure After a short time a small depression should be seen on the LOW side at which point the LOW side valve may be opened andthe evacu ation process completed If a vacuum is not registered on the LOW side it may indicate that the expansion valve is jammed closed or that the system is blocked This simple check may save time
320. k placed between the jack head andthe spring support pan Place an axle stand in position atthe ad jacent jacking point when the wheel has been raised 2 1 4 2 Front Both Wheels Positionthe jack centrally underthefront crossmember Fig 2 using a wooden block placed between the jack head and the crossmember Place axle stands under both front jack ing points when the vehicle has been raised 2 1 4 3 Rear Both Wheels Place the jack centrally under the rear crossmember Fig 3 using awooden block placed between the jack headandthe crossmember Place axle stands under both rear jacking points when the vehicle has been raised J08 025 Issue 1 August 1994 2 X300 VSM EN y Jacking Lifting amp Vehicle Recovery Z 2 2 VEHICLE RECOVERY 2 2 1 General Note Priorto vehicle recovery always ensure the vehicle keys are available andthe vehicle security system is OFF The safest and preferred method of vehicle recovery is by flat bed transporter although a rear suspended tow may also be used The front and rear towing eyes are provided for use only in an emergency to move the vehicle if it is causing an obstruction on police instructions or when winching the vehicle onto a recovery transporter Note A towing shackle cannot be fastened to the front towing eye until the grille vane has been removed To dothis removethe three quarter turnfasteners securing the grille vane Fig 1 and place the vane saf
321. ks al 12 Check adjust drive belt tensions Xoo A o 13 Renew wiper blade and clean windshield with Jaguar x Xx x Xx Xx x Screen Clean Paste Wt Check adjust parking Brake shoes ES N E 15 Inspect brake pads for wear rotor condition on pad Xx Xx Xx Xx A Xx change 16 Grease axle shaft universal joints Xx Xx X xX 17 Check front hub end float Xx X 18 Clean and adjust front hub bearings Xx 19 Check tire pressures tread depth general condition signs Xx xX xX xX X X of uneven wear and suitability including spare 20 Check top up automatic transmission fluid X Xx xX 21 Check top up brake fluid reservoir X 22 Check top up clutch Mud reservoir 23 Check top up cooling system and check specific gravity A Xx X X 24 X A X x 25 X X X 26 Check top up final drive oil X 27 Check top up PAS uid x 28 Check exhaust system for leakage and security a heck or oil Teake engine 30 Check for oil leaks automatic transmission 31 Check for oil leaks manual transmission a2 Check for oil Teak final drive a Check for fus eats Check all suspension dampers for fluid leaks Note This note only applies to V12 engines When renewing spark plugs apply silicon grease TBA to the spark plug and coil terminals of the ignition cable This will ensure that the terminal covers remain supple throughout their service life thus maintaining a good contact and preventing HT leakage rae ai PAR RN AAR AR A SE SS SE O
322. l To unlock the door pull the door lever out X300 VSM 15 Issue 1 August 1994 Id Security System RESTRICTED ISSUE y A5 6 SYSTEM DIAGNOSTIC METHODS The following informationdetails diagnostic proceduresforsystem fault identificationusinga Portable Diagnostic Unit PDU PDU is designed and supplied by Jaguar Cars Ltd to interrogatethe electroniccontrolcircuitry of the various vehicle systems diagnose fault conditions and indicate to the operator recordedfaults and possible remedies On initiation of diagnostic procedures PDU will display the model variant and control module type a list of enabled functions can also be accessed Ensurethat this informationis correct for the vehicle under test ie that the correct module is fitted and all appropriate options are enabled Detailed informationon testing using PDU is detailed inthe support documentation supplied with the unit Issue 1 August 1994 16 X300 VSM A5 7 SYSTEM TESTING Security System RESTRICTED ISSUE oot The following information details the proceduresfor acompletesystemtestto identify and locatepossiblefault condi tions Where faulty operation is identified refer to Diagnostic Sub Routines for possible causes and remedies Locking unlocking and setting the vehicle alarm system is carried out by key ar by radio frequency key ring trans mitter Note Ensure all doors are fully closed before initiating lock procedures Key ringtransmitterfu
323. l filler cap and arm the alarm system perimeter alarm system perimeter alarm system perimeter only inclination and intrusion only Direction indicatorsflash 2 s Direction indicators flash once Warning light cen An audible signal will be once Warning light cen tral locking switches heard and side lights will tral locking switches flashes when vehicle se Flash once Warning light flashes when vehicle secu cured centrallocking switches red flashes when vehicle se Headlamps on for 25 sec cured onds if vehicle previously Headlamps on for 25 sec locked and armed onds if vehicle previously locked and armed Japanese Market Only Lock all doors trunk lid fuel filler cap and arm the alarm system Headlamps on for 25 sec onds if vehicle previously locked and armed Deadlock all doors Arm the alarm system per imeter inclination and in Deadlock all doors Arm tthe alarm system per iimeter inclination and in Headlamps on for 25 sec onds trusion trusion Japanese Market Only Headlamps on for 25 sec onds Headlampson for 25 sec No Feature Headlamps on for 25 sec onds onds Note Japanese Market Only The headlamps will also No Feature some on if the large but ton is pressed whenever the vehicle is locked or deadlocked 13 Issue 1 August 1994 PEI Security System
324. l models All Models Solenoid compartment behind left hand head lamp assembly 18 30 34 Air Conditionin see starter All Models All Models g Water Pump motor solenoid Wiper Motor see starter All Models All Models On Off motor solenoid Wiper Fast see starter All Models All Models Slow motor solenoid 18 30 71 EMS Engine Engine All Models Management compartment System behind right Control hand head lamp assembly Ignition Coil see EMS Black All Models control Pl Main Relay see EMS Black All Models control 18 30 34 Air Pump see EMS Black Air Injection Air Injection 7 control only only 86 55 08 Air see EMS Black Air Con Model All Models Conditioning control only Compressor Clutch Relay Case Black Non Aircon White Stripe Models only Relay Case Engine Black Non Power Non Power 11 compartment White Stripe Wash Models Wash Models onthe right only only hand side inner wing valance PowerWash Black Optional Optional Screen Wash Black All Models All Models 10 Ignition Relay Engine All Models All Models 12 compartment inside right hand fuse box X300 VSM 33 Issue 1 August 1994 Electrical EC 5 12 2 Passenger Compartment Interior Relays General Description Tr Ji i 4 Asai J86 1694 Fig 1 Passenger Compartment Interior Relays Fig 1 shows the relays inside the passenger compartment located under the rear seats behindthe heel boards under the centre console wood veneer
325. lacking power Ignitionsystem Go to Test Step 1B Electronic engine controls Fuel System Restricted exhaust system 6 1 2 2 TestA Exhaust Leakage or Noise Test Step Result Action Step 1A Clamps and Brackets Check for broken or loose clamps and or exhaust yes Goto Step 2A outlet pipe frame brackets Are clamps and exhaust outlet pipe frame brackets OK Service and renew as necessary Restart engine If noise still exists go to Step 2 Step 2A System Components Check catalytic converters muffler Are system components OK Goto step 3A Renew exhaust outlet pipe frame brackets exhaust inlet pipe and or muffler as necessary If noise still persists go to Step 3 Step 3A Exhaust Manifold Inspect exhaust manifold for loose fasteners and cracks Is exhaust manifold OK Go to Test Step 1B Restricted exhaust system test Tighten fasteners or renew exhaust manifold X300 VSM 5 Issue 1 August 1994 Step 4B Vacuum Test Catalytic Converter s on Mufflers off Turn engine OFF 5 Exhaust System AJ16 6 1 2 3 Test B Restriction in Exhaust Systems Test Step Result Action Step 1B Visual Inspection s the exhaust system visually OK Yes Goto Step2B No Renew any collapsed exhaust components Goto Step 2 Step2B Vacuum Test Attach a Vacuum Gauge or equivalent to the intake manifold vacuum source Connect a Tachometer or equivalent Start engin
326. lamps 1 Fig 1 a Displace and remove the fluid pan 2 Fig 1 Drainthe fluid pan Remove and discard the fluid pan gasket if the gasket is damaged Removethe magnetsfromthe fluid panand place the fluid pan aside a Clean the gasket faces and magnets a Fit a serviceable gasket to the new fluid pan a Fitthe magnets in position inthe fluid pan a Fit and align the fluid panto the transmission unit Fitthe fluid panclamps fit andtorque tighten the fluid pan securing bolts a Lower the vehicle onthe ramp a Raise the hood and fit a fender cover a Refill the transmission unit with fluid see Sub section 8 1 2 Remove the fender cover and lower the hood 8 1 9 FLUID PAN GASKET RENEW 3 21 SRO 44 24 05 a Raise the hood and fit a fender cover a Raise the vehicle on a ramp a Drainthe transmission lubrication system see Sub sec tion 8 1 2 a Release and remove the fluid pan securing bolts clamps 8 1 1 Fig 1 y a Displace and remove the fluid pan 2 Fig 1 s Remove and discard the fluid pan gasket a Removethe magnetsfromthe fluid panand placethe fluid pan aside a Clean the fluid pan gasket faces and the magnets a Fit a new fluid pan gasket a Fitthe magnets in position in the fluid pan Fitand alignthe fluid panto the transmission unit fitthe fluid panclamps fit andtorquetightenthe fluid pan secur ing bolts a Lower the vehicle onthe ramp a Refill the transmission uni
327. le term s or Eng lish Equivalent E Exhaust Gas Recirculation EGR System which reduces NOx emissions by EGR adding exhaust gases to the incoming fuel air charge EGR Temperature EGRT Sensing EGR function based on temperature EGRT Sensor change EGR Vacuum Regulator EVR controls EGR flow by changing vacuum to the EGR valve EGR Valve Position EVP an EGR system that directly monitors EGR valve position to control EGR flow Electrical Diagnostic Manual EDM Manual which deals with the diagnosis of electrical faults see also Vehicle Service Manual and Unit Service Manual Electrically Erasable Program EEPROM EEPROM mable Read Only memory E2PROM Electrically Programmable EPROM Read only memory Electronic Engine Control EEC a system that provides electronic control of engine electronics Electronic Secondary Air Injection EAIR a pump driven system for providing secondary air usina an electric air pump ECT Sensor ECTS thermistor which provides engine coolant Coolant temp on time for cold start and warm up Engine Control Module ECU Engine Coolant Level ECL engine coolant level indicator Engine Coolant Temperature CT temperature signal to the PCME to trigger sensor ECT enrichment circuits which increase injector Engine Speed rev min RPM Engine Speed Sensor sensor fitted on flywheel of V12 engine provides engine speed information JA A ee et E Environmental
328. le coupling or its fixings be loosened or removedfromthe drive shaft flange Preliminary Checks Before this procedure is actioned it is advisable to ensure that The gearbox mounting center stud is positioned centrally in relation to the crossmember inspection hole The crossmember is central on the body fixings and not hard over to one side The differential spigot radial run out is within specification see preliminary pages Ifthe vehicle has beenstandingfor a periodthe tires may be flat spotted Hen this will clear in approximate 400 km 250 miles After this distance the source of vibration should be reassessed 12 Cylinder a Remove exhaust center section All Locate suitable plumb lines over drive shaft outside diameter but NOT over any balance weight or weld 1 Frontsection behind gearbox output coupling 12 7 mm 0 5 in diameter weight 1 Fig 1 2 Rear section immediately behind center bearing 2 Fig 1 3 Rear section in front of differential flange 3Fig 1 Note Itis essential that the front weight should be as specifiedso that the different diameters of the two shafts may be taken into account Method 1 Viewedfromthe rearwith the rear plumb line coincidentalwith the outside diameter of the front weight the center plumb line should align with the rear plumb line 4 Fig 1 a To re align the center bearing slacken bearing fixings and position to suit Tighten all fixings to
329. le hornsto operate if programmedto do so An errortone is generatedif active arming is selected with either hood or trunk open or the transmitter is pressedwith ignition key in auxiliary position Issue 1 August 1994 8 X300 VSM Security System RESTRICTED ISSUE A5 4 KEY FOB VARIATIONS Due to the varying applications for different world markets three types of key locking local and remote have been developed The following tables detail these variations A5 4 1 European UK markets variant 1 DOOR LOCKING Action Device operation Function Kev R ote signal transmitter Large button Small button Lock and arm Turnto lock position 1st press N A Locks all doors trunk and perimeter only and release fuel filler cap Arms alarm system Lock arm perimeter Turnto lock position Continued hold of N A Locks all doors trunk lid and only and all close and hold for 2 1stpressfor 2 fuel filler cap Arms alarm seconds seconds system Key only closes open windows and sliding roof in 1 5 seconds Deadlock perimeter Turnto unlock then 2nd press and N A Deadlocks all doors locks inclination intrusion lock within three hold for 2 trunk lid and fuel filler cap and all close seconds holdin seconds and arms alarm system lock for all close immediately Closes windows and sliding roof after 1 5 seconds Headlamps ON for 25 N A 3rd press 1st N A Switches headlights on for seconds press if button driver conven
330. le the steering no less than three 3 times from lockto lock this may be best achieved with the front wheels off the ground As air is expelledthe fluid level will fall the level should be corrected Start the engine and further cycle thesteering untilthe fluid level becomes stable Stop the engine and finally set the level in accordance with the fluid level check procedure 10 3 4 Fluid Reservoir The reservoir has an integral non serviceable return side filter Should any component be renewed or the system broken into for any reason it is essential that the reservoir and the fluid are changed Under normal operating condi tions it is not necessaryto change the fluid 10 3 5 Hydraulic Connections All hydraulic connections and surrounding areas should be scrupulously cleaned before and after work Please note that the steering rack valve block connections for FEED and RETURN are common in size Ensure that the pipes are correctly fitted the uppermost one beingthe high pressure FEED from the steering pump andthe lower RETURN hav ing a double depth hexagon tube nut X300 VSM 5 issue 1 August 1994 GH 10 4 10 4 1 Introduction Steering DIAGNOSTIC PROCEDURE The following diagnostic procedures are providedto rapidly pin point mechanical faults which are not interrogated by electrical means Diagnostic procedures which require dedicated electrically operated equipment are dealt with in the Electrical Diagnosti
331. lead multi plug a Undo fuel injector multi plug cover fixings 2 Fig 1 a Disconnect cover from injectors 3 Fig 1 a Undo fuel rail to feed pipe union nut 4 Fig 1 X300 VSM 7 Issue 1August 1994 E Fuel Emission Control amp Engine Management AJ16 a Repositionfuel feed pipe from fuel rail union and fit blanking plugsto rail and pipe Undo and remove regulator mounting bracket to inlet manifold bracket securing bolt 5 Fig 1 a Undo fuel rail to regulator union nut a Reposition regulatorfrom fuel rail union and fit blanking plugs Fig 1 a Undo and remove fuel rail securing bolts a Remove fuel rail assembly 1 Fig 1 from manifold Fit blanking plugsto manifold a Drainthe residual fuel from the fuel rail into a suitable drain tin e Remove the injector retaining clips 2 Fig 1 a Remove injectors 3 Fig 1 a Disconnect vacuum hose from regulator a Remove regulator mounting bracket a Undo fuel rail to regulator union nut Remove regulator assembly Refit in the reverse order of the removal procedure Issue 1 August 1994 X300 VSM Fuel Emission Control Engine Management AJ16 R 5 1 5 PURGE CONTROL VALVE ALL MODELS RENEW SRO 17 15 30 Remove a Remove blanking cover 1 Fig 1 a Release air cleaner cover retaining clips 2 Fig 1 Removefilter element 3Fig 1 a Removefilter cover 4 Fig 1 from inner wing grommet a Depress retaining clip 5 Fig 1
332. liding roof frame to body 3 5 5 Sliding roof outer panel to frame 3 5 5 UL SERVICE MATERIALS Bumper substrate repair See section A4 6 Kent Industries Urepatch Bumper substrate repair See section A4 6 Gurit Essex Betaseal 1855 Glazing adhesive See section A4 5 See section A47 IV SERVICE DATA Front track centre of read to centre sed mn Description 3M 5900 FPRM Issue 1 August 1994 iii X300 VSM d ue p Body Systems amp Body Repair rag A4 1 BODY REPAIR Introduction This section contains information specifications and procedures for body repairand rectificationof the Jaguar sedan range with standard wheelbase All repairs whether structural or cosmetic must ensure the continuance of the Paint Surface and Corrosionwarranty where applicable Following repair or rectification the vehicle must be returnedto the original manufacturedcondition with regardto occupant safety dimensional accuracy finish and corrosion protection Similarly repaired vehicles must be fully checked and where appropriate reset with regardto steering suspension restraint and braking systems A4 1 1 Healthand Safety Please Read TheFollowing Notes Carefully Where legislation governing working conditions and practises is applicable you should observe it Do notforgetthat you have a duty to yourself and those around you to act in a responsible manner in the workplace Inthe Uni
333. lign the lid hinge Fit and tighten the lid hinge securing screw Fit and align the lid latch release lever Fit and fully seat the lid inner to the lid a Fit and tighten the inner lid securing screws a Fit and align the lid assembly to the console a Fit and tighten the lid to console securing screws s Align the lid checkarm to the lid Fit and tighten the checkarm securing screw s Close the glove box lid Issue 1 August 1994 18 X300 VSM gt Body Components amp Trim aii 13 3 13 Console Glove Box Lid Hinge Renew SRO 76 25 20 Open the console glove box lid Undo and remove the glove box lid checkarmto lid secur ing screw a Reposition the checkarm a Undo and remove the glove box lid to console securing screws a Displace and remove the glove box lid assembly a Placethe lid assembly to the front a Undo and remove the lid inner securing screws a Displace and remove the lid inner a Displace and remove the lid latch release lever Undo and remove the lid hinge securing screw Displace and remove the hinge Fit and align the new lid hinge a Fit and tighten the lid hinge securing screw Fit and align the lid latch release lever a Fit and fully seat the lid inner to the lid a Fit and tighten the inner lid securing screws a Fit and align the lid assembly to the console a Fit and tighten the lid to console securing screws a Align the lid checkarm to the lid a Fit and tig
334. lit afterthe mirror timer has gone through its 11 minute cycle and will not go out until either completion ofthe 20 minute screen cycle or manual override 15 TEMPERATURE decrease button in 1 C or 1 F steps 16 TEMPERATURE increase button in 19C or 1 F steps Note Automatic temperature control operates over the range 17 C to 31 C 61 F to 90 F Extreme limits selected by items 15and 16 Lo and Hi provide maximum cooling or heating at maximum fans speed 17 FACE level manual distribution over ride push on push off button and state lamp 18 Bi LEVEL foot and face manual distribution over ride push on push off button and state lamp 19 FOOT level manual distribution over ride push on push off button and state lamp 20 DEMIST screen and foot level manual distribution over ride push on push off button and state lamp Note Selection of AUTOwill over ride any manual setting and deselection of any manual distribution will revertthe system to AUTO distribution 21 FACEVENTTEMPERATURE CONTROLthumb wheel Situated between dash centre face levelventsto reduceface air outlet temperature relative to that of the foot well X300 VSM 5 Issue 1 August 1994 Gu NY Y Climate ontrol Systems GX ES fe OE Climate Control Systems 14 4 TEMPERATURE CONTROL 14 4 1 Coolant Circuit The main coolant system supplies liquid at engine temperature to the heater matrix to provide heat to the vehicle interior Unlike previo
335. lly driven rotary vane pump AIP air pump driven through the AIRPC Secondary Air Injection Relay AIRR controls the injection of air into the exhaust air injection relay system Secondary Air InjectionSwitching AIRS vacuum operated valve backing up the AIRC air switching Valve valve Security amp Locking Control Mod SLCM modulecontrollingthe vehicle s security and ule closure locking functions sedan passenger car havingtwo orfour doors and saloon frontandrearseats for driver and passengers Sensor S generic name for a device that senses either the absolute value or a change in a physical quantity such as temperature pressure or flow rate and converts that change into an electrical auantitv sianal Service Bulletin SB Service Manual SM Service Manual Preliminary In SMPIB form of Service Bulletin specifically designed formation Bulletin to enable the rapid issue of temporary pages for inclusion inthe Service Manual Service Repair Operation SRO Number generated by Jaguar Methods amp number Techniques system which relatesto the time allowed to complete a repair operation Further information on the system can be found in the separate Jaguar Publications for each model range entitled Repair Operation Times X300 VSM Issue 1 August 1994 Introduction GLOSSARY OF TERMS Term s Abbreviation Definition Previously used
336. lock position Deadlock all doors lock No feature Deadlock all doors lock and then to lock position trunk lid and fuel filler cap trunk lid and fuel filler cap within 3 seconds Holdin Arm the alarm system Arm the alarm system ock position for 2 seconds perimeter inclination and perimeter inclination and 0o close windows andslid intrusion Close open win intrusion Close open win ng roof dows and sliding roof dows and sliding roof Once deadlocking is com Once deadlocking is com pleted the sounder gives pleted the sounder gives one audible tone one audible tone Note No deadlock feature in Ja panese market A5 5 2 Unlocking key Instruction Variant 1 Variant 2 Variant 3 Turn key to unlock position Unlock all doors trunk lid Unlock drivers door only Unlock all doors trunk lid and release fuel filler cap trunk lid fuel filler cap fuel filler cap Disarmthe On variant 1 unlocking with the key does not dis armthe alarm system An audible ticking indicates that the alarm will activate after 30 seconds unless the key is turned to posi tion Il in the ignition or the key ringtransmitter but ton small is pressed Disarm the alarm system Switch on the interior light for 15 seconds alarm system Switch on the interior light for 15 sec onds rurn key to unlock position No feature and hold for 2 seconds Issue 1 August 1994 Unlock all other doors and trunk lid 12 No
337. lt extrusion cloth covered A4 7 2 6 Typical Door Seal Sections The relationship of the sealsto the door and body aperture can be seen inFig 1 Pleasenote that the seals are shown inthe natural state ie not deformed by the door being inthe fully closed position Section roof door aperture Primary seal Draught welt Section door frame upper Secondary seal J76 1029 Section door lower at waist Draught welt Section body aperture at waist Primary seal Peg primary sealto door J76 1030 Fig 1 Issue 1 August 1994 48 X300 VSM Security System RESTRICTED ISSUE SECTION CONTENTS Sub Section Title SRO Page Aaa System Description 1 AD re ini Component Descriptions oocooooocoommmmarsrrrrrononcannanancocncoroconcconccnss 3 E WEE Central locking switch 00 00 cece cece eee eee eee teen eee eee ena eee tees 3 AS 2 2 ci Hes eee Door ajar switches 6 0 ccc cnn nen een eee nee ence enn ene n Enea seas 3 AD 23 Micki see Door lock actuator and switch 3 A524 coco occ Door lock switchen 3 ASI Hood SWICH 3 E EE Home a aai EEEE ANERE EEEE ETE a ES 3 AD 2 ts Ser Inclination sensor 1 0 66 cece ee nee ee rr rr 4 A5 2 8 inen R Intrusion Sensor susessesosessssssssssossecrenuascesseeressecocerasesesesaseseeeo 4 ADZO te de E Reader exciter coil EE 4 A5210 sori ieena Reader exciter module s osssoossossossssesresorsssessesosessesereeceseesorerere 4 ABQ iia Security ac
338. ly Dismantlethe assembly clean all components and exam ine for any signs of wear or damage Renew components as necessary 312 947 X300 VSM 5 Issue 1 August 1994 Cooling System AJ16 ES SECTION CONTENTS Sub Section Title SRO Page LOV ccoo Preliminary Pages yeei tea aaa E EEE eee Aa i TT Faria diia Cooling System Description eu 7 4 1 7 7 coco Cooling System Description Major COMponentsS ee cece eee e eee EE 7 EE Cooling System Description Components for Climate Control System ee EEN 7 EAR Cooling System Description Components for Supercharged Engine eessen 7 De EES Cooling System Description Operation EE 7 ATi Cooling System Configuration enoonnenocnnenncnnennann e eee eee ee eee eeeeeeeeeeeeeaee 2 AA Service PrOCOQUIES acia a a a a 3 4 73 7 ica io Service Procedures Safety Precautions EE 3 473 2 ccoo Service Procedures Working PractiCeS EE 3 PE ee Service Procedures Coolant Change EEN 3 ATA ieee ies Drain and Fill PrOCedures wae cece eee eee eee eee EE EE EE 4 BLAS ea aoa Drain and Fill Procedures Radiator Drain e 4 ATA awn eek Drain and Fill Procedures Engine Drain e EE ENEE En 4 4 1 4 3 coco Drain and Fill Procedures Radiator Fill ooooooccocnccnnnn 4 ATA coman Drain and Fill Procedures Complete System Fill ee 5 BOTS wea da Fault DiaGnOSis aie a s anise lead See ENEE ee sents a Cee a ea seme awe ewe eee wate ee eee 6 BADIA ia Fault Diagnosis Introduction ee ENEE EEN ENEE EE EE EE 6 A
339. ly drained out and immediately plug all orifices ready for refitting to the vehicle X300 VSM 13 Issue 1 August 1994 ba Oy EX Climate Control Systems De Drain and discard the transit lubricating oil from a new compressor before it is be fitted An adjustment must then be made to avoid over filling the system by taking into account a the quantity found inthe original compressor b the quantity deposited inthe recovery equipment oil separator from the charge recovery operation Typical example Drained from original compressor 50 ml Recoveredfrom oil separator 40 ml Quantity to be putin new compressor 50 40 90 mi Please note that the discrepancy betweenthe cumulative figure of recovered and drained oil andthe nominal capacity of 180 ml is caused by normally unrecoverable oil being trapped in components such asthe condenser receiver drier or evaporator The previous statements apply even if a problem has occurred dueto oil leakage The amount of oil lost dueto leakage is generally small so to avoid over filling please follow the example If however the recovery process has not been necessary because refrigerant has also been lost then ONLY replace the quantity drained from the original compressor 14 9 5 Adding Lubricating Oil Component Related Should a major component such as condenser receiver drier or evaporator be renewed then an adjustment to the system oil level must be made This may be carried out inthe same way
340. ly pressureto the weathershield edge to ensure adhesion to the door a Refit the lower trim pad upper trim pad and the veneer trim pad 386 1923 X300 VSM 43 Issue 1 August 1994 Las Security System RESTRICTED ISSUE y A5 18 REAR DOOR LOCK ASSEMBLY RENEW SRO 86 25 47 a Removethe veneer trim pad See Section 13 of the VSM a Removethe upper trim pad See Section 13 of the VSM a Removethe lower trim pad See Section 13 of the VSM a Using a suitable plastic knife cut through the weathershieldto door sealant and pull backthe weathershieldfor ac cess to the door lock assembly a Cut and removethe securing tie wrap from the door lock assembly harness multi plug Displace and reposition the door lock assembly multi plug from the mounting bracket and disconnect e Disconnect the door handle link rod a Disconnect and removethe door sill button link rod a Undo and removethe door lock assembly securing bolts a Undo and remove the lower securing bolt from the glass frame e Displace and repositionthe door lock assembly into the bottom of the door e Displace and removethe edge clip from the door handle release cable a Displace and reposition the door handle release cable a Displace and remove the door lock assembly A5 19 TRUNKLIDLOCKACTUATOR RENEW SRO 86 25 49 a Open the trunk lid a Removethe luggage compartment lamp assembly See Section 15 of the VSM Displace and remove the trunk lid liner fastener
341. m Air Cleaner Air box bracket screw 85 11 5 Air box to bracket 95 12 5 Air boxto instrumount Se Air cleaner support bracket 4 0 liter supercharged Air meter to intake gaiter 4 0 liter supercharged Air temperature sensorto air box 12 1 Hose clamp air box to air meter 16 Hose camp air boxto body Instrument bracket Taptite screw 95 12 5 Trumpet to body 95 12 5 Air Conditioning Compressor Mounting tS ee Belt tensioner assembly to compressor bracket Compressor bracket to cylinder block Compressor to bracket Idler pulley to tensioner assembly Cooling System Bypass elbow to thermostat housing 95 12 5 Fan drive unit setscrew 12 16 Issue 1 August 1994 ii X300 VSM Engine AJ16 Engine Mounting Fixing lighteningTorque Nm Cooling System continued Fan drive unitto pulley 21 57 28 5 Hose clamp breatherto thermostat 15 25 Hose clamp breather to throttle body 15 25 Hose clamp bypass hose 25 735 Hose clamp water pumpto pipe 25 35 Thermostat cover to housing 215 28 5 Thermostat to cylinder head 21 5 28 5 Water pipe bracketto inlet manifold 21 5 28 5 Water pump assembly 21 5 28 5 Water pump to timing cover 21 5 28 5 Water pumpto water rail 25 735 Water railto cylinder block 21 5 28 5 Water temperature sensorto thermostat housing 14 5 19 5 Water temperaturetransmitter to thermostat housing 14 5 19 5 Engine mounting bracket screw 44 5 5
342. m 16 20 Track rod end taper ball pinto steering arm 59 71 Track rod end lock nut 51 69 Tube nut fluid pipe at steering rack 2 off 17 23 a_a X300 VSM iii Issue 1 August 1994 Wi Steering ll SERVICE MATERIALS Description Retinax A grease Front hub II and seals SSR sees Sub Section IV Service Data Power steering hydraulic fluid Dexron 2E ATF minimum or equivalent See Sub Section IV Service Data Application Specification Front hub end float 0 025 to 0 08 mm Front hub bearing grease Quantity 4 ml in each race Toe in 12 cylinder 0 5 or 10 underside of front crossbeam 143mm from ground level 0 5 or 10 underside of front crossbeam 153mm from ground level Toe in 6 cylinder Steering system capacity Approx 1liter from dry Steering system operating pressure 100 gt 110 bar Steering system level checking frequency oo km Steering rack turns lock to lock Drive belt tension 12 cylinder only ete method New belt 790 N Iftension falls below 270 N reset at 630 N Clavis method New belt 114to 120 Hz below 70 Hz reset at 87 to 93 Hz For new belt rotate engine 3 revolutions minimum and retension If tension falls Drive belt tension measuring point Mid way between crankshaft and compressor pulley Issue 1 August 1994 X300 VSM Steering 10 1 STEERING SYSTEM DESCRIPTION 10 1 1 Steering Column Major Components Integratedcolumn assembly
343. m Panel Hee EN 70 2521 as 19 E e Cupholder Renew wee cece cece ee eee eee eee eee eeeeeee 70 2522 aioe Rare eas 20 139 9 10 aia ina Cupholder Latch Renew oooenononononnnnannn eee ee eeeeeeee 76 25 29 swe sow sine 20 TED ai Fascia Board Renew oococcconnancn neeeee eee eee e eens 76 46 01 cuireas ih tes 21 E EG Fascia Board Remove for Access and Refit ee 76 46 01 90 oonoonoo 24 X300 VSM i Issue 1 August 1994 E Body Components Trim salia Body Components amp Trim SECTION CONTENTS Sub Section Title SRO Page BSO das Underscuttle Pad Drivers Side Remove for Access and Heft eu 76 46 1 1 90 een 26 13 320 ees Underscuttle Pad Passenger Side Remove for Access and Refit 76 46 15 90 naasna 26 LEINER Fascia Closing Panel Passenger Side Hee 704027 iii SEN 27 13 3 22 rica ge Fascia Closing Panel Drivers Side Heem 76 46 28 wacccnccnees 27 EK Fascia Center Veneer Panel Renew oocoooonoonconcnncnncancnm s TOATO commons 28 13 324 ao Console Finisher Veneer Panel Renew cecceeceeeeeeeeeeeneeeeees 76 47 26 ina ene 29 EIERE Console Ashtray Lid Veneer Panel Renew ee VOAL DT wou Ge aioe ete 30 133 20 oooommooo Console Ashtray Surround Veneer Panel Renew e A PE taa tai 30 EE Console Rear Extension Veneer Panel Renew TOAT 30 os 30 VILO erger ee Console Ashtray Dee LO OF VS sind wie bie cati n 31 LIZ Steering Column Upper Cowl Renew HEIEREN 32 13330 caca Steering Column Lower cowl
344. m between the underfloor catalyst and the floor a Apply sealantto the downpipe joints and olives See Ser vice Materials in the preliminary pages this Section a Fit and seat the olives to the downpipes Reconnectthe underfloor catalyst to the downpipes Reposition the olive clamps a Tighten the underfloor catalyst to downpipe clamps secur ing bolts s Alignthe intermediate silencers to the underfloor catalyst assembly a Tighten the clamp securing bolts Lower the vehicle on the ramp Remove the fender cover and close the hood X300 VSM 9 Issue 1 August 1994 a Automatic Transmission V12 amp AJ16 Supercharged Powertrain 8 2 8 TEMPERATURE SENSOR RENEW 4 0L SC AND 6 0L The temperature sensor forms part of the internal wiring harness Shouldthe sensor require replacement anew wir ing harness must be fitted See Subsection 8 2 2 8 2 9 VARIABLE FORCE MOTOR RENEW 4 0L SC AND 6 0L SRO 44 15 43 a Open the hood and fit a suitable fender cover a Raisethe vehicle on a ramp a Drain the transmission lubrication system see Sub sec tion 8 2 13 e Removethe fluid pan see Sub section 8 2 14 4 0L SC or Sub section 8 2 15 6 0L e Remove the fluid filter see Subsection 8 2 18 e Disconnect the internal harness plug from the variable force motor e Release and remove the motor retaining clamp to valve body securing screw Foi a Remove the retaining clamp 2 Fig 1 and remove t
345. 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 inthis position Note Withthe Performance Mode switch inthe NORMAL position the vehicle will pull away in second gear How ever if morethan 75 per cent of throttle is appliedwhen the vehicle speed is between zero and 13km h 8mile h then first gear will be selected From 13to 61 km h 8 to 38 mile h first gear is obtainable by kick down In sport modethevehicle pulls away infirst gear andthe transmissionoperates fully in all four forward gears X300 VSM 1 Issue 1 August 1994 9 GC Automatic Transmission V12 AJ16 Supercharged Powertrain Issue 1 August 1994 1 Torque converter 14 2 Turbine shaft 15 3 Pressure disk 16 4 Converter turbine 17 5 Converter stator 18 6 Variable force motor 19 solenoid 20 7 Fluid pan 21 8 Filter 22 9 Interior detent lever 10 Manual shaft 23 11 Control valve 12 Front band 24 13 Parking lock actuator 25 Rear band Sun gear shaft Sun gear Parking lock pawl Transmission case Output shaft Rear extension housing Rear internal gear Output planetary carrier assembly Reaction planetary carrier assembly LO roller clutch Main shaft Fig 1 Powertrain 4L80 E automatic transmission 5 24 23 22 31 Intermedia
346. mbly for the airbag is provided by a dedicated harness which isencasedin ayellow sleeve A mechanisminthe stalk assembly calledthe cable reelcassette provides conti nuity from the static column to the steering wheel The cable reel cassette is driven by atang which locates inthe steering wheel Becausethe connection is by wires andthe cassette assembly is only capable of approximately five 5 full turns it is critically important that initial positioning is correct see Section 15 Itis equally importantihat fitting of the steering wheel connection of the column lower shaft and steering rackshould ONLY be made with the steering rack inthe center of its travel WARNING DO NOT REMOVE THE STEERING COLUMN FROM THE VEHICLE WITH THE STEERING WHEEL AT TACHED UNLESS THE STEERING IS CENTERED AND THE COLUMN LOCK B ENGAGED IF THE LOCK BARREL IS TO BE RENEWED LOCK WIRE THE ASSEMBLY TO PREVENT ROTATION FAILURE TO OB SERVE THIS AND CONSEQUENT DAMAGE TO THE CABLE REEL CASSETTE MAY RESULT IN AN INOP ERATIVE AIRBAG SYSTEM SEE LABEL ON STEERING WHEEL HUB 10 3 SERVICE PROCEDURES 10 3 1 Working Practices It is not recommended that either the steering rack or engine driven pump assemblies are repaired in any way other than in accordance with the repair procedures described in this manual The fluid reservoir and filter is a disposable assembly and no attempt should be made to clean it internally Genuine replacement units must be fitted following routi
347. mbly from release lever Remove clutch release lever retaining clip and remove lever a Remove release lever pivot pin e Removetransmission switch a Remove rear mounting spring retainer securing nut a Remove rear mounting spring retainer and remove rear mounting assembly a Reposition selector shaft pin cover Remove selector shaft yoke to selector shaft retaining pin and remove the yoke a Remove slave cylinder securing studs a Remove the transmission from the unit lift a Removetransmission drain plug and allow to drain refit the drain plug e Fit newtransmission to unit lift a Filltransmission with oil and refit the level plug a Clean components and mating faces a Fitthe slave cylinder mounting studs a Lubricate the selector output shaft a Fitselector shaft yoke 3Fig 1 to selector shaft and secure with retaining pin 2 Fig 1 Reposition the retaining cover 1 Fig 1 over the selector shaft yoke retaining pin gt a Fit the transmission rear mounting assembly and secure with bolt a Fit reverse lamp switch a Lubricate the clutch release lever a Fit and align lever to transmission and engage onto pivot pin e Fit and fully seat lever to pivot retaining clip Lubricate release bearing housing s Fit and fully seat bearing assembly to lever a Selectthird gear a Move transmission to vehicle and raise into position a Insert transmission input shaft into clutch and fully seat transmi
348. mes gaseous Never attempt to guess the amount of refrigerant in asystem always recover and recharge with the correct charge weight this is the only accurate method AUTION If oil was drawn out during the recovery process the correct amount may be added directly from your recovery recycle recharge station if so equipped prior to the charging process It must be stressed that the needto protect compressor oil from moistureis vital observethe procedures in HANDLING LUBRICATING OIL and those concerning excessive engine revolutions Issue 1 August 1994 14 X300 VSM ba 95 Climate Control Systems EX 14 10 FAULT DIAGNOSIS 14 10 1 Introduction Itis very importantto positively identifythe area of concern before starting a rectification procedure A little time spent with your customer to identify the conditions under which a problem occurs will be beneficial Relevantcriteria are Weather conditions ambienttemperature intermittentor continuous fault airflowfault temperature control fault dis tribution fault and air inlet problem 14 10 2 Functional Check This simple first line check will allow you to ascertain whether the system is operating within its design parameters without recourse to JDE Please carry out the following in order Oo Start engine and attain normal running temperature Presss AUTO to display selected temperature and illuminate AUTO amp AJC state lamps Rotate FAN to increase or decrease l
349. mp High pressure hose pump to rack dam aged or restricted Fluid level low Drive belt loose 12 cyl only Drive pulley loose Steering pump mounting s loose Drive dog loose slipping or incorrectly fitted 6cyl only _ Hose or pipe fretting on body or chassis structure Hose twisted or restricted Renew reservoir Renew pump Renew hose Rectify fluid loss and or top up Inspect for damage and renew as required Tighten pulley to specification Tighten to specification Investigate amp rectify as required Rectify routing Rectify routing Issue 1 August 1994 X300 VSM Steering 10 5 OUTER TRACK ROD BALL JOINT RENEW SRO 57 55 02 a Disconnect vehicle battery ground lead a Raisethe front of the vehicle and remove the appropriate road wheel Slacken the track rod locknut but do not wind away from the ball joint 1 Fig 1 Note Leavethe lock nutin its original positionto initially locate the new ball joint a Removethe track rodballjoint nut anddiscard 2 Fig 1 at the steering arm 3 Fig 1 a Using service tool JD 100 1 Fig 2 releasethe taper and remove the ball joint 2 Fig 2 Fig 1 157 458 Fitthe new track rod ball joint up to the lock nut and se E cure atthe steering arm with a new nut tighten to specifi cation a Fittingisthe reversal ofthis procedure notingthatthe sus pension should be fully settled prior to tracking adjust ment 10 6 FRONT HUB
350. multi plug Removethe rear air distribution outlet box a Undoand removethecenter console rear mounting secur ing screw Displace and remove the console assembly and place on the bench a Placethe console in position inthe vehicle a Fit and tighten the console front securing screws a Fit and tighten the console rear securing screw a Reconnectthe security system valet switch multi plug a Placethe air distribution outlet in position a Connectthe rear cigar lighter harness multi plug where fitted a Fit and fully seat the air distribution outlet a Refit the fascia center veneer panel Refitthe radio console a Refit the console finisher veneer panel Refit the console ashtray a Refitthe underscuttle pads a Reconnect the battery Refit the battery cover X300 VSM 9 Issue 1 August 1994 sli Body Components amp Trim 13 3 2 ConsoleAssembly Renew Daimler VDP SRO 76 25 01 50 s Remove the battery cover Disconnect the battery a Removethe console rear extension finisher see sub sec tion 13 3 5 a Removethe console rear extension veneer panel see sub section 13 3 27 Remove the console rear extension see sub section 13 3 6 a Remove the drivers side underscuttle pad see sub sec tion 13 3 19 a Remove the passenger side underscuttle pad see sub section 13 3 20 a Remove the console ashtray see sub section 13 3 28 a Remove the console finisher veneer panel see su
351. n 8 2 7 OUTPUT SPEED SENSOR RENEW 6 0L SRO 44 15 41 a Open the hood and fit a suitable fender cover a Raise the vehicle on a ramp a Slacken the underfloor catalyst to downpipe clamps se curing bolts Displace and reposition the olive clamps on the pipes a Slacken the underfloor catalyst to intermediate silencer clamps securing bolts a Displace the underfloor catalyst assembly rearwards to disconnect from the downpipes a Displace and remove the olives from the downpipes a Using awire brush clean the olives and downpipe joints e Place a suitable piece of wood between the underfloor catalyst and the body for access a Reposition the edge of the transmission tunnel insulation foam for access a Release and remove the output speed sensor securing bolt Reposition the speed sensor protection cover for access noting that the cover remains captive onthe harness a Disconnect the speed sensor harness multi pin plug a Displace and remove the speed sensor from the trans mission case Cleanthe transmission case sensor area a Fitanew O ring sealto a new output speed sensor a Lubricate the O ring seal Fit and fully seat the speed sensor to the transmission case Reconnectthe harness multi pin plug e Reposition and align the protection cover a Fit and tighten the speed sensor securing bolt Reposition the insulation foam to its original position a Remove the block of wood fro
352. n a Crank engine to depressurize fuel system Switch ignition off Disconnect battery see Section 15 s Remove engine cover See section 3 2 Remove engine cover 1 4 turn fastener receptacles 1 Fig 1 from fuel rail 2 Fig 1 a Undo fuel feed hose to fuel rail union nut 3 Fig 1 Reposition fuel feed hose 4 Fig 1 from fuel rail Undo fuel return hose to fuel pressure regulator union nut 5 Fig 1 Reposition fuel return hose 6 Fig 1 from fuel pressure regulator 7 Fig 1 X300 VSM 5 Issue 1 August 1994 Fuel Emission Control amp Engine Management V1 2 LA A COM INSTA ER H S AA AT T y J OR EE A IVA SAS BA hu ASS O 2 Y a KL CH Disconnect vacuum hose 1 Fig 1 from cruise control actuator 2 Fig 1 a Disconnect vacuum hose 3Fig 1 from fuel pressure regulator Disconnect throttle control rods from throttle pulley assembly ball pins 4 Fig 1 a Reposition throttle control rods to inner wings a Disconnect cruise control rodfrom throttle pulley assembly ball pin 5 Fig 1 a Undo and remove bolts securing fuel rail a Reposition cruise control rod below throttle pulley assembly a Remove cruise control actuator bracket assembly and fixings 6 Fig 1 a Disconnect injector harness plugs 7 Fig 1 Disconnect throttle potentiometer multi plug 8 Fig 1 a Remove throttle pulley bracket assembly and fixings 9 Fig 1 a Remove injector harness pla
353. n 7 1 18 7 1 17 CLUTCH SLAVECYLINDER OVERHAUL SRO 33 35 07 Removethe clutch slave cylinder see Sub Section 7 1 16 a Dismantle the cylinder The new parts inthe kit will indicate which used parts should be discarded a Cleanthe remaining parts and the cylinder thoroughly with unused brake fluid of the recommendedtype and place the cleaned parts onto aclean sheet of paper WARNING USE ONLY CLEAN BRAKE FLUID OR DENATURED ALCOHOL METHYLATED SPIRITS FOR CLEANING ALL TRACES OF CLEANING FLUID MUST BE REMOVED BEFORE RE ASSEMBLY ALL COMPONENTS MUST BE LUBRICATEDWITH CLEAN BRAKE FLUID AND ASSEMBLED USING THE FINGERS ONLY a Examinethe cylinder bore andthe pistons for signs of cor rosion ridges or score marks Provided the working sur faces are in perfect condition new seals from the kit can befitted butifthere is any doubt asto the condition ofthe parts then a newcylinder must be fitted a Fitthe newseal 1 Fig 2 tothe piston 2 Fig 2 withthe flat back of the seal against the shoulder Lubricatethe seal andthecylinder bore with unused brake fluid of the recommendedtype and assemble thecylinder a Before fitting the dust cover 3Fig 2 smear the sealing areas with rubber grease a Squeezethe remainder of the grease from the sachet into the cover to help protect the internal parts a Refit the clutch slave cylinder see Sub Section 33 15 01 Bleed the clutch hydraulic system see Sub Section 7 1 18
354. n This in responseto signals from the control module Closing of the isolation valve blocks delivery of the pumpto the secondary circuit item 2 of the TMC The pump now drawsfluidfrom the reservoirviathe open hydraulicallyoperated inletvalve item13 Increasedpressureis now avail able atthe inlet valves items 16 and 17 for actuating the rear brakes thus decreasing the tendency of wheel spin Note The hydraulicinlet valve item 13 switches when traction control is initiated to changethe suction connection of the pumpfrom the accumulators item 9 to the fluid reservoir item 6 via the TMC TMC 1 primary circuit Electricpump motor TMC 2 secondarycircuit Two cireuit hydraulic pump Tandem master cylinder Damping chamber Vacuum booster Hydraulic inlet valve Central valve Isolation valve NO Fluid reservoir Relief valve Fluid level indicator Inletvalve NO Motor pump unit Inletvalve NO Low pressure accumulator 18 Inletvalve NO Fig 1 1 2 3 4 5 6 7 8 9 Issue 1 August 1994 14 Inletvalve NO Outlet valve NC Outlet valve NC Outlet valve NC Outlet valve NC Rear brake circuit left Rear brake circuit right Front brake circuit left Front brake circuit right X300 VSM Brakes The pressure at the inlet valves corresponds to the opening pressure of the relief valve item 15 incorporated inthe isolation valve Excess brake fluid is drained to the suc
355. n damage to the seal and sealing surfaces accounts for most cases of failure of seals Care in fitting is essential if good results are to be obtained A3 2 7 joints And joint Faces Removeall traces of old jointing materials prior to reassembly Inspectjoint faces for scratches or burrs and remove with afine file or oilstone do not allow swarf or dirt to entertapped holes or enclosed parts Blow out any pipes chan nels or creviceswith compressedair refitting or renewingany O rings or seals which have beendisplaced by the com pressed air Always use the specified gaskets Use jointing compound only when recommended otherwisefit joints dry When jointing compound is used apply ina thin film to metal surfaces take great care to prevent it from entering oilways pipes or blind tapped holes A3 2 8 Hydraulic Flexible Pipes And Hoses Before removing a hose from the brake or power steering systems thoroughly cleanthe endfittings andthe area sur rounding them Obtain blankingcaps beforedetachinghose fittings so that ports can becoveredto excludedirt Clean the hose externally and blow through with compressedair Examinethe hose carefully for cracks separation of plies security of end fittings and external damage Reject any hose found to be faulty When refitting the hose ensure that no unnecessary bends are introduced and that the hose is not twisted before or during tightening of union nuts Do notstore hydraulicfluid in an unsealedcont
356. n damper mounting 9 Rear suspension differential strut mounting Rear face body bumper strut mounting point Issue 1 August 1994 10 X300 VSM y Body Systems amp Body Repair X300 VSM 11 Issue 1 August 1994 Z Body Systems amp Body Repair y A4 2 2 3 Key Side View Please referto the illustration on the opposite page Location Rear Master Datum Vertical rear longitudinal Tapped boss rear suspension A frame mounting bush Rear suspensionspring pan damper mounting 8 Rear suspension differentialstrut mounting 9 Rear face body bumper strut mounting Point 12 Wheel centreto bumper cover face 11 l Wheelbase centre to bumper cover face X300 VSM Issue 1 August 1994 12 a Body Systems amp Body Repair y A4 2 3 ZINC COATED PANELS A4 2 3 1 Description Approximately 65 of the body in white BIW mass is made up of zinc coated panels All exterior skin panels with the exception of the roof are double side zinc plated and this coating nominally 75 mi crons provides corrosion protection in two ways 1 Shouldthe outer layer of paint become cnippog butthe zinc coating remain intact the zinc will oxidize on contact with air This coat of oxidation is impermeable and will prevent corrosion damage to the base metal 2 Ifboththe outer layer of paint and the zinc coating become damaged the zinc will react
357. n indicators flash once the red warning light in the central locking switch lights for 2 seconds the flashes once the vehicle is armed Note There is no audible indication when passive arming occurs To disarm a passively armed vehicle the ignition key or key ring transmitter can be used as follows Q Ignition key Switch to position Il o Key ring transmitter Refer to A5 3 5 Unlocking A5 5 9 Trunk Release The trunk lid can be released in the following ways Q From the vehicle interior by pressing the trunk release switch mounted on the facia o By using the ignition key in the trunk lid if the vehicle is disarmed If not disarmed the the alarm system will be activated and can be switched off by ignition key or key ring transmitter Q Remotely as part of the unlocking procedure by the key ring transmitter A5 5 10 Trunk Valet Isolate A valet switch is located in the centre console compartment and is fitted on all variants The switch is provided to prevent unauthorized entry into the luggage compartment by a parking attendant by inhibit ing the luggage compartment remote release switch The green headed valet key can be used to park and lock the vehicle but does not unlock the luggage compartment A5 5 11 Flush Sill Buttons Variants 1 and 3 except Japanese market are fitted with flush sill buttons mounted in the door trim panel To lock the door from the interior press the sill button down flush with the door trim pane
358. n seriously affect the operation of the climate control system and can cause damage to the heater circuit pump and supercharger circuit pump if fitted Hoseclips should always be positionedso that there is proper access for tightening and that the clip does not foul or interfere with the operation of any components Drive belts must always be tensionedto the specified value and the tension checked at the correct point on the belt This information is given in Subsection IV inthe preliminary pages When tightening components the torque figures given in Sub section Il inthe preliminary pages should always be used for the fastenings listed 4 1 3 3 Coolant Change The coolant must be changed at intervals of four years The system should be drained from the radiator drain plug flushed andfilled with fresh coolant Flushing should be carried out thoroughly to remove all the old coolantfrom the engineand heater matrix Theheatervalveis open with the ignition OFF After filling check the coolant concentration with a hydrometer For the specified anti freeze and coolant concentration see Appendix Al X300 VSM 3 Issue 1 August 1994 ES Cooling System AJ16 4 1 4 DRAIN AND FILL PROCEDURES 4 1 4 1 Radiator Drain a Placea drain tray in position under the radiator drain plug Fig 1 a Removethe headertank pressurecap Releasethe captive radiator drain plug and drain the coolant Tighten the radiator drain plug CAUTION This proced
359. n the dip stick check the oil level replenish if necessary For recommended engine oil refer to Appendix Al 3 1 4 OIL ALTER CARTRIDGE RENEW SRO 12 60 04 Thewhite oil filter cartridgedisplayingthe Jaguar logo islo cated on the left hand side of the engine below the throttle assembly Fig 2 When refitting tighten the oil filter cartridge using hand pressure only On no account usean oilfilter strap designedfor the removal of cartridges Note Thenormaltightening torque of the oil filter is a 3 8 to 1 2 turn after initial contact A AN SN ETD X200 VSM 3 Issue 1 August 1994 lepers Engine AJ16 3 1 5 FRONT ENGINE MOUNTING BRACKETASSEMBL Y RENEW SRO 12 45 01 LH SRO 12 45 03RH Each of the two engine mounting bracket assemblies com prises a mounting rubber 1 Fig 1 with an insulator 2 Fig 1 clamped betweentwo brackets 3 amp 4 Fig 1 The front of the engine complete with attached mounting bracket assemblies is seated on support brackets welded to the front crossmember and is secured to the brackets by a single fixing arrangement comprising nuts bolts and washers a Jack up the vehicle and secure the engine hoist Service Tool MS53 C to lifting eyes of the front engine lifting brackets a Remove the front engine mounting bracket assembly to front crossmember fixing screws These can be accessed via two round openings positioned underneath the cross member Removeany obstructing
360. n the solenoid to the valve body using a new securing screw Connect the internal harness plug to the solenoid a Refit the fluid pan see Sub section 8 2 14 4 0L SC or Sub section 8 2 15 6 0L a Lower the vehicle on the ramp a Refill the transmission unit with fluid see Sub section 8 2 13 e Remove the fender cover and close the hood Issue 1 August 1994 12 X300 VSM i Automatic Transmission V12 amp AJ16 Supercharged Mem Powertrain 8 2 12 B SHIFT SOLENOID RENEW 4 0L SC AND 6 0L SRO 44 15 46 Open the hood and fit a suitable fender cover a Raise the vehicle on a ramp a Drain the transmission lubrication system see Sub sec tion 8 2 13 a Removethe fluid pan see Subsection 8 2 14 4 0L SC or Subsection 8 2 15 6 0L a Disconnect the internal harness plug from the B Shift solenoid a Release and remove the B Shift solenoid to valve body securing screw Remove the solenoid from the valve body Fig 1 a Remove and discard the O ring seal from the solenoid a Placethe solenoid aside a Fit a new O ring sealto anew D Shift solenoid a Lubricate the O ring seal a Fitthe solenoid to the valve body using atwisting motion a Fit andtighten the solenoid to the valve body using a new securing screw a Connectthe internal harness plug to the solenoid a Refit the fluid pan see Subsection 8 2 14 4 0L SC or Sub section 8 2 15 6 0L e Lowerthe veh
361. nates in EA direction in a sinusoidal wave form aluminum IN E ETT Ambient temperature Temperatureoftheairsurroundinganobject _______ Ampere SI unit of current Ampere hour 1 Atnpere flowing for one hour Amp hour Anti Lock Braking System system usually elec ji ib controlled but can be mechanically which prevents wheel lock up under braking by sensing lack of rotation of a wheel s and diverting fluid pressure away from it them Originally Anti Blockier System Bosch i i ABS CM ABS TC CM ABS control module ABS traction control control module antenna plural antennae or aerial antennas analog analogue Analoa Volt Ohm meter atmosph 2res unit of pressure 1 01325 bar automatic transmission auto auto gearbox axle shaft SE shaft transmitting power to the rear wheel drive shaft hubs X300 VSM 7 Issue 1 August 1994 o Introduction GLOSSARY OF TERMS A8 Term s Abbreviation Definition Previously used ifapplicable term s or Eng lish Equivalent o Babbitt metal white metal backlight backlight rear screen back up lamp reversing lamp balk ring rotating component of manual transmission baulk ring which prevents premature engagement of gears battery positive Voltage B The positive Voltage from a battery or any B ve VSS circuit connected directly to it B
362. nces thereof COPYRIGHT Copyright Jaguar Cars Ltd 1994 All rights reserved No part of this publication may be reproduced stored in a retrieval system or transmitted in any form electronic mechanical photocopying recording or other means without prior written permission of Jaguar Cars Ltd Service Department Browns Lane Coventry CV59DR England Issue 1 August 1994 2 X300 VSM md Introduction Jacking Lifting Vehicle Recovery sad A O O gt pa O gt N Engine AJ16 Engine V12 IA ha MS N Cooling System AJ16 EW 2 1 SW 1 Cooling System V12 da Mi Fuel Emission Control amp Engine Management AJ1 6 C1 Fuel Emission Control amp Engine Management V12 Exhaust System AJ16 Exhaust System V12 N Q Manual Transmission amp Clutch AJ16 k Automatic Transmission AJ16 GO _ GO N Automatic Transmission V12 amp AJ16 Supercharged Tei Driveshafts amp Final Drive Steering O mad wl es Suspension de y 2 o Y Y WA WM W We Body Components amp Trim Climate Control Systems Electrical es wech Vil amp 3 Issue 1 August 1994 3 x3 Contents Appendices Specification Routine Maintenance General Fitting Instructions Body Systems amp Body Repair Security System Restricted Issue Issue1 August 1994 5 X300 VSM o De Introduction GLOSSARY OF TERMS 1 Intr
363. nctions vary slightly between marketvariants The actionfor eachvariantis describedseparate ly where appropriate Note Certainfunctions differ due to market variations Differences will be detailed in the the following instruction tables The variants are defined as follows o Variant 1 Europeanand UK markets Q Variant 2 North American markets o Variant 3 Restof the World A5 7 1 Locking key nstruction Variant 1 Variant2 Variant 3 Turn key to lock position and release imeter only arms Check that all doors trunk lid and fuel filler cap lock andthat the alarm system per Turn key to lock position ease Check that all doors trunk lid and fuel filler cap lock the alarm system perimeter vold for 2 seconds andre only arms and all open windows and sliding roof close within 1 5 seconds Turn key to unlock position Check all doors are dead and then to lock position locked and trunk lid and vithin 3 seconds Holdin fuel filler cap are locked ock position for 2 seconds Check alarm system per o close windows andslid meter inclination and in ng roof trusion arms and all open windows andsliding roof close within 1 5 seconds ing is completed the sounder gives one audible tone A5 7 2 Unlocking key Variant 1 Check all doors trunk lid and fuel filler cap unlock Instruction Turn key to unlock position and release
364. nd bearings and renew if leaking rough or noisy Fault Flaking Cause Flaking of the surface material due to fatigue Remedy Renew the bearing and clean all related components Fault Indentations Cause Surface indentations in the track caused by rollers either vibrating or impactloadingwhile the bearingis not rotating Remedy Renewthe bearing if rough or noisy Fault Cage wear Cause Wear around the outside diameter of the cage and roller pockets caused by poor lubrication and abrasive material Remedy Renew the bearings and checkthe condition ofthe seals X300 VSM 9 Issue 1 August 1994 gt 3 General Fitting Instructions Fault Roller wear Cause Marks on track and rollers caused by fine abrasives Remedy Clean all components and housings Check the seals and bearings and renew if leaking rough or noisy Fault Cracked race Cause Racecracked dueto incorrectfitting to shaft tipping or poor seating Remedy J51 065 Renew the bearing and check the condition of the seals Fault Discolouration Cause Discolouration ranging from blackto light brown caused by moisture or incorrect use of lubricants Remedy Re use bearings if stains can be removedby light polishing or if no evidence of overheating is apparent Check the seals and other component part condition Renew as necessary Fault Discolouration Cause Heat discolouration ranging from blue
365. nd 6 0L ecoonnnnnnnnun 4A TS EEN 6 8 2 4 settee tee Input Speed Sensor Renew 4 0L SC ee 44 15 40 conan 7 EE Output Speed Sensor Renew 4 OL SC ee EEN 44 154 eu 7 A Cece ie ie ei ok input Speed Sensor Renew 6 0L ee dd IBAN 8 ELL shi aia Canara Output Speed Sensor Renew 6 0L nass ENEE EN ENEE En AAT SAD EE 9 E Lada TemperatureSensor Renew 4 0L SC And 6 0L e 10 Bie Dia rates wie treats Variable Force Motor Renewl4 OL SC and 6 OL ee EN 4415 43 ccoo 70 82 10 preon eies Pulse Width Modulator TCC Solenoid Renew 4 0L SC and 6 0L 44 15 44 coco 11 S IT A Shift Solenoid Renew 4 0L SC and 6 0L oconncononnnncnannnans 44 15 45 ii 12 8212 A B Shift Solenoid Renew 4 0L SC and 6 0L eneen 44 15 46 ccoo 13 B21 ase eeu Lubrication System Drain and Refill 4 0L SC and 6 0L oooo 4424 EE 14 ELM Fluid Pan Renew 4 0L SC ee A4 2404 ccoo 15 RADA EE S Fluid Pan Renew 6 0L oooooccooconcnnnccnnnn eeeeeeeeeeaes 44 240 coco 16 Ll Oia Fluid Pan Gasket Renew 4 0L ech 44 24 05 cono 17 EAR Fluid Pan Gasket Renew 6 0L enee ENEE ENEE 44 24 05 enen 18 EAR Fluid Filter Renew 4 0L SC andeelen EECHER 19 AER Transmission Internal Harness Multi pin Zocker 73 Ring Renew 4 0L SC andeelen ENEE ENEE En 24 24 20 Eu 20 8 2 20 000nooooon o Internal Lubrication Pipe Renew 4 0L SC and6 0L en E cance nnenee 21 82 21 O internal Dipstick Stop Renew 4 0L SC andeelen 44 24 22 ccoo 22 8222 iP aaa Beles Manual Detent Spring Renew 4
366. nd Solenoids General Description een 30 AD ads A 32 LEO ENEE Relays Engine Compartment General Description ee EEN ENEE 32 E EE Relays Passenger Compartment General Description ee EE EEN ENEE 34 15 123 AAA Relays Trunk General Description EE eee ence eee EE EE 36 15 13 ds Control MOQUICS oonoonononcnnnnnnnn EE EE eee ENEE ENEE 38 LEO EA PA Control Modules General Description 38 Issue 1 August 1994 ii X300 VSM Y Electrical L SERVICE TOOLS amp EQUIPMENT Illustration Jaguar Number Notes ESA ii TORQUE TIGHTENING SPECIFICATIONS Tightening Torque Fixing Nm Instrument packto support panel 1 8 Fasciato console 2 5 3 5 111 SERVICE MATERIALS Description to be issued AA X300 VSM Fasciato support bracket 22 28 Tunnel bracketto body 22 28 l Bolster to tunnel bracket 1 5 Instrument pack to fascia 2 5 3 5 Strut to fascia 1 5 2 5 Fascia support strut to BIW 7 10 CPU bracketsto fascia 5 7 Fascia demister bracketto fascia 1 5 Fascia and air conditioning location to body 1 Air distribution box duct to air distribution box 1 Airbag carrier mounting bracketto fascia 5 7 instrument pack support bracket to fascia 5 7 Airbag bracket to fascia 1 5 2 5 Air distribution box to fascia 1 5 2 5 Airbag upper bracketto carrier 1 5 2 5 Instrument pack support bracket and strut 5 7 Fascia assembly to BIW 22 28 Airbag door bracketsto fascia 5 7 Airbag
367. nd align the puddle lamp to the door pocket and se cure with the lamp securing quarter turn fastener Refitthe armrest 13 2 7 Rear Door lower Trim Pad Renew SRO 76 34 06 a Removethe rear door armrest see sub section 13 2 8 From inside the door pocket release the puddle lamp 1 Fig 1 securing quarter turn fastener e Disconnect lamp multi plugs 1 Fig 2 and remove lamp e Displacethe trim panel 2 Fig 1 from door retaining clips a Displace trim padfrom the upper retaining tang 3 Fig 1 a Disconnect the door speaker multi plug 2 Fig 2 andthe window lift switch multi plug 3 Fig 2 a Feedthe lamp harnessthroughthe trim pad and lowerthe trim pad assembly a Remove the rear door pocket see sub section 13 2 9 7 a Displace and remove the retaining clips and remove the a M trim a Place the new door trim padto the front a Fit and fully seat the trim pad retaining clips a Refit the rear door pocket Fig 2 a Positionthe trim pad to the vehicle a Feed the puddle lamp harness through the trim panel Connect the window lift switch and speaker multi plugs a Locate the trim pad upper retaining tang a Fit and fully seat the trim pad retaining clips a Place the puddle lamp to position e Connectthe lamp multi plugs a Fit and align the puddle lamp to the door pocket and se 1 3 cure with the lamp securing quarter turn fastener Refitthe armrest J76 1085 issue 1 August 1994
368. nd outer bearing cups a Clean all components paying particular attentionto the re movalofalltracesof lockingcompoundfromthe hub AND axle shaft splines a Using service tools JD 550 4 2 4 1and 18G 134 fit new cups to the hubcarrier ensuring that they are square and fully seated Fitthe new outer bearing raceto the hub EM Note Do notfit seals or pack bearing at this point a Assemble the hub and race to the carrier along with bear ing spacer noting orientation and the largest available adjustable spacer i e 3 47 mm a Fitthe new inner bearing and ABS rotor to the hub s Apply acompressive loadto the hub bearing assembly using a press vice or longbolt Ensurethat the force that the axle shaft fixing would normally provide is not exceeded a Measure the hub end float using service tool JD 13B dial test indicator DTI a Using the indicated endfloat dimension select a suitable adjustable spacer to give the specified pretoad Note See Service Data preliminary pages for pre load specification and typical example Remove the outer bearing from the hub a Lubricate the bearings as specified a Locate the outer bearing to the hub carrier assembly gd Issue 1 August 1994 8 X300 VSM Driveshafts amp Final Drive Tal a Using service tools JD 550 4 2 4 1and 18G 134 fit new seal to the hub carrier ensuring that it is square and fully seated Invert the assembly and locate the bearing spacer
369. nd switch off the engine for 30 sec onds a Finally remove and wipe cleanthe dip stick Fig 1 check the oil level replenish as necessary For recommended engine oil refer to Appendix Al 3 2 4 OIL FILTER CARTRIDGE RENEW SRO 12 60 04 Thewhite oilfilter cartridgedisplayingthe Jaguar logo islo cated onthe lower left handside of the engine near side of the sump Access for removing the cartridge is from under neath the vehicle Fig 2 Removethe catalyst heat shield wherefitted and use a coil spring type filter wrenchto removethe cartridge Start and run the engine for a few seconds to charge the filter then stop the engine andcheck the oil level Replenish as necessary 312 785 X300 VSM 3 Issue 1 August 1994 Issue 1 August 1994 3 2 5 OIL COOLER RENEW SRO 12 60 68 The oil cooler is located belowthe radiator behindthe front bumper and is fitted to the radiator lower mounting using two securing bolts The coolerfeed pipe comprising several sections and return pipe Fig 1 are connected to the oil cooler by means of easily detachable quick fit connectors 3 2 6 FRONT ENGINE MOUNTING BRACKET ASSEMBLY RENEW SRO 12 45 01 LH SRO 12 45 03 RH Each of the two engine mounting bracket assemblies com prises a hydraulic mount 1 secured to an engine side mounting bracket 2 which inturn is boltedto the lower en gine housing The engine mounting heat shield 3 is fixed to the hydraulic mount studs 4
370. ne service or diagnostic confirmation of the failure of any component The importance of cleanliness cannot be over stressed not only with new parts but alsothose which may havefailed In service contamination ofthe hydraulic system is a major cause of failures and may be avoided with good working practices and care All new units and pipes must be supplied with suitable blanks in every orifice Should a unit not have blanks fitted do not use it return itto the supplier with an appropriate reason for your action To help the manufacturer diagnose problems and avoid post removal contamination provide full details of the fault and plug all connections as soon as they are released All suspect units must be returned to Jaguar Cars complete with relevant documentation CAUTION Itisimperativethat the power steering system does not becomecontaminatedinany way Always de cantfluidfrom afresh sealedcontainer and cleanthe area aroundthe reservoirneck bothbeforeand after topping up Never return drained fluid to the system 10 3 2 Fluid Level Check and Top up Position the vehicle on a level surface with the engine sta tionary andfluid cold Add fluid ifrequired sothatthe level falls BETWEEN the marks Fig 1 10 3 3 System Bleed followingmaintenance To avoid fluid aeration and possible pump damage the in itial fill process must be carried out with the ignition OFF Set the fluid level approximately 20 mm above the upper dipstick level and cyc
371. nelclearances are specified WITHOUT the edge seal refer to the illustration onthe following page A4 7 1 3 Criteria Alignment o Panels must be correctly profiled to maintain cosmetic appearance pressure on seals and control wind noise Particular areas of concern Hood to fender Trunk lidto fender and saddle Door to aperture Door to fender and adjacent door The relationship of the sliding roof panel leading and trailing edges to the main roof panel A4 7 1 4 Criteria Exterior Fitments Q Bezels trims and lamps must be centered within apertures and have equal clearances with adjacent panels Particular areas of concern Headlampto hood fender andtrim panel Exhausttailpipe trim to bumper cover cut out Rear lamp assembly to trunk lid fender and bumper cover trim Feature lines fender to door and door to door this includes body side mouldings A4 7 1 5 Exterior clearancesand alignments Illustrations Specifications for gaps and profile may be found on the illustrations onthe following three pages X300 VSM 43 Issue 1 August 1994 Q cc gt CH O a e Ha E Ha Ka Wu Kal CH O a Body Systems amp Body Repair 449 A4 7 2 DOORS A4 7 2 1 Features The doors feature Lubricated for life lift off hinges Welded drop glass frames Integral primary and secondary seal channels A4 7 2 2 Removal Apply tape as Fig 1to avoid paint damage during the re moval
372. ner is fitted to the rear of the trunk belowthe sill Interior trim finisher panels are fitted to the rear lamp units accessed from the trunk opening The trunk lid 5 Fig 1 is fitted with a removable moulded liner and two trunk illumination lights the lid is supported bytwo gas struts attachedthrough press on fittings between the inner wheel arch andtrunk hinge 6Fig 1 A warning triangle is attached by a brackettothe trunk lid and retainedinthe open position by a rubber block Europe inc UK only Trunk locking is based on acentral latch and striker operated electrically through the central locking system by an ad jacent actuator or by key in a barrel lock located behind the trunk lid badge For details on renewal of trunk front and side liners trunk carpet trunk seal retainer and battery cover see relevant Service Repair Operations 4 3 376 1056 1 Trunk Liners A Treadplate 2 Removable floor board 5 Trunk lid 3 Battery cover 6 Hinge Fig 1 Trunk Components and Trim issue 1 August 1994 38 X300 VSM Body Components amp Trim sii 13 4 2 Trunk Side Liner Left Hand Renew SRO 76 19 22 Raise trunk lid a Remove the trunk floor carpet 1 Fig 1 see subsection 13 4 4 a Remove the trunk front liner 2 Fig 1 see subsection 13 4 5 a Removethe trunk seal retainer 5Fig 1 see subsection 13 4 6 a Displace and remove the trunkside liner 3Fig 1 passing the fu
373. net long life Indicator bulbs Bulb Designation Holder Colour Exhaust temperature warning indicator bulb Orange 12 5V 1 2W Low oil pressure indicator bulb Orange 12 5V 1 2W Seat belt warning indicator bulb Orange 12 5V 1 2W Boot open warning indicator bulb Orange 12 5V 1 2W Door open warning indicator bulb Orange 12 5V 1 2W Coolant level warning indicator bulb Orange 12 5V 1 2W Air bag fault indicator bulb Orange 12 5V 1 2W Parking brake on indicator bulb Orange 12 5V 1 2W Brake system warning indicator bulb i Orange 12 5V 1 2W Main beam on indicator bulb Orange 12 5V 1 2W Right turn indicator bulb Orange 12 5V 1 2W LCD illumination bulb right Orange 12 5V 1 2W LCD illumination bulb left Orange 12 5V 1 2W Left turn indicator bulb Orange 12 5V 1 2W Traction control off indicator bulb Orange 12 5V 1 2W Transmission sport mode indicator bulb Orange 12 5V 1 2W Charging fault warning bulb Orange 12 5V 1 2W Check engine warning indicator bulb Orange 12 5V 1 2W Issue 1 August 1994 A1 95MY 12 X300 VSM Specification Indicator bulbs continued Bulb Designation T Holder Colour Low fuel level warning indicator bulb i Orange Rating 12 5V 1 2W Anekta indicator bul Orange Traction control fail indicator bulb Orange 12 5V 1 2W J eege Bulb failure warning indicator bulb Oranae
374. never cup or race in isolation a Hub At this point the hub may be renewed if required Assembly a Bearing Assemble the inner bearing track to the hub using service tool 18G 134 and adaptor JD 550 5 1 Assemble the outer bearing cup to the hub using service tool 18G 134 and adaptor JD 550 5 2 Pack each race with approximately 4 mi of grease and position the inner race onto the stub axle Apply a smear of grease to hub inner surfaces and bearingcups Assemble the hubto the stub axle followed by outer race bearing washer and hub nut Note Itis not necessary to fill the hub cavity with grease merely protectfrom corrosion with a coat of lubricant Seat the bear ings by slightly tightening the hub nut whilst rotating the hub Do not apply load without rotation a Endfloat Set a Dial Test Indicator DTI as shown in Fig 1 and adjustthe hub nutto achieve the correct end float Asthe adjustmentis made continually loadthe hub axial ly in both directions a Without disturbing the end float setting fit the castellated nut retainer so that it aligns with both hub nut and stub axle drilling a Secure nut retainer using a new cotter pin 2 Assembly andfitting isthe reversal of this procedure not ing that all fixings MUST be tightened to specification and operation of the braking system verified Fig 1 Issue 1August 1994 10 X300 VSM Qu Suspension Systems Sa SECTION CONTENTS Sub Section Title SRO P
375. new ia td Ee CN ENN 52 13 8 14 ooo Rear Center Static Seat Belt Renew oooononnnnncna eens eee e eee eee eens 53 X300 VSM iii Issue 1 August 1994 aid A SERVICE TOOLS amp EQUIPMENT Body Components amp Trim Illustration Jaguar Number Description Notes not illustrated SRO 76 46 1 1 90 and SRO 76 46 15 90 Underscuttle pad securing clip removaltool JD 202 not illustrated Fascia center vent removal SRO 76 46 06 tool IL TORQUE TIGHTENING SPECIFICATIONS Fixing Tightening Torque Nm Fascia Instrument pack to support panel 1 8 E Fascia to support bracket Fascia to console ene bracket to body Bolster to tunnel bracket Instrument pack to fascia Strut to fascia Fascia support strut to body CPU bracket to fascia 5 7 Fascia demister bracket to fascia 1 5 Fascia and air con locationto body 1 0 Air dist box duct to air dist box 1 0 Airbag carrier mounting bracket to fascia 5 7 Instrument pack support bracket to fascia 5 7 Airbag bracketto fascia 2 0 Air dist box to fascia 2 0 Inst pack support bracket to fascia 5 7 Fascia assembly to body 22 28 Airbag door brackets to fascia 5 7 Airbag door bracket to fascia and strut 4 0 Gas strut ball pinto weld nut 7 10 Hood lever 5 7 Clamp hood adjust cable 6 8 Interior Sun Visor fixin
376. ng bolt 5 Fig 1 a Undo fuel rail to regulator union nut a Reposition regulatorfrom fuel rail union and fit blanking plugs s Undo and remove fuel rail securing bolts a Remove fuel rail assembly 1 Fig 1 from manifold Fig 1 Fit blanking plugsto manifold a Drainthe residual fuel from the fuel rail into a suitable drain tin a Remove the injector retaining clips 2 Fig 1 a Remove injectors 3Fig 1 Disconnectvacuum hose from regulator a Remove regulator mounting bracket a Undo fuel rail to regulator union nut s Remove regulator assembly Refit in the reverse order of the removal procedure Issue 1 August 1994 6 X300 VSM Y Fuel Emission Control amp Engine Management AJ16 R 5 1 4 FUEL RAIL PRESSURE REGULATOR VALVE INJECTORS NORMALLY ASPIRATED ENGINE RENEW SRO 19 60 13 SRO 19 45 11 SRO 18 10 01 INJECTORS SRO 18 10 02INJECTORS VEHICLE SET 4 ISS 1 YA PAC CA E ARS Se US ES 319 464 Fig 1 Remove a Reposition top edge of trunk front liner for access a Disconnect multi plug from evaporative loss flange inset Fig 1 Switch ignition on a Crank engine to depressurize fuel system a Switch ignition off a Disconnect battery see Section 15 a Disconnect earth lead eyelet 1 Fig 1 from inlet manifold stud a Disconnect engine harness to oxygen sensor leads multi plug a Disconnect engine harnessto starter motor solenoid link
377. ng directed against the rack bar piston inthe 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 Section on X X CY SN AN A 8 357 277 Steering rack F Torsion bar Radial groove Driving pinion G Oil pump Speedometer Power cylinder H Pressure amp flow SCM Rotary disc valve limiting valve Transducer Control sleeve N Radial groove Fig 1 Major components amp hydraulic flow Neutral position Issue 1 August 1994 2 X300 VSM Steering With the vehicle travelling straight ahead the valve restrictions are balanced thus providing equal pressure on each side of the piston When load is applied at the steering wheel the two halves of the pinion valve are displaced making the restrictions unequal The differential pressurethen directs the rack piston in favour of the higher pressure As the turning loadis removedthe pressures equalize andthe steering returnsto the straight ahead position aided by suspen sion geometry The displacement of the halves of the pinion valve rotor and sleeve is controlled by the elastic deformation of the torsion bar which is concentric with the pinion and valve Outlet Outlet Inlet Inlet Radial groove return Radial groove feed Feedgroove Axial groove Axial groove Return groove 357 278 J K L M N O P Q R S Fig 1 P
378. ng if the action is not perfectlysmooth Lubricatethe bearing generously with lubricant appropriateto the installation Inspectthe shaft and bearing housing for discolouration or other marking which may suggestthat movementhastaken place betweenthe bearing andbearingseat If markingsarefound use Loctitewhen installing the replacement bearing Ensure that the shaft and housing are clean and free from burrs before fitting the bearing If one bearing of a pair shows an imperfection it is generally advisable to renew both bearings an exception could be made only if the bear ings hadcovered a low mileage and it could be established that damage was confinedto the one bearing Inthe case of bearingswhich are lubricatedwith grease e g hub bearings the space between the bearings should be smeared with a recommended grade of grease and the bearings and seal should be re packed When fitting the bearing to the shaft apply force only to the inner ring of bearing Fig 1A When fitting the bearing to the housing apply force only to outer ring Fig 1B Always mark components of separable bearings e g taper roller bearings when dismantling to ensure correct reassembly Neverfit a new inner roller assembly to a used outer track cremas ye WI A3 2 6 Oil Seals SS Always fit new oil seals when rebuilding an assembly Examinethe seal beforefitting to ensure that it is clean and undamaged Smear sealing lips with clean grease pack pa dus
379. nk Damaged or worn lower wishbone stabilizer bar insulator Weak spring s Worn or deteriorated rear stabilizer bushing s Supercharged sports and XJ12 only Damagedtires or unbalancedwheels and incorrect tire pressure Incorrect wheel alignment Steering system malfunction Damagedfront suspension lower and upper ball joints Incorrecttire pressure Damagedfront suspension lower and upper ball joints Braking system malfunction Steering system malfunction Damaged or worn sub frame to body mounting Damagedtires unbalancedwheels and incorrect tire pressure Poor lubrication wear of wheel bearing Wear of front suspension lower and upper ball joints Damagedor worn front stabilizer bar Damagedor worn stabilizer bar link Damagedor worn stabilizer bar bracket Loosenessof suspension connections Damaged or worn rear wishbone bushing Front and rear damper malfunction Weak spring Worn or deteriorated rear stabilizer bushing s supercharged sports and XJ12 only Action Renew front stabilizer bar 3enew insulators Renew link Renew bushing Renew damper if necessary Renew Bushina Renew bushings and springs Renew Bushings Renew dampers Renew springs Check the tires Adjust the wheel alignment Check steering system Renew ball joints Renew bushing Renew link Renew insulator Renew springs Renew bushing Check tires Adjust the wheel alignment Check steering
380. nnnnnnnnnnnn 7 A38 2 17 weueuunnes General Fitting Instructions LOCKING Wire eene 7 KAREN General Fitting Instructions Screw ThreadS EEN 7 AB 2 19 e General Fitting Instructions Unified Thread Identification BO S ee EE 7 KEE General Fitting Instructions Unified Thread Identification NUtS ee ENEE ENEE 7 AB2L2 sonnononos General Fitting Instructions Unified Thread Identification Studs Brake ROdS et 7 ABS cuuuuunnnnnnn Taper Roller Bearings Fault DiaQnOSiS ane 8 X300 VSM i Issue 1 August 1994 General Fitting Instructions 3 A3 1 SAFETY PRECAUTIONS Whenever possible use a ramp or pit whilst working beneath a car in preference to jacking Position chocks at the wheels as well as applying the handbrake Never rely on ajack alone to support a car Use axle stands or blockscare fully placedatthe jacking points to provide a rigid location Checkthatany lifting equipment used has adequate capac ity and is fully serviceable Ensure that a suitable form of fire extinguisher is conveniently located When using electrical tools and equipment inspectthe power lead for damage and check that it is properly earthed Disconnec the earth grounded terminal of the car battery Do not disconnect any pipes of the air conditioning refrigeration sys tem unlessyou aretrained and instructedto do so A refrigerantis used which can cause blindness if allowedto come into contact with the eyes Ensurethat adequate ventilation is provid
381. nnseeees itov AAA ee eis General Description REENEN EE EE 1 Mee Door and FuelFiller Flap 2 ia d d A 2 13 2 1 AA Doors Description oonmcccccccnnncccc eee eee eee eeeeaee 2 VO EN Front Door Trim Pad Veneer Panel Renew En LOARAT Scone eek 2 EPA Rear Door Trim Pad Veneer Panel Here OAT AD e SEN SEENEN 2 13 2 3 EE Rear Door Upper Trim Pad Remove For Access and Refit o 76 34 05 90 coc 3 EA EE Rear Door Upper Trim Pad Renew EE EK SCENE 3 1 LD Rear Door Window Lift Switch Veneer Panel Renew 76 47 34 cono 3 13 20 a Rear Door Lower Trim Pad Remove for Access and Refit 76 34 06 90 ooo 4 LRD tic rien Rear Door Lower Trim Pad Renew uassssunnnunnnnnnnnnnnnnnnnnnn 26 2406 sinana 4 UECHT Rear Door Armrest Renew oooocnnonococcn e eee eeeeeeeee CSC 5 132 9 AAA Rear Door Pocket Renew ooocoonnccconnannnn e eens 70 94 28 wise chee eee 5 13210 iaa Front Door Upper Trim Pad Renew EE 6 BRA A sone eine oho Front Door Lower Trim Pad Renew waescecc cece eee e eee eee eee eee 6 LG EEN Door Lock Barrel Fee ag 99 N NEK NNN KENE NRNN KAN ES EN AN EENS EN EEN SE EN AEN EN AN 6 T3218 ti Front or Rear Door Lock Striker Renew EN 6 13 2 14 tiparita Front or Rear Door Outer Handle Operating Rod Renew ENEE EE 6 Y dree Geis Front Armrest RENEW ws es ees ea oe heed ee ee eA ee eid ieee ee eee eee E 7 13 2 16 ononmmnoso Front or Rear Armrest Support Renew w ceeeeee eee ec cece eee e een nee eee ene eeeeeeeeeee 7 EE EE Fron
382. nocooncconnccnnnncnn EE EE 8 L523 EE E Instruments Indicator Lompen NEEN EEN ENEE 8 LILA t ia ie Instruments Liquid Crystal Display ooooomencnnocnennonnnnan ence ee eee eee eeeeeeeenaee 8 TI 2N RK NR EN Instruments Transducers ee ENEE EEN ENEE ENEE ENEE EE 8 102 Ox ia Instruments Panel General ee 8 LID SR aaa Kee aaa Instruments GAUGES saesae ns eee eee eee eee ee eee eee eee eeeeeeeenee 9 ee ee EN Instruments Odometer eresse eens 10 LS 2 9 ee KE ECKE Instruments Trip Computer ENEE EE EEN 10 IS 210 daa Nie Instruments Driver Information Messages ENEE EEN EE ENEE EEN EEN Eu 10 EZE Instruments illumination s nassunasannasannasannasannasannasannanansanansanansnnannnn 10 15272 TEE Instruments General Repair Notes ee EN 10 e EE Speed Control EE 11 ISA ccoo Driver ErQOnOMiCS reaa aaia i i a EE EE EE 12 ISS aa Battery amp Charging System 13 Sl da Battery General aiii ini 13 dE ai Battery Reserve Capacity cononcnnnncncananc n 13 EE Battery Cranking Performance une ENEE EE ENEE EEN 13 A A Battery Electrical Data ooconnnnnnnnnnnnn u 13 DEDO acre Biere Battery State Of Charge EE 13 AO uaia raa Battery Rate OFCHarg serian a E ENEE E a a aa 13 LONA ari eas a Battery Load Test EEN a a a ii aatia 13 15 5 8 coo Battery Specific Gravity Test EEN ENEE EE EE EE 14 1505 9 Eege g Battery Electrolyte Temperature Correction ee EEN EE EEN H 15 510 can Battery Health amp Safety Precautions ENEE EE EEN ENEE EE Eu 14 O e date a Battery R
383. note the reading a Ifthe end float exceeds 0 15 mm firstly verify the shim preloadand if this is found to be correct renew the output shaft bearing See 51 10 22 this section for shim check and renew operations 9 4 OUTPUT SHAFT HOUSING O RING RENEW SRO 51 20 19 a Disconnectvehicle battery ground lead a Priorto removal of shaft assembly check output shaft end float in accordance with operation 51 10 24 e See operation 51 10 22 this section for process detail less bearing oil seal renew 9 5 OIL SEAL PINION FLANGE RENEW SRO 51 20 01 a Disconnect vehicle battery ground lead Support the vehicle at the rear a Disconnect main handbrake cable at compensator e Match mark the FLEXIBLE COUPLING to the differential DRIVE FLANGE and remove fixings Removefixings center bearing to crossmember and push drive shaft rear section forward to disengage from pinion spigot CAUTION Under nocircumstancesmustthe flexible coupling orits fixings be loosened or removedfromthe drive shaft flange Support the drive shaft do not allow itto hang s Match mark the drive flange retaining nutto both the pinion and the drive flange Fig 1 a Slackenthe flange retaining nut approximately halfaturn and retightentothe match mark notingthe requiredforce If the force does NOT exceed 135 Nm the final drive unit MUST be replaced a Remove the retaining nut washer and drive flange CAUTION Use only special tools 18G 1
384. nthe ramp a Refill the transmission unit with fluid see Sub section 8 2 13 Remove the fender cover and close the hood Jm Issue 1 August 1994 16 x300 VSM d Automatic Transmission V12 amp AJ16 Supercharged po Powertrain 8 2 16 FLUID PAN GASKET RENEW 4 0L SC SRO 44 24 05 Openthe hood and fit a suitable fender cover a Raise the vehicle on a ramp e Drain the transmission lubrication system see Sub sec tion 8 2 13 a Slacken the downpipe catalyst to intermediate catalyst clamp securing bolts a Slacken the intermediate catalyst to intermediate si lencers clamp securing bolts a Disconnect the intermediate catalyst pipe from the down pipe Cleanthe downpipe and intermediate pipe joint a Release and remove the fluid pan securing bolts a Removethe fluid pan 1 Fig 1 and gasket 2 Fig 1 a Drainthe residual fluid from the fluid pan a Remove and discard the fluid pan gasket e Removethe magnet 3Fig from the fluid pan clean the magnet a Placethe magnet on a clean surface a Clean the transmission fluid pan joint face a Clean the fluid pan a Place the fluid pan aside a Attach the magnet to the recess in a new fluid pan a Fit and align a new gasket to the fluid pan a Fit the fluid pan and gasket to the transmission unit a Fit and tighten the fluid pan securing bolts a Apply sealant to the intermediate pipe joint See Service Materials inthe preliminar
385. ntil the next arming action The active indicator mounted in the switch housing will flash to confirm this action To disarm a passively armed vehicle the ignition key or key ring transmitter can be used as follows o Ignition key Switch to position WW o Key ringtransmitter Referto A5 3 5 Unlocking A5 7 8 Passive Arming Passive arming is a dealer option on variants 1 and 3 only With the ignition switch inthe OFF position check that passive arming of the vehicle takes place 30 seconds after the last closure of the doors trunk lid hood or sliding roof Ensurethatwhen passive arming occurs the direction indicatorsflash once andthe security active indicator inthe cen tral locking switch lights for 2 seconds then flashes once when vehicle arming is complete Note There is no audible indication when passive arming occurs A5 7 9 Trunk Release Check that the the trunk lidcan be released in the following ways Q Fromthe vehicle interior by pressingthe trunk release switch mounted on the facia o Byusingthe ignition key inthe trunk lid if the vehicle is disarmed If not disarmedthe the alarm system will be activated and can be switched off by ignition key or key ring transmitter o Remotely as part of the unlocking procedure by the key ring transmitter A5 7 10 Trunk Valet Isolate Check that valetswitch operation prevents unauthorized entry into the luggagecompartmentby inhibiting the luggage compartment remote releaseswit
386. nuts Renew all bolts that were originally fitted with thread locking adhesive Replace all locking wire and split pins cotter pins Tighten all fixings to the specified torque Correct the final drive oil level if required Check and adjust rear wheel camber setting as required 9 9 AXLE SHAFT ASSEMBLY RENEW SRO 47 10 01 Disconnect vehicle battery ground lead a Slacken appropriate axle shaft hub nut s Support the vehicle at the rear and remove rear road wheel a Remove brake caliper in accordance with 70 55 03 Sec tion 12 but do not disconnect hydraulics Slacken hub carrier fulcrum and remove ABS sensor from hub carrier a Remove axle shaft hub nut and collar a Remove fixings axle shaft to differential output shaft flange note camber shim a With servicetools JD 1D 7 Fig 1 andJD D Fig 2 push shaft through hub a Remove axle shaft assembly CAUTION Take care not to introduce debris into the hub bearings or damage seal a Priorto assembly remove all traces of adhesive from hub splines a Assembly and fitting is the reversal of this procedure taking note of the following Adhesive should be appliedto axle shaft splines over a radial area of 30 to 50 Renewall bolts that were originally fitted with thread locking adhesive Replace all locking wire and split pins cotter pins Tighten all fixings to the specified torque Check and adjust rear wheel camber setting Verify operation o
387. ny 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 Z Manual Transmission amp Clutch AJ16 Wee SECTION CONTENTS Sub Section Title SRO Page TON cono Preliminary PAGES oooononononnncnnnnc EE i to iii ALA WEE Manual Transmission Description EE EE 1 Z AA eee Manual TransmissionAssembly Heem ZELT cia 2 LAS ad ia Front Oil Seal Renew usuasssssannnunnnnnnnnnnnnnnnnnnnennnnnnnnn SLL SOG ai 5 TNA eee ee Rear Oil Seal Renew oocccccnnnnnnn SLO NEEN 6 Ken NEEN Gearshift Lever Renew EK EE 6 AO as Gearshift Lever Draught Excluder Renew EN EI A 6 V Aes EE Gearshift Lever Knob Renew ST AGAD vii id dos 7 TO ies d NENNEN Gearshift Lever Remote Control Assembly Renew 1 eee cece eee eeees BTANOCZO cas 7 FED SE Gear Selector Shaft Rear Overhaul en ST 16A ll coco 9 LINO A Reverse Lamp Switch Renew ececeeeceee cence eee eeneneeeeenees KLORE 9 LAT ere Layshaft Front Seal Renew KICHE EE 9 Kei EEN Clutch DESCIIDUON EE 10 TD DS an wie eee Clutch Fault Diagnosis a ee eee eee bees Pee es 1 LAVA A O ETEA Clutch Assembly Renew EE OT cationes 14 Li aere ees AC Clutch Master Cylinder Renew En 3320 0T td
388. o and remove the defrost vents clip location bracket securing screws Displace and remove the clip location brackets Removethe defrost vent spire clips from the fascia Place the fascia aside a Place a new fascia onthe bench a Fit and fully seat the defrost vent spire clips a Fit and align the defrost vent clip location brackets Fit andtighten the location brackets securing screws a Fit and align the fascia location brackets to the fascia a Fit and align the location bracket securing nuts a Fit and align the center vent flap assembly a Fit and tighten the flap assembly securing nuts a Fit and align the side vent ducts to the fascia assembly a Fit and fully seat the side vent ducts securing clips a Fit and fully seat the side vent outlets to the fascia En and alignthe airbag module BPU mounting bracket as sembly and align the spacers a Fitand tighten the airbag module BPU mounting bracket securing nuts bolts a Fit and align the airbag module to the fascia a Fit and tighten the airbag module securing bolts a Fit and align the airbag deployment door assembly to the fascia a Fit but do not fully tighten the door securing bolts a Align the door assembly to the fascia a Finally tighten the door securing bolts a Position the harness Route the harness speaker solar sensor multi plugsthrough the aperture inthe fascia a Fully seat the harness grommet to the fascia aperture a Route the twee
389. o driving position memory 2 The key ringtransmitter is activated by pointing ittowards the vehicle and pressing one of the two operating buttons the large button locks the vehicle and arms the alarm system whilst the small button unlocksthe vehicle and disarms the alarm system When either one of the buttons are pressed an indicator light on the key ring transmitter flashes red for the large button green for the small button Ifthe ignition key is left inthe ignition switch the following features will be inhibited Q Alarm system A5 7 4 o Remote luggage compartment release locking Key ring Transmitter Ifthe ignition key is left inthe ignition switch in position 1the remote headlampconveniencefeature will be inhibited nstruction Variant 1 Variant 2 Variant 3 ress large button once gt ress large button again Nithin 3 seconds of first oress Check all doors trunk lid and fuel filler cap lock and the alarm system per imeter only arms Ensure direction indicators flash once andthe security active indicator flashes when vehicle secured Check that headlamps are illuminated for 25 seconds if vehicle was previously locked and armed and but ton has not been pressed within 4 seconds Check all doors are dead locked andthe alarm sys tem perimeter inclination and intrusion is armed Check all doors trunk lid and fuel filler cap lock and the alarm system arms Ensurethat an audi
390. o sump pan bolts 15 18 Transmission oil cooler pipes ro 20 111 SERVICE MATERIALS Description Uses Notes To be issued 8 1 IV SERVICE DATA D 2 Issue 1 August 1994 ii X300 VSM Z Automatic Transmission AJ16 a 8 1 1 GENERAL DESCRIPTION This section provides information relating to the automatic transmissionsfitted tothe 32 liter engine ZF 4HP 22 trans mission and the 4 0 liter normally aspirated engine ZF 4 HP 24 E transmission The general arrangement of the two units is shown in Fig 1 and Fig 2 The two automatic transmission units differ inthe type of control unit employed the purely hydraulic control used inthe ZF 4 HP 22 unit shifts gears automatically at predetermined points while the electronic hydrauliccontrol of the ZF 4HP 24 E unit providesforoptimized shift pointsand shift quality basedon engine and transmission data received by the Transmission Control Module TCM Te S 4 4 Es D as ge Een gt la es ai A aa 10 P R 344 687 1 Torque converter 8 Shift lever positions 2 Throttle cable P Park 3 4 speed gear train H Reverse A Output flange NI Neutral 5 Transmission control unit D Drive Fully automatic control 6 Oil outlet drain plug 9 Dipstick oil filler tube 7 Shift cable attachment 10 Oil cooler connection Fig 1 ZF 4HP 22 Transmission X300 VSM 1 Issue 1 August 1994 ZF e Automatic Transmission AJ16
391. ock deadlock status Trunk release actuator switches Driver s door unlock shorting link Trunk release switch fascia RH WA post base fuse box Trunk release switch 5 Valet switch Issue 1 August 1994 24 X300 VSM y Security System RESTRICTED ISSUE Bai A5 9 1 Centrallocking switch Check continuityfrom 22 way multi plug pin 19to ground open circuit should be recorded Operate switch and check that short circuit to ground is now present Check wiring continuity from 22 way multi plug pin 19 to switch connector pin 3 ZS bb a Check wiring continuity from switch connector pin 1to ground Note lf switch is faulty the whole clock module must be renewed refer to sub section 15 9 10 Fig 1 Central Locking Switch Circuit X300 VSM 25 Issue 1 August 1994 Beet Security System RESTRICTED ISSUE y A5 9 2 Door ajar switches 1 Close all four doors and turn ignition to ON 2 Open each door in turn checking that instrument pack indicator lamp illuminates at every opening action 3 On identification of non illuminationcheck continuity across suspect door switch door closed switch open circuit door open switch short circuit 4 If switches test correctly check wiring continuity between SLCM connector and switches then to ground as detailed below Door SLCM Switch Ground Driver s Pin07 12 way Pin 06 Pin 07 Passenger s Pin OT 16 way Pin 06 Pin 06 front Passengers r
392. oduction This glossary of terms is intended to cover both general and emissions related to SAE J 1930 terminology Itis in tended to enable the userto ascertain the meaning of standardized terms and acronyms usedthroughout the Manual The requiredterm may be looked upinthe left hand column and subsequent columns give the standard abbreviation or acronym definitions and previously used terms as applicable As this Manualis a world wide publication and mustcomply with certain Society of Automotive Engineers Standards it has been necessary to adopt the terminology etc demanded by that Standard Term s Abbreviation Definition Previously used if applicable term s or Eng lish Equivalent A accelerator pedal AP throttle pedal across flats AF measurement across the spanner flats of a nut or bolt head adapter after bottom dead center ABDC event occurring after BDC aftertop dead center ATDC event occurring after TDC Air Cleaner Air Conditioning ee Le Air Conditioning Signal conditioning compressor clutch operation is signalled to the PCM which induces idle speed corrections to compensate for engine load changes Air ning Control Module module controlling air conditioning heating and ventilation airfoil wing or similar designed to obtain some aerofoil effect from the flow of air over it alternating current ac electrical current whose flow alter
393. oes lightly grease the shoe tips and back plate contact area The brake shoes and the expander assembly should befittedto the backplate with the lower return spring in position When the brake shoes are located the adjuster upper return spring and hold down springs should then be fitted The brake shoes should be adjusted so that the brake rotor hub can just be fitted Final adjustment should allow the brake rotor hub to rotate without excessive drag Light running contact is permissible Issue 1 August 1994 10 X300 VSM Brakes l 12 1 8 Wheel Speed Sensors A toothed wheel which turns with the road wheel induces an ac voltage signal in the wheel speed sensor The fre quency and amplitude of the ac voltage varies directly in relationto wheel speed providing the control module with wheel speed information Wheel speed sensors are fitted to each road wheel Front The front sensors are mounted on the vertical link 1 Fig 1 Rear The rear wheel sensors are mountedon the hub carrier Fig 2 X300 VSM 11 Issue 1 August 1994 Brakes 12 1 9 Hydraulic Operation ABSCM The TMC primary circuit item 1 applies brake pressureto the front brakes Individual control of the front wheels is provided by solenoid valves Valves items 15 and 18 control the front left brake circuit item 21 Valves items16 and 19 controlthe front right brake circuit item22 The TMC secondary circuit item2 applies brak
394. olutions per minute right hand right hand drive vehicle rocker panel roof lining door sill sill head lining Issue 1 August 1994 22 X300 VSM Introduction 23 GLOSSARY OF TERMS Term s Abbreviation Definition Previously used if applicable term s or Eng lish Equivalent A 3 Scan Tool ST device that interfaces with and communicates information on a data link Seat Control Module SCM module controlling the seat motor systems not electric raise lower only seats Secondary Air air providedto the exhaust system Secondary Air Injection AIR system used for a period of time each time AIP Al Thermac the engine is started unless certain air injection sys temperature criteria are met Pumps air tem directly into the exhaust system which generates extra heat and reduces the time taken for the catalytic converters to reach operating temperature Secondary Air Injection Bypass AIRB vents secondary air to atmosphere Secondary Air Injection Check AIRC valve which prevents back flow of exhaust NRV non return Valve gas to the AIR system when the system is valve inoperative Secondary Air Injection Diverter AIRD diverts secondary air to either the catalyst or exhaust manifold Secondary Air Injection Magnetic AIRPC clutch mounted on the AIRP drive shaft air pump clutch Clutch Secondary Air Injection Pump AIRP mechanica
395. om the downpipes a Using a wire brush clean the olives and downpipe joints s Place a suitable piece of wood between the underfloor catalyst andthe body for access Drainthe transmission lubrication system see Sub sec tion 8 2 13 e Release and remove the fluid pan securing bolts Fia 1 Drainthe residual fluid from the fluid pan a Remove the fluid pan 1 Fig 1 and gasket 2 Fig 1 a Cleanthe fluid pan gasket which can be re used if ingood condition a Place the fluid pan gasket aside a Removethe magnet 3Fig 1 from the fluid pan a Clean the magnet and place on a clean surface a Clean the transmission fluid pan joint face a Clean the fluid pan a Place the fluid pan aside a Attach the magnet to the recess in a new fluid pan a Fit and align a serviceable gasket to the fluid pan a Fit the fluid pan and gasket to the transmission unit a Fit and tighten the fluid pan securing bolts a Remove the block of wood from between the underfloor catalyst and the floor Apply sealant tothe downpipe joints and olives See Ser vice Materials inthe preliminary pages this Section 8 2 Fit and seat the olives to the downpipes Reconnect the underfloor catalyst to the downpipes a Repositionthe olive clamps a Tightenthe underfloorcatalystto downpipe clamps secur ing bolts a Align the intermediate silencers to the underfloor catalyst assembly a Tighten the clamp securing bolts Lower the vehicle o
396. omatic inputs Temperature and solar sensors Flapservo motor potentiometers Circulation pump amp coolant flow valve Power transistor fan speed control Compressor lock sensor 12 cylinder only Instrument pack coolant temp amp road speed engine revolutions via engine control module outputs Blower motors Left amp Right amp associated relays Flap servo motors Heatedfront rear screens amp exterior mirror relays Motorized in car aspirator Compressor clutch request to engine control module not heater only cars Circulation pump relay Coolant flow valve X300 VSM 7 Issue 1 August 1994 he WE Climate Control Systems 14 5 2 ControlModule Interfaces mm a Recirculation switch a Air con onloff switch a System onloff switch a Auto Man select a Set temperature a Air flow outlet mode set a Heatedfront screen switch a Heated rear screen amp heated mirror switch Air Temperature Control a External temp display a switch a Coolant recirculation valve a Fahrenheit Centigrade a Coolant recirculation pump switches e Cool air by pass Air Flow Speed Control CONTROL PANEL a External temp display signal Vehicle speed signal Circulation pump a Coolant flow valve a Powertransistor fan speed control Servo motor potentiometers LH air inlet flap Air Inlet Control ia LH air inlet im RH air inlet a Solar sensor a LH blower motor amp
397. on of the cooling system for normally aspirated and supercharged 4 0 liter engines is shown in Sub section 4 1 2 The cooling system is pressurized which allows the system to operate at a higher temperature without overheating The header tank is fitted with a pressure relief cap to protect the system against overpressure Undercold start conditions coolantisforced by the enginedriven water pumpthrough the cylinder block andcylinder headto the thermostat housing The thermostat isclosedto give rapid engine warm up hencethe coolant is returned directly to the water pump inlet When normal engine operating temperature is reached the thermostat opens and coolantis divertedthrough the radiator beforereturning to the water pumpinlet Invehiclesfitted with a supercharger coolant is circulatedthrough the supercharger radiator and intercooler by the superchargerwater pump The super charger cooling circuit uses the same coolant header tank as the main engine cooling system The radiator cooling fans operate in series and parallel under the control of the double action radiator mountedtem perature switch The fans are also controlled by the climate control system on vehicles fitted with air conditioning Under hot operating conditions the fans may continue to operate after the engine has been switched off The fans stop automatically when the coolant temperature has been reduced sufficiently The system also provides the coolant supply for the climate
398. on the radio console assembly from the mounted position a Disconnect the assembly harness multi plugs a Disconnect the antenna co axial connector Undo and remove the ground lead to radio securing nut a Repositionthe ground lead from radio stud a Disconnectthe radio harness multi plugs a Reposition the radio harness from the center console a Displace the radio console assembly a Remove the radio assembly from the console a Remove the radio retaining plate a Undo and remove the air conditioning control module se curing screws a Displace and remove the module a Undo and remove switch clock module securing screws a Displace and remove the module assembly a Place the radio console aside a Place the new radio console to the front a Fit and fully seatthe switch clock module to the console a Fit and tighten the module securing screws a Fit and fully seat air conditioning module to the console a Fit and tighten the securing screws a Fit and fully seat the radio mounting plate to the console a Place the radio console to the center console position a Place the radio to the center console position s Route the radio harness multi plugs through the radio console into the center console position a Connect the radio harness multi plugs ns Connectthe radio console harness multi plugs a Route the radio ground and antenna leads through the radio console a Fully seat the radio console inthe mounted posi
399. onal twin branch down pipes 6Fig 1 hencethere are no oxygen sensors or exhaust gas temperature sensors Conventional mufflers are fitted in place of the underfloor converters X300 VSM Issue 1 August 1994 Issue 1 August 1994 2 gt Exhaust System V12 J330 233 Fig Components of the Exhaust System Two heated oxygen sensors are fitted to the downpipe assembly 1 Fig 1 which is connectedto the manifold andtwo on the underfloor catalyticconverter assembly infront of the catalysts There are two sensorsfor the ROW and Japan markets 2 Fig 1 andtwo additional sensors 3Fig 1 for the NAS markets The sensors are located on A bank and B bank 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 gas temperature sensors 4 Fig 1 The exhaust system is held in a predetermined position by a fixing arrangement to the manifold by exhaust centre mountings 5 Fig 1 by rear axis mountings Fig 1 and tail pipe mountings 7 Fig 1 Clamps 8Fig 1 used on each slip joint are welded to the pipes and tightened to a higher torque setting than non welded clamps X300 VSM Exhaust System V12 et The exhaust system must be free of leaks binding grounding and excessivevibrations These conditions are usually caused by loose broken or misaligned clamps shields brackets or pipes Should a
400. onents andtools clean Recovery Recycle and Recharge equipment must comply with or exceed the standard detailed in the preliminary pages O O 14 1 2 Handling Refrigerant Q Wear eye protection at all times Use gloves keep skin that may come into contact with HFC 134A covered Should refrigerant come into contact with your eyes or skin wash the affected area with cool water and seek medical advice do not attemptto treat yourself Q Avoid breathing refrigerant vapour it may cause ir ritationto your respiratory system O Never use high pressurecompressedair to flush out a system Under certain circumstances HFC 134A compressed air a source of combustion welding and brazing operations in the vicinity may result in an explosion andthe releaseof potentially toxic com pounds o HFC 134A and CFC 12 must never come into contact with each other Fig 2 they will form an inseparable mixture which can only be disposed of by inciner ation Q Do not vent refrigerant directly to atmosphere al 382 986 ways use Jaguar approved recovery equipment Re member HFC 134A is costly but recycleable continued X300 VSM 1 Issue 1 August 1994 m PE Climate Control Systems Q Because HFC 134A is fully recycleable it may be cleaned by the recovery equipment and re used following removalfrom a system O Leaktests should only be carried out with an electronic analyzer which is dedicatedto HFC
401. onnect vehicle battery ground lead a Remove the door trim veneer door upper trim pad door lower trim pad a Disengagethe handle operating rod retaining clip and free the rod from the operating pivot a Allow the latch levertocontact the release mechanism re position the operating rod and replace the retaining clip 1 3 a Check that the setting is correct by operating the door mechanism e To refit carry out reversal ofthe above procedure Issue 1 August 1994 6 X300 VSM Body Components amp Trim all 13 2 15 Front Armrest Renew a Disconnect vehicle battery ground lead s Remove access covers to armrest fixings a Remove screws securing armrest to support bracket a Remove armrest and remove fixing screw inserts from armrest a To refit carry out reversal of the above procedure 13 2 16 Front or Rear Armrest Support Renew a Disconnect vehicle battery ground lead Remove door armrest a Remove lower trim pad from door a Drilloutrivetsandremoveretainingscrewsfromfront and rear armrest support brackets a Remove drilling debris and swarf Make good any damage to body finish caused by drilling use zinc primer and body colour a To refit carry out reversal of the above procedure 376 1952 13 2 17 Front Door Pocket Renew 1 Primary seal 5 Uppertrim i 2 Secondary seal 6 Lowertrim a Disconnect vehicle battery ground lead 3 Armrest 7 Coin box a Remove armrest 4 Door pocket
402. oof and open windows Interiortrunk lid release Trunk lid unlockingfrom fascia mounted switch Flush sill buttons intrusion override Sill buttons fitted flush to door trim panelto prevent unauthorized override operation buttons are latched in position when deadlocking is applied X300 VSM 7 Issue 1 August 1994 Saxe Security System RESTRICTED ISSUE y A5 3 2 Security system Base system Provides standard vehicle arming ie door ajar actuator lockstatus trunk lid or hood ajar and passenger door unlock ing does not include inclination or Intrusionsensing Detection of intrusion into the passengercompartment by removal or breakage of any glazed area entry via any pro tected enclosure and unauthorized door opening detection Inclination tilt sensing Detection of unauthorized jacking towing Passive arming Arming of the security system excluding intrusion sensors without audible confirmation Audible tones Audible indication of driver error when attempting to arm the system or on initiation of deadlocking Engine immobilization Automatic immobilization of the engine crank facility whenever the ignition key is turned to position 0 A5 3 3 Convenience All close Automatic closure of open windows and sliding roof by prolonged action of key or remote fob transmitter after door locking Headlamp convenience Automatic illumination of headlamps for driver convenience on operation of key fob button after lockin
403. operating on rear drums within bell of the rear brake discs 28mm wear limit 27mm 20mm wear limit 18 5mm Vacuum power hydraulic operation Bore diameter 25 4mm Jurid 518 Jurid 101 Ferodo 3612 6 5 1 vacuum Electrical inductive sensors at the wheels which detect rotational speed Hydraulic vehicles with traction control contains four solenoid valves one for each wheel vehicles without traction control contains three solenoid valves one for each front wheel and one for both rear wheels Solid state digital unit integral with hydraulic module Issue 1 August 1994 A Lem Specification Steering and Suspension Note When checkingthe steering geometry usethe pull downtools front and rearto set the ride heightfront and rearto the following dimensions 6 cyl Front nde height ocoooconacccnnccanc rr 153 5mm to underside of front crossbeam Rear ride height ENEE EE EEEE ENEE teina ENEE EE EE EE AER E 160 mm to underside of rear edge of A frame V12 Front ride height 1 cece eee eee eee iinta iei a niia 143 5mmto underside of front crossbeam Rear ride height cceeccceeccceeecceescceesereeserecsereceereae 160 5mm to underside of rear edge of A frame Note Sportspack derivatives whose kerb height is below the above figures can have their geometry checked at that height Front Suspension TIPO iia rl RS a a wa wwe we ate wn ee a Independentfront suspension consisting of double wishbon
404. or pulley 4 rib Poly vee X 1010 mm long Burroughs method New belt 556 to 578 N Iftension falls below 245 N reset at 378 to 400 N Clavis method New belt 167to 173 Hz Iftension falls below 85 Hz reset at 127to 133 Hz Mid way between crankshaft and compressor pulley on the upper run Feature Recovery rate Cleaning capability Oil separator Moisture indicator Vacuum pump Standard for Recovery Recycle Recharge Equipment Requirement 0 014 0 062 m min 1 36 kg in 20 minutes 15 parts per million ppm moisture 4000 ppm oil 330 ppm non condensable gases in air With hermetic compressor and automatic oil return Sight glass type sensitive to 15 ppm minimum 2 stage 0 07 0 127 m min Filter Replaceablewith moisture indicator Charge Selectable charge weight and automatic delivery Hoses Dedicated HFC 134A port connections Charge pressure Heating element to increase pressure X300 VSM Issue 1 August 1994 yA a Climate Control Systems Aer 14 1 WORKING PRACTICES 14 1 1 General o Beawareof andcomply with all health and safety requirements whether they be legislative or commonsense This applies to conditions set both for the operator and workshop o Before commencing any repair or service procedure disconnect the vehicle battery ground connection and protectthe vehicle where appropriate from dirt or damage Work in a well ventilated clean andtidy area Fig 1 Keep all comp
405. oratortemperaturefrom falling below0 C The graph is typical of HFC 134A Issue 1 August 1994 22 X300 VSM Ox Climate Control Systems YE 14 16 SYSTEM PRESSURE FAULT CLASSIFICATION This table should be used inconjunction with the graphical representations of High side pressure ambienttempera ture and Low side pressure evaporator temperature this section Low Side Gauge High Side Gauge Fault Cause Normal Normal Discharge air initially cool then Moisture in system warms up Normal to low Normal As above As above Low Low Discharge air slightly cool HFC 134A charge low Low Low Discharge air warm HFC 134A charge very low Low Low Discharge air slightly cool or frost Expansionvalve stuck closed build up at expansion valve Low Low Discharge air slightly cool sweat Restriction in High side of ing or frost after point of restriction system High Low Compressor noisy Defectivecompressor reed valve High High Discharge air warm and high side HFC 134A charge high or pipes hot inefficientcondenser cooling due to air flow blockage or engine cooling fans not working Lu High High Discharge air warm Expansion valve stuck open Sweating or frost at evaporator Note If erratic or unusual gauge movements occur check the equipment against a known calibrated manifold gauge set X300 VSM 23 Issue 1 August 1994 24 C Electrical e SECTION CONTENTS Sub Section
406. orn for combating fire Material near fires must be cooled with water spray to prevent ignition Fires should be allowedto burnthemselves out if notthreatening to life or property Iffire isthreateningto life or prop erty use copious quantities of water to extinguish 15 1 7 Ventilation Localexhaustventilation designed by a professionalengineershould be provided if vapours fumes or dusts are gen erated whilst working with airbag module The latest issue of the manualfor recommendedpractices on Industrial Ventilation is available from the ACGIH Com mittee on Industrial Ventilation PO Box 16153 Lansing MI 48910 USA The need for local exhaust ventilation should be evaluated by a professional industrial hygienist 15 1 8 Respiratory Precautions To prevent the inhalation of dangerous fumes and dusts an approved mask should be worn 15 1 9 Eye Protection Chemical protective goggles are recommendedwhere there is a possibility of eye contact with the propellant Safety glasses with side shields are recommendedfor all other operations 15 1 10 Protective Clothing Approved protective gloves overalls and shoes boots should be worn 15 1 11 Handlingand Storage Precautions Do not store airbag module near live electrical equipment or circuitry Store in a dry environment at ambienttempera tures Good housekeeping and engineering practices should be employedto prevent the generation and accumulation of dusts Store in complianc
407. orque damper springs in clutch driven plate Free driven plate and check for wear and distortion Renew if necessary Engine mounting Check for damaged or deteriorated engine mountings Check fixings for tightness Renew if necessary Issue 1 August 1994 12 X300 VSM Clutch Fault Diagnosis Symptom Slipping clutch indicated by vehicle speed not respondingto engine speed increase Dragging or spinning Manual Transmission amp Clutch AJ16 im Possible Cause Check Remedy Poor driving tech Ensure that none of the remedy Do notincreaseengine speed nique conditions prevail with clutch partially en gaged Do not drive with left foot resting on clutch pedal Operating mechan Check for binding withdrawal lever Free lever and check for wear ism faulty and distortion Check for binding of clutch pedal movement components components Clutch unit faults Check for oil on friction faces Free off seized or Clean off metal faces Renew driven plate Rectify oil leak Operating mechan ism faulty Checkfor binding withdrawal lever Free lever and check for wear and distortion Check for binding of clutch pedal movementcomponents Free off seized or binding components Clutch unit faults Clutch unit faults Check for oil on friction faces Check for broken rv springs Check clutch plates and for wear and distortion Check clutch driv
408. ort not equal sideto side from center Variation from heavyto easy when driving Transducer not closed Transducer not closed ground short Transducer not closed no feed voltage Transducer not closed defective cable SCM defective Delivery pressureor flow too low Internal rack leakage tire pressures low Transducer open too early Transducer open too early incorrect SCM type Transducer open too early incorrect Speedometer signal Rack reaction limitation valve CLOSED or setting incorrect Transducer not open no oil flow Transducer not open SCM faulty Transducer not open incorrect speedom eter signal Rack reaction limiting valve OPEN or setting incorrect Low pressure pipe flattened or re stricted Blocked reservoirfilter tire pressure high Rack check valve leak Rotary valve blockage Incorrect lower column assembly see Cyclic load variations Incorrectspeedometer signal Transducer cable connectionfaulty or grounded Inspectand check for debris Renewtransducer Investigate and repair Renew cable Renew module Renewpump Renew rack Set to specification Renewtransducer Renewscm Renew speedometertransmitter Renew rack Inspectand check for debris Renew SCM Renew speedometer transmitter Renew rack Renew pipe Renewfilter Set to specification Renew rack Renew rack Rectify as required Renew speedometer transmitter In
409. orting amp hydraulic flow LOW speed clockwise rotation X300 VSM 3 Issue 1 August 1994 Qu Steering The rotaryvalve withinthe pinion housingonthe Servotronic system isfittedwith a Hydraulic Reaction Piston HRP The HRP moves axially relative to the rotor on ball bearing travellers acting as a face cam and is connected to the sleeve by afour bearing helicalscrew Pressureapplied eitherside of the HRPistranslatedinto arotationalforce which resists torsion bar valve displacement thus increasing steering effort The amount of pressure applied to the HRP is controlled by a the differential pressure onthe rack piston proportionaltovehicle corneringforce and b the position ofthe transducer valvecontrolledby the SCMfrom information gathered on road speed Roadspeed data is processed from the left hand rear wheel speed sensor Electronic speedometei SCM Transducer Reaction area Reaction area Checkvalve Checkvalve Choke Choke Reaction limiting valve Reaction piston Radial groove return Radial groove feed OO YO OB WP oss S Fig 1 Sensors valves amp hydraulic flow HIGH speed anti clockwise rotation Issue 1 August 1994 4 X300 VSM Steering 10 2 SERVICE PROCEDURES SAFETY RELATED 10 2 1 Airbag The electrically activated driver s side airbag is attached to the steering wheel hub and is fed by two wires from the column stalk assembly Electrical inputto the column stalk asse
410. ose products specifically designed for this application and follow the manufacturers recommendations A4 2 3 4 Refinishing Use only those products approved by Jaguar Cars Ltd and take special care with zinc coated panels Replacement panels are supplied ready primed so there should be no needfor bare metalto be exposed other than those areas preparedfor welding etc see Welding Preparation sub section 4 2 3 2 Where any partof a panelis dressedback to a bare surface it should be treated with a zinc rich primer compatiblewith the chosen paint application system please refer to section A4 4 1 1 Issue 1 August 1994 14 X300 VSM E Body Systems Body Repair A4 2 4 PANELS ASSOCIATED RENEW SRO 77 10 02 Note Whereothercomponentsmustberemovedto gain access pleaserefer to the relevantmanualsectionfor guid ance This is critically important with regardto steering braking suspension electrical and safety systems a Exposethe resistancespot welds for those spot welds which are not obviously visible use a rotary wire brush fitted to an air drill or ahand held wire brush A Fig 1 WARNING DO NOT BURN UNDERSEAL OFF USE A HOT KNIFE OR SUITABLE SOLVENT Cut out the spot welds using a Zipcutter or Roto Bor B Fig 1 At this point it may be necessaryto cut out the bulk of the panel using a pneumaticsaw C Fig 1 Note Onsome panels before removing the bulk of panel with the pneumaticsaw brazed areas and MIG welded
411. ot applicable not applicable Note Tires other thanthose recommended by Jaguar must be inflated to the following cold inflation pressure 2 9 bar 44 Ibf in2 both front and rear Snow Chains Snow chains may be fitted to rear wheels only Use Jaguar snow chains The chains must not be used on roads which are clear of snow Maximum speed without snow chains fitted is 210 km h 131 mile h Maximum speed with snow chains fitted is 48 km h 30 mile h OO OO o X300 VSM A1 95MY 11 Issue 1 August 1994 mm Specification Description Capacity Type Door guard lamp 12V5W Capless long life Flasher side repeater Capless long life Fog lamp Front 12v55w Fog lamp Rear guard 12v21w Bayonetlong life Frontturn indicator if 12V 21W Bayonetlong life Pilot lamp 12V 5W Headlamp 12V 55W High mounted stop lamp wherefitted 12v 5x5W Capless long life Halogen H Capless long life Roof console central courtesy lamp Capless long life Roof console reading lamp Capless Luggage compartment lamp Capless long life License plate lamp Festoon Rear turn indicator 12v21w Rear quarter courtesy lamp lower section Rear quarter reading lamp upper section 12V6W Back up lamp 12v21w Stop Tail lamp 12V 21V 5W Sun visor vanity mirror lamp 12v1 2W Tail lamp 12V5W Capless long life Twin filament bayonet long life Capless 286 Bayo
412. ote 111 Caliper to carrier securing bolts IV SERVICE DATA Front brake disc run out Front brake disc parallelism E Rear brake disc run out 0 101 mm 0 004 in max Rear brake disc parallelism 0 0127mm 0 0005in max 0 101 mm 0 004 in max Issue 1 August 1994 ii X300 VSM Brakes 12 1 ANTI LOCK BRAKING SYSTEM ABS GENERAL DESCRIPTION The anti lock braking system ABS components are combined with a hydraulic booster andtandem master cylinder TMC to provide a two circuit braking system The anti lock braking system comprises the following components Q Four inductive wheel speed sensors hub end mounted o ABS warning light o Hydraulic module The hydraulic module consists of an electric motor driven pump two low pressureaccumulators valve block and an ABS electronic control module Note Electroniccontrol modulesfor vehicles without traction control are designated ABS CM Control modules for vehicles with traction control are designated ABS TC CM The valve block houses solenoid operated valves which are activated by voltage signals from the control module The signals are generated using wheel speed information receivedfrom the wheel speed sensors For vehicles without traction control the valves operate on three circuits two front and one rear as necessary to pre vent wheel locking during braking Brake pressureis modulatedindividually atthe front wheels andcollectively atthe rear Rear
413. ould also be applied It is necessary to have the ignition ON and the footbrake appliedto move the shift lever from the Park position For ignition key removal the shift lever must be inthe Park position The engine can be started inthe Park position R Reverse enables the vehicle to be operated in a rearwards direction The engine cannot be started inthe Reverse position N Neutral position enablesthe engineto be started and operatedwithout drivingthe vehicle Italso allowsthe 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 maximumefficiencyandfuel economy On acceleration down shifts are obtained by depressingthe accelerator pedal or by manual selection The engine cannot be started in this position 3 Manualthird 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 inthis position 2 Manual second position allows automatic operation of the two lower gear ratios but inhibits selection of the third andfourth ratios This position is usedfor heavy traffic congestion or negotiating hilly terrain when even greater en gine braking control is requiredthan is provided by manualthird This ratio
414. ounting bracket a Fit and tighten the speaker securing screws s Fit and align the speaker harness P clip a Fit and tighten the clip securing nut s Fitand align the switchgear mounting bracket Connect the speaker harness multi plug a Positionthe harness to the mounting bracket a Refit the cassette and cancellation module a Refitthe steering wheel a Refitthe driver airbag a Reconnect the battery and refit the battery cover 1 3 a Close the trunk a Refit the steering column upper and lower cowls Issue 1 August 1994 34 X300 VSM ES Body Components amp Trim 13 3 32 A Post lower Trim Pad Renew SRO 76 13 30 a Locally displace the draught welting from the front door aperture flange a Undo and removethe A post lower trim pad quarter turn fastener a Displace and removethe A post lower trim pad by pulling rearwardsto disengage clips and place aside a Fit and seatthe new A post lowertrim pad engaging the clips on the front door flange a Fit and securethe A post lowertrim pad quarter turn fas tener e Reposition and fully seat the draught welting to the front door aperture flange 13 3 33 Rear Quarter Upper Trim Pad Renew a Remove the rear seat belt upper anchorage RH or LH a Remove the trim pad securing screw a Slacken but do not remove thecombined grab handle and coat hook securing screws a Unclip the rear quarter trim pad and remove a To refit carry out reversal of the
415. ovethe captive washers and the siren securing bolts a Fitthe siren securing bolts to a new siren a Fit and fully seat the captive washers s Align the siren securing bolts to the vehicle chassis Tighten the siren securing bolts Refittingthe remaining components isthe reverse of the re moval procedure A5 16 SECURITY SIREN 6CYL RENEW SRO 8652 03 a Open the trunk and remove the battery cover s Disconnect the battery ground lead a Open the hood and remove the headlamp relay cover See SRO 76 11 22 Section 13 a Identifythe RH forward harness relays for subsequent re fitting Removethe relays and relay basesfromthe mount ing bracket a Disconnectthe siren harness multi plug Repositionthe side harnessto gain access to the siren se curing bolts Undothe siren securing bolts and remove the siren Note Thesiren securing bolts remain captive e Removethe captive washers and the siren securing bolts a Fitthe siren securing bolts to a new siren a Fit and fully seat the captive washers Align the siren securing bolts to the vehicle chassis Tighten the siren securing bolts Refittingthe remaining components isthe reverse ofthe re moval procedure a LE Issue 1 August 1994 42 X300 VSM De Security System RESTRICTED ISSUE ai A5 17 FRONTDOOR LOCK ASSEMBLY RENEW SRO 86 25 45 e Removethe veneer trim pad See Section 13 of the VSM a Removethe upper trim pad See Section 13 of the VSM
416. ovethe fluid pan see Sub section 8 2 14 4 0L SC or Sub section 8 2 15 6 0L a Displace and remove the filter 1 Fig 1 from the trans mission unit and place aside a Fit and align a newfilter to the transmission unit a Refit the fluid pan see Sub section 8 2 14 4 0L SC or Sub section 8 2 15 6 0L a Lower the vehicle on the ramp a Refill the transmission unit with fluid see Subsection 8 2 13 s Removethe fender cover and close the hood X300 VSM 19 Issue 1 August 1994 Powertrain d W s Automatic Transmission V12 AJ16 Supercharged 8 2 19 TRANSMISSION INTERNAL HARNESS MULTI PIN SOCKET O RING RENEW 4 0L SC AND 6 0L SRO 44 24 20 Open the hood and fit a suitable fender cover a Raise the vehicle on a ramp a Drain the transmission lubrication system see Sub sec tion 8 2 13 a Removethe fluid pan see Sub section 8 2 14 4 0L SC or Sub section 8 2 15 6 0L a Disconnect the external harness multi pin plug from the internal harness multi pin socket Note The plugissecuredto the socket by its captive lock ing ring s Releaseand remove the internal harness multi pin socket to transmission casing securing nut a Displace the internal harness multi pin socket from the transmission casing Remove and discard the O ring seal Fig 1 from the 5 144 709 multi pin socket a Fit and seat a new O ring seal to the multi pin socket a Reposition and seatthe internal
417. ower speed verify bar graph representation Operate A C to toggle on or off Becausethe compressor can be inhibited by the engine management system ensure that the engine temperature is normal and that the ambient is above 5 C Operate RECIRC state lamp should be lit and the flap behind the blower grille open Operate distribution buttons inturn verify correct air distribution and relevant state lamp Operate DEFROST check max fans and air to front screen Cycle TEMPERATUREto H and Lo to verify demanded variations and display operation Notethat extremes will provide max heat or cold independent of in car temperature Operate EXT to toggle between ambient and control temperatures Operate HFS and HRW to note timer and mirror operation Initiate System Self Testto checkfor and extract stored faults should any of the above not perform as stated 0000 000 ooo 14 10 3 System symptoms There are five basic symptoms associated with air conditioning fault diagnosis The following conditions are not in order of priority No Cooling Q ls the electrical circuit to the compressor clutch functional o Isthe electrical circuit to the blower motor s functional Q Slack or broken compressor drive belt o Compressor partially or completely seized o Compressor shaft seal leak o Compressor valve or piston damage may be indicated by small variation between HIGH SL OW side pressures relative to engine speed o Broken refrigerant pipe
418. p 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 intothe engine is controlled by the fuel injectors combined with the engine control module ECM Any excessivefuel flowing through the system is returned to the fuel tank via the fuel regulator valve mounted onthe 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 inthe higher speed range switching on at4000rpm and off at 3200rpm The fuel lines are made up of an assembly combining steel under floor pipes and flexible conductive anti permeation tubing Inorderto perform speedy remove and refit operations the underfloorsteel lines are linkedthrough 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 insidethe engine bay are of d
419. pads Check pipework for leaks Renew brake pads Check caliper and repair renew as necessary Seizedor incorrectly adjusted parking brake or cable Broken or weak parking brake return springs Caliper pistons seized Brake pedal binding at pivot points Vacuum booster binding Tandem master cylinder faulty Lack of vacuum at the vacuum booster Tandem master cylinder pushrod binding Frozen tandem master cylinder pis ton Brake caliper piston or caliper guide pins seized Worn brake pads Bent or cracked parking brake shoes Foreign objects in brake pads or park ing brake shoes Broken loose parking brake hold down springs or returnsprings Loose caliper mounting bolts Examine parking brake and repair renew as necessary Renew parking brake return springs Examine calipers and repair renew as necessary Examine brake pedal bushings and repair renew as necessary Renewvacuum booster Examinetandem mastercylinder and repair renew as necessary Check vacuum hose Repair or renew as necessary Renew tandem master cylinder Renew tandem master cylinder Examinecaliperand renew repair as necessary Renew brake pads Renew parking brake shoes Examine brake pads and and parking brake shoes Clean or renew as necessary Examineparking brake assembly Re pair or renew as necessary Re torque caliper mounting bolts X300 VSM 17 Issue 1 Au
420. pensions or steering components Worn or damaged drive shaft slip yoke joint Front disc rotor runout Loose engine or transmission supports Engine driven accessories Driveline alignment 0000000 Before investigating any other vibration concerns aroad amp esand a customer interview if possible should be carried out This can provide much of the information neededto find the source of vibration Drivethe vehicle on aroadthat is preferablysmooth andfree of undulation and ifvibration is apparent note the speed atwhichthevibration occurs what type of vibration occurs in each speed range mechanicalor audible how the vibra tion is affected by changes in vehicle speed engine speed and engine torque and the type of vibration sensitivity torque sensitive vehicle speed sensitive or speed sensitive Some of the condition terms used when describing sources of vibration are explained as follows o Torque Sensitive This condition can be improved or worsened by accelerating decelerating coasting maintaining a steady vehicle speed and application of enginetorque o Vehicle Speed Sensitive This meansthat the vibration always occurs atthe same vehicle speed and is not affected by engine torque engine rpm or transmission gear selection o Engine Speed Sensitive This meansthat the vibration occurs at varying vehicle speeds when a different transmission gear is selected Itcan sometimes be isolated by increasing or decreasing en
421. plug a Undo and remove the fascia to center console securing screws a Displace and remove the passenger side outlet duct a Disconnect the fascia harness to console harness multi plugs Disconnect the let3 hand fascia harness to cabin harness multi plug a Undoand removethe fascia ground eyeletsto body secur ing nut a Displace and repositionthe ground eyeletsfromthe stud a Displace and reposition the airbag control module from the mounting bracket Undoand removethe fascia assembly lower securing nut a Undo and remove the fascia outer body bracket to fascia securing bolts e Carefully displace the fascia rearwards Issue 1 August 1994 24 X300 VSM Body Components amp Trim mico a From behind the fascia passenger side disconnect the passenger airbag harness multi plug a With assistance remove the fascia from the vehicle and place on a suitably protected bench Place the fascia in position inthe vehicle with the center location peg correctly engaged Reconnect the passenger airbag module harness multi plug a Carefully fit and align the fascia to the mounting position a Fit and tighten the fascia to outer body brackets securing bolts a Fit and tighten the fascia assembly lower securing nut Reposition andfit the airbag control moduleto the mount ing bracket Reposition and fit the fascia harness ground eyeletsto the ground stud Fit and tighten the ground eyelet sec
422. plunger fitted between valve stem and cam lobe valve tappet bucket vapor vapour Vehicle Condition Monitor VCM instrument panel display which warns of faults Vehicle Emission Control VECI Label Information Label Vehicle Service Manual VSM Service Manual which pertains to a specific family of Jaguar vehicles see also Unit Service Manual and Electrical Diagnostic Manual Vehicle Speed Sensor vss sensor which provides vehicle speed sor Vehicle Identification Number VIN Viscosity Index Vi valve lifter number assigned to the vehicle by the manufacturer primarily for licensing and identification purposes 1 vaporizing at roomtemperature liquid fC 2 not permanent memory device which regulates the variable output eee voltage of a generator information volatile Voltage Regulator X300 VSM 27 Issue 1 August 1994 __ Introduction GLOSSARY OF TERMS Term s Abbreviation if applicable Definition Previously used term s or Eng lish Equivalent W Warm up Oxidation Catalytic WU OC catalytic converter system designedto lower Converter HC and CO emissions during the warm up period Usually located in or near the exhaust manifold Warm up Three way Catalytic WU TWC catalytic converter system designedto lower Converter HC CO and NOx emissions during the w
423. power transistor a Motorized in car aspirator a RH blower motor amp power transistor a Ambient temp sensor a LH high speed relay Evaporator temp sensor a RH high speed relay a Heater matrix temp sensor gt Compressor lock sensor a Face differential temp control gt a Refrigerant pressure switch a Engine speed signal gt a Centre vent flap Foot flap a Engine coolant temperature Defrost flap ken e km gt RH air inlet fla gt Compressor Centre vent flap 4s Front screen heater to EMS Foot flap Heated rear screen Defrost flap and door mirrors Air by pass flap Fig 1 Schematic view A CCM Inputs amp Outputs Issue 1 August 1994 8 X300 VSM a Bas Climate Control Systems YE 14 6 CONTROL MODULE FAULT CONDITION SELF ANAL YSIS 14 6 1 System Health The climate control system has a self test facility accessiblefrom the control panel The self test sequence hastwo basic modes o System error information is stored inthe A CCM upto a maximum offive faults Should afault occur there will be an audible beep andthe message Er will be displayed onthe control panel LCDfor approximately five 5 seconds after ignition on Please note that this will happen only once in any ignition switch cycle The error source may be accessed by the procedure described in Self Test System Diagnosis this section Q Panelcommunication check may be init
424. pping o Motorized in car aspirator or evaporator temperature sensor faulty causing temperature variations possible codes 11 or 13 o Blocked or partially restricted evaporator or condenser Noisy System o Loose or damaged compressor drive belt Loose or damaged compressor mountings Compressor oil level low look for evidence of leakage Compressor damage caused by low oil level or internal debris Blower motor s noisy Excessiverefrigerant charge witnessed by vibration and thumping inthe high pressure line may be indicated by high HIGH amp high LOW side pressures Low refrigerant charge causing hissing at the expansion valve may be indicated by low HIGHside pressure Excessive moisture in the system causing expansion valve noise Air lock in water pump 00000 OO oO Insufficient Heating Coolant flow valve stuck inthe closed position Motorized in car aspirator seized Cool air by pass damper stuck or seized possible code 43 Blocked or restricted blower inlet or outlet Low coolant level Blower fan speed low Coolantthermostat faulty or seized open Water pump inoperative or blocked Air lock in matrix 000000000 Please see Sections 4 1 and 4 2 for specific coolant fill bleed procedures Note Electrical faults may be more rapidly traced using JDE please refer to the EDM Issue 1 August 1994 16 X300 VSM L 03 Climate Control Systems S ZS 14 11 SYSTEM SELF
425. process s Disconnect door harness at connector a Remove locking screws Fig 2 s Disconnect check arm fixings at the body Fig 2 a Open the door fully carefully lift and disengage from the hinge pins 376 1028 A4 7 2 3 Fitting Before re fitting the door assembly all traces of thread lockingcompound must be removedfrom the hinge pins careful use of a suitable thread tap is recommended a Refitthe door assembly and secure to specificationusing new locking screws Note There is no needto lubricatethe hinge when refit ting the door Apply grease to the check arm 3 Fig 2 Ensurecorrect alignment and remove the protectivetape A4 7 2 4 Alignment Hinges are set during the body manufacturing process and should not require adjustment during the life of the vehicle However where damage has been sustained at the body or door hinge location points please refer to Body fits and clearances section A4 7 1 5 for setting criteria 376 962 1 Locking screw 2 Check arm 3 Grease Fig 2 Detailfront door X300 VSM 47 Issue 1 August 1994 Z Body Systems amp Body Repair A4 7 2 5 Seals Location Fixing method Note Primary Sponge rubber hollow Door periphery C channel in upper section frame and pegged to door inner panel Sponge rubber solid Door upper frame C channel inframe Outboard of primary section Draught Metal reinforced rubber Door aperture periphery Flange edge straddle we
426. put shaft flange and remove fixings note camber shim a Thoroughly clean the area around the output shaft housing and differential case a Releasefixings and remove output shaft assembly discard O ring a Mark bearing retaining collar axially and drill3 off holes 4 0 mm diameter equally spaced to a MAXIMUM depth of 5 0 mm 1 Fig 1 a With a suitable chisel 2 Fig 1 strike the collar across the three drilled holesto relieve tension within the steel CAUTION Do not drill into the output shaft it is not necessary to break the inside diameter of the collar There is no needto to split the collar when chiselling Using a suitable press remove bearing and collar remove the oil seal and discard it along with bearing CAUTION The original bearing must NOT be cleaned and reused always renew it Inspect the output shaft oil seal surface for damage corrosion or grooving and replace as necessary Note Do not use abrasive cloth or paperto remove imperfections from the seal surface a Using special tools JD 550 1 and 18G 134 assemble new oil seal to housing ensuring that the seal top face is 18 mm below the housing top face and NOT down onthe counterbore face Lubricate the output shaft seal diameter and oil seal lip and position the housing assembly to the shaft Using special tool SL7 and a suitable press assemble bearing to output shaft a Using special tool SL7 and a suitable press assemble retaining collar to output shaft s F
427. r ness multi pin plug e Displace and remove the Performance Mode switch sur round finisher Displace and remove the shift lever surround finisher a Release and remove the veneer panel wing nuts Displace and remove the console finisher veneer panel Cutandremove the rotary switch harness securing straps Disconnect the rotary switch harness multi pin plugs Reposition the tunnel carpet for access to the harness grommet Displace and reposition the grommet down through the tunnel Feed the harness through the tunnel to the underside of the vehicle a Raise the vehicle on a ramp From beneath the vehicle release and remove the rotary switch harness to transmission PB 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 e Release and remove the rotary switch protection cover 1 Fig 1 securing bolts displace and remove the switch cover Disconnect the transmission multi pin socket 2 Fig 1 a Reposition the harness clear of the transmission unit a Release and remove the rotary switch securing nuts a Displace and remove the switch assembly a Displace and remove the P clips from the harness a Fit and align the P clips to the new harness switch as sembly a Displacethe rubber sealing plug 3Fig 1 fromthe rotary switch ey Automatic Transmission AJ16 164 690
428. r and therefore must be closed when the vehicle is fully alarmed these components are doors windows trunk hood and sliding roof Method UK EUROPE ROW NORTH AMERICA of x3116 SOV DAIM XJ16 SOV DAIM XJ16 XJ12 Operation Sport XJ12 DD6 Sport XJ12 DD6 XJR Locking Central locking Remote central locking Deadlocking Remote wo stage unloc Remote es Drive away locks Gr X DD X DD p Switch x close interior trunk tid release Switch xX x X Flush sill buttons Xx Xx intrusion override security Key inrasionsensing ful Awo AAA 007 o 2 7 inclination sensing Ao fo o 007 07 DY gt Passive amina ees o f o 5 for or or e gt Panic alarm Remote Audible tones error Auto D Zip DD X DD X DD X DD X DD deadlock Engine immobilization Auto X X xX Convenience All close Key X X X X X Xx D D D Headlampconvenience Remote Xx Xx Xx x x x x X x Trunk lid release Remote X X X S x TX X X X Trinik valet isolate Switch e x Xx x x x Xx Diver seat menor sea Fene I X 37007 EE cv 07 37 Key Notes X Standard 1 Standard with security system lO Factory option 2 Only available with security option D Dealer option 3 Standard only with power memory seats DD Dealer deletable Not available Except Japan as NAS X300 VSM 1 Issue 1 August 1994
429. r battery inoperative 2 Rear screen aerial cable damaged disconnected 3 Memory switch pack faulty Remedy 1 Renew battery 2 identify and repair aerial cable fault 3 Refer to Section 15 4 Note For door hood and trunk ajar fault diagnosis refer to Section 15 2 EOI gq 50 FF St SR SS TT X300 VSM 23 Issue 1 August 1994 Las Security System RESTRICTED ISSUE A5 9 PIN POINT TESTS The following information details test proceduresto identify specific componentfaults The table below provides a key to items identified on the following schematic diagrams Peer OSC Security Loking ControlModule 21 Hoodswih CS Central lockingswieh 22 tHEnginebayfusebox Front passenger door ajarswileh 2 Homrelay AH rear passengerdoor ajarswich 24 Fomu F rear passenger door ajar swch Fomu Driver s door ajar switch Horn switches Intrusion sensor LH Dinars door oneek ay NASo muno E Non deadlock shorting links NAS only a Passenger door key barrel switch Front left rear right deadlock relay Driver s door key barrel switch Front right rear left deadlock relay Reader exciter module Door lock relay Reader exciter coil Door unlock relay Trunk fuse box LH Rear door actuator and switch Security active indicator RH Rear door actuator and switch a8 Sers Security sounder Front door actuator lock deadlock status Trunk release relay switches Driver s door actuator l
430. r by passesthe matrix via the Gool air by pass damper within the range coldto hot The flaps for FOOT COOL AIR CENTRE VENT RH LHRECIRCULATION and DEFROST are electrically driven by indi vidual motor potentiometer units Face outlet Defrost outlet End of dash outlet Cool air by pass damper Evaporator Airin Foot outlet front Foot outlet rear Rearface outlet 0 Heater matrix 382 494 Fig 1 82 495 582 496 Solid arrow Hot Line arrow Cold Issue 1 August 1994 10 X300 VSM Climate Control Systems Bi Level min temp difference X300 VSM 11 Bi Level max temp difference Issue 1 August 1994 E PE Climate Control Systems ed 14 8 REFRIGERATION CYCLE The Compressor draws low pressure low temperature re frigerantfromthe evaporator and bycompression raisesre frigerant temperature and pressure High pressure hot vaporized refrigerant enters the Condenser where it is cooled by the flow of ambient air A change of state occurs as the refrigerant cools inthe condenser and it becomes a reduced temperature high pressure liquid From the condenser the liquid passes into the Receiver Drier which has three functions ULL P L CH 4 LLL a Storage vessel for varying system refrigerant demand b Filter to remove system contaminants c Moisture removal via the dessicant With the passagethroughthe receiver drier completed the still high pressure liquid refrigerant
431. r connectors faulty 3 Relay faulty 4 Actuator faulty Remedy 1 Check fuse F1 in RH WA post fuse box 2 Examine and repair or renew faulty harness 3 Renew relay 4 Renew actuator Fault Panic feature inoperative Possible causes 1 Transmitter battery inoperative 2 Rear screen aerial cable damaged disconnected Remedy 1 Renew battery 2 Identify and repair aerial fault Fault Central locking switch inoperative Possible causes 1 Harness wiring or connectors faulty 2 Switch faulty Remedy 1 Examine and repair or renew damaged harness 2 Renew switch a o 0 0 o o o o o o o o o o o o Issue 1 August 1994 22 X300 VSM Security System RESTRICTED ISSUE Fault Trunk lid locking unlocking faulty Possible causes 1 No power to actuator relay Wiring harness or connectors faulty Relay faulty Actuator faulty Switch faulty np Remedy Check fuse F8 in trunk fuse box Examine and repair or renew faulty harness Renew relay Renew actuator Renew switch TPN Fault Valet isolate facility inoperative Possible causes 1 Faulty switch 2 Harness wiring or connectors faulty Remedy 1 Renew switch 2 Examine and repair or renew faulty harness Fault Sill buttons inoperative Possible causes 1 Mechanical failure 2 Door microswitch faulty Remedy 1 Refer to VSM 2 Renew door lock assembly complete Fault Memory position selection inoperative Possible causes 1 Transmitte
432. r gear is supported by two caged roller bearings is in constant mesh and is situated on a stationary shaft Longitudinal location of the idler gear is controlled by a spacer abutting the shaft J37 099 Fig 1 The Getrag 290 Transmission X300 VSM 1 Issue 1 August 1994 Wee Manual Transmission amp Clutch AJ16 7 1 2 MANUAL TRANSMISSIONASSEMBL Y RENEW SRO 37 20 01 a Disconnectthe battery a Remove inlet manifold rear securing nuts a Remove injector harness mounting bracket a Fit lifting bracket 18G 1465 and secure with the nuts a Fit Service Tool MS 53B Fig 1 across the wing channels and align to rear lifting bracket e Fit and engage retaining hook a Tighten hook nut to take weight of engine a Disconnect lambda sensor block connectors a Remove the exhaust front pipe to the intermediate pipe securing nut bolt a Remove the front pipe to manifold securing nuts and E 4 remove the front pipe assembly Pee 12 70 a Carefully ease exhaust system down for access Removethe drive propeller shaft assembly see Section 9 SRO 47 15 01 Fig 1 a Fit blanking plug to rear of transmission a Remove clutch slave cylinder complete with push rod from bell housing and secure clear Disconnecttransmissionswitch multi wayconnector and secure clear a Place jack in position beneath the transmission a Take weight on the jack and remove rear mounting to body securing bolts a Lower jack
433. r scene ENN EENEN a ele ER dE 35 SOUNDER EE 36 Trunk lid release actuator and relay 37 Trunk lid reiege SWIICNES ais ic a a eee NEE Na VEER ee teeta eee 38 Val ts wite wake aw WE SEENEN RER ENN NEE E RENE wis A a Gedy Sivas ale 39 Inclination Sensor Renew EN 86 522 eee ieee 40 Security and Locking Control Module SLCM Renew 5 86 52 01 weeeeeeenees 40 Intrusion Sensor Renew aeecececcee ween e ee eee eee e eee eeeeeneees 86 52 20 e 41 Hand Transmitter Battery Renew EE EEN ENEE ENEE 86 52 28 EE 41 Valet Switch Hee 86 52 08 ononnnnnno 41 Security Siren 12Cyl Deem EE 86 52 03 e 42 Security Siren 6 Cyl Renew EE 86 52 03 en 42 Front Door Lock Assembly Renew ENEE ENEE EE BOLITAS cono 43 Rear Door Lock Assembly Renew EELER EN En 6 2 44 Trunk Lid Lock Actuator Renew Eu 86 25 49 cono 44 Clock Module ReneW arta a ie wette d ege 86 80 73 NEEN 44 Reader Exciter Coil and Module Renew ccccseccen eee e ence e eee e eens eee eeeeeeeeeeeee 44 ii X300 VSM Security System RESTRICTED ISSUE spine A5 1 SYSTEM DESCRIPTION The vehicle closures switching system comprises the security and central locking features applicable to that vehicle variant as detailed inthe table below Central locking and security systems are controlled by a common electronic module designated as the Security and Locking Control Module SLCM Theterm closures refersto items which allow access to the vehicle interio
434. re taking careto correctly locate switch and bulb holders prior to se curing the mirror 13 6 4 Exterior Mirror Renew a Disconnect vehicle battery ground lead e Remove door trim pad veneer panel and upper trim pad Remove the cheater by sliding off a Remove mirror fixings a Disconnect the mirror harness block connectors a Removethe mirror securing screws and remove the mir ror assembly a To refit carry out reversal of the above procedure 13 6 5 Exterior Mirror Glass Renew a Switch ignition on and positionthe mirror to inboard posi tion a Disconnect vehicle battery ground lead a Slide assembly outboard and pull outwards a To refit carry out reversal of the above procedure Issue 1 August 1994 44 X300 VSM Body Components amp Trim a a 13 7 CARPETS 13 7 1 Carpets Description The passenger compartment carpet is a one piece moulded construction with integrated sound deadening heel mats and driver s footrest The carpet is attached to the vehicle floor by plastic clips fitted below the door treadplates Re moval of the carpet requires removal of front seats and the lifting the rear console and removal of the heelboard carpet 13 7 2 Removal of Stains General Information When carrying out any stain removal procedures observe the following points Q Immediate action is essential if permanent staining is to be avoided Endeavour to clarify stain ie water oil or combinations and treat a
435. rear extension finisher see sub sec tion 13 3 5 and Fig 2 sa Reposition the front of the veneer panel upwards for ac cess and displace the rear of the panel upwardsto release a Fitandseat the newveneer panel to the extension and en sure that the rear pegs are fully seated Refit the trim finisher Ba 376 790 issue 1 August 1994 30 X300 VSM 13 3 28 Console Ashtray Renew SRO 76 67 18 a Raise the trunk lid Removethe battery cover and disconnect the battery Open the glove box lid a Undo and remove the ashtray assembly securing screws a Displace the ashtray for access Disconnect cigar lighter illumination Lucar connectors a Displace and remove the ashtray assembly a Place the ashtray assembly to the front a Open the ashtray lid Displace and remove the inner ashtray a Displace and remove the cigar lighter element assembly Carefully displace and remove the cigar lighter illumina tion bulb holder assembly a Carefully displace and remove the cigar lighter assembly from the ashtray a Carefully remove and discardthe ashtray surround veneer panel securing clips Displace and remove the ashtray surround veneer panel a Carefully remove and discard the ashtray lid veneer panel securing clips a Close the ashtray a Displace and remove the ashtray lid veneer panel Displace and remove the inner ashtray retaining clips a Place the ashtray aside a Place the new a
436. relating to temperature the prevailing ambient temperature conditions should be taken into account The climate control system is dealt with in Section 14 4 1 5 2 Diagnostic Procedures Symptom Possible Cause Iverheating Thermostat 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 Insufficient coolant Internally collapsed hoses Incorrect ignition timing Fuel air mixture too weak Incorrect valve timing Cylinder head gasket leaking Brakes binding Test thermostat Check thermostat operating temperature Referto EDM Referto 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 Pressuretest system and check for deformation of hoses Referto EDM Referto 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 Renewthermostat Renewthermostat Renew gauge Renewtransmitter Flush or renew radiator Remove obstruction from grille Drain and fill with coolant of correct concentration Adjust belt to correct tension or renew belt
437. reportableto local state and or federal authorities Materialshould be disposedof by incinerationor chemical oxidation under carefully controlledconditionsby specially trained individuals in accordance with local State and Federal regulations 15 1 14 Scrapping Vehicles With Live Airbag s When scrapping a vehicle with a live airbag first deploythe airbag in accordance with following procedures This procedure assumes airbag wiring is undamaged See Handling Safety information Ifthe airbag isto be removedsee Airbag ModulesAssembly Removal Service Instructions Equipment required Insulation Displacement Connectors IDC Scotchloks two off battery two off ten meter lengths of 1mm wire fitted with crocodile clips at one end See Fig 1 WARNING THE DEPLOYMENT PROCEDURE SHOULD BE PERFORMED OUTDOORS AWAY FROM OTHER PERSONNEL Remove any loose debrisfromaroundairbag and ensure no flammable liquids are present Disconnect the vehicle battery Link harness connection amp deployment method WARNING ALWAYS CONNECTTO AIRBAG FIRST AS THE BAG WILL DEPLOY IMMEDIATELY ON CONNECTIONTO THE BATTERY Remove passenger side and driver side under scuttles knee bolster a Disconnectthe airbag connector under the facia a Look for the yellow harness connectors and cut the wires originating from the airbag just above the mating plug Note The harnessconnectedbetweenthe driver s airbag andthe yellow connector has one red pu
438. returnedto Jaguar Cars Ltd or their importer for replacement Tampering or mishandlingcan result in personal injury Keep away from heat sparks and open flames Do not store at temperatures exceeding 93 Celsius 200 F Keep away from electrical equipment as electrical contact may cause ignition Do not drop or impact airbag module Always position module cover up Ensure that the connector is protectedto prevent damage 376 1058 Fig 1 The Driver side Airbag Store modules in a secure lockable cabinet Never position projectile material over the undeployed airbag as this can cause injury in the event of inadvertent deployment Issue 1 August 1994 2 X300 VSM De Electrical Donotwrap arms around module whencarrying and always carry modulewith cover andventsfacing awayfrom body to avoid personal injury inthe event of inadvertent deployment Never carry airbag module by wires orthe connector The chemical propellant mixture deployingthe airbag is a solid and therefore inhalation exposure is unlikely even if module is ruptured without deployment As far as practicable avoid skin contact with or ingestionof the materials present after combustion Exposureto high concentrations of propellant mixture may cause headache nausea blurred vision faintness cyanosis lowering of blood pressure tachycardia and shortness of breath WARNING SODIUM AZIDE HAS BEEN LISTED AS AN EXTRAORDINARY HAZARDOUS SUBSTANCE OR
439. reversal of the above procedure 13 3 38 Sun Visor Assembly RH or LH Renew Disconnect vehicle battery ground lead Lower the sunvisor a Remove the screws securing the sunvisor retaining block and support the sunvisor Disconnect the multi plug situated behind the headlining and remove the sunvisor assembly To refit carry out reversal of the above procedure Issue 1 August 1994 36 X300 VSM S Body Components amp Trim ab 13 3 39 Roof lining Headlining Description The roof lining is a one piece construction of 6mm thick polyurethane foam covered with brush finish suede effect knitted polyester 13 3 40 Roof Lining Renew a Positionfront seatsfully rearwardsand reclinethe passen ger seat squab a Disconnect vehicle battery ground lead a Remove Sliding roof flange where fitted Front passenger door Rear console where fitted Center console Sunblind and bezel Combined grab handle and coat hook Rear quarter upper trim pad LH amp RH Cantrail crash roll Illuminated sun visor Roof console a Release multi plug connectors from clips at roof console aperture Remove roof console retaining clip from headlining a Remove security sensors where fitted and disconnect multi plugs a Release roof lining to body tags and lower roof lining a Remove the roof lining Position the roof lining with the rear corner through the passenger side rear door andthe opposit
440. ric cooling fan s operat Referto EDM Rectify as required ing continuously Faulty temperature gauge Referto EDM Renew gauge Faulty temperature transmitter Referto EDM Renewtransmitter X300 VSM 5 Issue 1 August 1994 ES 4 2 Cooling System V12 Diagnostic Procedures continued Symptom Possible Cause Check Remedy 05s of cool Loose clips on hoses Check clips for correct tight Tighten clips as required at ness Issue 1 August 1994 Hoses perished Radiator core leaking Water pump seal leaking Thermostat gasket s leaking Header tank cap defective Porosity in castings Corrosion caused by con centration of anti freeze being too low Cylinder head gasket s leak ing Cracked or damaged internal engine component Visual check Pressure test system Pressure testsystem Pressure testsystem Check for distortion of thermostat housing s Inspect cap or test cap spring pressure Pressure test system Pressure testsystem Check strength of coolant Pressure testsystem Check for contamination of coolant and engine lubrication system Identify component s affected Checkfor contamination of engine lubrication system Renew hoses as required Repair or renew radiator Renew water pump Renew gasket Renewhous ing s if required Renewcap Rectify as required Rectify as required Drain and fill with coolant of correct con centration Renew
441. roduction line to suit the market requirements of a particular vehicle PROM ROM with some provision for setting the stored data after manufacture enaineer s blue ory Prussian blue pump device used to raise transfer or Ge fd fluids by suction pressure or both purge cock drain A drain tap X300 VSM Issue 1 August 1994 e introduction GLOSSARY OF TERMS R i Radio Data System Abbreviation Definition if applicable Previously used term s or Eng lish Equivalent DS local traffic information service which automatically breaks in to whichever station is being received Also programmable to lock onto the strongest available frequency for a given nationally available radio station regardless ofthe geographical locationofthe receiver i Random Access Memory IRAM fast access memory store which is accessible for entry or extraction of data fast access memory inwhich data isfixed and may not be entered or extracted Read Only Memory rear wheel drive RWD relay an usually electro mechanical device in which connections in one circuit are opened or closed by changes in another circuit relay module RM a module containingtwo or more relays reservoir RES container usually for oils coolants or hydraulic fluids a dedicated sensor ground circuit shaft speed of a device usually an engine or motor return rev
442. rom bar multiply the figure by 14 5 Pressure bar Temperature C Fig 1 High side pressure plotted against Ambient temperature Probablecauses offaults may befound by comparing actual system pressures registered on your manifold gauge set or recovery recharge recycle station and the pressure to temperature relationship graph for high side pressures plotted in Fig 1 The chart in Sub Sectionl4 16 shows the interpretation that may be made by this difference The Normal condition is that which is relevant to the prevailing ambient temperature X300 VSM 21 Issue 1 August 1994 yA Du eX Climate Control Systems 14 15 PRESSURE TEMPERATURE GRAPH LOW SIDE EVAPORATOR TEMPERATURE To obtain Ibf in from bar multiply the figure by 14 5 foes e ne La Pressure bar 8 7 6 5 4 3 2 10 12 3 4 5 6 7 8 9 1011 12 13 14 15 16 17 18 19 20 21 Temperature C Fig 1 Low side pressure plotted against Evaporatortemperature Probablecauses of faults may befound by comparing actualsystem pressures registeredon your manifold gaugeset or recovery recharge recycle station and the pressureto temperature relationship graph for low side pressures plotted in Fig 1 The chart in Sub Section14 16 shows the interpretationthat may be made by this difference The Normal condition is that which is relevant to the prevailing evaporator temperature Note The system controls will preventthe evap
443. rosion protection Q Trim and seat materials Q Paints which contain isocyanates Q Adhesive and sealing compounds When heatedto atemperature of 300 C polyurethanebased compounds may liberate small quantities of isocyanate Many types of nitrogen containing chemicals may be liberated as breakdown products these chemicals can contain isocyanates oxides of nitrogen and hydrogencyanide Potentiallytoxic or asphyxiant fumes and gases are produced by welding for example zinc oxide with zinc coated panels and ozone gas from the MIG process A4 1 3 3 Metal Repair There is considerable risk of damage to eyes ears and skin when metal cutting forming or dressing is being carried out Soldering may be hazardous because of heat generatedfumes and skin contact with the materials A4 1 4 PRECAUTIONS A4 1 4 1 Paint The inhalation of sprays fumes or dust during paint application or sanding processesshould always be avoided En sure that there is efficient ventilation extraction at all times Paint spraying should be confined as far as possible to spray booths Personnel with a history of asthma should not be engaged in any process which involves the use of isocyanates Any operatorworking insidea spray booth where isocyanatematerial is present must use air fed breath ing equipment Suppliedair to the visor should befed at the recommended pressure andfiltered to remove oil water andfumes Operators involved in handling mixing or spraying shoul
444. rple feed wire and one pink brown return wire The harness connected between the passenger s airbag and the yellow connector has two red purple feed wires and one pink purple returnwire Passa 10 meter 33ft link harness containing two 1mm wires through the window aperture and connect using an Insulation DisplacementConnector IDC andtwo crocodile clips to the airbag wires a Close all doors leave window with lead open a Ensure no personnel are inthe car or inthe area around the car a Move back 10 meters 33ft and connect harness crocodile clipsto battery the airbag will immediately deploy e Allow the unitto cool for at least 20 minutes Cooling modules should be continuously monitoredto ensure heat generated does not create a fire with spilled liquids or other debris continued next page X300 VSM 5 Issue 1 August 1994 E Electrical E continuedfrom previous page a The vehicle is nowto be scrapped in normal manner with module installed a Inthe event of any problems or queries contact Jaguar Cars Ltd or the importer 15 1 15 Scrapping Vehicles With Deployed Airbag s Q Verify that all installed airbags have been deployed or removed o Inthe eventof one airbag beingdeployedand one not deployed it must be assumedthatthe undeployedairbag is still live therefore it must first be deployed o The vehicle is nowto be scrapped in a normal manner 15 1 16 Disposal of Live Airbag Modules Note Modulesremoved r
445. rry out final tightening of the valve body assembly to main casing securing screws Fit andtighten the harness multi pin socket to maincasing securing nut a Connect the rotary switch harness multi pin plug to the transmission multi pin socket a Refit the speed sensor see Sub section 8 1 10 Renewthe fluid filter see Sub section 8 1 6 a Refit the fluid pan see Sub section 8 1 7 a Lower the vehicle onthe ramp a Reconnect the battery a Refill the transmission unit with fluid see Sub section 8 1 2 Removethe fender cover and lower the hood Issue 1 August 1994 14 X300 VSM zF Automatic Transmission AJ16 meas 8 1 12 VALVEBODY ASSEMBLY RENEW 4 0L SRO 44 40 01 a Raisethe hood and fit a fender cover a Disconnectthe battery a Raise the vehicle on a ramp a Drain the transmission lubrication system see Sub sec tion 8 1 2 a Removethe fluid pan see Subsection 8 1 7 a Remove the fluid filter see Sub section8 1 6 a Remove the transmission speed sensor see Subsection 8 1 10 a Disconnect the rotary switch harness multi pin plug from the transmission multi pin socket a Release and remove the multi pin socket to main trans mission casing securing nut e Releaseand removethe valve body assembly to maincas ing securing screws a Displace and remove the valve body assemblv ensurina thatthe multi pin socket is freed fromthe maincase aper ture a Removethe valve body harness multi p
446. rs and power transmission units The labelswhichcarry this information are known as Label anti theft VIN USA body panel only or Label anti theft engine and gearbox U S A only A Fig 1 see location illustrations A4 4 3 2 Replacement Components When avehicle suffers damage only genuine Jaguar replacement panels units should be used inthe repair further if any parts originally carried a VIN label then a different type of label MUST be affixed Label anti theft replacement part USA body panel only or Label anti theft replacement part engine and gearbox U S A only B Fig 1 NOT inthe same location as the previous label see location illustrations A protective maskis usedto preventthe replacement partlabelfrom beingdamagedor obscured duringthe refinishing protection processes This protective mask MUST be removed prior to customer hand over Note All service panels are supplied in electrocoat primer and where appropriate MUST have an anti theft label in the correct location A4 4 3 3 Procurement Anti theft labels may only be ordered from Jaguar Cars through Product Compliance Dept Jaguar Inc 555 MacArthur Blvd Mahwah NJ 07430 EE R DOT JAGUAR 376 1041 X300 VSM 27 Issue 1 August 1994 Body Systems amp Body Repair A4 4 3 4 Location of Anti theft Labels Front ef VAN We z S Body Systems amp Body Repair y A4 4 3 6 Location of Anti theft Labels
447. s 76 KE EE E tas Clutch Slave Cylinder Renew EN BEBO Vo 17 Lilia Clutch Slave Cylinder Overhaul EEN 33 35 07 circa 17 TAMING EE Clutch Hydraulic System Bleed EN 33 15 01 eu 18 X300 VSM i Issue 1 August 1994 d ne Bee Manual Transmission amp Clutch AJ16 18G 1465 Engine lifting brackets Engine support beam _ support beam v i TORQUE TIGHTENING SPECIFICATIONS Fixing Tightening Torque m Bell housing to adaptor plate Bleed nipple to slave cylinder Center bearing to body Center bearing to mounting plate Clutch cover to flywheel 23 27 Clutch damper to mounting bracket 7 10 Flywheelto crankshaft Front cover to transmission 23 27 Front pipeto intermediate pipe 15 18 Gearshift lever housing to transmission 23 27 71 Hydraulic pipe to master cylinder Hydraulic pipe to slave cylinder Master cylinder to housing Pedal housing to body Pedal steady bracket to housing Drive propeller shaft center mounting to body 22 28 Drive propeller shaft to transmission 95 105 Slave cylinder to bell housing 15 21 Issue 1 August 1994 ii X300 VSM L Manual Transmission amp clutch AJ16 D Hi Molykote FB 180 grease Withdrawal arm pivots Gearshift lever ball Brake clutch fluid minimum Clutch hydraulic system DOT 4 Dexron IID Transmission oil also used in ZF automatic transmissions Loctite 573 Front cover securing bolts A Tivoli
448. s and reposition for access a Undo and remove actuator mounting bracket securing bolts a Disconnectthe actuator harnessmulti plug e Disconnect the actuator to lock mechanism link rod a Removethe actuator and motor Undo and removethe actuator to mounting bracket securing screws Fitting a new actuator is the reverse of the removal procedure 15 20 CLOCKMODULE RENEW SRO 86 80 13 a Remove centre console ashtray and veneer panel refer to VSM section 13 a Release and remove gear selector illumination module securing screws a Re position illumination module as necessaryfor removal of radio console Release radio console securing screws partially withdraw radio consolefrom center console sothat console harness and radio aerial connectors can be removed a Release radio ground lead from securing nut a Remove dedicated radio harness connector from multi plug a Fully withdraw radio console and remove radio unit Release securing screws and removeclock module 15 21 READER EXCITER COIL AND MODULE RENEW a Access to the reader exciter coil is gained by removing top and bottom ignition cowls referto VSM Section 13for remove refit instructions e The exciter coil is mounted around the ignition switch and can be removed by releasing spring tension coil clips a The module is mounted on the steering column assembly secured by two bolts a To remove the module disconnect the harness multi plug and remove the securing bolts
449. s instruc tions Issue 1 August 1994 16 X300 VSM y Body Systems Body Repair 449 A4 2 5 2 PANELS ALIGN AND WELD SRO 77 10 05 77 10 06 Observe all appropriate safety procedures Apply appropriate sealer or joint preparation a Align the replacement panel with associated panels and clamp in position with certain panels it may be necessary to MIG tack weld A Fig 1 or use PK screws a Recheck alignment and panel contours and re adjust as necessary a Select the correct ams for resistance spot welding and ensure that tips are correctly trimmed Note Itisrecommendedthat arms of not morethan 300 mm 12 in longare usedandtest the equipment for satis factory operation by producingtest coupons B Fig 1 Inthe absence of test equipment a satisfactory weld can be verified by pulling the test coupons apart and viewing the welded condition Resistance spot weld where required C Fig 1 Note the presence of zinc coated panels and treat as detailed inthe previous sections a Dress back all MIG tack welds MIG seam weld the butt joints D Fig 1 a As required dress all welds a Final braze and fill as necessary prior to paint preparation X300 VSM 17 Issue 1 August 1994 Body Systems amp Body Repair SE A4 2 6 CUTTING AND WELDING SYMBOLS Saw Cut Chisel Cut Cut Out Spot Weld Resistance Spot Weld MIG Tack Weld MO m ee mm ee EE um MIG Seam Butt Weld D J D 1 J
450. se the correct equipment surface plates micrometers dial gauges etc in serviceable condition The use of makeshift equipment can be dangerous Reject a component if its dimensions are outside the limits quoted or if damage is apparent A part may be refitted if its critical dimension is exactly to the limit size and it is otherwise satisfactory Use Plastigauge 12 Type PG 1 for checking bearing surface clearance e g big end bearing shell to crank journal Instructions for the use of Plastigauge and a scale giving bearing clearances in steps of 0 0025 mm 0 0001 in are supplied with the package EE Issue 1 August 1994 2 X300 VSM General Fitting Instructions S A3 2 5 Ball And Roller Bearings CAUTION Never replacea ball or roller bearing without first ensuring that it isin as new condition Remove all traces of lubricant from the bearing by washing it in petrol or a suitable degreaser Maintain absolut cleanlinessthroughout the operations Inspectvisually for markings of any form on rolling elements bearing tracks outer surface of outer rings or innersurfaceof inner rings Rejectany bearings found to be marked since any markings inthese areas indicates the onset of wear Holdthe inner race betweenthe fingers andthumb of one hand spinthe outer raceandcheckthatit revolves absolutely smoothly Rotate the outer ring with a reciprocating motion while holding the inner ring feel for any obstructionto rotation and reject the beari
451. seams should be removed Separate the spot weldedjoints and remove the panel remnants ht SS A A E X300 VSM 15 Issue 1 August 1994 Body Systems amp Body Repair y A4 2 5 SURFACES OLD PREPARE SRO 77 10 03 Observe all appropriate safety procedures WARNING DO NOT BURN UNDERSEAL OFF USE A HOT KNIFE OR SUITABLE SOLVENT Removethe weld nuggets with a sander and 36 grit disc e Clean allflanges to a bright smooth finish A Fig 1 e Straighten existing paneljoint edges as required A4 2 5 1 SURFACES NEW PREPARE SRO 77 10 04 e Observe all appropriate safety procedures Markoff the area of new panel and cut to size leaving approximately two inches overlap onthe existing panel Offer up new panel or section and align with associated parts i e new rear fender alignedwith door luggage com partment lid backlight aperture Clamp the panel into position e Where necessary cut the new and original panels to form a buttjoint Remove all clamps and the new panel s f required apply inner panel protection and or sound insulation Preparethe new panel joint edges for welding by cleaning to bright metal A Fig 1 this includes all interior and exterior edges Apply weld through primer or interweld sealer B Fig 1 to all surfaces to be resistance spot welded e Where appropriate apply meta to metal adhesive or sealer C Fig 1 inaccordancewith the manufacturer
452. section 8 2 15 6 0L a Lowerthe vehicle on the ramp a Refill the transmission unit with fluid see Subsection 8 2 13 Remove the fender cover and close the hood X300 VSM 5 i Automatic Transmission V12 amp AJ16 Supercharged CT Powertrain Jah 582 Fig 1 Issue 1 August 1994 Pao Automatic Transmission V12 amp AJ16 Supercharged Powertrain 8 2 3 PRESSURE SWITCH MANIFOLD RENEW 4 0L SC AND 6 01 SRO 44 15 39 a Openthe hood and fit a suitable fender cover Raisethe vehicle on a ramp a Drainthe transmission lubrication system see Subsec tion 8 2 13 Removethe fluid pan see Sub section 8 2 14 4 0L SC or Sub section 8 2 15 6 0L a Removethe fluid filter see Sub section 8 2 18 e Disconnect the internal harness plug from the pressure switch manifold Releaseand remove the pressureswitch manifoldto valve body securing bolts a Removethe manifold from the valve body a Retrievethe manifoldto valve body O ring seals Fig 1 and discard e Cleanthe valve body manifold seating area a Fit new O ring seals to the grooves in a new pressure switch manifold e Fit the manifold to the valve body a Fit and tighten the manifold to valve body securing bolts Connect the internal harness plug to the pressure switch manifold Refit the fluid filter see Sub section 8 2 18 e Refit the fluid pan see Sub section 8 2 14 4 0L SC or Sub section 8 2 1
453. shness is suppressed by rubber mounting of both the center bearing and the connection of the drive shaft to differential drive flange The hypoid final drive assembly is available with either a conventional or a limited slip differential The limited slip Powr LoK unit may be identified by either a tag carrying the legend PL or a label with an X both to be found on the rear cover lo C2 ES St j Sp a Vd FAA hime WS LO JU Z N II WM y KC OLLA 351 113 Fig 1 sectional view of Powr Lok unit ER Forged axle shafts formerly known as drive shaft transmit drive from the differential to the rear wheels each shaft having two universaljoints The axle shaft acts as an upper suspension link and controls static wneel camber by insertion of appropriate shims between the final drive unit and axle shaft inner flanges Each axle shaft is supported at the outer end by preloaded taper roller bearings housed in a cast aluminium hub carrier ATARI UIE EAE TETRIS ATONE SEEDS SES OS ESS TEE DAI OE PAR SS DDSI DRAE AAA PAT ST ST AAT CAEN ET EA IRL T Issue 1 August 1994 1 X300 VSM gt Driveshafts Final Drive 9 2 DRIVE SHAFT ALIGN SRO 47 15 51 CAUTION To preserve drive line refinement individual parts other than fixings MUST NOT be renewed Inthe eventof any balanceor driveshaft component relatedproblem the complete assembly mustbe renewed Under no circumstances mustthe flexib
454. shtray to the front a Fit and fully seat the inner ashtray retaining clips a Fit and align the lid veneer panel a Fit and fully seat the veneer panel securing clips a Open the ashtray lid a Fit and align the ashtray surround veneer panel a Fit and fully seat the veneer panel securing clips a Fit and fully seat the cigar lighter assembly a Fit andfully seatthe illumination bulb assembly ensuring that the ground tag contacts the cigar lighter body a Fitthe cigar lighter element assembly a Fitthe inner ashtray and close the ashtray lid a Place the ashtray in position Reconnect the Lucar connectors a Reposition and fit the ashtray assembly a Fit and tighten the ashtray securing screws a Close the glovebox lid a Reconnect the battery and refit the battery cover X300 VSM 31 Body Components amp Trim 376 802 Issue 1 August 1994 A Body Components Trim 13 3 29 Steering Column Upper Cowl Renew SRO 76 46 02 Motor the drivers seat fully rearward e Undo and remove the lower cowl fixing screws 1 Fig 1 a Displace and reposition the lower cowl 2 Fig 1 discard the ignition lock rubber gaiter 3 Fig 1 a Motor the steering column fully upwards Undo and removethe upper column securing screws Motor the column fully downwards Displace and remove the upper cowl 4 Fig 1 e Fit and align the new cowl into position a
455. side the tank The two filters prevent contaminants from entering the fuel rail and possible damage to the fuel injectors the engine the pump and underfloor filter The second fuel pump is controlled by the engine control module ECM and works of a mappedfuel map The pumps switch on time depends on the fuel requirement which is depending on the engine load The fuel lines are made up of an assembly combining steel underfloor pipes and flexible conductive anti permeation tubing Inorder to perform speedy remove and refit operations the underfloorsteel lines are linkedthrough the engine bay bulkheadtotheflexibletubing leadingto the fuel rail andthe 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 to correspond with the difference in pipe diameter where as the connectors for the feed and return lines at the fuel tank are the same size Exceptfor the return line connector at the fuel tank two releasetools one for each size of connector are required to release all remaining connectors X300 VSM 3 Issue 1 August 1994 Fuel Emission Control amp Engine Management V1 2 The connectors are releasedby pushingthe tool into the female half of the connector and atthe sametime disengaging the latches Viton hosing surrounds the tubing thus preventing any po
456. simmediately prior to connection Tighten the gland nuts Fitthe PCRVs 4 Fig 1 to the hydrauliccontrol module re moving plugs immediately prior to connection Tighten the PCRVs Connect the rear hydraulic brake pipes 3 Fig 1 to the PCRVs removing the plugs immediately prior to connec tion Tighten the gland nuts Note Take necessary steps to prevent rotation of the PCRVs when fitting the rear brake pipes 370 296 Connectthe TMC hydraulic brake pipes 2 Fig 1 to the hy draulic control module removing the plugs immediately prior to connection Tighten the gland nuts a Removethe absorbent materialandcleanthesurrounding area a Reposition and connectthe multi plug connector Tighten the securing bolt 1 Fig 1 a Ensurethat allfixings aretorque tightenedto specifiedtol erances a Release the brake pedal hold down tool and remove a Bleedthe brake system referto sub section 12 4 4 a Examine the hydraulic control module for leaks Issue 1 August 1994 24 X300 VSM Brakes 12 8 PRESSURE CONSCIOUS REDUCING VALVES RENEW SRO 70 60 21 Referto Section 12 4 Brake System Bleeding before carrying out this procedure Pay particular attentionto the warn ings and cautions relatingto brake fluid cleanliness and cleaning materials Note The illustration shows the hydraulic control module of a 6 cyl vehicle with traction control Hydraulic control modules on non traction control vehicles have only
457. sion output to rear axle diffi i downshift change down draft draught drivability driveability driveshaft longitudinal shaft transmitting powe c propeller shaft driveshaft tunnel tunnelinfloorabovethedri t Il shaft transmission tunnel dry sleeve cylinder sleeve which is not in contact with coolant dry liner control EGR flow Dual Overhead Cam DOHC engine configuration with two camshafts med ab the valves Data US t or group of facts English Group of facts i e plural of datum Data Link Connector DLC connector providing access and or control of the vehicle information operating conditions and diagnostic atic Data Output Line DOL circuit that sen certain atio from the PCMto the instrument cluster defogger backlight defogger HRW rear screen heater demister degree angle or temperature deg 2 Department of Transportation DOT US Department of Transport UK DTp Deutsche Institut fur DIN German Standards regulation body Normuna diameter dia Diagnostic Module DM Supplemental Restraint System non controlling module for diagnostics overview Diagnostic Test Mode DTM a level of capability in an OBD system May Self Test Mode include different functional states to observe signals a base levelto read DTCs a monitor level which includes information on signal levels bi directional control with on off board aids and the ability to interface with
458. specificationensuring that the anti twist plate is allowedto freely align beforethe center bear ing fixings are secured JL7 043 Issue August 1994 2 X300 VSM Driveshafts amp Final Drive MO Method 2 A refinement to Method 1 may be made by stretching a line horizontally along the center line of the vehicle to touch the outside diameter ofthe front weight and the rear plumb line Take care notto bias the vertical lines with the hori zontal line Set the center plumb line to touch the horizontal line by movement of the center bearing Fig 1 To realign the center bearing slacken bearing fixings and positionto suit a Tighten all fixings to specification ensuring that the anti twist plate is allowed to freely align beforethe center bear ing fixings are secured 12 7 mm 0 5 in 347 046 Recommendedlocally made tools Plumb line Locally made Weight Locally made 127 mm 0 5 in diameter mild steel Issue 1 August 1994 3 X300 VSM Ta Driveshafts amp Final Drive Dy 9 3 OUTPUT SHAFT END FLOAT CHECK SRO 51 10 24 e Disconnect vehicle battery ground lead a Support the vehicle at the rear Mount a dial test indicator DTI to the differential housing with the probe restingonthe output shaft flange DTI probe must be parallel to the output shaft center line and NOT at an angle Pushthe wheel shaft assembly inwards and zero the DTI pull outwards and
459. ss multi plug a Fit pipe clamps to throttle housing cooling hoses and disconnect hoses from throttle housing Issue 1 August 1994 10 X300 VSM Fuel Emission Control amp Engine Management AJ16 a Remove throttle housing a Remove throttle potentiometer a Remove screws securing idle speed actuator to throttle housing a Remove and discard gasket a Remove spacer and undo bolt securing throttle lever assembly to throttle housing Remove butterfly outer bush spring and inner bush Refit in the reverse order of the removal procedure 5 1 7 IDLE SPEED CONTROL VALVE GASKETS SUPERCHARGED RENEW SRO 18 30 74 IDLE SPEED CONTROL VALVE SRO 18 30 77 IDLE SPEED CONTROL VALVE GASKET Remove Remove the throttle housing and gasket Undo and remove bolt securing idle speed control valve a Remove valve a Remove gasket Refit in the reverse order of the removal procedure eegend X300 VSM 11 Issue 1 August 1994 Fuel Emission Control amp Engine Management AJ16 5 1 8 IDLE SPEED CONTROL VALVE GASKETS NORMALLY ASPIRATED RENEW SRO 18 30 74 IDLE SPEED CONTROL VALVE SRO 18 30 77 IDLE SPEED CONTROL VALVE GASKET Remove a Disconnect battery a Remove the intake elbow to throttle housing hose Disconnect idle speed control valve multi plug a Disconnect throttle potentiometer multi plug a Remove clevis pin circlip a Reposition link arm from quadrant a Disconnect kick do
460. ssion against adaptor plate ensuring that trans mission is in line as it is fitted and seatedto the plate X300 VSM 3 Issue 1 August 1994 a Fit upper rubberto mounting spring e Using a jack fit and seat the mounting assembly to the Bi Wee Manual Transmission amp clutch AJ16 e Fit and tighten transmission to adaptor plate securing bolts 1 Fig 1 a Slacken chain adjuster a Release securing peg from adjuster a Displace securing chain from the unit lift a Slacken clamp from wing nuts a Release clamps from transmission a Lower lift and traverse aside Refit front clamp to unit lift a Connect transmission switch andfit multi way connector into securing clip a Clean and lubricate clutch slave cylinder push rod and fit to slave cylinder a Fitslavecylinderto mounting studs and secure with nuts Fit and seat remote control mounting rubbers and spacers a Align remote control assembly to transmission a Fit mounting rubber backing washers a Refit remote control mounting and secure with bolts 1 Fig 2 a Fit wavy washer to gearshift lever a Position selector shaft yoke to gearshift lever a Apply lubricant to selector shaft yoke gearshift lever assembly a Fitandtighten selector shaft yoke to gearshift lever secur ing nut bolt 3 Fig 2 a From above Tighten MS 53B hook nut to raise trans mission into position Fig 3 a Position the jack beneath the transmission a a Fi
461. ssue 1 August 1994 ii X300 VSM Cooling System AJ16 ES 4 1 1 COOLING SYSTEM DESCRIPTION 4 1 1 1 Major Components o Main engine crossflow radiator incorporating a concentric tube cooler for the power steeringfluid mounted in the right hand radiator side tank Vehicles with automatic transmission have a transmission fluid cooler mounted inthe left hand radiator side tank for 4 0 liter supercharged engines a six plate cooler is fitted other vehicles have atube type cooler Adouble action temperatureswitch for controlling the radiatorcooling fans is mounted in the left hand radiator side tank Two electrically operated radiator cooling fans mounted behind the main radiator Coolant circulating pump belt driven from the engine crankshaft Coolant header tank with pressure relief cap and coolant level probe Engine thermostat OO OG 41 12 Components for Climate Control System Q Heater matrix o Electrically operated coolant circulating pump mounted on the left hand side of the engine bulkhead Q Solenoid operated valve located adjacent to the coolant circulating pump 4 1 1 3 Components for Supercharged Engine o Supercharger crossflow radiator mounted in front of the main radiator The supercharger radiator is reverse circuited i e the coolant inlet is at the bottom of the radiator Q Electrically operated coolant circulating pump located at the left hand side of the main radiator 4 1 1 4 Operation The configurati
462. ssure testsystem Check Rectify as required Drain and centration of anti freeze being strength of coolant fill with coolant of correct con too low centration Cylinder head gasket leaking Pressure testsystem Check Renew head gasket for contamination of coolant and engine lubrication system Cracked or damaged internal Identify component s Rectify as required engine component affected Checkfor contamination of engine lubrication system X300 VSM Issue 1 August 1994 Cooling System V12 Cooling System Description Major COMPONENTS ooonoconocnnnnnnnncn eee eee eens Cooling System Description Components for Climate Control System EN Drain and Fill Procedures Radiator Drain ccecccenew nee w ne eee eee eee ene e eee Drain and Fill Procedures Complete System Fill ne EE EE EE Drain and Fill Procedures System Air Bleeding EEN We be O Aaa A AAA AHO HO 00 NM o o o o SECTION CONTENTS Sub Section Title To wien eee eens Preliminary Pages oooomonnnonnannmmo AL di Cooling System Description o o ADAM ia 4 2 1 2 coo ALT rn a nre Cooling System Description Operation e Ee EECH Cooling System Configuration ALO EE Service Procedures EEN EAR Service Procedures Safety Precautions A tse acy a acn Service Procedures Working Practices ADIGE e RES Service Procedures Coolant Change ADA e ark anal aida Drain and Fill Procedures o o ooo BOAT a wae A DAD alada diag 0
463. st 1994 2F CT Automatic Transmission AJ16 8 1 11 TRANSMISSION INTERNAL HARNESS MULTI PIN SOCKET O RING RENEW 4 0L SRO 44 24 20 Raise the hood and fit a fender cover a Disconnect the battery a Raise the vehicle on a ramp a Drain the transmission lubrication system see Sub sec tion 8 1 2 a Removethe fluid pan see Sub section 8 1 7 a Removethe fluid filter see Sub section 8 1 6 a Removethe transmission speed sensor see Sub section 8 1 10 a Disconnect the rotary switch harness multi pin plug 1 Fig 1 from the transmission multi pin socket a Release and remove the multi pin socket to main trans mission casing securing nut a Release and remove the valve body assembly ensuring e j 364 693 that the multi pinsocket is freed from the main case aper ture a Remove the valve body harness multi pin socket O ring and discard a Clean the valve body and mating faces a Fita new O ring to the multi pin socket a Fitthe valve body assembly tothe transmission unit Dur ing valve body fitment engage the shift lever quadrant peg into the manual valve and seat the multi pin socket through the main case orifice Note The flat onthesideofthe multi pinsocket should be located onthe vertical left hand side of the case a Fit but do not tighten the valve body assembly securing screws a Gently pushthe valve body assembly forward to assume this position during the final tightening operation a Ca
464. stic clips 10 Fig 1 from fuel rail a Remove fuel rail injector assembly 1 1 Fig 1 Issue 1 August 1994 6 X300 VSM y Fuel Emission Control amp Engine Management V1 2 R J19 L76 Remove injector to fuel rail retaining clips 1 Fig 1 a Remove injector 2 Fig 1 Remove fuel regulator retaining plate and fixings 3 Fig 1 a Remove fuel regulator 4 Fig 1 a Remove and discard O ring seals Refit in the reverse order of the removal procedure X300 VSM 7 Issue 1 August 1994 _ 5 2 4 PURGE CONTROL VALVE RENEW SRO 17 15 42 A BANK SRO 17 15 43 B BANK SRO 17 15 44 VEHICLE SET Fuel Emission Control amp Engine Management V12 de H er a ME A o Da Ae i a gt NI H Wa d BA rs Fi j S 319 474 Remove a Removethe left hand headlamp relay cover 1 Fig 1 see Section 15 a Remove the left hand air cleaner element 2 Fig 1 a Removethe right hand air cleaner assembly 3 Fig 1 Remove air box mounting bracket 4Fig 1 a Disconnect A bank purge valve multi plug 5 Fig 1 a Release securing clip ig 1 a Disconnect all hoses 7 Fig 1 from valve a Remove valve 8Fig 1 Refit the purge valve in the reverse order of the removal procedure Issue 1 August 1994 8 X300 VSM Fuel Emission Control amp Engine Management V1 2 _ 5 2 5 IDLE SPEED CONTROL VALVE GASKETS
465. strictly adhered to o Locking devices where specified must be fitted Ifthe efficiency of a locking device is impaired during removal it must be renewed Owners purchasing accessories while travelling abroad should ensure that the accessory and its fitted location on the vehicle conforms to mandatory requirements existing intheir country of origin Q The vehicle warranty may be invalidated by the fitting of other than genuine Jaguar Daimler parts All Jaguar Daimler replacements have the full backing of the factory warranty Q Jaguar Daimler dealers are obliged to supply only genuine service parts REFERENCES References to the left or right hand side of the vehicle are made as if viewing from the driver s seat SPECIFICATION Purchasers are advised that the specification details set out inthis Manual apply to a range of vehicles and notto any specific one Forthe specification of a particular vehicle purchasers should consult their dealer The Manufacturers reserve the right to vary their specifications with or without notice and at such times and in such manneras they thinkfit Major as well as minorchanges may be involvedin accordancewith the Manufacturer s policy of continuous improvement Whilst every effort is made to ensure the accuracyof the particulars contained inthis Manual neither the Manufacturer northe Dealer by whom this Manual is supplied shall in any circumstances be held liable for any inaccuracy or the conseque
466. sue 1 August 1994 6 Brakes Parking Brake Adjustment Cable slack must be removed by adjustment of the intermediatecable length The handbrakeshould be fully on be tween three and five clicks Parking Brake Shoe Assembly The parking brakes are of the duo sewo type The expander assembly 6 Fig 1 is mounted on the backplate mounting lug The brake shoes locate on the expander assembly and the adjuster 1 Fig 1 These are heldinposition by the upper and lower return springs 4 and 5 Fig 1 andthe hold down springs 2 Fig 1 The adjuster allows manual adjustmentof the brake shoes To remove the brake shoe assemblies the handbrake must be released and the adjuster slackened The use of a spring removaltool is recommended when re moving the brake shoes Strong pliers may be used but there is a risk of both personal injury and loss of compo nents should the pliers slip 370 302 Inspection and Cleaning Clean and examine all componentsfor wear or damage re newing parts as necessary When reassembling the expander assembly liberally greasethe components using a proprietary mechanical brake grease Lightly grease the threads of the adjuster CAUTION Donotgetgreaseonto the lining material Lightsurfacecontaminationcan be removedwith emery cloth but heavy penetration of grease or fluid will renderthe material unsuitable for further use and the linings must be renewed Re assembly When reassemblingthe brake sh
467. sure that it does not empty a Runthe engine untilthetemperature gauge reads normal Theenginespeed may be raisedto reduce warm uptime a Switch off the ignition and wait for one minute s Check that the coolant level inthe header tank is between MAX and 10 mm above MAX Add coolant as necessary a Fitthe header tank cap 4 2 4 3 Complete System Fill a Add coolant until the level inthe header tank is steady at MAX Do not fit the header tank cap Switch onthe ignition The climate control system must be OFF a Start the engine and add coolant to the header tank if required to ensure that it does not empty a Runthe engine untilthe temperature gauge reads normal The engine speed may be raisedto reducethe warm up time a Turn the climate control system ON Set the temperature to HI Manually select afan speed of approximately 50 a Runthe engine for four minutes Ensurethatthe climate control system outlet air temperature is hotto very hotand that there is no noisefrom the heater coolant circulating pump Theengine speed may be raisedto assistwith heat ing a Switch off the ignition and wait for one minute a Check that the coolant level inthe header tank is between MAX and 10 mm above MAX Add coolant as necessary a Fitthe header tank cap 4 2 4 4 System Air Bleeding After filling the system with coolant any air present must be purged before effective cooling is possible Providedthe correct fill procedure has been followe
468. suspension components for wear and damage Renew bracket housing insulators Check and adjust toe in Correct tire pressure Checktoe and adjust if needed Checkthe camber and if incorrect inspect the related components for wear or damage Loose missing front dampers and front damper boltto front suspension lower wishbone Tighten renew damper bolts Inspect wheel hubs X300 VSM Suspension Systems 11 4 8 Diagnostic Procedure continued Qu Condition Possible Cause 3ody rolls 3ody leans Weak front stabilizer bar Damagedor worn lower wishbone stabilizer bar insulator Damaged or worn stabilizer bar link Damaged or worn rear suspension wishbone bushing Damper malfunction Worn or deteriorated rear stabilizer bar bushing s supercharged sports and XJ12 only Damaged or worn rear wishbone bushing and weak springs Worn or deteriorated rear stabilizer bar bushing s supercharged sports and XJ12 only oor ride comfort 3eneral driving nstability Steering wheel does jot return properly Steering wheel pulls o one side Abnormal noise from suspension system X300 VSM Front or rear damper malfunction Weak spring s Damagedtires or unbalancedwheels Incorrect wheel alignment Steering system malfunction Damagedfront suspension lower and upper ball joints Damaged or worn sub frame to body mounting Damaged or worn stabilizer bar li
469. suspension loads except the damper are fed into a pressed steel crossbeam which is isolatedfrom the body by rubber bushes This mounting method allows the necessary amount of compliance The degree of caster is adjustable via shims positionedon either side of the upper ball joint assembly but camber is factory set and is not adjustable The vertical link and the steering arm form a single forging Cast iron hubs rotate on twin tapered roller bearings x300 VSM 1 Issue 1 August 1994 Ne Suspension Systems Fig 1 Rear Suspension layout 11 3 REAR SUSPENSION DESCRIPTION The vehicle s rear suspension layout features a cast wishbone complete with integral lower spring pan 1 Fig 1 sup porting the independently mounted damper 2 Fig 1 and road spring 3Fig 1 Thelowerwishbonearmis bolted to the hub carrier 4 Fig 1 by means of a pivotbolt 5 Fig 1 allowing for toe in adjust ment When the pivot bolt is seated correctly inthe plate located on the wishbone arm it has a small clearance at the sides butfull clearance at the top and bottom Rotationof the bolt head with eccentric constrained betweenthe vertical faces causes the bolt shankto be movedin the horizontal plane thus displacing the hub carrier and effecting wheel alignment adjustment The snubber 6Fig 1 positioned above the hub carrier prevents this from touching the vehicle body The hubcarrier wishbone assembly is pivotedon the wishbone fulcrum bolt 7 Fig 1
470. t Door Pocket erem 202 er eked d Nee a Nee 7 13 2 18 onononmono Fuel Filler Flap Description enen a a a ae a a Ae a ei 8 13 2 19 casonas Filler Flap and Hinge Renew ssssnununnunnnnnnnnnnnnununnnenennnnnnnnnnnnnnnnnenennnn 8 UK Filler Cap Retention Magnet Renew EE 8 LKA Filler Flap Latching Assembly Renew EEN EE EE 8 EE Passenger COMpartMeMt eoncccnnnnnnnnnnccnnn EE aariaa 9 TEA EE Console Assembly Remove for Access and Refit EEN 76 25 01 90 saasaa 9 13 3 2 coro Console Assembly Renew Daimler VDP ooconconnnnnconnnnncm 76 25 01 50 ooooooomo 10 133I ee Console Assembly Remove for Access and Refit Daimler VDP 76 25 01 9T ssassn 12 EE EE Console Assembly Renew EN 76 25 01 mi iaioe aa aa 13 LIN Console Rear Extension Finisher Renew oconoconnenoennennnannans 76 25 04 a 14 13 3 Oi dd oi Console Rear Extension Renew EN 76 25 05 uma ai wt wee 14 13 3 7 ccoo Selector Trim Finisher Renew 3 2 Liter ooncononoomonmnnmnn9nmm9oso 76 25 07 connnnannnma 14 1382 Bite ini sce tlese nies Selector Trim Finisher Renew 4 0 Liter 4 0 Liter SC and 6 0 Liter 76 25 07 snooooommono 15 133 Do Mode Switch Finisher Renew ooconnnonnnnnncnnnannnn 16 25 09 ai 15 133107 ria Radio Console RCN W NN FO DONG va 16 ABBA vt im Console Glove Box Renew oooccccccccnnnnnnnnn DE EE 17 so ARPA Console Glove Box Lid Pore O25 AB eee eee ss 18 LKA Console Glove Box Lid Hinge Renew ENEE 76 25 20 cononnnonnos 19 13314 a Cupholder Tri
471. t excluder seals with grease and pack grease into the _ a cavity betweenthe sealing lips of duplex seals Ensurethat el the seal spring if provided is correctly fitted Place the lip of the seal towards the fluid to be sealed and slide it into position on the shaft using a fitting sleeve Fig 2 when possibleto protect the sealing lip from damage by threads splines or sharp edges on the end of the shaft If afitting sleeve is not available use plastictube or adhesive tape to prevent damageto the sealing lip Grease the outsidediameter of the seal place it squareto the housing recess and press it into position using great care and where available a seal installer Fig 3 to ensure that the seal does nottilt Insome cases it may be preferable to fit the seal to the housing beforefitting itto the shaft Never letthe weight of an unsupportedshaft rest in a seal Ifthe correct servicetool is not available use a piece of tube which is approximately 04 mm 0 015 in smaller than the outside THIS diameter of the seal Use a pressto install the seal or use a 7 ASS EZ hammer VERY GENTLY on the tubular drift if a press is un suitable or not available JO7 003 X300 VSM 3 Issue 1 August 1994 S General Fitting Instructions Pressordrifttheseal intothefull depthofthe housingifthe housingis shouldered or flush withthefaceofthe housing where no shoulder is provided Note Careless fitting of oil seals which can result i
472. t is preferable to fit a complete set Shouldeitherfront or reartires only i e not the full set show a necessityfor renewal newtires must befittedto replace the worn ones No attempt must be madeto interchangetires fromthe front to the rear orvice versa as wear produces acharacteristic pattern on eachtire depending upon its position onthe vehicle Ifthis position is changed after wear has occurred the performance of the tire will be adversely affected It should be remembered that new tires must be balanced The radial ply tires specified here are designedto meetthe high speed performance ofthis vehicle Only tires of ident ical specification as shown inthis section must be fitted as replacements Iftwo replacement tires are fittedto one axle they must be of the same type and pattern as those on the other axle i e tires must be used in sets of four of the same manufacturer and tread pattern not intermixed Tire Fitments 4 0 Liter 4 0 Liter 6 0 Liter Daimler amp Normally Aspirated Federal XJ12 XJ12 Standard 225 60 ZR16 225 60 ZR16 225 60 ZR16 225 55 ZR16 225 55 ZR16 225 55 ZR16 Supercharged Space saver where fitted 115 85 R18 115 85 R18 Recommendedtires The following tires are recommended 225 BOER 1G ee ENNEN vee ds ENEE NN SEENEN Pirelli P4000 E 225 55 ZR Gites saica aE EEE STEET Pirelli P6000 DIS 554R 16 it AAA ata at
473. t spring to rear mounting assembly 7 y 337 095 body transmission a Fit but do not fully tighten mounting securing bolts a Lower and remove jack a Removejack channel a From above Fully undo MS 53B hook nut a From below Final align mounting to transmission body a Finaltighten the mounting assembly securing bolts a Clamp the front exhaust pipe in a vice n Remove and discard the front pipe to manifold sealing rings a Clean the faces a Fit andfully seat new rings to pipe a Remove the front pipe from the vice and align to the manifold a Align retaining ringsto the studs and secure with the nuts Issue 1 August 1994 4 X300 VSM P Manual Transmission Clutch AJ16 Wee Fit drive propeller shaft to transmission see Section 9 SRO 47 15 01 a Clean exhaust joint area smear with sealant and fit to intermediate pipe Connect exhaust system to front pipe Fit and tighten clamp securing nut bolt Reposition lambda sensor harness to allow connection from above Reconnect lambda sensor block connectors s Remove MS 53B hook and retaining tool Undo and remove lifting bracket securing nuts Remove lifting bracket a Fit injector harness mounting bracket a Fit and tighten manifold securing nuts Secure injector harness to mounting bracket 7 1 3 FRONT OIL SEAL RENEW SRO 37 23 06 Remove the transmission assembly see Sub Section 7 1 2 and place it on a
474. t the procedure for the other side e Open the driver side door a Removethe underscuttle pad a Disconnectthe inner cablesfromthe hood release handle Removethe bolts securing the hood release handleto the body remove the cables from the handle and remove from the vehicle 1 3 e To refit carry out reversal of the above procedure X300 VSM 43 Issue 1 August 1994 ie Body Components amp Trim 13 6 GLAZING FIXED 13 6 1 Glazing Fixed Description The fixed glazing comprises internal and external driving mirrors sunvisor mirror and rear quarter light glass see Ap pendix A4 Body Components and Trim for details of the windscreen and rear screen glazing 13 6 2 Interior Mirror Renew a Disconnect vehicle battery ground lead a Rotate mirror stem approximately one quarter turn clock wise to release stem from spring contact on windscreen boss a Disconnect mirror harness To refit locate mirror stem base on windscreen boss with stem parallelto top of windscreen ie one quarter turn dis placed from normal position apply firmly over boss and turn anti clockwise to lock stem on windscreen boss a Reconnect mirror harness 13 6 3 Sun Visor Mirror Assembly Renew a Disconnect vehicle battery ground lead a Lower the sunvisor a Raise the sunvisor cover and remove the lenses Remove the screws securing the mirror to the sunvisor and remove the mirror a To refit carry out reversal of the above procedu
475. t to differential Road wheel Alloy 88 102 Road wheel Steel Upper link to differential Upper linkto wide mounting bracket A frame Wide mounting bracket to A frame Wishbone pivot nut 80 100 Wishbone tie to differential stud 85 105 Issue 1 August 1994 iv X300 VSM Driveshafts amp Final Drive ER Description es Me Loctite 270 Adhesive Axle shaft spline 30 50 radial coverage Hylosil 102 Sealant Output shaft bearing housingto differential as case Retinax A grease Rear hub bearings and seal pre lubrication See Sub Section IV Service Data Specification minus 0 08 3 07 mm required adjustable spacer Minimum specified pretoad o 0 025 therefore 3 15 minus 0 025 3 125 mm required adjustable spacer Adjustable spacers are available in0 05 mm increments from 2 22 to 3 47 mm Rear hub bearing grease Quantity Inner bearing race115 ml Outer bearing race 90 ml Final drive unit pinion spigot radial run out Must not exceed 0 08 mm TIR total indicator reading Should the run out exceed the stated limit renewthe final drive unit X300 VSM v Issue 1 August 1994 vi Driveshafts amp Final Drive Ta 9 1 MAJOR COMPONENT DESCRIPTION Power is transmitted from the gearboxto the final drive unit via atwo piece drive shaft formerly known as propeller shaft which is supported by a center bearing Isolationfrom vibration and transmitted har
476. t with fluid see Sub section 8 1 2 a Removethe fender cover and lower the hood Issue 1 August 1994 12 X300 VSM 8 1 10 TRANSMISSIONSPEED SENSOR RENEW 4 0L SRO 44 15 34 s Raise the hood and fit a fender cover a Raise the vehicle on a ramp a Drain the transmission lubrication system see Sub sec tion 8 1 2 e Removethe fluid pan see Sub section8 1 7 a Displacethe transmission speed sensor harnessfrom the valve body rear securing clip Release and remove the speed sensor and connector re taining clip fromthe valve body a Displacethe speed sensor and connector from the trans mission main casing a Disconnect and remove the speed sensor from the har ness connector a Clean the speed sensor retaining clip and mating surface Connectthe new speed sensor to the harness connector a Fully seat the speed sensor into the transmission unit main casing a Fit the speed sensor and connector retaining clip to the valve body engaging the tangs onto the connector a Fit and tighten the speed sensor and connector retaining clip securing screws a Reposition and fully seat the speed sensor harness into the valve body rear secure the clip a Refitthe fluid pan see Sub section 8 1 7 a Lower the vehicle on the ramp a Refill the transmission unit with fluid see Sub section 8 1 2 a Removethe fender cover and lower the hood X300 VSM 13 Automatic Transmission AJ16 Issue 1 Augu
477. tabilizer bar torsion bar across the vehicle connecting anti roll bar body and suspension standard std station wagon estate car shoot ing brake stop lamp brake lamp sulfur sulfuric sulphur ic supercharger sc an intake system which utilizes a supercharger mechanically driven device that pressurizesintake air thereby increasing density of charge air and the consequent power output from a given displacement Suercharger Bypass SCB S if t Rt System SRS airbag restraint system for driver and front seat passenger supply port SP supply port of valve issue 1 August 1994 24 X300 VSM Term s switch Abbreviation if applicable Introduction device for making breaking or changing the connections in an electrical circuit Previously used term s or Eng lish Equivalent synchromesh synchro manual transmission mechanism consisting of a cone shaped clutch inside a coupling sleeve which ensures that the sleeve and the gear are turning at the same speed as they mesh system group of interacting mechanical or electrical components serving acommon purpose X300 VSM 25 Issue 1 August 1994 e Introduction GLOSSARY OF TERMS T tachometer Abbreviation Definition if applicable Previously used term s or Eng lish Equivalent TACH a circuit that provides input for an electronic tachometer display controls vacuum levels or
478. te clutch Intermediate sprag clutch Direct clutch Forward clutch Overdrive planetary carrier assembly Overdrive roller clutch Overrun clutch Fourth clutch Pump assembly Converter pump Stator roller clutch Output speed sensor X300 VSM Automatic Transmission V12 amp AJ16 Supercharged aa Powertrain 8 2 1 2 Shift Speeds 4 0 Liter Supercharged Lightthrottle D1 D2 D2 D3 D3 D4 D4 TCC on Normal mile h 8 10 18 20 25 39 45 51 kmih 13 15 28 33 40 46 72 83 sport mile h 10 12 20 23 30 34 47 55 kmih 16 19 32 37 48 55 76 88 Upto Detent D1 D2 D2 D3 D3 D4 Normal mile h 34 37 60 66 86 94 kmih 54 59 97 107 138 151 sport mile h 43 47 74 81 103 113 kmih 69 76 118 130 166 182 Maximum shift speeds through detent D1 D2 D2 D3 D3 TCC on Normal Sport mile h 47 50 81 84 116 128 kmih 75 80 130 134 187 205 Zero throttle TCCoffinD4 D4 D3 D3 D2 D2 D1 Normal mile h 36 40 15 17 10 12 km h 58 64 24 27 16 19 sport mile h 36 40 18 20 12 14 9 9 kmih 58 64 29 32 20 22 14 15 Up to detent D4 D3 D3 D2 D2 D1 Normal mile h 67 74 39 44 9 9 kmih 107 118 63 70 14 15 sport mile h 81 89 57 63 27 29 kmih 130 144 92 101 43 47 Kick down available throughdetent TCC4 D3 D3 D2 D2 D1 Normal Sport mile h 103 113 67 74 36 40 kmih 165 183 107 118 58 64 TCC Torque converter clutch
479. ted Kingdomthe Health and Safety at Work Act 1974 placesa duty on employers and employeesto ensure whenever possible safe working conditions and practices Wherever a potential hazard is notifiedto or identified by the operator he must employ the correct safety procedures and equipment Shoulda personalinjury occur as a result of any workshop activity seek medical help as soon as possible and do not attempt self treatmentother than by the applicationof first aid With the constant introductionof new materials inthe manufacture of vehicles it is importantthat potential risks are identified and precautions made known WARNING READ AND UNDERSTAND WORKING PRACTICES CLIMATE CONTROL SYSTEMS SECTION 14 WITH SPECIAL REFERENCE T O DO NOT VENT REFRIGERANT DIRECTLY TO ATMOSPHERE ALWAYS USE JAGUAR APPROVED RECOV ERY RECYCLE RECHARGE EQUIPMENT WEAR SUITABLE EYE AND SKIN PROTECTION OBSERVE ALL APPLICABLE SAFETY REQUIREMENTS X300 VSM 1 Issue 1 August 1994 l eddi a Body Systems amp Body Repair y A4 1 2 Notification Of Hazards Symbols which convey important information will be posi tioned at the beginning of any specific operation or text Standard symbols will be usedwhere repairs or service pro cedures are detailed All symbols will conformto standard ANSI 2535 3 Ameri can National Standards Institute o The surround shape of the symbol will indicate the Mandatory Action basis ofthe messageto becon
480. ter speaker harnesses along the defrost vent aperture a Place the defrost vent assemblies to the fascia a Connect the speaker harness multi plugsto the speakers Reposition and fit the vent assemblies to the fascia a Fit and tighten the vent securing screws Place the solar sensor assembly to the fascia a Reconnect the solar sensor harness multi plug a Fully seat the solar sensor assembly to the fascia a Reposition the fascia assembly on the bench a Secure the harnessto the fascia assembly using tiestraps a Reconnect the BPU harness multi plugs a Reposition and fit the fascia harness to console harness multi plug to the mounting bracket a Reconnectthe fascia vent motor gearbox assemblies har ness multi plug Issue 1 August 1994 22 X300 VSM Body Components amp Trim fir a Reposition and fitthe motor gearbox assemblies harness multi plugto the mounting bracket a Fully seat the through panel connectors to the fascia a Placethe air conditioning differential potentiometer tothe fascia and route the differential potentiometer harness through the vent aperture a Reconnect the differential potentiometer harness multi plug e Refit the fascia board a Refit the center veneer panel a Refit the fascia closing panels a Refit the steering wheel a Refit the drivers airbag module a Refit the underscuttle pads a Reconnect the battery and refit the battery cover X300 VSM 23 Issue
481. the hexagon with the strength grade symbol 8 12 or 14 Some nuts with a strength 4 5 or 6 are also markedand some havethe metric symbol M onthe flat which is oppositeto the strength grade marking Aclockfacesystem is used as an alternative method of indi cating the strength grade 3 Fig 2 The external chamfers or aface of the nut is markedin a position relativeto the ap propriate hour mark on a clock face to indicatethe strength grade A dot is usedto locatethe 12 o clock position and a dash to indicate the strength grade If the grade is above 12 two dots identify the 12 o clock position Issue 1 August 1994 4 X300 VSM General Fitting Instructions gt A3 2 11 Hydraulic Fittings Metrification Metric fastenings are being used increasinglyin motor vehicle manufacture butthe use of some UNF threaded parts must be expected Technicians musttake note of warningsthat dangers exist while UNF and metricthreaded hydraulic parts continue to be usedtogether UNF pipe nuts should not be fitted into metric parts nor vice versa Experience indicates that it is not safe to rely upon the difference in thread size Providing permanent identification of metric parts is not easy but recognition has been assisted by the following means All metric pipe nuts hose ends unions and bleedscrews are coloured black The hexagon area of pipe nuts is indented with the letter M Metric and UNF pipe nuts are slightly dif ferent in s
482. tion a Fit and tighten the securing screws e Repositionthe ground lead to radio securing stud Fit and tighten the securing nut Connect the antenna co axial to the radio a Reposition the excess harness leads into the radio mounting hole ensuring that the harnesses are posi tioned to allow the radio to be pushed fully home a Fully seat the radio into the console a Reposition and fit the selector ident plate a Fit and tighten the ident plate securing screws a Refit the console veneer panel Refit the console ashtray Reconnect the battery Refit the battery cover Issue 1 August 1994 16 X300 VSM Body Components amp Trim 13 3 11 Console Glove Box Renew SRO 76 25 16 a Remove the console glove box lid see subsection 13 3 12 Undoandremovethe glovebox ashtray securing screws a Carefully displace the ashtray upwards for access a Displace and remove the ashtray lid catch a Displace and reposition the glove box assembly a Disconnect the security valet switch harness multi plug a Removethe glove box Place the glove box to the front a Displace and remove the valet switch a Displace and remove the glove box lid checkarm s Displace and remove the glove box lid checkarm guide Place the glove box aside a Place the new glove box to the front a Fit and fully seat the checkarm guide to the glove box a Fit and align the checkarm to the glove box a Fit and fully seat the v
483. tion of baking soda or ammonia and water may be used Inthe event of skin or eye contact rinsethe affected areas with water and should this not be sufficient seek medical attention Any trace of acid spilled or splashed on the vehicle should be rinsed with clean water BEFORE AND WHILST WORKING WITH THE BATTERY BE AWARE OF THE FOLLOWING SAFETY PRECAUTIONS particularly during charging highly explosive hydrogen is emitted do not smoke when working near the battery avoid sparks short circuits or other sources of ignition switch off current before connecting or disconnecting any electricalterminals always disconnect battery ground lead first and reconnectlast ensure battery is charged in a well ventilated area switch off the charger before disconnecting 0000000 WARNING WHEN PREPARING ELECTROLYTE OF A DESIRED SPECIFIC GRAVITY ALWAYS POUR THE CONCENTRATED ACID SLOWLY INTO THE WATER AND NOT WATER INTOTHE ACID HEAT IS GENERATED WHEN MIXING ACID WITH WATER HENCE ADD SMALL AMOUNTS OF ACID AND STIR SLOWLY INTOTHE WATER ALLOW TO COOLIF NOTICEABLE HEAT DEVELOPS EXCEPT FOR LEAD LINED CONTAINERS ALWAYS USE NON METALLICCONTAINERS AND OR FUNNELS DO NOT STORE ACID IN EXCESSIVELY WARM LOCATIONS OR DIRECT SUN LIGHT FUEL VAPOUR IS EXTREMELY FLAMMABLE HENCE GREAT CARE MUST BE TAKEN WHILST WORKING ON THE FUEL SYSTEM Issue 1 August 1994 14 X300 VSM y Electrical 15 5 11 Battery Remove amp Refit SRO 86 15 01 386 1787 R
484. tion side of the pump via the relief valve and returns either to the TMC secondary circuit and on to the fluid reservoir or is directly drawn on by the pump As soon as the spinning wheel has been braked down into the normal range of wheel spin the NO valves items 16 or 17 close to prevent any further increase in brake pressure Depending uponthe acceleration of the wheel the NC valve item20 or 21 may opento decreasethesecondary circuit brake pressure NC valves item 17 or 18 may remain closed inorder to achieve a brake pressure holding phase Ifthe pressureinthe secondarycircuit needsto be increased again the NC valve closes again ifopen andthe NOvalve opens diverting the necessary volume flow This control action keeps the wheel inthe range of optimum slip untilthe spinning tendency ceases The NO isolation valve 14 remains closed throughout the traction control cycle An actuation of the brake sensed by the control module causes the traction control modeto be terminated and the isolation valve item 14 to be opened The TMC pressure simultaneously closes the hydraulic inlet valve item 13 so that the pump can no longer draw fluid from it The ABS TC CM now operates in normal ABS mode Note Whentraction control is initiated speed control is deactivated ifin operation and requires re setting after the traction control mode hasterminated Gear shift is inhibited on automatic transmission vehicles no down shifts are allowed an
485. tive indicator EE 4 ASL Z eii Security and locking control module 4 Allo MEN T T A AA RARAS OC ee 7 E E EE Trunk lid release external oooooooroccconorrrnoconcn eee een tenn enna EEE EES 7 AS 2 1D o aeien Trunk lid release internal EE 7 AS 216 A Valet switchen 7 ELE iia General Information EE 7 ASII ee Locking 7 A3 Security sveiem E 8 ASA aan Convenience A AS a A AA AS 8 AR A OS erg greng EA aes Zeg ine ARES d e er al deed EE 8 ASA ii Key Fob Variations E IN 9 AR AT European and UK markets ooooocococommmmo der E RITO a S 9 ARA North American markets EE 10 ASA eiea Rest of the world markets EE 11 ARA n aaa How to operate the system 12 ASD T id Locking key ee ere 12 ADD isc Unlocking key oo ccc ccc cece cece ce nee conca narrar rr rr ee EE 12 AB e Locking unlocking key ring transmitter e 13 ASA coco Locking key ring transmitter ooooooooonororomrncrnorccrcnao roo rca rr 13 ASS ccoo Unlocking key ring transmitter ooooooocooommmmmmononsaninncaonananaconcccnaa os 14 A5 5 6 e ooo Panic feature key ring transmitter Only oooooooooommmormoncorcananncccoranarn aso 14 A557 e Central locking 15 A558 ccoo PASSIVE arming raro rr raro rr 15 AH hg Trunk release EE 15 AR RI Trunk valet isolate EE 15 ASSAT oe ceca Flush Sill buttons 0 0 6 c ce ne eee eee eee nett ete rr 15 A5 15 6 cecccceens System Diagnostic Methods 0c c cece cece ncn een aro nro nera er rr 16
486. to give ita caster self steering effect Catalytic Converter in line exhaust system device usedto reduce the level of engine exhaust emissions Celsius C Sltermfor the Centigradescale with freezing point at zero and boilina point at 100 center centre centimeters cm centimetres charge current current developed by the generator charging current Closed Loop CL Closed Loop System CLS control system with one or more feedback loops Clutch device which uses mechanical magnetic or friction type connections to facilitate engaging or disengaging two shafts or rotating members clutch disc clutch disk friction disc of a clutch assembly clutch plate centre plate driven plate clutch throwout bearing bearing mounted on clutch throw out fork clutch release which depresses the pressure _plate s bearing diaphragm spring to releasethe clutch disc color colour column mirror control module C M CM connecting rod bearing bearing usually split plain at the lower end big end bearing of the connecting rod where it connects with the crankshaft X300 VSM 9 Issue 1 August 1994 Introduction GLOSSARY OF TERMS Term s Abbreviation Definition rev used if applicable term s or Eng lish Equivalent Cantiroll a means or device to direct and regulate a process or guidethe operation of a machine apparatus or system Control Module convertible top CM a self conta
487. to points circled in Fig 1 Q Items such as sliding roof drain tubes andthe harness from the rear left hand bulkheadthrough to the luggage compartment must be in position BEFORE the introduction of the foam J76 1047 X300 VSM Issue 1 August 1994 24 Body Systems amp Body Repair Q A4 4 1 PAINT SYSTEMS APPROVED The manufacturer s paint systems listed below are currently approved for refinishing Jaguar vehicles Clear lacquer Bare metal etch primer Primer surfacer Base color coat Akzo Sikkens Washprimer Autocry Autonova Autobase iAutoclear 1000 3000 Automat Dupont Centari 600 Centari 600 Glasurit Wash Etch System 54 solid metallic Clear lacquer 923 85 System 56 micatallic System 59 amp 69 pearl Metal pre treatment amp Standox Basislak Standox Clearlak rust remover 301 2595 Deltron Concept 2001 HS clear D880 Herberts PPG Galvaprep D840 Wash primer D831 Deltron HS 2 Hi build primer D855 Epoxy surfacer DP40 Deltron non lso cyanate Primer D828 RM Prof Maxfill Diamont Basecoat Eurofil l Diamont Clearcoat Note Not available North America In markets which do not support any ofthe nominated systems alternatives may be used providedthat they comply with the following company standards CAUTION To avoid damageto the vehicle interior trim and plastic items effective panel temperat
488. trical diagnostic information on the ABS traction control systems referto EDM Section 12 J70 286 Issue 1 August 1994 6 X300 VSM Brakes 9 12 1 6 Calipers Both front and rear brakes on all vehicles are fitted with single piston caliper assemblies that act upon 28mm thick ventilated brake rotors front brakes and 20mm thick venti lated brake rotors hubs rear brakes Rearventilated brake rotors hubs are fitted to cope with the increased demands brought about by traction control The brake rotors must be renewed when the minimum thick ness specified below is reached Q Front brake rotor 27mm Q Rear brake rotor 18 5mm On the front brakes Fig 1 two bolts secure the caliper carrier to the suspension vertical link 370 301 Onthe rear brakes Fig 2 two bolts wirelocked securethe caliper carrier to the hub carrier X300 VSM 7 Issue 1 August 1994 E3 Brakes The caliper 1 Fig 1 is mounted on the carrier 2 Fig 1 by means of two guiding pins 3 Fig 1 and a caliper retaining clip 5 Fig 1 The guiding pins 3 Fig 1 slide in bushes 4 Fig 1 fitted to the caliper The guiding pins are fitted with dust caps which must be fitted when reassembling the caliper Inspection and Cleaning WARNING BRAKE LINING DUST CAN IF INHALED DAM AGE YOUR HEALTH ALWAYS USE A VACUUM BRUSHTO REMOVE DRY BRAKELININGDUST NEVER USE AN AIR LINE When fitting new brake pads always take n
489. tronically controlled transmissions indicates temperature of transmission fluid the range in which the transmission ae operating indicates rotational speed of transmission he output shaft or turbine shaft track between tire contact centers not to be track confused with tire contact tread pattern boot luggage compartment Transmission Control Module of the transmission Transmission Control Switch Transmission Oil Temperature Al TOT Transmission Range TR Transmission Speed Sensor direction indica tor principle of engine which fires every second two stroke stroke of the piston turn indicator turn signal lamp Issue 1 August 1994 26 X300 VSM introduction GLOSSARY Of TERMS Term s Abbreviation Definition Previously used if applicable term s or Eng lish Equivalent undercoating underseal unitized construction unitary construc tion Unit Service Manual USM Service Manual which pertains to a major unit e g transmission engine fitted to a Jaguar vehicle see also Vehicle Service Manual and Electrical Diagnostic Manual V a device by which the flow of liquid gas vacuum or loose materials may be started stopped or regulated by a movable part which opens shuts or partially obstructs one or more passageways or ports A Valve is also the movable part of such a device inan OHC engine the
490. ue 1 August 1994 A1 95MY 14 X300 VSM Specification Engine Bay Fuse Box right hand side FuseNo Fuse Colour Code Value Circuit amps F1 E po gt Notused o F2 Red Main beam headlamp right hand side F ELE F4 Red Lowered beam headlamp right hand side F5 Red 10 Side light front right hand side Turn indicator front right hand side Side repeater flasher right hand side F6 Tan Engine control module ECM F7 Clear 25 Air pump 6cyl where fitted Ignition coils V12 F8 Red 10 Air conditioning clutch F9 Not used F10 Tan 5 Generator Front lighting control module right hand Air conditioning clutch Windshield wash headlamp power wash heaters and relays F11 Yellow 20 Engine management system relay supply Injectors F12 Red 10 Engine management system Starter relay Ignition coil sensing and air pump relay 6cy Fuel injection relay Engine management sensing V12 F13 Red Windshield washer pump F14 Red 10 Lambda heaters idle speed control valve Mowa OO F16 Red 10 Air pump control Solenoid vacuum valve V12 Water pump supercharged F17 Light Green Headlamp power wash pump F18 Red 10 Frontfog lamp right hand side where fitted x300 VSM A1 95MY 15 Issue 1 August 1994 Specification Rear CompartmentFuse Box left hand side heelboard Fuse No Fuse Colour
491. ugust 1994 Engine V12 3 2 2 ENGINE GEARBOX TRANSMISSIONASSEMBL Y 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 isa mounting bracket and spring assembly fitted and secured to body underframe longitudinal members For access to removethe engine carry out the following procedures WARNING WHEN WORKING WITHIN THE ENGINE COMPARTMENT KEEP CLEAR OF THE RADIATOR COOLING 3 k 2 FANS AS THEY COULD START WITHOUT WARNING EVEN IF THE ENGINE IS NOT RUNNING Removethe hood see SRO 76 16 01 section 13 a Remove the two air cleaner assemblies see SROs 19 10 01 8 19 10 02 a Remove the engine cover see SRO 12 29 93 V12 Engine Service Manual Depressurizethe fuel system see SRO 19 50 02 section 5 1 s Disconnectthe battery Inline with the relevant SROs and sections remove all appropriate obstructing parts including their fixing and mounting arrangements a Disconnect all mechanical and isolate all electrical linkages leading to and from the engine a De gas the air conditioning system see section 14 Charge Recovery System depressurization AUTION Donotvent refrigerantdirectly to the atmosphereand alwaysuse Jaguar approved recovery recycle re charge equipment Drainthe engine oil see 3 2 3 this section Drainthe coolant
492. ulous cleanliness when dismantling components particularly when parts of the brake fuel or hydraulic system are being worked on A particle of dirt or afragment of cloth could cause a dangerous malfunction if trapped inthese systems Clean all tapped holes crevices oilways and fluid passages with compressed air WARNING DO NOT PERMIT COMPRESSED AIR TO ENTER AN OPEN WOUND ALWAYS USE EVE PROTECTION WHEN USING COMPRESSED AIR Ensurethat any O rings used for sealing are correctly refitted or renewed if disturbed Mark mating partsto ensure that they are replaced as dismantled Whenever possible use marking materials which avoidthe possibilities of caus ing distortion or the initiation of cracks which could occur if acenter punchor scriber were used Wire together mating parts where necessaryto prevent accidental interchange e g roller bearing components Tie labels onto all parts to be renewed andto parts requiring further inspection before being passedfor reassembly Place labelled parts and other parts for rebuild in separate containers Do not discard a part which is due for renewal until it has beencompared with the new part to ensure that the correct part has been obtained A3 2 4 Inspection Before inspecting acomponentfor wear or performing adimensional check ensure that it is absolutely clean aslight smear of grease can conceal an incipient failure When acomponent isto be checked dimensionally against figures quoted for it u
493. ure Constructional Steel Classification Table ene 9 A422 cn Body Alignment A NNEN EE EEN EE 9 A4 2 2 1 ccoo Body Alignment Datum Location ee cence ene EEN EEEEEEEEE EE E 10 EEGEN Body Alignment Plan View Key to IlluStrati0N sssssunsnunnssnnnnnnnnnnnnnnnnnnnnnnn 10 A4223 wunnnnnnen Body Alignment Side View Key to IlluStrati0N EE EE EEN 12 A423 ccoo Zinc Coated EE EE 14 A cununcnnen Zinc Coated Panels Description eeeeee cent cece eee ence eee ee ee eeeeeeeeeeeeeeeeeanees 14 A4232 canon Zinc Coated Panels Welding Preparation ENEE EE EE EE 14 A423 3 conan Zinc Coated Panels Body FillerS ee e eee eee EE EEN 14 EE NEEN Zinc Coated Panels Refinishing ee ENEE NEEN EE EE EE EEN 14 PALA unan Panels Associated Renew ocononnononcnnnncnnnnnn nana 77 10 02 a 15 A425 ccoo Surfaces Old Prepare EEN 77 10 03 wanununnunan 16 EELER Surfaces New Prepare ENEE EEN 77 10 04 conan 16 A4252 no Panels Align And Weld ee 77 10 05 amp 06 connunn 17 A426 sunno CuttingAnd Welding SYMDOIS enoonoenonnncnnnnanncan ee eee ee eee eee eeeeeeeaeeneee 18 GEAR Adhesive Sealers and Body Protection Approved SyStemMS EE ENEE EE En 19 A4 B 1 A Body Sealing amp Preservation Manual Section Relevance ane ENEE EEN ENEE 19 Ad HD ccoo Cavity Wax INJECTION EEN 19 A4 3 2 1 sannnnnnes Cavity Wax Injection Points Front Illustration e EEN 20 A4 3 2 2 nn Cavity Wax Injection Points Rear IIUStratiOn ue EN 21 EK Underseal Application Area NEEN ENEE EE EE EEN E
494. ure does not drain the heater circuit 4 1 4 2 Engine Drain Note This procedure should only be necessary when the engine is being dismantled a Drainthe radiator Seethe procedure above a Place a drain tray underthe cylinder block drain plug Fig 2 Removethe block drain plug and drain the coolant a Fit the block drain plug 426 276 Fia 2 WARNING DO NOT REMOVE THE HEADER TANK PRESSURE CAP WHILE THE ENGINE IS HOT IF THE CAP MUST BE REMOVED PROTECT THE HANDS AGAINST ESCAPINGSTEAM AND SLOWLY TURNTHE CAP ANTI CLOCKWISE UNTIL THE EXCESS PRESSURE CAN ESCAPE LEAVE THE CAP INTHIS POSITION UNTIL ALL THE STEAM AND PRESSURE HAS ESCAPED AND THEN REMOVE THE CAP COMPLETELY WARNING WHEN DRAININGTHE COOLANT WITH THE ENGINE HOT PROTECT THE HANDS AGAINST CONTACT WITH HOT COOLANT 4 1 4 3 Radiator Fill a Add coolant until the level inthe header tank is steady at MAX Do not fit the header tank cap a Switch on the ignition Theclimate control system must be OFF Start the engine and wait until the cooling fans operate for the second time The engine speed may be raised to reduce the warm uptime While the cooling fans are operating raisethe engine speed to 1500RPM for one minute Returnto idle speed a Switch off the ignition and wait for one minute Check that the coolant level inthe header tank is between MAX and 10 mm above MAX Add coolant as necessary Fit the header tank cap Issue 1 August 199
495. ure must notex ceed 95 C during paint cure process A4 4 1 1 GeneralRecommendations Recommendations and advice covering all aspects of refinishing may befound inthe Paint Refinishing Manual which is available inthe following languages Language Dutch English Italian French German Spanish A4 4 1 2 Manual Section Relevance Section Relevance Defect diagnosis Applicable Refinish processes Applicable less De waxing process Refinishing system Applicable less model references seetable above Color technique Applicable Facilities and equipment Applicable Safety Legislation applicable U K only general precautions and advice applicable to all geed X300 VSM 25 Issue 1 August 1994 i a ES Body Systems amp Body Repair A4 4 2 BLACK OUT AREAS To avoid visibly unsightly areas between panels and through gaps the application of matt black paint is required in certain areas It should be noted that this processis NOT required on dark colored vehicles The paint which should have a heat resistance of 40 to 120 C should be applied in accordance with Fig 1to the areas marked with an asterisk J76 1042 Issue 1 August 1994 26 X300 VSM Body Systems amp Body Repair A4 4 3 ANTI THEFT LABELS NORTH AMERICAN MARKET ONLY A4 4 3 1 Original Components North American specification vehicles havethe VIN marked on all major external panels certain structural membe
496. uring nut a Reconnect the left hand fascia harness to cabin housing harness multi plug a Reconnect the fascia harness to console harness multi plugs Fit and align the passenger side outlet duct a Fit and tighten the fascia to console securing screws a Reconnect the speed control harness multi plug a Reconnect the speaker tweeter harness multi plug a Reconnect the exciter coil harness multi plug Reconnect the column switchgear and column motor har ness multi plugs a Reconnect the right hand fascia harnessto cabin harness multi plug a Place the instrument pack fascia switchpack in position a Reconnect the instrument pack harness multi plugs a Reposition and fit the instrumentpack assembly to the fas cia Reconnect the fascia switchpack harness multi plugs Reconnect the steering column harness multi plugs a Reposition and fit the switchpack harness multi plug mounting bracket a Fit and tighten the instrument pack switchpack securing bolts a Fit and align the fascia tie bars a Fit and tighten the tie bar securing nuts a Refit the center veneer panel e Refit the fascia closing panels a Refit the steering wheel a Refit the drivers airbag module a Refit the underscuttle pads a Reconnect the battery and refit the battery covers X300 VSM 25 Issue 1 August 1994 Body Components amp Trim 13 3 19 Underscuttle Pad Drivers Side Remove For Access And Refit SRO 76
497. us air blend constant matrix temperature systems in car temperature is now controlled by mixing recirculatedcoolant in the heater circuit with engine temperaturecoolant Matrix temperature is controlled by avalve which opens to raise temperature admit engine coolant and closesto reduce it recirculatescoolant within the circuit The coolantflow valve operates on a six 6 second duty cycle during which it may be open for whatever periodthecontrol system dictates FACE vent airtemperature of howeveriscontrolledbythe cool air by passdamper which allows incoming air to flow aroundthe top of the the heater matrix andthus remain unheated Because the engine coolant pump is driven proportionally to engine speed the coolant delivery rate changes with engine revolutions thus causing temperature variations To stabilize the flow through the matrix and thus the temperature an electrically driven circulation pump has been introduced into the system Engine Coolant flow valve Circulation pump Heater matrix Bottom hose Engine cooling system radiator Fig 1 Coolant circuit schematic view Issue 1 August 1994 6 X300 VSM L Ban Climate Control Systems Ce 145 AIR CONDITIONING CONTROL MODULE A CCM 14 5 1 Description Theclimate control system peripheralscommunicate withthe A CCM via three maindevicecategories plusthevehicle power supply and ground connections Manual Inputs Control panel Face Vent Temperature Control Aut
498. using Intercooler water pipes Outlet elbow to supercharger Pulley to carrier Supercharger mounting bracket to engine Supercharger mounting stud Superchargerto mounting bracket 25 35 85 11 5 22 28 22 28 22 28 22 28 22 28 22 28 22 28 43 57 22 28 43 57 22 28 22 28 85 11 5 4 ON gt o O O o D Q lt D pha 3 J Q Q O lt ON o Q lt Q D g o Q Tensioner bracket to adapter Throttle body adapter to bypass actuator 5 g Z 111 SERVICEMATERIALS Aa Description Uses Notes Hylosil 102 sealant Half moon sealsto cylinder head lk siramerto transter housing Thermostathousingto extension Locktite 501 locking compound Oil pump drive plate bolt Oil pumpfront cover to body Oil pump rear cover to body Tivoli Kay Adhesives No 5696 Exhaust system joints sealant Issue 1 August 1994 iv X300 VSM Engine AJ16 ron 3 1 1 ENGINE GENERAL The 3 2 4 0 liter normallv aspiratedandthe 4 0 litersupercharged enginedvehicles are equippedwith the AJ16 family of six cylinder in line engines The engines havea fully mapped engine managementsystem with digital ignition and individual on plug ignition coils This section describes the service proceduresto be carried out with the engine in situ It also coversthe renewal of the engine transmission unit d 1 For information relating to strip down inspection fault diagnos
499. ust 1994 a Q LI KA S A E E S SE K lk Sly o a E A4 3 2 1 Cavity wax i X300 VSM 21 Issue 1 August 1994 a S Body Systems amp Body Repair A4 3 3 UNDERSEAL APPLICATION Inderseal should be applied as indicated by the hatching and omitted from areas indicated in solid black SS SS e Ee yn SS e Loy AAR NEN NA SS SS SSE SS SS ING QV ala Be Sao T T EN SO AN SE ie S S SS SIS S EN SS lt a SS O S SNS y SS OS SS OS DS RG SE E a OS PTE A SS Zp Wy ES Uy Wy SS SS RR RON SS Le X 376 1046 SS Areas to be left clear Fig 1 CAUTION Do not apply undersealto rotating or hot components Issue 1 August 1994 22 X300 VSM SE S OI Ge gt E ea o N E 2 N YN a O Le co A4 3 4 INSULATION PADS rdance with the illustration below Insulation pads should be located in acco Issue 1 August 1994 X300 VSM l D 2 S X Body Systems amp Body Repair y IN DAN A4 3 5 FOAM INJECTION Where any of the sections shown in the following illustration are renewed then expanded foam must be introduced into the area after all other repair refinishing protective processes Q Tapeshouldbe appliedto the areas defined by arrowsto ensure the travel ofthe foam alongthe hollowsection o Expandedfoam should be introduced in
500. ve The flywheel is extremely heavy and great care must be taken when lifting it from the vehicle 333 069 Fig 1 The Clutch Assembly CAUTION The hydraulicfluid used inthe clutch hydraulicsystem is injuriousto car paintwork Utmost precautions MUST at all times be taken to prevent spillage of fluid Should fluid be accidentally spilled onto the paintwork wipe fluid off immediately with a cloth moistened with denatured alcohol methylated spirits Issue 1 August 1994 10 X300 VSM Manual Transmission amp Clutch AJ16 Da 7 1 13 CLUTCH FAULT DIAGNOSIS symptom Possible Cause difficult gear Hydraulic system ngagement defects Rattling clutch Operating mechan ism faults Clutch unit faults Check fluid level in reservoir Replenish as necessary and bleed system if necessary Bleedthe system Renew return spring if necessary Check for damaged pressure plate Renew pressure plate Check splines on clutch driven Renew as necessary clutch plate and primary pinion shaft for plate or primary pinion wear Check clutch driven plate for loose Renew driven plate or brokensprings and for warping Check for wear in the clutch with Renew as necessary drawal mechanism Check for worn primary pinion Renew as necessary bearing Check for air inthe system Check for defective pedal Primary pinion bear ing fault squeaking clutch Lubricate or nec
501. vestigate and repair Zyclic load variation at steering wheel 2 per evolution Lower column universaljoint fitting error Zlosely spaced cyclic Nheel Note E _ _oo i TRA E E a eoa a e a Issue 1 August 1994 X300 VSM Verify that the lower column assembly is correct for that drive RH and LH assem blies MUST NOT be interchanged dueto joint phase differences oad variation at steering Rack damper too tight Renew rack Items marked should be validated using EDMtest procedures Gi 10 4 4 Trouble Hydraulic noise when turning lock to lock Steering Diagnostic chart 3 Fluid level low Air ingress at connections Air ingress through feed hose lining or skin Air ingress at pump front seal Water contamination caused by fractured cooler pipe within engine coolant radi ator Pump starvation or cavitation caused by twisted or trapped feed hose Rectify fluid loss and or top up Check and tighten all connections to spec ification Renew faulty O rings or Dowty washers Renew porous damaged hoses Renew pump Renewradiator Flush and drain steering system twice minimum check for noise and system performance Pump is most susceptible to damage due to loss of lu brication and may have to be renewed Re route or relieve pressure Continuous pressure relief valve operation Continuous noise Pump starvation caused by blocked filter Worn pu
502. veyed seetopthree el ements of Fig 1 o Theicondepictingthe messagewill be within the sur roundingshape Information o Once nominatedthe icon will retain its meaning Flammable Explosion Poison Eye protection Ear protection Respiratory protection air fed Respiratory protection self contained Hand protection Extinguisher ElOOSGO OPPPY OOP Fig 1 Symbols Issue 1 August 1994 2 X300 VSM Body Systems amp Body Repair Z A4 1 3 POTENTIAL RISKS A4 1 3 1 Paint Organic solvents found in paints may cause damage or severe irritationto liver kidneys digestivetracts and respira tory system if inhaled over long periods of time Prolongedexposureto isocyanates may cause lung sensitization Asthma like symptoms may develop with subse quent exposureto very low concentrations of isocyanates Solvent inhalation can cause dizziness or loss of consciousness Inhalation of spray dust and sanding debris may cause lung damage Splashes of solvents paint activators and additivescan cause damageto the eyes and may cause dermatitis Peroxide and acid catalysts may cause burns A4 1 3 2 Applied Heat Welding There is considerable risk of damage to eyes and skin when welding or flame cutting Fire is aserious danger and many materialsor fluids within the vehicle are highly flammable Toxic and dangerous fumes may be liberated when any of the following are subjected to heat o Expandedfoam o Cor
503. wear A3 2 13 Split Pins Fit new split pins throughout when replacing any unit Al ways fit split pins where split pins were originally used Do not substitute spring washers for split pins All split pins should be fitted as shown Fig 3 unless otherwise stated A3 2 14 Tab Washers Fit new tab washers in all places where they where used originally Never refit a used tab washer Ensure that the newtab washer is of the same design as that which was re moved A3 2 15 SpecialFixings Bolts with a blue coating applied to the thread are used in various areas ofthevehicle Should any of these bolts be re moved they MUST be replaced with NEW bolts of the same type Nyloc nuts are used in various areas of the vehicle If removed these MUST be replaced with NEW nuts of the same type Issue 1 August 1994 6 X300 VSM General Fitting Instructions E A3 2 16 Nuts Whentightening a slotted or castellated nut never slacken itin order to insertthe split pin or locking wire buttighten itto alignthe nextslot The exceptionis inthose recommendedcases where slackeningthe nutforms partof an adjust mente g bearing endfloat or preload adjustment If difficulty is experienced alternative washers or nuts should be selected or a washer of a different thickness used Where self locking nuts have been removed replacethem with new ones A3 2 17 Locking Wire Fit new locking wire of the correct type to the assemblies incorporating
504. will be heard and the direction indicator will flash twice during the unlocking dis arming process Instruction Press small button once vehicle locked and armed Press small button again Unlocks all passenger doors Releases luggage com partment Button must be pressed within ten sec onds of first press Press small button again No feature Releases luggage com No feature partment Button must be pressed within ten sec ondas of first Dress Note The sounder gives a short high pitched warble every time a button on the key ring transmitter is pressed whenever on of the following conditions is present o Thetrunk lid or hood is not properly closedwhen an attemptto arm the security system is made Q The ignition key is in the ignition switch o Ifthere is a failure within the security system A5 5 6 Panic Feature Key ring Transmitter Only When inor near the vehicle the alarm can beset off to deter awould be offender This feature will also unlockthedoors and fuel filler flap Forthis feature to operate the ignition key must not be in position P or W The panic alarm will sound for five times the normal full alarm period The alarm can only be stopped by turning the ignition key to position TT or Il The key ring transmitter can not be used to cancel the panic alarm To operate the panic alarm Q Variants 1 and 3 press and
505. with the air and sacrifice itself to corrosion rather than the base metal Inthis processthe zinc is known as a sacrificial anode Note To maintainthe protectivequalities of the zinc treatment repairsto any damaged coated area MUST be made as soon as possible after the damage has occurred A4 2 3 2 Welding Preparation Where resistance spot welding is employed the zinc coating should be lightly abraded away on the mating surfaces and those in contact with the electrodetips Do not remove more of the zinc coating than is absolutely necessary Before welding a weld through primer or inter weld sealer should be applied as detailed inthe Body Sealing and Preservation manual Contamination of the weld will occur if the platingis not removed thus makingthe joint less strong another side effect of this will be a greater need for electrodetip dressing and increasedtool down time In exceptionalcases where the plating must remain intact increasethe tip pressure and welding current by 10to 20 Where MIGwelding is used as an alternativeto resistancespotwelding for plug buttwelds or limitedaccess the prob lems caused by the presence of zinc coating are much the same as those previously mentioned There may also be the added problems of increased weld spatter and nozzle contamination A4 2 3 3 Body Fillers Conventional polyester fillers do not adhere satisfactorily to zinc plated panels Therefore it is importantto use only th
506. with the key does not dis arm the alarm system An audible ticking indicates that the alarm will activate after 30 seconds unless the key is turned to posi tion ll inthe ignition or the key ring transmitter but ton small is pressed Ensure that once deadlock No feature Variant 2 Check drivers door and fuel filler cap unlock Check that the alarm sys tem disarms andthe in terior light illuminates for 15 seconds Turn key to unlock position No feature and hold for 2 seconds X300 VSM Check all passenger doors and trunk lid lock panese market Check all doors are dead locked andtrunk lid and fuel filler cap are locked Check alarm system per imeter inclination and in trusion arms and all open windows and sliding roof close within 1 5 seconds Ensurethat once deadlock ing is completed the sounder gives one audible tone Note No deadlock feature in Ja Check all doors trunk lid and fuel filler cap Check that the alarm system dis arms and the interior light illuminates for 15 seconds No feature Issue 1 August 1994 ost A5 7 3 Security System RESTRICTED ISSUE Locking Unlocking Key ring Transmitter Each vehicle is supplied with two radio frequency transmitters designedto be attached to the drivers key ring Key ringtransmitter 1isdedicatedto driving position memory 1andkey ringtransmitter 2 is dedicatedt
507. 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 6Fig 1 by rear axis mountings 7 Fig 1 andtail pipe mountings 8Fig 1 Clamps 9Fig 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 misalignedclamps shields brackets or pipes Should any of these conditions exist check the exhaust system components and alignment Adjust and renew if necessary Do not attemptto service brackets clamps and insulators Issue 1 August 1994 2 X300 VSM Exhaust System AJ16 et 430 224 Fig 1 Plan View AJ16 Supercharged The only visible difference between the normally aspirated engine s exhaust system and the supercharged version Fig 1 is that the downpipe for the supercharged engine Fig 1 and next page is slightly shorter The remove amp refit proceduresare the same as for the AJ16 normally aspirated X300 VSM 3 Issue 1 August 1994 Exhaust System AJ16 Fig 1 Section Layout AJ16 Supercharged X300 VSM Issue 1 August 1994 Exhaust System AJ16 Rm T 6 1 2 DIAGNOSIS AND TESTING WARNING THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM S VERY HI
508. wn cable where fitted from quadrant Open throttle fully and disconnect inner cable from quad rant Carefully releasethrottle against stop 5 1 Fit pipe clamps to throttle body heater feed and return e hose e Disconnect feed hose from throttle body stub pipe a Removethrottle body assembly from inlet manifold J18 227 Remove idle speed control valve from throttle body a Remove gasket a Retrieve distance piece from throttle body recess Refit inthe reverse order of the removal procedure Issue 1 August 1994 12 X300 VSM Fuel Emission Control amp Engine Management AJ16 NM 5 1 9 FUEL CUT OFF INERTIA SWITCH ALL MODELS RENEW SRO 18 30 35 Remove a Disconnect battery poa J86 1761 Fin 1 Remove the A post lower trim pad a Remove the EMS control module see Section 15 a Disconnect vehicle harness through panel connector Disconnect inertia switch multi plug Fig 1 a Remove switch Refit in the reverse order of the removal procedure X300 VSM 13 Issue 1 August 1994 14 Fuel Emission Control amp Engine Management V12 EM SECTION CONTENTS Sub Section Title SRO Page Don ewes Preliminary Pages 1 0 00 cc cece eee nn i A O Fuel System Layout rs is amene cece u 1 Da ae General Description occ cece eee eee eee eee eee eens 3 O ER Fuel Rail Pressure Regulator Injectors Renew ooooomoommmmn r 18 10 01 18 10 02 18 10 04 18 10 05 19 45
509. y Circuit Issue 1 August 1994 30 X300 VSM y Security System RESTRICTED ISSUE Aci A5 9 7 Inclination sensor Check harness wiring from multi plug 26 way connector pin 6 to sensor connector pin 2 Check harness wiring from multi plug 22 way connector pin 7 to sensor connector pin 1 Check harness wiring continuity from sensor connector pin 5 to ground Bown a Removetrimto gain access to sensor and loosen fixings Lock and arm the vehicle an error beep will sound indicating boot open but alarm will still set then tilt the sensor a minimum of 15 away from horizontal checking that the alarm is activated J86 1912 Fig 1 Inclination Sensor Circuit X300 VSM 31 Issue 1 August 1994 Bee Security System RESTRICTED ISSUE y A5 9 8 Intrusion sensors 1 Check harness wiring continuity as shown below SLCM connector Sensor connector Function Left hand side sensor pin 10 pin2 ground pin 11 pin 4 40kHz pin 12 pin5 I P pin 13 pin3 av Right hand side sensor pin2 pin2 ground pin3 pin4 40kHz pin 4 pin 1 I P pin5 pin3 av 2 Lock and armthe vehicle while sat inside wait 15 seconds then attemptto cover either sensor area with the palmofthe hand Checkthat sensor detects movement and activates alarm Repeattest for second sensor 8v P13B 40KHz P11B VP P128 p Fig 1 Intrusion Sensor Circuit J86 1913 Issue 1 August 1994 32 X300 VSM Security System RESTRICTED ISSUE S
510. y Locking Retractor Automatic locking Retractor Seat Belts Where emergency locking retractor automatic locking retractor seat belts are provided the belts have two operating modes 1 Inertia reel mode emergency locking retractor for adult passengers 2 Static reel mode automatic locking retractor for children inchild seats The inertia reel mode operatestoallowthe occupant some freedom oftorso movement The static reel mode prevents belt payout and thereby does not allow the occupant freedom of torso movement When the seat belt is attached to a child seat which has its own independent harness the static mode must be used The seat belt defaults to the inertia reel adult passenger mode when in the stowed fully retracted position To activate the static reel child seat mode pay out the belt to its full extension The ratchet mechanism is now en gaged When retracting the belt back into the reel the ratchet operation may be felt It can be noticed that the belt is unable to reverse direction To revert to the inertia reel mode pay the belt back into the reel to the stowed position 7 376 1055 1 Height adj to post 7 Static inertia buckle bracket body 2 Height adj to belt anchor 8 Tear loop buckle bracket 3 Inertia belt anchor 9 Belt buckle bracket 4 Inertia bracket body 10 Reel bracket body 5 Inertia reel bracket body 11 Belt anchor body 6 Inertia static buckle bracket body 12 Upper guide bo
511. y be displayed on the LCD andthe relevant warning lights illuminated Should both faults exist at the same time each message is displayed alternativelyfor ap proximately 2 seconds Messages may becancelled by pressingthe ODC buttonwhich allowsthe LCDto returnto its last displayed message The warning lamps will not be extinguished Ifthe fault is not repairedthe message s andthe warning lamp s will be re displayed when the ignition is switched on 15 2 11 Illumination Warning indicator lamp illumination is controlled by a microprocessor located inside the instrument panel The seven right handwarning indicators are primary warning lamps illuminating RED andthe seven left handwarn ing indicators are secondary warning lamps illuminating AMBER The eight lower lamps are a mixtureof status and warning lamps With the ignition OFF the LCD is not illuminated With ignition ON and side lights OFF the LCD is illuminated at maximum brightness Withthe ignition on and side lights OFF the LCD is dimmed as are the gauges The longlifetype bulbs are enclosed by orange and brown coloured bulb holders which must never be interchanged Replacement bulbs must always be of the same colour CAUTION Alwaysdisconnect the battery ground lead beforecommencingwith any instrumentrenewa procedure 15 2 12 General Repair Notes Q After lens removaldo not rest instrumentpanelface down as this causes damageto the delicate gauge needles Avoid scratchin
512. y be setfor cross car pitch andcenter withinthe clearancesaroundthe strutto body fixings a TO initially achievethe relationshipbetweenthe bumpertop face andthe rear panel the strut height adjustersshould be set to the dimension shown Fig 1 BEFORE the cover is fitted Settheguide blockstothespecifieddimensiontoachievethecorrect bumpertofender gap BEFORE fitting the cover because adiustmentscan onlv be made with the cover off a With all fixing points set the bumper cover may be fitted and adjusted as necessaryto achieve the specified gap conditions Note Access to the beam height adjusters may be made with the cover fitted by removing the tailpipe trims a With the bumpercorrectly adjustedto the body andall fixings tightenedto specification it is important that the ex hausttailpipes are then centered within the bumper cover cut outs This may be achieved by slackening the rear section clamp and rotating the rear exhaust assembly Please notethat this may only be achievedbeforethe tailpipe trims are fitted these must also be correctly aligned for good appearance 376 1019 Fig 1 Rear bumper setting dimensions Issue 1 August 1994 38 X300 VSM d H Wh y Body Systems Body Repair 49 A4 6 2 COVER DAMAGE A4 6 2 1 Damage Assessment Prior to any action damage should be assessed and categorized in accordance with the following notingthat ifthe cover has been holed or torn it should be discarded The following c
513. y cold cranking 21 11 9 6V amps UK 295A Load to half battery cold cranking 10 00 amps ROW 295A f 4 44 1 11 6 66 12 22 17 77 Electrical y 15 5 8 Specific Gravity Test The specific gravity of the electrolyte determines the level of the float inthe liquid With the float in a high position the specific gravity is high and when the specific gravity is low the float sinks to the lower position Usinga hydrometerthe specificgravity readings are taken when the liquid level crossesthe scale onfloat This should give a accurate indication of the state charge of the battery The volume and the specific gravity of the electrolyte varies with the change in temperature 15 5 9 Electrolyte TemperatureCorrection For every 10 C below 15 C subtract 0 007 from the hydrometer reading and for every 10 C above 15 C add 0 007 to the hydrometer reading Note Use only distilledwater for topping up electrolyte The electrolyte must not exceed 51 66 C during charging If after 30 minutes charging the battery current is not equal or greater than 3A dispose of the battery 15 5 10 Health and Safety Precautions As batteriescontain sulphuric acid and explosive mixtures of hydrogenand oxygengases itis strongly recommended that protective clothing is worn Avoid spilling acid to prevent damage to clothing and skin bums Ifaccidentalty spilled or splashed on clothing or skin rinse with cold water As a neutralizer a solu
514. y pages this Section a Reconnect the intermediate pipe to the downpipe a Align the intermediate catalyst assembly a Tighten the intermediate pipe to downpipe securing clamp a Align the intermediate silencers to the intermediate cata lyst assembly alightenthe intermediate silencer securing clamps a Lowerthe vehicle on the ramp a Refill the transmission unit with fluid see Sub section 8 2 13 a Remove the fender cover and close the hood JA X300 VSM 17 Issue 1 August 1994 i Dup Automatic Transmission V12 amp AJ16 Supercharged Powertrain 8 2 17 FLUID PAN GASKET RENEW 6 01 SRO 44 24 05 Open the hood and fit a suitable fender cover a Raise the vehicle on a ramp a Slackenthe underfloor catalyst to downpipe clamp secur ing bolts a Displace and reposition the olive clamps on the pipes a Slacken the underfloor catalyst to intermediate silencer clamps securing bolts a Displace the underfloor catalyst assembly rearwards to disconnect from the downpipes Displace and remove the olives from the downpipes Using a wire brush cleanthe olives and downpipe joints a Place a suitable piece of wood between the underfloor catalyst and the body for access Drain the transmission lubrication system see Sub sec E tion 8 2 13 Release and remove the fluid pan securing bolts Fig 1 a Remove the fluid pan 1 Fig 1 and gasket 2 Fig 1 Drainthe residual fluidfrom the fluid pan
515. y this is controlled bythe spring units issue 1 August 1994 4 X300 VSM Ly 14 Suspension Systems A 11 4 6 Rear Suspensioninspection Check for evidence of fluid leaks on rear dampers Check damper operation Check condition of rear wishbone bushings and rear suspension strut bushings Renew damaged or worn components 11 4 7 Vehicle Inspection a Check all tires for correct inflation pressure Checktireconditionto confirmcorrectfront endalignment tire balanceandoveralltire conditionssuch as separation or bulges Check the vehicle attitude for evidence of possible overload or sagging e Check luggage compartment area a Roadtest vehicle to confirm customer s concern X300 VSM 5 Issue 1 August 1994 Su AS Suspension Systems 11 4 8 Diagnostic Procedure Condition Wander Pull Drift Hard steering Possible Cause Side to side difference in caster Tire pressure Steering gear or linkage worn or defective Tire conicity Power steering gear or linkage worn damaged or incorrect adjusted Wear of front suspension lower upper wishbone ball joints Action Checkthe alignment and if incorrect adjust the caster if needed Inspect components for wear or damage Check for abnormal loading Check steering system Inspect tire for excessive wear Check and adjust the tire air pressure Note Excessively worn or uneven tires can cause pull drift Check steering system
516. ystem Description ee EE EE 3 LE is an Climate Control System Features EE EE EE 3 AB e Climate COMO Pala a a e EE Ee 4 Mba Femperature COMO A a ains 6 14 4 1 AA Temperature Control Coolant Circuit oooeonoennonmmananaannncn narra 6 AD Air Conditioning Control Module occconnccnnncnnnnnnn eee e eee eee eee neon ee eenee 7 14 5 1 owen ian Air Conditioning Control Module Description ee EE EE EE EE En 7 AD Air Conditioning Control Module Interfaces ENEE ENEE EE 8 TAG ian is Control Module Fault amp Condition Self AnalySiS ENEE EEN 9 14 6 1 coco Control Module Fault Condition Self Analysis System Health e EE 9 E TEE Control Module Fault amp Condition Self Analysis System Protection oooonoonconconennonmommo 9 VAL eta oye eee as All DISTIDULION ii EEN NEE ge EE nieve Selb ie A EA geed d 10 LECH Refrigeration Cycle ee eee eee eeeeeeeeeeeeeeneeee 12 eege General System ProcedureS EEN 13 14 91 rr General System Procedures Leak TeSt EE EE EEN 13 LIESER General System Procedures Charge Recovery System DepresSurizati0N ess ENEE 13 LEICK General System Procedures Evacuating the System ae EEN EEN 13 14 9 4 conc General System Procedures Adding Lubricating Oil Compressor Related aen 13 14 9 5 rias General System Procedures Adding Lubricating Oil Component Related ee 14 149 0 EE General System Procedures Adding Refrigerant ENEE ENEE EE EE 14 LEINER Fault DiAQnOSiS ssunsusunsunnnunnnnnnnnnnnnennnnnnnnnnnnunnnnnnnnnnnnnnnnnnnnnnnnnn 15 1

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