Workshop Manual 1999 - 3000pp

Workshop Manual
Ja
gD
XKK 8
4.0L, 4.0L S/C
www.JagDocs.com
oc
s.
co
TABLEOFCONTENTS
1:GeneralInformation
10000:GeneralInformation DescriptionandOperation GeneralServiceInformation TerminologyGlossary 10001:IdentificationCodes DescriptionandOperation IdentificationCodes
www.JagDocs.com
10002:JackingandLifting GeneralProcedures UsingtheVehicleJack UsingtheWorkshopJack DescriptionandOperation Jacking SafetyPrecautions VehicleRecovery EmergencyTowing RearTowingEye
2:Chassis
20400SuspensionSystemGeneralInformation Specifications GeneralProcedures FrontCamberAdjustment DescriptionofEccentricBolt InstallingtheEccentricBolt FrontCasterAdjustment FrontCamberandCasterAdjustment
RearToeAdjustment WheelBearingCirclipInspection WheelBearingInspection DescriptionandOperation SuspensionSystem 20401:FrontSuspension Specifications DescriptionandOperation FrontSuspension RemovalandInstallation BallJoint(60.15.02) FrontLowerArmandRearLowerArmAssembly(60.35.02) LowerArmBushing(60.35.45) RearLowerArm(60.35.54) ShockAbsorberandSpringAssembly(60.30.02) StabilizerBar(60.10.01) StabilizerBarBushing(60.10.04) StabilizerBarLink(60.10.02) UpperArmBushing WheelBearing(60.25.40) WheelHub WheelKnuckle(60.25.23) WheelKnuckleandWheelHubAssembly(60.25.38.90) Disassembly ShockAbsorberandSpringAssembly(60.30.21) 20402:RearSuspension Specifications DescriptionandOperation RearSuspension RemovalandInstallation AxleBumpStop(64.30.15) RearSuspensionandAxleAssembly(64.25.01) ShockAbsorber(64.30.02) Spring(64.20.01) StabilizerBar(64.35.08)
www.JagDocs.com
StabilizerBarBushing(64.35.18) StabilizerBarLink(64.35.24) StabilizerBarLinkBushing(64.35.25) StabilizerBarMountingFrameVehiclesWithout:ConvertibleTop(64.25.12) StabilizerBarMountingFrameVehiclesWith:ConvertibleTop(64.25.12) StabilizerBarMountingFrameBushingVehiclesWithout:ConvertibleTop(64.25.13) StabilizerBarMountingFrameBushingVehiclesWith:ConvertibleTop(64.25.13) WheelBearing(64.15.14) WheelHubSeal(64.15.15) WheelKnuckleBushing(64.15.24)
20404:WheelsandTires Specifications DescriptionandOperation WheelsandTires DiagnosisandTesting WheelsandTires GeneralNotes SafetyNotes InspectionandVerification TreadWearIndicator TireVibrationDiagnosis TorqueSensitive VehicleSpeedSensitive EngineSpeedSensitive Uneventirewear. Tiresshowexcesswearonedgeoftreads. Tiresshowexcesswearonedgeoftreads(withtirepressurescorrect). Tiresshowexcesswearincenteroftread. Wheelmountingisdifficult. Wobbleorshimmyaffectingwheelrunout. Vehiclevibrationsfromwheelsandtires. Damagedwheelstudthreads. Brokenwheelstuds. Corrosion/contaminationstreaksfromwheelstudholes. Damagedwheelnuts. Seizedwheelnuts.
RemovalandInstallation WheelandTire(74.20.05)
20405:VehicleDynamicSuspension DescriptionandOperation VehicleDynamicSuspension DiagnosisandTesting VehicleDynamicSuspension RefertoPDUUserGuide BasicChecks RemovalandInstallation AdaptiveDampingModule(86.56.35) 20500:DrivelineSystemGeneralInformation DescriptionandOperation DrivelineSystem 20501:Driveshaft Specifications DescriptionandOperation Driveshaft RemovalandInstallation Driveshaft(47.15.01) 20502:RearDriveAxle/Differential Specifications GeneralProcedures DifferentialOutputShaftEndFloatCheck DescriptionandOperation RearDriveAxleandDifferential RemovalandInstallation AxleAssembly(51.25.13) InVehicleRepair AxleShaft(47.10.01) DifferentialOutputShaftBearing(51.10.22) DrivePinionFlangeandDrivePinionSeal(51.20.01)
20600:BrakeSystemGeneralInformation Specifications GeneralProcedures BrakeSystemBleeding FrontBrakeDiscRunoutCheck RearBrakeDiscRunoutCheck DescriptionandOperation BrakeSystem DiagnosisandTesting BrakeSystem InspectionandVerification ComponentTests 20603:FrontDiscBrake Specifications DescriptionandOperation FrontDiscBrake RemovalandInstallation BrakeCaliper(70.55.02) BrakeDisc(70.10.10) BrakePads(70.40.02) 20604:RearDiscBrake Specifications DescriptionandOperation RearDiscBrake RemovalandInstallation BrakeCaliper(70.55.03) BrakeDisc(70.10.11) BrakePads(70.40.03) 20605:ParkingBrakeandActuation Specifications
www.JagDocs.com
GeneralProcedures ParkingBrakeCableAdjustment ParkingBrakeShoeandLiningAdjustment DescriptionandOperation ParkingBrake RemovalandInstallation ParkingBrakeControl(70.35.08) ParkingBrakeControlShroud(76.13.63) ParkingBrakeFrontCable(70.35.14) ParkingBrakeLinkageLever(70.35.22) ParkingBrakeLinkageLeverMountingPlateVehiclesWithout:ConvertibleTop (70.35.42) ParkingBrakeLinkageReturnSprings(70.35.41) ParkingBrakeLinkageRod(70.35.40) ParkingBrakeShoes(70.40.05) 20606:HydraulicBrakeActuation Specifications DescriptionandOperation HydraulicBrakeActuation RemovalandInstallation BrakeFluidReservoir(70.30.16) BrakeMasterCylinder(70.30.08) BrakePedal BrakePedalandBracket(70.35.03) BrakePedalandBracket,BrakeBoosterandBrakeMasterCylinder(70.35.39) 20607:PowerBrakeActuation Specifications DescriptionandOperation BrakeBooster RemovalandInstallation BrakeBooster(70.50.17) BrakeBoosterandBrakeMasterCylinder(70.50.18)
20609:AntiLockControl Specifications DescriptionandOperation AntiLockControl DiagnosisandTesting AntiLockControl Principleofoperation InspectionandVerification DiagnosticDriveCycles VisualInspection FuseIdentificationTable DiagnosticTroubleCode(DTC)Index PinpointTests RemovalandInstallation AntiLockBrakeSystem(ABS)Module(70.60.02) FrontWheelSpeedSensor(70.60.03) HydraulicControlUnit(HCU)(70.60.18) RearWheelSpeedSensor(70.60.04) WheelSpeedSensorRing(70.60.25) WheelSpeedSensorRingGreaseDeflector(70.60.26) 21100:SteeringSystemGeneralInformation Specifications GeneralProcedures PowerSteeringSystemFillingandBleeding FluidLevelIndicator PowerSteeringSystemVacuumFillingandBleeding FluidHoses SteeringGearCentralizing SteeringGearAlignmentMarkers SteeringWheelCentralizing DescriptionandOperation SteeringSystem DiagnosisandTesting SteeringSystem InspectionandVerification SteeringRelayHarnessConnector
www.JagDocs.com
SteeringLinkageInspectionandBacklash(Freeplay)Check PowerSteeringFluidConditionCheck PowerSteeringPressureTest SteeringFaultDiagnosisbySymptomCharts DescriptionofGeneralSteeringSystemNoises DescriptionofSpecificSteeringSystemNoiseTypes SteeringSystemVibrationsandHarshness SteeringLinkage 21102:PowerSteering Specifications DescriptionandOperation PowerSteering DiagnosisandTesting PowerSteering PowerSteeringPressureTest InstallingTestEquipment RemovingTestEquipment PowerSteeringControlModule RefertoPDUUserGuide ControlModuleConnections RemovalandInstallation PowerSteeringControlValveActuator(57.10.32) PowerSteeringFluidCooler(57.15.11) PowerSteeringFluidReservoir(57.15.08) PowerSteeringFluidReservoirtoPowerSteeringPumpSupplyHose(57.15.20) PowerSteeringPump(57.20.14) PowerSteeringPumptoSteeringGearPressureLine(57.15.29) SteeringGear(57.10.01) SteeringGearBushing(57.10.30) SteeringGeartoFluidCoolerReturnHose(57.15.30) 21103:SteeringLinkage Specifications DescriptionandOperation SteeringLinkage
21104:SteeringColumn Specifications DescriptionandOperation SteeringColumn RemovalandInstallation SteeringColumn(57.40.02) SteeringColumnControlRelay(57.40.34) SteeringColumnLowerShaft(57.40.05) SteeringWheel(57.60.01) Tilt/TelescopicMotors(57.40.40) 21105:SteeringColumnSwitches Specifications DescriptionandOperation SteeringColumnSwitches DirectionIndicators. SidelampsandDippedHeadlamps. OffPosition. SidelampsPosition. HeadlampsPosition. HeadlampMainBeamPosition. MainBeamFlash. MessageCenterFunctionButton. Position'O'.WipersOff. Position'I'.IntermittentWipe. Position'II'.NormalWiperOperation. Position'III'.HighSpeedWiperOperation. FlickWipe. ProgrammedWash/Wipe. RemovalandInstallation IgnitionSwitch(86.65.03) SteeringColumnControlSwitch(57.40.33) SteeringColumnLockModule(86.80.36) SteeringColumnMultifunctionSwitch(86.65.92) SteeringColumnMultifunctionSwitchMountingBracket(76.46.33)
www.JagDocs.com
3:Powertrain
30300:EngineSystemGeneralInformation Specifications DescriptionandOperation Engine
30301:Engine Specifications GeneralProcedures ValveClearanceAdjustment ValveClearanceCheck DescriptionandOperation Engine InVehicleRepair ConnectingRodBearings(12.17.16) CrankshaftFrontSealVehiclesWithout:Supercharger(12.21.14) CrankshaftFrontSealVehiclesWith:Supercharger(12.21.14) CrankshaftInnerSprocket(12.65.76) CrankshaftPulleyVehiclesWithout:Supercharger(12.21.09) CrankshaftPulleyVehiclesWith:Supercharger(12.21.09) CrankshaftRearSealVehiclesWithout:Supercharger(12.21.20) CrankshaftRearSealVehiclesWith:Supercharger(12.21.20) EngineFrontCover(12.65.01) EngineFrontCoverGasket(12.65.04) ExhaustCamshaftLH(12.13.17) ExhaustCamshaftRH(12.13.15) ExhaustCamshaftSprocketLHVehiclesWithout:Supercharger(12.65.74) ExhaustCamshaftSprocketLHVehiclesWith:Supercharger(12.65.74) ExhaustCamshaftSprocketRHVehiclesWithout:Supercharger(12.65.73) ExhaustCamshaftSprocketRHVehiclesWith:Supercharger(12.65.73) ExhaustManifoldLH(30.15.55) ExhaustManifoldRH(30.15.56) FlexplateVehiclesWithout:Supercharger(12.53.13) FlexplateVehiclesWith:Supercharger(12.53.13) OilPan(12.60.44) OilPanGasket(12.60.38)
OilPressureSwitch(88.25.07) OilPumpVehiclesWithout:Supercharger(12.60.26) OilPumpVehiclesWith:Supercharger(12.60.26) PrimaryTimingChainLH(12.65.67) PrimaryTimingChainRH(12.65.66) SecondaryTimingChainLH(12.65.69) SecondaryTimingChainRH(12.65.68) SecondaryTimingChainTensionerLH(12.65.64) SecondaryTimingChainTensionerRH(12.65.63) UpperOilPanVehiclesWithout:Supercharger(12.60.48) UpperOilPanVehiclesWith:Supercharger(12.60.48) ValveCoverLH(12.29.43) ValveCoverRH(12.29.44) 30303A:EngineCooling GeneralProcedures CoolingSystemDraining,FillingandBleedingVehiclesWithout:Supercharger Drain Refill CoolingSystemDraining,FillingandBleedingVehiclesWith:Supercharger Drain Refill RemovalandInstallation CoolantExpansionTankVehiclesWithout:Supercharger(26.15.01) CoolantExpansionTankVehiclesWith:Supercharger(26.15.01) CoolantOutletPipe(26.31.08) CoolingFanMotor(26.25.24) CoolingFanMotorandShroud(26.25.25) DegasBottle(26.15.03) EngineCoolantLevelSwitch(26.40.11) RadiatorVehiclesWithout:Supercharger(26.40.01) RadiatorVehiclesWith:Supercharger(26.40.01) RadiatorLowerHose(26.30.07) RadiatorUpperHose(26.30.01) ThermostatVehiclesWithout:Supercharger(26.45.07)
www.JagDocs.com
ThermostatVehiclesWith:Supercharger(26.45.07) ThermostatHousingCover(26.45.22) ThermostatHousingCoverSeal(26.45.20) WaterPumpVehiclesWithout:Supercharger(26.50.01) WaterPumpVehiclesWith:Supercharger(26.50.01) WaterPumpPulleyVehiclesWithout:Supercharger(26.50.05) WaterPumpPulleyVehiclesWith:Supercharger(26.50.05) 30303B:SuperchargerCooling RemovalandInstallation WaterPump
30304:FuelChargingandControls Specifications DescriptionandOperation FuelChargingandControls DiagnosisandTesting FuelChargingandControls InspectionandVerification DriverInformationChart DefaultmodeDefinitions DiagnosticTroubleCode(DTC)index PinpointTests RemovalandInstallation FuelInjectionSupplyManifoldVehiclesWithout:Supercharger(19.60.13) FuelInjectionSupplyManifoldLHVehiclesWith:Supercharger(19.60.05) FuelInjectionSupplyManifoldRHVehiclesWith:Supercharger(19.60.04) FuelInjectorVehiclesWithout:Supercharger(18.10.01) FuelInjectorVehiclesWith:Supercharger(18.10.01) FuelInjectorsVehiclesWith:Supercharger(18.10.02) ThrottleBodyVehiclesWithout:Supercharger(19.70.04) ThrottleBodyVehiclesWith:Supercharger(19.70.04)
www.JagDocs.com
30305:AccessoryDrive DescriptionandOperation AccessoryDrive CrankshaftPulley IdlerPulley CoolantPumpDrive PowerAssistedSteeringPumpDrive AirConditioningCompressorDrive GeneratorDrive RemovalandInstallation AccessoryDriveBelt(12.10.40) AccessoryDriveBeltIdlerPulley(12.10.43) AccessoryDriveBeltTensioner(12.10.41) AccessoryDriveBeltTensionerPulley(12.10.42) SuperchargerBelt(18.50.08) SuperchargerBeltIdlerPulley(18.50.09) SuperchargerBeltTensioner(18.50.24) 30306:StartingSystem DescriptionandOperation StartingSystem IgnitionSwitchtoONPosition IgnitionSwitchatCRANKPosition DiagnosisandTesting StartingSystemVehiclesWith:Supercharger InspectionandVerification DiagnosticTroubleCode(DTC)Index PinpointTests StartingSystemVehiclesWithout:Supercharger VerificationandInspection SymptomChart DiagnosticTroubleCode(DTC)index PinpointTests RemovalandInstallation StarterMotor(86.60.01)
30307:EngineIgnition Specifications DescriptionandOperation EngineIgnition DiagnosisandTesting EngineIgnitionVehiclesWith:Supercharger InspectionandVerification DriverInformationChart DefaultmodeDefinitions DiagnosticTroubleCode(DTC)index PinpointTests EngineIgnitionVehiclesWithout:Supercharger InspectionandVerification DriverInformationChart DefaultmodeDefinitions DiagnosticTroubleCode(DTC)Index PinpointTests RemovalandInstallation IgnitionCoilOnPlugLH(18.20.44) IgnitionCoilOnPlugRH(18.20.43) SparkPlugs(18.20.02) 30308:EngineEmissionControl DiagnosisandTesting EngineEmissionControlVehiclesWithout:Supercharger InspectionandVerification DiagnosticTroubleCode(DTC)Index PinpointTests EngineEmissionControlVehiclesWith:Supercharger InspectionandVerification DiagnosticTroubleCode(DTC)Index PinpointTests
30312:IntakeAirDistributionandFiltering RemovalandInstallation ChargeAirCoolerLH(18.50.19) ChargeAirCoolerRH(18.50.18) ChargeAirCoolerGasketLH(18.50.22) ChargeAirCoolerGasketRH(18.50.21) Supercharger(18.50.15) SuperchargerOutletPipe(18.50.16) SuperchargerOutletPipeGasket(18.50.17) ThrottleBodyElbow(19.70.28) ThrottleBodyElbowGasket(19.70.29) 30313:EvaporativeEmissions DescriptionandOperation EvaporativeEmissions EvaporativeEmissionsCanisterPurgeValve CanisterPurgeOperation VehiclesWithOnboardRefuelingVaporRecovery. OperationOfOnboardRefuelingVaporRecovery FuelVaporVentValveHousingVehiclesWithOnBoardRefuelingVapor Recovery FuelVaporVentValveHousingVehiclesWithoutOnboardRefuelingVapor Recovery DiagnosisandTesting EvaporativeEmissions PreliminaryInspection DiagnosticDriveCycles DiagnosticTroubleCode(DTC)index/SymptomChart PinpointTests RemovalandInstallation EvaporativeEmissionCanister(17.15.13) EvaporativeEmissionCanisterPurgeValve(17.15.30) FuelVaporVentValveHousing(19.55.24)
www.JagDocs.com
30314:ElectronicEngineControls Specifications GeneralProcedures EngineControlModule(ECM)AdaptationVehiclesWithout:Supercharger Whentocarryoutadaptations DTCsP1000/P1111 Conditionsforadaptation FuellingAdaptationsDriveCycle DiagnosticMonitorCompletion EntryConditions DriveCyclefor40thouleaktest DriveCyclefor20thouleaktest(2001myononly) DescriptionandOperation ElectronicEngineControls EngineSensors ElectronicEngineControl ThrottlePosition(TP)Sensor CamshaftPosition(CMP)Sensor CrankshaftPosition(CKP)Sensor EngineCoolantTemperature(ECT)Sensor KnockSensor(KS) HeatedOxygenSensor(HO2S) Catalystmonitorsensor VariableCamshaftTimingOilControlSolenoidVehiclesWithoutSupercharger. MassAirFlow(MAF)Sensor DiagnosisandTesting ElectronicEngineControlsVehiclesWithout:Supercharger InspectionandVerification DriverInformationChart DefaultmodeDefinitions DiagnosticTroubleCode(DTC)Index PinpointTests ElectronicEngineControlsVehiclesWith:Supercharger InspectionandVerification DriverInformationChart DefaultmodeDefinitions
DiagnosticTroubleCode(DTC)Index PinpointTests RemovalandInstallation CamshaftPosition(CMP)SensorLHVehiclesWithout:Supercharger(18.31.12) CamshaftPosition(CMP)SensorLHVehiclesWith:Supercharger(18.31.12) CamshaftPosition(CMP)SensorRHVehiclesWithout:Supercharger(18.31.11) CamshaftPosition(CMP)SensorRHVehiclesWith:Supercharger(18.31.11) CatalystMonitorSensorLH(18.30.81) CatalystMonitorSensorRH(18.30.80) CrankshaftPosition(CKP)Sensor(18.30.12) EngineControlModule(ECM)(18.30.01) EngineCoolantTemperature(ECT)Sensor(18.30.10) HeatedOxygenSensor(HO2S)LH(18.30.79) HeatedOxygenSensor(HO2S)RH(18.30.78) IntakeAirTemperature(IAT)Sensor(18.30.52) KnockSensor(KS)LHVehiclesWithout:Supercharger(18.30.92) KnockSensor(KS)LHVehiclesWith:Supercharger(18.30.92) KnockSensor(KS)RHVehiclesWithout:Supercharger(18.30.93) KnockSensor(KS)RHVehiclesWith:Supercharger(18.30.93) MassAirFlow(MAF)Sensor(18.30.15) VariableCamshaftTiming(VCT)OilControlSolenoid(18.30.90) 30701A:AutomaticTransmission/TransaxleVehiclesWithout:Supercharger Specifications GeneralProcedures TransmissionFluidDrainandRefill Removal Installation DescriptionandOperation TransmissionDescription DiagnosisandTesting DiagnosticStrategy Normaltransmissionoperationbutfaultcodesstored Sportmodewillnotselect Modeswitchstatelampnotworking Poor,orreducedshiftquality Outofsequenceshift
www.JagDocs.com
Notorqueconverterlockup Harshshifts,enginestalling(torqueconverterstuckon) Defaultto4thgear Defaultto5thgear Removal TransmissionRemoval(44.20.01) Installation TransmissionInstallation(44.20.01) InVehicleRepair ElectronicPressureControl(EPC)Solenoid(44.15.51) ExtensionHousingSeal(44.20.18) ExtensionHousingORingSeal(44.20.19) MainControlValveBody(44.40.01) OutputShaftSpeed(OSS)Sensor(44.15.41) ShiftSolenoids(SS)(44.15.50) TransmissionControlModule(TCM)(44.15.32) TransmissionFluidFilter(44.24.07) TransmissionFluidPan(44.24.04) TransmissionFluidPanGasket(44.24.05) TransmissionInternalWiringHarness(44.15.35) TransmissionInternalWiringHarnessElectricalConnectorORingSeals(44.24.20) TransmissionRange(TR)Sensor TurbineShaftSpeed(TSS)Sensor(44.15.40) Disassembly/Assemblyofsubassemblies InputShaftSeal(44.32.07) TorqueConverter(44.17.07)
30701B:AutomaticTransmission/TransaxleVehiclesWith:Supercharger Specifications GeneralProcedures TransmissionFluidDrainandRefill Removal TransmissionRemoval(44.20.01) Installation TransmissionInstallation(44.20.01) InVehicleRepair ExtensionHousingSeal(44.20.18)
MainControlValveBody(44.40.01) TransmissionFluidFilter(44.24.07) TransmissionFluidPanGasket(44.24.05) TransmissionInternalWiringHarnessElectricalConnectorORingSeals(44.24.20) Disassembly/Assemblyofsubassemblies InputShaftSeal(44.32.07) TorqueConverter(44.17.07) 30702A:Transmission/TransaxleCoolingVehiclesWithout:Supercharger DescriptionandOperation TransmissionCooling 30702B:Transmission/TransaxleCoolingVehiclesWith:Supercharger DescriptionandOperation TransmissionCooling 30705A:AutomaticTransmission/TransaxleExternalControlsVehiclesWithout: Supercharger GeneralProcedures BrakeShiftInterlockActuatorAdjustment BrakeShiftInterlockActuatorManualOverride KickdownSwitchAdjustment SelectorLeverCableAdjustment DescriptionandOperation ExternalControls DiagnosisandTesting ExternalControls DTCP0706Transmissionrangesensorcircuitrange/performance PinpointtestA:P0706 RemovalandInstallation BrakeShiftInterlockActuator(44.15.48) KickdownSwitch(44.15.23) SelectorLeverCableandBracket(44.15.08) SelectorLeverGateFinishPanel(76.25.24) SelectorLeverIndicatorAssembly(44.15.14) SelectorLeverIndicatorDisc(44.15.15)
www.JagDocs.com
SelectorLeverSwitch(44.15.52) TransmissionSelectorLeverKnob(44.15.06) Disassembly SelectorLever(44.15.05) 30705B:AutomaticTransmission/TransaxleExternalControlsVehiclesWith: Supercharger GeneralProcedures BrakeShiftInterlockActuatorManualOverride KickdownSwitchAdjustment SelectorLeverCableAdjustment DescriptionandOperation ExternalControls DiagnosisandTesting ExternalControls Shift stuck inP VehiclerollsonP Rdoesnotengage Nnotachieved Ddoesnotengage Lowerratioswillnothold Shiftleverpositionnotvisuallycorrect Shiftleverhasnoeffectuponthetransmissionandresistancecannotbefelt Shiftleverpositionnotaligncorrectlyfollowingmanualselectionoflowerratios Shiftleverdetentindistinctin3causingpoorlocation ShiftmaybemovedfromPwithoutbrakepedaloperation EnginemaybestartedinpositionsotherthanPorN Shiftlevervibration Noise/rattlefrom'J'gate RemovalandInstallation BrakeShiftInterlockActuator(44.15.48) KickdownSwitch(44.15.23) SelectorLeverCableandBracket(44.15.08) SelectorLeverGateFinishPanel(76.25.24) SelectorLeverIndicatorDisc(44.15.15) TransmissionControlSwitch(44.15.12) TransmissionSelectorLeverKnob(44.15.06)
30900:ExhaustSystem Specifications DescriptionandOperation ExhaustSystem MonitoringProcedure HeaterResistanceCheck PerformanceCheck DiagnosisandTesting ExhaustSystem DTCP0420Catalystsystemefficiencybelowthreshold(Bank1) DTCP0430Catalystsystemefficiencybelowthreshold(Bank2) DTCP0131O2sensorcircuitlowvoltage(Bank1sensor1) DTCP0132O2sensorcircuithighvoltage(Bank1sensor1) DTCP0133O2sensorcircuitslowresponse(Bank1sensor1) DTCP0135O2sensorheatercircuitmalfunction(Bank1sensor1) DTCP0137O2sensorcircuitlowvoltage(Bank1sensor2) DTCP0138O2sensorcircuithighvoltage(Bank1sensor2) DTCP0140O2sensorcircuitnoactivitydetected(Bank1sensor2) DTCP0151O2sensorcircuitlowvoltage(Bank2sensor1) DTCP0152O2sensorcircuithighvoltage(Bank2sensor1) DTCP0153O2sensorcircuitslowresponse(Bank2sensor1) DTCP0155O2sensorheatercircuitmalfunction(Bank2sensor1) DTCP0157O2sensorcircuitlowvoltage(Bank2sensor2) DTCP0158O2sensorcircuithighvoltage(Bank2sensor2) DTCP0160O2sensorcircuitnoactivitydetected(Bank2sensor2) DTCP0430Catalystsystemefficiencybelowthreshold(bank2) PinpointtestA:P0131,P0132,P0135 PinpointtestB:P0133 PinpointtestC:P0137,P0138 PinpointtestD:P0140 PinpointtestE:P0151,P0152,P0155 PinpointtestF:P0153 PinpointtestG:P0157,P0158 PinpointtestH:P0160 RemovalandInstallation CatalyticConverterLHVehiclesWithout:Supercharger(17.50.15) CatalyticConverterLHVehiclesWith:Supercharger(17.50.15)
www.JagDocs.com
CatalyticConverterRHVehiclesWithout:Supercharger(17.50.16) CatalyticConverterRHVehiclesWith:Supercharger(17.50.16) CatalyticConverterGasketLHVehiclesWithout:Supercharger(17.50.06) CatalyticConverterGasketLHVehiclesWith:Supercharger(17.50.06) CatalyticConverterGasketRHVehiclesWithout:Supercharger(17.50.07) CatalyticConverterGasketRHVehiclesWith:Supercharger(17.50.07) FrontMufflerVehiclesWithout:Supercharger(30.10.18) FrontMufflerVehiclesWith:Supercharger(30.10.18) IntermediateMufflerLH(30.10.15) IntermediateMufflerRH(30.10.16) MufflerandTailpipeLH(30.10.22) MufflerandTailpipeRH(30.10.52) 31000:FuelSystemGeneralInformation GeneralProcedures FuelSystemPressureCheck FuelSystemPressureRelease Allvehicles Vehicleswithsupercharger Vehicleswithoutsupercharger Allvehicles Vehicleswithoutsupercharger Vehicleswithsupercharger Allvehicles DescriptionandOperation FuelSystem 31001:FuelTankandLines DescriptionandOperation FuelTankandLines FillerCapandPipe CheckValve PurgeValve FuelLines FuelFilter FuelPump FuelGaugeSenderUnit FuelValves
Fuel Cut-off Inertia Switch FuelTankEarthStrap Fuel Pump Relay MonitoringProcedure AccesstoLuggageCompartmentComponents RemovalandInstallation FuelFilter(19.25.02) FuelLevelSensor(88.25.32) FuelPump(19.45.08) FuelPumpRelay(19.22.39) FuelTank(19.55.01) FuelTankAccessPanel(76.11.32.90) InertiaFuelShutoff(IFS)Switch(18.30.35) 31002:AccelerationControl GeneralProcedures AcceleratorCableAdjustment RemovalandInstallation AcceleratorCable(19.20.06) 31003:SpeedControl DescriptionandOperation SpeedControl DiagnosisandTesting SpeedControl Principlesofoperation InspectionandVerification DiagnosticTroubleCode(DTC)index Pinpointtests
www.JagDocs.com
4:Electrical
41200:ClimateControlSystemGeneralInformation Specifications GeneralProcedures AirConditioning(A/C)SystemCheckRetailProcedure EvacuatingtheManifoldGaugeSet ConnectingtheManifoldGaugeSet
StabilizingtheSystem AirConditioning(A/C)SystemRecovery,EvacuationandCharging Recover/Reclaim Evacuation Charging ContaminatedRefrigerantHandling ManifoldGaugeSetConnection PartsList Manifold. LowSidePressureGauge. HighSidePressureGauge. RefrigerantAdding RefrigerantOilAdding OriginalCompressor NewCompressor SystemComponents RefrigerantSystemTests DescriptionandOperation ClimateControlSystem DiagnosisandTesting ClimateControlSystem Introduction FunctionalCheck Systemsymptoms Nocooling Insufficientcooling Intermittentcooling Noisysystem Insufficientheating 41201:AirDistributionandFiltering DescriptionandOperation AirDistributionandFiltering DiagnosisandTesting AirDistributionandFiltering RemovalandInstallation CenterRegisters(82.20.38)
DriverSideBlowerMotor(82.25.56) PassengerSideBlowerMotor(82.25.55) PollenFilter(76.10.09) 41201:HeatingandVentilation DescriptionandOperation HeatingandVentilation DiagnosisandTesting HeatingandVentilation RemovalandInstallation HeaterCore(80.20.29) HeaterCoreandEvaporatorCoreHousing(82.25.21) 41203:AirConditioning DescriptionandOperation AirConditioning DiagnosisandTesting AirConditioning RemovalandInstallation AirConditioning(A/C)Compressor(82.10.20) CondenserCore(82.15.07) EvaporatorCore(82.25.20) ReceiverDrier(82.17.01) 41204:ControlComponents DescriptionandOperation ControlComponents DiagnosisandTesting ControlComponents ConnectorPinsIdentification ConnectorPinIdentityChartforAC002 ConnectorPinIdentityChartforAC003 ConnectorPinIdentityChartforAC004 ConnectorPinIdentityChartforFC043 ControlPanelCommunication ControlPanelInputs/Outputs A/CCMConnections
www.JagDocs.com
SystemSelftest FaultCodeExtractionandDeletionProcedure 0Normaloperationnofaultcodespresent 11Motorizedincaraspiratormalfunction 12Ambienttemperaturesensormalfunction 13Evaporatortemperaturesensormalfunction 14Watertemperatureinputmalfunction 15Heatermatrixtemperaturesensormalfunction 21Solarsensor 22Compressorlocksignalfault 23Refrigerantpressureswitchmalfunction 23Refrigerantpressurelowrefrigerantcharge* 24Faceventdemandpotentiometerfault 31LHfresh/recirc.potentiometerfault 32RHfresh/recirc.potentiometerfault 33Coolairbypasspotentiometerfault 34Defrostventpotentiometerfault 35Centreventpotentiometerfault 36Footventpotentiometerfault 41LHfresh/recirc.motorfault 42RHfresh/recirc.motorfault 43Coolairbypassmotorfault 43CoolAirbypassmotorfault 44Defrostventmotorfault 45Centreventmotorfault 46Footventmotorfault AssociatedFaults PanelCommunicationCheck ActuatorCheckProcedure ActuatorFaultCodes RemovalandInstallation AirDischargeTemperatureSensor(82.20.64) ClimateControlAssembly(82.20.07) ColdAirBypassBlendDoorActuator(82.20.86) DefrostVent/RegisterBlendDoorActuator(82.20.84) FootwellVent/DuctBlendDoorActuator(82.20.85) InstrumentPanelBlendDoorActuator(82.20.83)
41300:InstrumentClusterandPanelIllumination DescriptionandOperation InstrumentClusterandPanelIllumination RemovalandInstallation HighBeamIndicatorBulb(86.45.65) InstrumentClusterBulb(86.46.22) InstrumentPanelConsoleInstrumentClusterBulb(86.46.21)
41301:InstrumentCluster DescriptionandOperation InstrumentCluster DiagnosisandTesting InstrumentCluster TestsUsingthePortableDiagnosticUnit ReplaceableParts RemovalandInstallation InstrumentCluster(88.20.01) InstrumentClusterLens(88.20.28) InstrumentPanelConsoleInstrumentCluster(88.20.29) InstrumentPanelConsoleInstrumentClusterLens(88.20.32) 41306:Horn DescriptionandOperation Horn DiagnosisandTesting Horn TestsUsingthePortableDiagnosticUnit RemovalandInstallation Horn(86.30.02) 41307:Clock DescriptionandOperation Clock DiagnosisandTesting Clock TestsUsingthePortableDiagnosticUnit
www.JagDocs.com
41308:InformationandMessageCenter DescriptionandOperation InformationandMessageCenter DiagnosisandTesting InformationandMessageCenter TestsUsingthePortableDiagnosticUnit 41400:ChargingSystemGeneralInformation DescriptionandOperation ChargingSystem 41401:Battery,MountingandCables GeneralProcedures BatteryConnect DescriptionandOperation BatteryandCables RemovalandInstallation Battery(86.15.01) BatteryGroundCable(86.15.19) BatteryPositiveCable(86.15.17) BatteryRetainingBracket(86.15.12)
41402:GeneratorandRegulator DescriptionandOperation Generator Features DiagnosisandTesting Generator RefertoPDUUserGuide InspectionandVerification TestingtheBatteryCircuit UsingaSubstituteBattery CheckingGeneratorConnections MultiplugConnector RemovalandInstallation Generator(86.10.02)
VoltageRegulator(86.10.28) 41501:AudioUnit DescriptionandOperation AudioSystem DiagnosisandTesting AudioSystem TestsUsingthePortableDiagnosticUnit RemovalandInstallation AudioUnit(86.50.03) AudioUnitAmplifier(86.50.10) Capacitor(86.10.33) CompactDisc(CD)Changer(86.50.06) 41502:Antenna DescriptionandOperation Antenna DiagnosisandTesting Antenna TestsUsingthePortableDiagnosticUnit RemovalandInstallation Antenna AntennaMotor(86.50.21) 41503:Speakers DescriptionandOperation Speakers SpeakerLocationConvertible DiagnosisandTesting Speakers TestsUsingthePortableDiagnosticUnit RemovalandInstallation DoorSpeaker(86.50.13) InstrumentPanelTweeterSpeaker(86.51.02) InstrumentPanelTweeterSpeakerGrille(86.51.04) QuarterPanelSpeakerVehiclesWithout:ConvertibleTop(86.50.12) QuarterPanelSpeakerVehiclesWith:ConvertibleTop(86.50.12)
www.JagDocs.com
QuarterPanelSpeakerGrilleVehiclesWithout:ConvertibleTop(76.13.70) SubwooferSpeakerVehiclesWithout:ConvertibleTop(86.51.05) SubwooferSpeakerGrille(76.13.72) 41701:ExteriorLighting Specifications DescriptionandOperation ExteriorLighting DiagnosisandTesting ExteriorLighting TestsUsingthePortableDiagnosticUnit RemovalandInstallation BrakePedalPosition(BPP)Switch FrontFogLamp(86.40.96) FrontFogLampBulb(86.40.94) FrontSideMarkerLamp(86.40.59) FrontSideMarkerLampBulb(86.40.58) FrontTurnSignalLampBulb(86.40.41) HeadlampAssemblyLH(86.41.33) HeadlampAssemblyRH(86.41.36) HeadlampLens(86.41.39) HeadlampLevelingMotorLH(86.42.09) HeadlampLevelingMotorRH(86.42.10) HighBeamHeadlampBulb(86.40.12) HighMountedStoplampVehiclesWith:ConvertibleTop(86.41.01) LicensePlateLamp(86.40.86) LicensePlateLampBulb(86.40.85) LowBeamHeadlampBulb(86.40.08) RearLampAssembly(86.41.46) RearLampAssemblyBulb(86.40.73) RearSideMarkerLamp(86.41.08) RearSideMarkerLampBulb(86.41.07) SideLampBulb(86.40.27) SideTurnSignalLampBulb(86.41.42) SideTurnSignalLampLH(86.40.54) SideTurnSignalLampRH(86.40.53)
www.JagDocs.com
41702:InteriorLighting Specifications DescriptionandOperation InteriorLighting DiagnosisandTesting InteriorLighting TestsUsingthePortableDiagnosticUnit RemovalandInstallation DoorCourtesyLamp(86.40.38) DoorCourtesyLampBulb(86.40.47) DoorLockControlSwitchBulb(86.46.23) FootwellLamp(86.46.20) FootwellLampBulb(86.46.24) FrontInteriorLamp(86.45.12) GloveCompartmentLamp(86.45.08) GloveCompartmentLampBulb(86.45.07) LuggageCompartmentLamp(86.45.16) LuggageCompartmentLampBulb(86.45.15) MapReadingLampBulb(86.45.09) RearInteriorLampBulbVehiclesWithout:ConvertibleTop(86.45.06) VanityMirrorLamp(76.10.50) VanityMirrorLampBulb(86.45.95) 41704:DaytimeRunningLamps(DRL) DescriptionandOperation DaytimeRunningLamps(DRL) DiagnosisandTesting DaytimeRunningLamps(DRL) TestsUsingthePortableDiagnosticUnit 41800:ModuleCommunicationsNetwork DescriptionandOperation CommunicationsNetwork DiagnosisandTesting CommunicationsNetwork PrinciplesofOperation InspectionandVerification
DriverInformationChart DefaultmodeDefinitions DiagnosticTroubleCode(DTC)index PowerSupply/Groundtestindex Pinpointtests RemovalandInstallation AuxiliaryJunctionBox(86.70.55) BatteryJunctionBox(BJB)(86.70.69) CentralJunctionBox(CJB)LH(86.70.57) CentralJunctionBox(CJB)RH(86.70.56) 41907:NavigationSystem DescriptionandOperation NavigationSystem RemovalandInstallation NavigationSystemAntenna(86.62.06) NavigationSystemCompactDisc(CD)Unit(86.62.05) NavigationSystemDisplayModule(86.62.07) NavigationSystemModule(86.62.05) 41901:MultifunctionElectronicModules RemovalandInstallation DriverDoorModule(DDM)(86.80.29) DriverSeatModule(DSM)(86.75.28) MultifunctionElectronicModule(86.80.31) PassengerDoorModule(PDM)(86.80.30) PassengerSeatModule(PSM)(86.75.16)
5:BodyandPaint
50100:BodySystemGeneralInformation DescriptionandOperation Body 50102:FrontEndBodyPanels Specifications DescriptionandOperation FrontEndBodyPanels RemovalandInstallation BulbAccessPanel(76.10.91) CowlPanelGrille(76.10.01) CowlVentScreen(76.10.01) FenderSplashShield(76.10.90) RadiatorGrilleOpeningCrossBraceVehiclesWithout:Supercharger(76.10.03) RadiatorGrilleOpeningCrossBraceVehiclesWith:Supercharger(76.10.03) RadiatorGrilleOpeningPanel(76.10.06) RadiatorSplashShield(76.22.90)
www.JagDocs.com
50103:BodyClosures GeneralProcedures LuggageCompartmentLidAlignment DescriptionandOperation BodyClosures Doors Hood TrunkLid RemovalandInstallation DoorOpeningLowerWeatherstripVehiclesWithout:ConvertibleTop(76.40.30) DoorOpeningUpperWeatherstrip(76.40.01) FuelFillerDoor(76.10.25) Hood(76.16.01) HoodInsulation(76.16.06) HoodStrut(76.16.15) LuggageCompartmentLid(76.19.01) LuggageCompartmentLidOpeningWeatherstrip(76.19.06)
LuggageCompartmentLidStrut(76.19.27) 50105:InteriorTrimandOrnamentation DescriptionandOperation InteriorTrim RemovalandInstallation APillarTrimPanel(76.13.31) CoatHanger(76.10.54) CowlSideTrimPanel(76.13.30) DoorTrimPanel(76.34.01) DriverSideFloorCovering(76.49.09) Headliner(76.64.01) LuggageCompartmentFrontTrimPanel(76.19.31) LuggageCompartmentRearTrimPanel(76.19.44) LuggageCompartmentSideTrimPanel(76.19.22) ParcelShelfVehiclesWithout:ConvertibleTop(76.67.06) PassengerAirBagModuleFinishPanel(76.47.40) PassengerSideFloorCovering(76.49.10) RearQuarterPanelArmrestVehiclesWithout:ConvertibleTop(76.13.66) RearQuarterPanelArmrestandSpeakerGrilleVehiclesWithout:ConvertibleTop (76.13.71) RearQuarterTrimPanel(76.13.73) RearQuarterUpperTrimPanelVehiclesWith:ConvertibleTop ScuffPlateTrimPanel(76.13.22) SunVisor(76.10.48) SunVisorRetainingClip(76.10.58) DoorWindowControlSwitchFinishPanel(76.47.33) 50108:ExteriorTrimandOrnamentation DescriptionandOperation ExteriorTrim RemovalandInstallation DoorMoulding(76.43.72) DoorWindowMoulding(76.43.04) FenderMoulding(76.43.73) HoodGrille(76.16.37) LicensePlateHousing(76.43.22)
LuggageCompartmentLidMoulding(76.43.79) RadiatorGrille(76.55.03) RearQuarterWindowMoulding(76.43.81) RearWindowMouldingVehiclesWithout:ConvertibleTop(76.43.46) RoofMouldingVehiclesWithout:ConvertibleTop(76.43.11) 50109:RearViewMirrors DescriptionandOperation RearViewMirrors RemovalandInstallation AutodimmingInteriorMirror(76.10.56) ExteriorMirror(76.10.52) ExteriorMirrorCover(76.10.55) ExteriorMirrorGlass(76.10.53) ExteriorMirrorMotor(76.10.57) InteriorMirror(76.10.51) InteriorMirrorMountingBlock(76.10.62)
www.JagDocs.com
50110:Seating Specifications DescriptionandOperation Seats RemovalandInstallation FrontSeat(76.70.01) FrontSeatBackrestCover(76.70.15) FrontSeatBackrestHeaterMat(86.75.14) FrontSeatBackrestTrimPanel(76.70.03) FrontSeatHeightAdjustmentMotor(86.75.29) FrontSeatReclinerMotor(86.75.04) FrontSeatTrackMotor(86.75.33) LumbarMotor(86.75.12) RearSeatBackrest(76.70.38) RearSeatCushion(76.70.37) SeatControlSwitch(86.75.23)
50111:Glass,FramesandMechanisms GeneralProcedures DoorWindowGlassAdjustment DescriptionandOperation Glass,FramesandMechanisms RemovalandInstallation AutomaticWindowControlSwitch(86.65.97) DoorWindowGlass(76.31.01) DoorWindowGlassWeatherstrip(76.31.55) DoorWindowGlassWeatherstripVehiclesWith:ConvertibleTop(76.31.55) DoorWindowRegulatorMotor(86.25.57) DriverDoorWindowControlSwitch(86.25.03) PassengerDoorWindowControlSwitch(86.25.06) RearQuarterWindowGlass(76.31.31) RearQuarterWindowGlassWeatherstripVehiclesWith:ConvertibleTop(76.40.33) RearQuarterWindowGlassLowerWeatherstrip(76.40.32) RearQuarterWindowGlassUpperWeatherstrip(76.40.31) RearQuarterWindowRegulatorMotorVehiclesWith:ConvertibleTop(86.25.11) RearWindowGlassVehiclesWithout:ConvertibleTop(76.81.11) RearWindowGlassVehiclesWith:ConvertibleTop(76.81.11) WindshieldGlass(76.81.40) WindshieldMoulding(76.43.40) 50112:InstrumentPanelandConsole Specifications DescriptionandOperation InstrumentPanelandInstrumentPanelConsole RemovalandInstallation AudioUnitHousing(76.25.15) FloorConsole(76.25.01) FloorConsoleAshtray(76.25.25) FloorConsoleFinishPanel(76.47.26) FloorConsoleStowageCompartment(76.25.16) FloorConsoleStowageCompartmentLid(76.25.18) GloveCompartment(76.52.03) GloveCompartmentLid(76.52.02)
InstrumentClusterFinishPanel(76.47.24) InstrumentPanel(76.46.01) InstrumentPanelFinishPanel(76.47.06) InstrumentPanelLowerTrimPanel(76.46.11) OverheadConsole(76.13.69) RearCupHolder(76.25.27) SteeringColumnLowerShroud(76.46.03) 50114:Handles,Locks,LatchesandEntrySystems DescriptionandOperation Handles,Locks,LatchesandEntrySystems RemovalandInstallation DoorAjarSwitch(86.65.98) DoorAjarWarningIndicatorSwitch(86.65.96) DoorLatch(76.37.12) DoorLatchCable(76.37.67) DoorLockActuator(86.65.16) DoorLockControlSwitch(86.80.32) DoorLockCylinder(76.37.71) ExteriorDriverDoorHandle(76.58.07) ExteriorPassengerDoorHandle(76.58.08) GloveCompartmentLidLockCylinder(76.52.23) HoodAjarSwitch(86.65.99) IgnitionLockCylinder(57.40.29) LuggageCompartmentLidandFuelFillerDoorReleaseSwitch(86.65.95) LuggageCompartmentLidLatch(76.19.25) LuggageCompartmentLidLatchActuator(76.19.25) LuggageCompartmentLidLockCylinder(76.19.19) LuggageCompartmentLidWarningIndicatorSwitch(86.65.93) 50116:WipersandWashers Specifications DescriptionandOperation WipersandWashers RemovalandInstallation HeadlampWasherJet(84.20.08) RainSensor(86.56.62)
www.JagDocs.com

RainSensorModule(86.56.60) WindshieldWasherPumpandHeadlampWasherPump(84.10.21) WindshieldWasherReservoir(84.10.01) WindshieldWiperMotor(84.15.13) WiperPivotArm(84.15.03) 50118:ConvertibleTop DescriptionandOperation ConvertibleTop RemovalandInstallation ConvertibleTopAssembly(76.86.15) ConvertibleTopHeadliner(76.86.16) ConvertibleTopHydraulicLiftCylinder(76.86.17) ConvertibleTopHydraulicLiftCylinderHoses(76.86.24) ConvertibleTopHydraulicPump(76.86.06) ConvertibleTopLatch(76.86.19) ConvertibleTopLatchHydraulicCylinder(76.86.21) ConvertibleTopLatchHydraulicCylinderHoses(76.86.22) ConvertibleTopMaterial(76.86.12) HeaderRailLowerTrimPanel(76.64.16.70) HeaderRailUpperTrimPanel(76.86.20) HeaderRailWeatherstrip 50119:Bumpers Specifications DescriptionandOperation Bumpers RemovalandInstallation BumperBracket(76.22.87) BumperIsolator(76.22.88) FrontBumper(76.22.08) FrontBumperCover(76.22.78) FrontBumperIsolator(76.22.31) RearBumper(76.22.27) RearBumperCover(76.22.77) RearBumperIsolator(76.22.70)
50120A:SafetyBeltSystem Specifications DescriptionandOperation SafetyBeltSystem RemovalandInstallation FrontSafetyBeltRetractorLH(76.73.10) FrontSafetyBeltRetractorRH(76.73.21) RearSafetyBeltRetractorVehiclesWithout:ConvertibleTop(76.73.18) RearSafetyBeltRetractorVehiclesWith:ConvertibleTop(76.73.18) 50120B:SupplementalRestraintSystem Specifications DescriptionandOperation AirBagSupplementalRestraintSystem(SRS) RemovalandInstallation AirBagControlModuleLHD(76.73.41) AirBagControlModuleRHD(76.73.41) CrashSensor(76.73.55) DriverAirBagModule(76.73.39) PassengerAirBagModule(76.73.37) 50125:BodyRepairsGeneralInformation DescriptionandOperation BodyRepairs 50200:UniBody,SubframeandMountingSystem RemovalandInstallation FrontAxleCrossmember FrontAxleCrossmemberFrontBushing(60.35.24) FrontAxleCrossmemberRearBushing(60.35.26) RearAxleCrossmember(64.25.16) RearAxleCrossmemberBushing(64.25.02)
www.JagDocs.com
Emergency Towing
1999 XK RANGE - General Information - 100-00
General Service Information

Safety Notice
Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles, as well as the safety of the person doing the work. This manual provides general directions for accomplishing service and repair work with tested, effective, techniques. Following them will help assure reliability. There are numerous variations in procedures, techniques, tools, and parts for servicing vehicles, as well as in the skill of the person doing the work. This manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Accordingly, anyone who departs from the instructions provided in the manual must first establish that neither personal safety nor vehicle integrity is compromised from choices of methods, tools or parts.
Notes, Cautions and Warnings

Throughout this manual, important information is highlighted by the use of notes, cautions and warnings. NOTES give additional information on a topic or procedure, CAUTIONS are given to prevent damage to the vehicle, and WARNINGS are given to prevent personal injury.
Copyright Statement
Copyright. Jaguar Cars Ltd. 1997. 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, CV5 9DR, England.
Workshop Manual Organization

This manual incorporates descriptive, diagnostic, and repair information to help trained Jaguar technicians complete service and rectification procedures. The information can be accessed by choosing the appropriate five digit section number. For example, Section <<412-03>> covers air conditioning, which is part of the Climate Control System. The manual is organized into six groups covering generic aspects of the vehicle systems; the first digit of the section number represents a group selected from the following: 1. General Information. 2. Chassis. 3. Powertrain. 4. Electrical. 5. Body and Paint. 6. Routine Maintenance. Each of the six groups comprises sections relating to specific areas of the vehicle. The second and third digits of the section number indicate the vehicle system. The last two digits of the section number define the system covered, more specifically. Each section comprises one or more of the following sub-sections: Specification
2012-07-21
General specifications (including setting-up information, capacities, lubricants, fluids, sealants and adhesives). Torque specifications. Description and Operation A general illustration and parts list to identify the components which comprise a particular system or assembly. A brief description of the system operating characteristics or description of the assembly. A description of each component and its function. Diagnosis and Testing Descriptions of how to identify system problems. Inspection and verification information. Symptom charts comprising fault conditions, possible sources and actions. General Procedures General maintenance procedures, including adjustment, alignment, bleeding and filling, with illustrated steps and supporting text. Tightening torque specifications, shown in the illustrations. Removal and Installation Component removal and installation maintenance procedures, with illustrated steps and supporting text. Tightening torque specifications, shown in the illustrations. An illustrated tool chart for each procedure requiring the use of special tools. Disassembly and Assembly Component disassembly and assembly maintenance procedures, with illustrated steps and supporting text. Tightening torque specifications, shown in the illustrations. An illustrated tool chart for each procedure requiring the use of special tools.
www.JagDocs.com
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: 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. Torque wrench setting figures given in this manual must be strictly adhered to. Locking devices, where specified, must be fitted. If the 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 conform to mandatory requirements existing in their country of origin. 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. Jaguar/Daimler dealers are obliged to supply only genuine service parts.
2012-07-21

Thread Locking Devices Patched Fasteners
Two types of patched fastener are essentially used on certain suspension, steering and other critical components, where operational movement of the component necessitates positive thread locking. Standard patched fasteners have part numbers bearing the suffix letter M. For identification of special patched fasteners, refer to the list of patched fasteners below, or the relevant component drawings. Jaguar Specification JFS 02.01.02 patched fasteners incorporate a micro-encapsulated adhesive which is released into the mating threads during tightening. Following final tightening, the adhesive in this type of patched fastener must be allowed a period to cure before the component/vehicle is used. On removal, this type of fastener must be discarded and a new patched fastener of the same specification fitted. All mating threads must be thoroughly cleaned prior to fitting of the new fastener. Jaguar Specification JFS 02.01.04 patched fasteners incorporate a plastic/polyester on the thread. Acting as a wedge between the mating threads, this compound imposes a prevailing torque during tightening. Whilst this type of patched fastener can be re-used, the imposed torque diminishes. It is therefore recommended that following third removal, this type of patched fastener is discarded and a new fastener of the same specification is fitted. Special fasteners bearing the following part numbers are of the micro-encapsulated adhesive type and following removal, must be discarded and replaced by new items of the same specification: CAC 8223 JZB 10060; JZB 10061; JZB 10078. JZH 100027. JZS 100082; JZS100087; JZS 100088; JZS 100089; JZS 100090; JZS 100118; JZS 100157; JZS 100164; JZS 100166. NCA 1451 AA.
Vehicle Specifications
Purchasers are advised that the specification details set out in this manual apply to a range of vehicles and not to any specific one. For the specification of a particular vehicle, purchasers should consult their dealer. The Manufacturer reserves the right to vary the specifications, with or without notice, and at such times and in such manner as the Manufacturer thinks fit. Major as well as minor changes may be involved, in accordance with the Manufacturer's policy of continuous improvement. Whilst every effort is made to ensure the accuracy of the particulars contained in this manual, neither the Manufacturer nor the Dealer, by whom the manual is supplied, shall in any circumstances be held liable for any inaccuracy or the consequences thereof.
Service Repair Operation Numbering

A master index of numbered operations has been compiled for universal application to all vehicles manufactured by Jaguar Cars Ltd. Each operation is allocated a number from the master index and cross-refers with an identical number in the Repair Operation Times schedule. The number consists of six digits arranged in three pairs. Each maintenance procedure in this manual is described in the sequence necessary to complete the operation in the minimum time, as specified in the Repair Operation Times schedule for this range of vehicles.
References to Left- and Right-Hand

References to the left- or right-hand side of the vehicle are made as if viewing from the driver's seat.
2012-07-21
References to Engine Banks

With the engine installed in the vehicle, the right-hand cylinder bank is designated Bank A, and the left-hand cylinder bank is designated Bank B.
Special Tools
Any special tools and equipment required to perform a maintenance procedure, are shown at the beginning of each maintenance procedure.
Torque Specifications
Torque specifications are shown in maintenance procedure illustrations and also in the torque specifications chart located at the front of the relevant section.
Disconnecting/Connecting the Battery

Owing to the electronic components used on the vehicle, it is important that the battery is disconnected when specified in a maintenance procedure. When the battery is connected, the specified procedure must be followed, to ensure the correct operation of all vehicle systems; refer to Section <<414-01>>.
www.JagDocs.com
Use of Control Modules

Control modules may only be used on the vehicle to which they were originally fitted. Do not attempt to use or test a control module on any other vehicle.
Functional Test
On completion of a maintenance procedure, a thorough test should be carried out, to ensure that the relevant vehicle systems are working correctly.
Protecting the Vehicle

Always fit covers to protect the fenders 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 vehicle. Avoid spilling hydraulic fluid, antifreeze or battery acid on the paintwork. In the event of spillage, wash off with water immediately. Use polythene sheets in the trunk to protect carpets. Always use the recommended service tool, or a satisfactory equivalent, where specified. Protect temporarily exposed screw threads by replacing nuts or fitting caps.
Preparation
Before disassembly, clean the surrounding area as thoroughly as possible. When components have been removed, blank off any exposed openings using grease-proof 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 associated parts. Before dismantling a component, clean it thoroughly with a recommended cleaning agent; check that the agent will not damage any of the materials within the component. Clean the bench and obtain marking materials, labels, containers and locking wire before dismantling a component.
2012-07-21
Dismantling
Observe scrupulous cleanliness when dismantling components, particularly when parts of the brake, fuel or hydraulic systems are being worked on. A particle of dirt or a fragment of cloth could cause a dangerous malfunction if trapped in these systems. Clean all tapped holes, crevices, oilways and fluid passages with compressed air. Do not permit compressed air to enter an open wound. Always use eye protection when using compressed air. Ensure that any O-rings used for sealing are correctly refitted or renewed if disturbed. Mark mating parts to ensure that they are replaced as dismantled. Whenever possible use marking materials which avoid the possibilities of causing distortion or the initiation of cracks, which could occur if a center punch or scriber were used. Wire together mating parts where necessary to prevent accidental interchange (e.g roller bearing components). Tie labels on to all parts to be renewed and to parts requiring further inspection before being passed for 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 been compared with the new part, to ensure that the correct part has been obtained.
Inspection
Before inspecting a component for wear or performing a dimensional check, ensure that it is absolutely clean; a slight smear of grease can conceal an incipient failure. When a component is to be checked dimensionally against figures quoted for it, use 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.
Safety Precautions
WARNING: WORKING ON THE FUEL SYSTEM RESULTS 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. DISCONNECT THE BATTERY BEFORE WORKING ON THE FUEL SYSTEM. DO NOT CONNECT/DISCONNECT ELECTRICAL CIRCUITS, USE ELECTRICAL EQUIPMENT OR OTHER TOOLS OR ENGAGE IN WORKING PRACTICES WHICH IN ANY WAY MAY RESULT IN THE PRODUCTION OF SPARKS. ENSURE THAT A CO2 FIRE EXTINGUISHER IS CLOSE AT HAND. ENSURE THAT DRY SAND IS AVAILABLE TO SOAK UP ANY FUEL SPILLAGE. EMPTY FUEL USING SUITABLE FIRE PROOF EQUIPMENT INTO AN AUTHORIZED EXPLOSION PROOF CONTAINER. DO NOT EMPTY FUEL WHILE WORKING IN A WORKSHOP OR A PIT. ENSURE THAT WORKING AREA IS WELL VENTILATED. ENSURE THAT ANY WORK ON THE FUEL SYSTEM IS ONLY CARRIED OUT BY EXPERIENCED AND WELL QUALIFIED MAINTENANCE PERSONNEL. ENSURE THAT FUME EXTRACTION EQUIPMENT IS USED WHERE APPROPRIATE. WARNING: FUME EXTRACTION EQUIPMENT MUST BE IN OPERATION WHEN SOLVENTS ARE USED E.G. TRICHLOROETHANE, WHITE SPIRIT, SBP3, METHYLENE CHLORIDE, PERCHLORETHYLENE. DO NOT
5 2012-07-21
SMOKE IN THE VICINITY OF VOLATILE DEGREASING AGENTS. General workshop practices: Disconnect the grounded terminal of the vehicle battery. Do not apply heat in an attempt to 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. Keep oils and solvents away from naked flames and other sources of ignition. Adhere strictly to handling and safety instructions given on containers and labels. Ensure that a suitable form of fire extinguisher is conveniently located. When using electrical tools and equipment, inspect the power lead for damage and check that it is properly earthed. Do not leave tools, equipment, spilt oil etc. around the work area. Working beneath a vehicle: Whenever possible, use a ramp or pit in preference to jacking. Position chocks at the wheels as well as applying the parking brake. Never rely on a jack alone to support a vehicle; use axle stands, or blocks carefully placed at the jacking points, to provide a rigid location. Check that any lifting equipment used has adequate capacity and is fully serviceable. Working on air conditioning systems: Do not disconnect any pipes of the refrigeration system unless you are trained and instructed to do so; a refrigerant is used which can cause blindness if allowed to come into contact with the eyes.
www.JagDocs.com
Health Protection
Prolonged and repeated contact with mineral oil will result in the removal of natural oils from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. Washing facilities and adequate means of skin protection should be provided. Observe these recommendations: Wear protective clothing and impervious gloves when necessary. Do not put oily rags in pockets. Avoid contaminating clothes, particularly underwear, with oil. Overalls must be cleaned regularly; discard oil impregnated clothing and footwear which cannot be washed or cleaned. 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 and grease from the skin. Wash with soap and water to ensure that all oil is removed (skin cleaner and a nail brush will help). The use of preparations containing 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, suitable eye protection should be worn goggles or face shield. An eye wash facility should be provided. Ensure that adequate ventilation is provided when volatile degreasing agents are being used.
2012-07-21

Environmental Protection
In some countries it is illegal to pour used oil onto the ground, down sewers or drains, or into water courses. The burning of used engine oil in small space heaters or boilers is not recommended unless emission control equipment is fitted. Dispose of used oil through authorized waste disposal contractors, to licensed waste disposal sites or to the waste oil reclamation trade. If in doubt, contact the Local Authority for advice on disposal facilities.
On-Board Diagnostics (OBD)

Vehicles use programmed electronic control systems to provide engine management and emission regulation, automatic transmission operation and anti-lock braking control. These control systems have an integral On-Board Diagnostics (OBD) facility for use in conjunction with either Jaguar diagnostic equipment or a scan tool which is capable of retrieving DTCs, PIDs and performing active commands. The OBD information in this manual provides diagnostic and rectification procedures for emission related electrical and mechanical systems. The information is intended to facilitate fault diagnosis and the subsequent rectification of vehicles without recourse to the portable diagnostic unit (PDU). OBD related information can be found in the following sections: General Information Engine Management System Automatic Transmission Anti-lock Braking System Where appropriate a section comprises the following sub-sections: Description and Operation A general illustration and parts list to help the identification of the particular system or component. A brief description of the system operating characteristics and monitoring procedure accompanied by a component illustration. Additional information, where appropriate, is provided in the form of component calibrations, characteristics and cross sectional views. A localized circuit diagram is included to provide circuit identification and details of connectors, splices, fuses, wire gauge and colors. See Circuit Diagrams. Diagnosis and Testing (dedicated to fault analysis and rectification) Recommended special tools. Symptom chart; a chart containing all relevant Diagnostic Trouble Codes (DTC), their possible causes and an indication of the appropriate test. Specific pinpoint test(s), designed so that fault diagnosis can be carried out in a logical and efficient manner. NOTE: For convenience, pinpoint test illustrations indicating voltage measurements do not always accurately reflect the conventional method of connecting a multimeter. More explicitly, if the multimeter probes are connected as shown in some illustrations (positive probe to ground), the voltage reading would be preceded by the negative sign '-', indicating that the probes have been connected in the reverse manner to the normal convention. The accuracy of the reading is not affected and the '-' sign can be ignored when comparing the reading with the results indicated in the text of the pinpoint test. Removal and Installation Removal procedure(s), formatted in the recommended sequence Illustrated guide to the use of special tools Illustrations to support the relevant text Installation procedure as above and including special recommendations for processes, lubricants and
2012-07-21
tightening torques.
Circuit Diagrams
To understand the relationship between the vehicle electrical system and the system circuit diagrams, refer to the appropriate Electrical Guide.
Fault Identification (DTC)

The diagnostic trouble codes (DTCs) are listed in Section <<303-00>> under Diagnostic Trouble Codes and include, where applicable, the corresponding manual section reference.
www.JagDocs.com
2012-07-21
Terminology Glossary
This glossary of terms is intended to cover emissions-related (to SAE J 1930) terminology, and other abbreviations that may be used in this manual. The required term may be looked-up in the left-hand column, and subsequent columns give the standard acronym, unit or abbreviation, and definition. Term(s) A Accelerator Pedal After Bottom Dead Center After Top Dead Center Airbag / Supplementary Restraint System Air Cleaner Air Conditioning Air Conditioning Control Module Air Conditioning Signal AP ABDC ATDC Airbag, SRS ACL A/C A/CCM ACS Module controlling air conditioning, heating and ventilation Air conditioning compressor clutch operation is signalled to the ECM which induces idle speed corrections to compensate for engine load changes Nominally 14.7 parts air to one part fuel SI unit of current A current of one ampere flowing for one hour System which prevents wheel lock-up under braking by sensing lack of rotation of a wheel(s) and diverting fluid pressure away from it (them) Event occurring after BDC Event occurring after TDC Airbag restraint system for driver and front seat passenger Acronym / Unit / Abbreviation Definition
Alternating current Air Fuel Ratio Ampere Ampere hour Anti-Lock Braking System ABS Control Module ABS / Traction Control Control Module Atmosphere Automatic Stability Control B Barometric Absolute Pressure Sensor Battery positive voltage Before Bottom Dead Center Before Top Dead Center Blower Body Processor Module Bottom Dead Center Brake horsepower Brake Mean Effective Pressure Brake On/Off
ac AFR A Ah ABS ABS CM ABS / TC CM atm ASC Unit of pressure (1.01325 bar) A form of vehicle control in which the ECM reduces engine torque to control wheel-spin Sensor measuring the pressure of surrounding air at any given temperature and altitude The positive voltage from a battery or any circuit connected directly to it Event occurring before BDC Event (usually ignition) occurring before TDC Device which supplies a current of air at moderate pressure, e.g. heater or A/C blower Control module for body electrical systems, e.g. interior lamps, windshield wash / wipe control Lowest point of piston travel in a reciprocating engine Effective horsepower developed by an engine or motor, as measured by a brake applied to its output shaft That part of the effective pressure developed in a cylinder that would result in a cylinder output equal to the bhp of the engine Indicates the position of the brake pedal
BARO B+ BBDC BTDC BLR BPM BDC bhp BMEP BOO
2012-07-21
British Standard British Standard Automotive Bus Bypass Air C Camshaft Position Sensor Canadian Motor Vehicle Safety Standard Canister Purge Carbon dioxide Carbon monoxide Case Ground Catalytic converter Celsius Central Processor Unit
BS BSAu
Standard specification issued by the British Standards Institution
Topology of a communication network BPA CMPS CMVSS CANP CO2 CO CSE GND Controls purging of the EVAP canister Colorless gas with a density of approximately 1.5 times that of air Poisonous gas produced as the result of incomplete combustion Control module casing ground In-line exhaust system device used to reduce the level of engine exhaust emissions C CPU SI term for the Centigrade scale, with freezing point at zero and boiling point at 100 The section of a computer that contains the arithmetic, logic and control circuits. It performs arithmetic operations, controls instruction processing, and provides timing signals and other housekeeping operations Control system with one or more feedback loops Mechanical control of throttle bypass air Indicates camshaft position
www.JagDocs.com
Closed Loop Closed Loop System Column/Mirror Control Module Control Module Controller Area Network Crankshaft Position Sensor Crankshaft Position Timing Ring Crankcase Ventilation System Cubic centimeter Curb weight D Data Link Connector Degree Department of Transportation (US) Department of Transport (UK) Deutsche Institut fr Normung Diagnostic Module
CL CLS C/MCM CM CAN CKPS CKPTR CV cm3 Weight of vehicle with fuel, lubricants and coolant, but excluding driver, passengers or payload DLC deg, DOT DTp DIN DM German standards regulation body Supplemental Restraint System (non-controlling) module for diagnostics overview Connector providing access and/or control of the vehicle information, operating conditions, and diagnostic information Angle or temperature A self-contained group of electrical/electronic components, designed as a single replaceable unit, and controlling one or more processes A communication system which allows control modules to be linked together in a network. Generates crankshaft position information in conjunction with the CKPTR (also generates speed information in certain applications) Toothed ring which triggers the CKPS System which scavenges camshaft cover and crankcase emissions and feeds them into the inlet manifold
2012-07-21
Diagnostic Test Mode
DTM
A level of capability in an OBD system. May include different functional states to observe signals, a base level to read DTCs, a monitor level which includes information on signal levels, bi-directional control with on/off board aids, and the ability to interface with remote diagnosis An alpha/numeric identifier for a fault condition identified by the On-Board Diagnostic (OBD) system A mechanical measuring instrument, with a rotary indicating pointer connected to a linear operating probe Pressure difference between two regions e.g. between intake manifold and atmospheric pressures
Diagnostic Trouble Code Dial test indicator Differential pressure Differential Pressure Feedback EGR Direct current Dual linear switch E EGR Temperature EGRT Sensor EGR Vacuum Regulator EGR Valve Position Electrically Erasable Programmable Read-Only Memory Electrically Programmable Read-Only memory Electronic Secondary Air Injection Engine Control Module End of dash Engine Coolant Level Engine Coolant Temperature ECT Sensor
DTC DTI
DPFE dc DLS EGRT EVR EVP EEPROM
An EGR system that monitors differential EGR pressure across a remote orifice to control EGR flow Current which flows in one direction only, though it may have appreciable pulsations in its magnitude J-gate switch connected to the TCM on SC vehicles Sensing EGR function based on temperature change Controls EGR flow by changing vacuum to the EGR valve An EGR system that directly monitors EGR valve position to control EGR flow
EPROM
EAIR ECM EOD ECL ECT ECTS
A pump-driven system for providing secondary air using an electric air pump
Referring to a vehicle fascia, eg EOD air vent
Thermistor which provides engine coolant temperature signal to the ECM to trigger enrichment circuits which increase injector 'on' time for cold start and warm-up
Engine speed Environmental Protection Agency Evaporative Emission
RPM EPA EVAP System designed to prevent fuel vapor from escaping into the atmosphere. Typically includes a charcoal filled canister to absorb fuel vapor
Evaporative Emission Control Valve Exhaust Gas Recirculation Exhaust Gas Recirculation Solenoid Vacuum Valve Exhaust Gas Recirculation Temperature Sensor
EVAPP EGR EGRS System which reduces NOx emissions by adding exhaust gases to the incoming fuel/air charge
EGRT Sensor
2012-07-21
Exhaust Gas Recirculation Valve F Fan Control Federal Motor Vehicle Safety Standard (US) Figure Flash Electrically Erasable Programmable Read-Only Memory Flash Erasable Programmable Read-Only Memory Flywheel Sensor Fuel Injectors Fuel Pressure Regulator Control Fuel Pump Fuel Pump Monitor Fuel Pump Relay Fuel rich/lean Full Scale Deflection G Generator Gramme centimeter Gramme (force) Gramme (mass) Ground H Hard fault Headlamp Heated Oxygen Sensor Hertz (frequency) High Mounted Stoplamp High tension (electrical) Hour Hydrocarbon I Idle Air Control Idle Air Control Valve Ignition Ignition amplifier
EGRV
FC FMVSS Fig. FEEPROM
Engine cooling fan control
Illustration reference
FEPROM
CKFS FI FPRC FP FPM FPR
Sensor mounted so as to be triggered by each flywheel ring gear tooth to give an engine speed signal Solenoid operated devices that spray a metered quantity of fuel into the inlet ports Controls fuel pressure regulator; used primarily to give extra fuel at cold start-up Monitors operation of fuel pump Qualitative evaluation of air/fuel ratio based on a ratio known as stoichiometry, or 14.7:1 (Lambda)
www.JagDocs.com
FSD GEN gcm gf g GND
The maximum indication point on an analogue meter or gauge Rotating machine which converts mechanical energy into electrical energy
Electrical conductor used as a common return for an electrical circuit or circuits, and with a relative zero potential A fault currently present in the system
HL HO2S Hz HMSL ht h HC IAC IACV ign IA Device which amplifies the ignition system output Electrical control of throttle bypass air Stepper motor driven device which varies the volume of air by-passing the throttle to maintain the programmed idle speed Electrically heated oxygen sensor which induces fueling corrections Frequency, one cycle per second
2012-07-21
Ignition ground Inertia Fuel Shut-off Inertia Fuel Shut-off Switch Intake air Input Intake Air Temperature Intake Air Temperature Sensor Intake Air Temperature Sensor Ignition Intake Air Temperature Sensor Injection Internal diameter International Standards Organization J K Kilogramme (mass) Kilogramme (force) Kilogramme force per square centimeter Kilometer Kilometer per hour Kilopascal Kilovolt Knock Sensor L Left-hand Left-hand drive vehicle Left-hand thread Light Emitting Diode Liquid Crystal Display Liter Low tension M Malfunction Indicator Lamp Manifold Absolute Pressure Manifold Absolute Pressure Sensor Manifold Surface Temperature
IGN GND IFS IFSS An inertia system that shuts off the fuel supply when activated by pre-determined force limits brought about by (e.g.) collision Shuts down fuel and ignition systems in the event of a vehicle impact Air drawn through a cleaner and distributed to each cylinder for use in combustion I/P IAT IATS IATSI IATSF i.dia ISO An electrical input signal to a controlling device Temperature of intake air Device used to measure IAT Thermistor which signals the ECM to retard the ignition timing in response to high inlet air temperatures Thermistor which inputs air density information to the ECM
kg kgf kgf/cm2 km km/h kPa kV KS Sensor which detects the onset of detonation, and signals the ECM to retard the ignition
LH LHD LH Thd LED LCD L lt Primary circuit of the ignition system, linking the battery to the primary winding in the ignition coil A required on-board indicator to alert the driver of an emission related malfunction Absolute pressure of the intake manifold air Sensor located in the ECM and ported to the intake manifold Light-emitting semiconductor diode used in alphanumeric displays and as an indicator lamp Optical digital display system, applied voltage to which varies the way the crystals reflect light, thereby modifying the display
MIL MAP MAPS MST
2012-07-21
Mass Air Flow Mass Air Flow Sensor Maximum Meter (measurement) Metric (screw thread, e.g. M8) Microfarad Millimeter Millimeter of mercury Millisecond Minimum Minute Model Year Module Modulating signal Motorized In-Car Aspirator Multi Protocol Adaptor N National Institute of Occupational Safety and Health (US) Newton Newton meter Nitrous Oxide Non-Volatile Random Access Memory Normally aspirated Normally Closed Normally Open North American Specification Number O Occupational Safety and Health Administration (US) On-Board Diagnostic
MAF MAFS max. m M MFD mm mmHg ms min. minute MY M MD MIA
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
Unit of electrical capacitance, one millionth of a farad
Self contained group of electrical/electronic components which is designed as a single replaceable unit A shift process signal to the TCM on SC vehicles Device which constantly samples cabin temperature by passing air over a sensor, and communicates with the A/CCM to modify A/C system performance to suit An interpreter for the various data languages present on a vehicle
www.JagDocs.com
MPA NIOSH
N Nm NOx NVRAM
SI unit of force. 1 N = 0.2248 pounds force SI 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 RAM which retains memory even if power supply is interrupted Fueling system using intake air at atmospheric pressure; not supercharged or turbocharged
NC NO NAS No. OSHA Vehicles for sale in the USA and Canadian markets
OBD
A system that monitors some or all computer input and output control signals. Signal(s) outside the pre-determined limits imply a fault in the system or a related system
On-Board Refueling Vapor Recovery Original Equipment Manufacturer Output Outside diameter
ORVR OEM O/P o. dia An electrical output signal from a controlling device
2012-07-21
Oxides of nitrogen Oxygen sensor P Parameter Identifier Park Neutral Position Park Neutral Position Switch Part number Portable Diagnostic Unit Position Power Assisted Steering Power Steering Pressure Programmable Electronic Control Units System Programmable Read-Only Memory Pulse Width Modulation Q R Random Access Memory Read-Only Memory Reservoir Return Revolutions Per Minute Right-hand Right-hand drive vehicle S Scan Tool Seat Control Module Secondary Air Secondary Air Injection
NOx O2S PID PNP PNPS part no. PDU pos'n PAS PSP PECUS PROM PWM Process whereby a common ECM is programmed on the production line to suit the market requirements of a particular vehicle ROM with some provision for setting the stored data after manufacture A method of control in an electronic control system in which the duration of pulses in a pulse train is proportional to the amplitude of the modulating signal Hydraulic pump-assisted steering system Comprehensive electrical diagnosis system specific to Jaguar vehicles Indicates the selected non-drive modes of the (automatic) transmission A sensor which detects oxygen content in the exhaust gases An index number referring to a parameter within a module without knowledge of its storage location
RAM ROM RES RTN RPM RH RHD
Fast access memory store which is accessible for entry or extraction of data Fast access memory in which data is fixed and may not be changed Container, usually for oils, coolants or hydraulic fluids A dedicated sensor ground circuit Shaft speed of a device, usually an engine or motor
ST SCM
Device that interfaces with and communicates information on a data link Module controlling the seat motor systems (not electric raise/lower-only seats) Air provided to the exhaust system System used for a period of time each time the engine is started, unless certain temperature criteria are met. Pumps air directly into the exhaust system which generates extra heat and reduces the time taken for the catalytic converters to reach operating temperature Vents secondary air to atmosphere Valve which prevents back-flow of exhaust gas to the AIR system when the system is inoperative Diverts secondary air to either the catalyst or exhaust manifold Clutch mounted on the AIRP drive shaft
AIR
Secondary Air Injection Bypass Secondary Air Injection Check Valve Secondary Air Injection Diverter Secondary Air Injection Magnetic Clutch
AIRB AIRC AIRD AIRPC
2012-07-21
Secondary Air Injection Pump Secondary Air Injection Relay Secondary Air Injection Switching Valve Security and Locking Control Module Sensor
AIRP AIRR AIRS SLCM S
Mechanically driven rotary vane pump, driven through the AIRPC Controls the injection of air into the exhaust system Vacuum operated valve backing-up the AIRC Module controlling the vehicle's security and closure-locking functions 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 quantity signal Number generated by Jaguar Methods and Techniques system which relates to 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' A shift process signal to the TCM on SC vehicles Controls shifting in an automatic transmission
Service Repair Operation (number)
SRO
Shift signal Shift Solenoid Signal return Sliding Roof Control Module Society of Automotive Engineers Speed Control Control Module Square centimeter Standard Standard Corporate Protocol Supercharger
SD SS SIG RTN SRCM SAE SCCM cm2 std SCP
www.JagDocs.com
Module controlling Speed Control System
A high-speed, serial communications system linking all body system control modules. Control messages and data are passed between modules at up to 786 messages per second An intake system which utilizes a supercharger (mechanically driven device that pressurizes intake air, thereby increasing density of charge air and the consequent power output from a given displacement)
SC
Supercharger Bypass Switch T Tachometer Thermal Vacuum Valve Throttle Body Throttle Position Throttle Position Sensor Top Dead Center Torque Converter Clutch Total indicator reading Transmission Control Module Transmission Control Switch Transmission Oil Temperature
SCB SW TACH TVV TB TP TPS TDC TCC TIR TCM TCS TOT The total indicated movement on a DTI with the test piece rotated through 360 Controls the shifting pattern of the (automatic) transmission Modifies the operation of electronically controlled transmissions Indicates temperature of transmission fluid Interprets throttle position and movement to identify idle, acceleration and full-power demands A circuit that provides input for an electronic tachometer display Controls vacuum levels or routing based on temperature Device containing the throttle
2012-07-21
Transmission Range Transmission Speed Sensor V Vacuum Solenoid Valve Vacuum Solenoid Valve (atm) Vacuum Solenoid Valve (rel) Vacuum Solenoid Valve (vac) Variable Valve Timing Vehicle Battery Adapter Vehicle Condition Monitor Vehicle Emission Control Information Label Vehicle Identification Number Vehicle Interface Adapter Vehicle Speed Sensor Viscosity Index Voltage Regulator W Watt Wide Open Throttle
TR TSS
The range in which the transmission is operating Indicates rotational speed of transmission output shaft or turbine shaft
VSV VSV VA VSV VR VSV VV VVT VBA VCM VECI Label VIN VIA VSS VI VR W WOT
Vacuum operated valve used in the speed control system Vacuum atmospheric valve used in the speed control system Vacuum release valve used in the speed control system Vacuum valve used in the speed control system A system by which the relationship of the crankshaft and camshaft may be altered during engine running Provides electrical power to the PDU and supplies a battery reference level Instrument panel display which warns of faults
Number assigned to the vehicle by the manufacturer, primarily for licensing and identification purposes Extends the PDU capability and provides a parallel interface to vehicle harnesses and ECMs Sensor which provides vehicle speed information Device which regulates the variable output voltage of a generator SI unit of power (1 hp = 745.7 watts) Full throttle position
2012-07-21
1999 XK RANGE - Identification Codes - 100-01
Identification Codes
Engine Number
The engine number (10 digits) is stamped on a raised pad on the front of the engine block near the thermostat housing. The piston grade reference (8 digits) is also shown.
Automatic Transmission Number

The serial number of the transmission unit is displayed on a metal or bar code label attached to the LH side of the transmission casing.
Vehicle Identification
The VIN and other information according to market, is displayed on a label located on the LH door post above the door striker plate, visible when the door is open. For certain markets, the VIN appears on a bar code label referred to as the Certification Label and additionally carries the month and year of manufacture, vehicle weight data and paint and trim codes. The VIN is also displayed on a plate visible through the windshield. It is essential that the vehicle identification number (VIN) is quoted when ordering parts and in all associated correspondence.
Date of Manufacture (Certain markets only)

The date of manufacture (Build Date) of a vehicle is defined as the calendar month and year in which the body and powertrain are combined and the completed vehicle leaves the production line. For certain markets, VIN labels carry the month and year of manufacture. For other markets, the vehicle Build Date is also displayed on a metal plate located at the top of the battery tray in the trunk.
www.JagDocs.com
Item GVWR GAWR F GAWR R Paint Trim
Description Gross Vehicle Weight Rating Gross Front Axle Weight Rating Gross Rear Axle Weight Rating Paint Code Trim Code
2012-07-21
1999 XK RANGE - Identification Codes - 100-01
Item 1 2 3
Description Gross Vehicle Weight Maximum Permitted Front Axle Loading Maximum Permitted Rear Axle Loading
ANTI-THEFT LABELS
For some markets, anti-theft labels bearing the VIN printed on a special anti-forgery background are positioned on certain body components. An additional anti-theft label is positioned on the LH side of the engine/automatic transmission casing. Anti-theft labels must not be removed from a vehicle unless necessitated by component renewal.
2012-07-21
1999 XK RANGE - Jacking and Lifting - 100-02
Using the Vehicle Jack
www.JagDocs.com
1.
WARNING: ENSURE THAT THE VEHICLE IS STANDING ON FIRM, LEVEL GROUND.
Position the jack at one of the four vehicle jacking points. Put the parking brake ON and the transmission in Park. Chock the wheels to prevent movement of the vehicle.
2. Locate the head of the jack securely in the sill profile. 3. Raise/lower the vehicle using the jack ratchet handle. Fit the handle to the jack using the socket extension.
2012-07-21
Jacking
The vehicle jack and wheel chock are stored in the trunk as part of the vehicle toolkit. Use of the vehicle jack and workshop jacks is described in the general procedures in this section.
Jacking Points
The vehicle jacking points: Are situated below the body side members on the sill flange. Consist of a reinforced plate, profiled to provide positive engagement with the vehicle jack. Are located behind the front wheels for lifting the front of the vehicle. Are located in front of the rear wheels for lifting the rear wheels. Provide the support points for the four lifting pads of a wheel-free lift.
2012-07-21
Safety Precautions
The following safety precautions must be observed when raising the vehicle to perform service operations: Never rely on a jack alone to support a vehicle; use suitable vehicle stands to provide rigid support. When working beneath a vehicle, whenever possible use a ramp or inspection pit instead of a jack and vehicle stands. Ensure that the vehicle is standing on firm, level ground before using a jack. Do not rely on the parking brake alone; chock the wheels and put the transmission into Park if possible. Check that any lifting equipment used has adequate capacity for the load being lifted and is in proper working order.
www.JagDocs.com
2012-07-21
Vehicle Recovery
NOTE: Prior to recovery, ensure that the vehicle keys are available and the security system disarmed. Vehicle recovery methods are: By flat-bed transporter. By rear suspended tow. By emergency towing for very short distances. The selector lever can be manually unlocked from the Park position in the event of electrical failure or when moving the vehicle without power. Refer to the general procedure in this section.
Transporter or Trailer Recovery
When the vehicle is being recovered by transporter or trailer: The parking brake must be be applied and the wheels chocked. The gear selector lever must be in Neutral. Do not select Park as the parking lock mechanism may be damaged by the forward and backward rocking motion of the vehicle. The vehicle must be securely tied down to the transporter or trailer. Do not use the vehicle towing eyes.
2012-07-21

Rear Suspended Tow
When the vehicle is being recovered by rear suspended tow: The ignition key must be removed from the ignition switch to lock the steering. The rear wheels must be correctly positioned in the lifting cradle and securely tied down.
www.JagDocs.com
Emergency Towing
WARNING: IF THE ENGINE IS NOT RUNNING, THE STEERING WILL BECOME HEAVY AND THE FORCE NECESSARY TO EFFECTIVELY APPLY THE BRAKES WILL BE GREATLY INCREASED. CAUTION: A vehicle with a defective transmission must be towed by rear suspended tow. When the vehicle is being towed on its own wheels: Local regulations for the towing of vehicles must be followed. In some countries the registration number of the towing vehicle and an 'On Tow' sign or warning triangle must be displayed at the rear of the towed vehicle. The gear selector lever must be in Neutral. The ignition switch must be in position II to release the steering lock and make the direction indicators, horn and stop lamps operate. A distance of 0,8 km (0.5 mile) must not be exceeded. A speed of 48 km/h (30 mph) must not be exceeded. The tow rope must be attached at one of the front towing eye positions.
Front Towing Eye
2012-07-21
The front towing eye: Is stored with the vehicle toolkit in the trunk. Can be used for emergency towing or winching the vehicle onto a transporter.
Front Towing Eye Location
The front towing eye screws into the front lower body crossmember at the left- or right-hand side of the vehicle, after the removal of a blanking plug.
Rear Towing Eye

The rear towing eye is a welded double loop on the right-hand side of the trunk floor. This eye must not be used for towing another vehicle.
2012-07-21
1999 XK RANGE - Suspension System - General Information - 204-00
Lubricants, Fluids, Sealants and Adhesives Unit Loctite Grease Grease Specification 270 Shell Retinax 'A' Castrol 'NTR'
Front Wheel Bearings Type Cartridge Maximum End Float 0.13 mm
Front Suspension Dimensions Component Hub face - maximum run-out Dimension 0.038 mm
www.JagDocs.com
Rear Suspension Dimensions Component Hub face - maximum run-out Dimension 0.057 mm
Vehicle ride height Model ' XK8 XKR Model Year ' 1997 to current ' VIN RANGE ' 001246 ' Market From Current ' Showroom mm(in) To All All Curb mm(in) Front 401 (15.78) 401 (15.78) Rear 416 (16.37) 415 (16.33) Front 400 (15.74) 400 (15.74) Rear 405 (15.94) 405 (15.94) Ride height is measured from the center of the wheel to the apex of the wheel arch, through the wheel center line. Showroom is with all fluids at full and 9 liters (9.5 US quarts) of fuel. Curb is with all fluids at full and a full tank of fuel. All figures quoted assume a +/- 15 mm (0.59in) anticipated build variance and condition.
2012-07-21

Wheel Alignment - Front Camber 1997 onwards VIN - 001246 to current ' ' All Right-Hand drive and Japan ' USA, Canada and Mexico ' Rest of World ' ' ' Degrees/minutes Decimal degrees Degrees/minutes Decimal degrees Degrees/minutes Decimal degrees Left - Hand Min -1 17' -1.28 -1 11' -1.18 -1 14' -1.24 Right Hand Max -0 17' -0.28 -0 11' -0.18 -0 14' -0.24 Balance (RH LH) Min -0 45' -0.76 -1 18' -1.30 -1 17' -1.28 Max +0 14' +0.24 -0 18' -0.30 -0 17' -0.28 Min -0 11' -0.19 -0 50' -0.83 -0 44' -0.74 Max +1 13' +1.21 +0 34' +0.57 +0 40' +0.66 All the above figures are at 'showroom' height. (See ride height section above). Tires must be inflated to normal pressure. <<204-04>> Wheel Alignment - Front Castor 1997 onwards VIN - 001246 to current ' ' All Right-Hand drive and Japan ' USA, Canada and Mexico ' Rest of World ' ' ' Degrees/minutes Decimal degrees Degrees/minutes Decimal degrees Degrees/minutes Decimal degrees Left - Hand Min +6 28' +6.47 +5 52' +5.87 +6 15' +6.25 Right Hand Max +7 52' +7.87 +7 16' +7.27 +7 39' +7.65 Balance Min +6 20' +6.33 +6 38' +6.64 +6 28' +6.47 Max +7 44' +7.73 +8 02' +8 04 +7 52' +7.87 Min -0 50' -0.84 +0 04' +0 06 -0 29' -0.49 Max +0 34' +0.57 +1 28' +1.46 +0 55' +0.91 All the above figures are at 'showroom' height. (See ride height section above). Tires must be inflated to normal pressure. <<204-04>> Units Castor Units Camber
2012-07-21

Wheel Alignment - Front Toe 1997 onwards VIN - 001246 to current ' All Right-Hand drive and Japan ' USA, Canada and Mexico ' Rest of World ' ' Degrees/minutes Decimal degrees Degrees/minutes Decimal degrees Degrees/minutes Decimal degrees Min +0 05' +0.08 +0 05' +0.08 +0 05' +0.08 Max +0 25' +0.42 +0 25' +0.42 +0 25' +0.42 All the above figures are at 'showroom' height. (See ride height section above). Tires must be inflated to normal pressure. <<204-04>> Wheel Alignment - Rear Camber 1997 onwards VIN - 001246 to current ' ' All Markets ' ' ' Degrees/Minutes Decimal Degrees Left Hand Min -0 54' -0.90 Right Hand Max -0 06' -0.10 Balance (RH LH) Min -0 54' -0.90 Max -0 06' -0.10 Min -1 00 -1.00 Max +1 00 +1.00 All the above figures are at 'showroom' height. See vehicle ride height section above. Tires must be inflated to normal pressure. <<204-04>> Wheel Alignment - Rear Toe 1997 onwards VIN - 001246 to current ' ' All Markets ' ' ' Degrees/Minutes Decimal Degrees Left Hand Min +005' +0.08 Right Hand Max +0 15' +0.25 Total Toe Min +005' +0.08 Thrust Angle Max +0 15' +0.25 Min 0 10' 0.17 Max +0 30' +0.50 Min -0 05' -0.08 Max +0 05' +0.08 All the above figures are at 'showroom' height. See vehicle ride height section above. Tires must be inflated to normal pressure. <<204-04>> Units Toe Units Camber Units Total Toe
www.JagDocs.com
2012-07-21
Front Camber Adjustment

1. The front suspension on vehicles up to VIN 031302 does not provide the facility to adjust the camber angle. This can only be achieved by replacing the original rear fulcrum-bolt of the lower-wishbone, with an eccentric fulcrum-bolt. The eccentric bolt should only be fitted when directed by Jaguar Technical Support. See operation (<<57.65.02>>). Eccentric fulcrum bolts are supplied by Jaguar Cars Ltd.
Description of Eccentric Bolt
1. Both ends of the eccentric fulcrum bolt, i.e. the threaded section and the head are concentric with the holes in the crossbeam fulcrum flanges. However, the center section of the bolt (arrowed), which retains the wishbone rear bush, is eccentric to the two ends of the bolt. When the bolt is installed; rotation of the bolt will cause the lower-wishbone rear arm to move in and out. A raised strip (arrowed) on the bolt head flange indicates the position of the bolts eccentric section, to aid positioning when adjusting the camber.The function of the eccentric bolt when it is rotated, is to increase or decrease the distance between the lower-wishbone fulcrum center at the crossbeam and the ball joint center, therefore altering the camber angle.
Installing the Eccentric Bolt Removal
1.
CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used. See section <<100-00>> for information. NOTE: An eccentric bolt must be fitted to both front lower wishbones.
Open engine compartment and fit paintwork protection covers to fenders.
2012-07-21
2. Raise vehicle on a four-post lift. 3. Position road wheels in the central position. 4. Raise front of vehicle and support on stands. Refer to section <<100-02>>.
www.JagDocs.com
5. Release steering column from pinion shaft. 1. Remove clamp bolt. Move column upwards to release.
6. Disconnect connector from steering rack transducer.
2012-07-21
7. Release hose from steering rack. 1. Remove tie straps. 2. Remove insulation rubbers.
8. Lower steering rack. CAUTION: Do not allow the weight of steering rack to hang on the PAS pipes. 1. Remove bolts from brackets. 2. Carefully lower steering rack.
2012-07-21
www.JagDocs.com
9. Remove nut and bolt from rear arm of lower wishbone. Repeat procedure on opposite-side wishbone.
Installation
1. Fit eccentric bolt to rear arm of lower wishbone. 1. Fit bolt, make sure bolt is fully entered into crossbeam flange. 2. Fit and tighten nut but leave loose enough to allow bolt to be rotated. Repeat procedure on opposite-side wishbone.
2012-07-21
2. Fit steering rack. Align steering rack to vehicle. Fit and tighten bolts.
3. Secure hose to steering rack. 1. Fit insulation rubbers. 2. Secure hose to steering rack with tie straps.
2012-07-21
www.JagDocs.com
4. NOTE: Make sure steering wheel and road wheels are in the central position before fitting steering column. Fit steering column to pinion shaft. Move column downwards onto pinion shaft. 1. Fit and tighten clamp bolt.
5. Connect electrical connector to steering rack transducer.
2012-07-21
6. Rotate eccentric bolt until the raised indicator strip on the bolt head flange is in the 6 o'clock position. This position will set the camber angle to its original setting. Repeat procedure on opposite-side eccentric bolt. 7. Remove stands and lower jack. 8. Lower four-post lift and remove vehicle. 9. Remove paintwork protection covers from fenders. 10. Adjust camber. See below.
Adjusting Camber
NOTE: Both eccentric bolts should now be in the position as detailed above, i.e. with the indicator strip in the 6 o'clock position. Rotating the eccentric bolt through 90 degrees from the 6 o'clock position, so that the indicator strip is outboard of the bolt center will cause the lower-wishbone rear fulcrum to move outward. This will, depending on original camber angle, either decrease the positive camber or increase the negative camber. Rotating the eccentric bolt through 90 degrees from the 6 o'clock position, so that the indicator strip is inboard of the bolt center will cause the lower-wishbone rear fulcrum to move inward. This will, depending on original camber angle, either increase the positive camber or decrease the negative camber. 1. Adjust the camber angle to the correct setting. Refer to <<204-01>> specifications for settings. 2. After adjustment of the camber angle, measure the suspension geometry, record the results and re-adjust if necessary.
2012-07-21
www.JagDocs.com
3. Tighten eccentric fulcrum bolt. Repeat procedure on opposite-side eccentric bolt. 4. Check toe setting and adjust if necessary. See <<204-01>> specifications. 5. Road test vehicle.
2012-07-21
Front Caster Adjustment

CAUTION: If a vehicle has a suspension geometry problem, all geometry settings must be investigated and corrected before making any adjustments to the caster setting.
1. If a suspension problem is suspected the 'Suspension Geometry Record Form' provided by Jaguar Technical Support must be completed, and Technical Support consulted, before any adjustments are carried out. See operation (<<57.65.02>>). 2. NOTE: Alteration of the caster setting will affect the camber and toe settings. Fit paintwork protection covers to fenders. 3. Raise front of vehicle and support on stands. Refer to section <<100-02>>. 4. Remove front wheels. Refer to section <<204-04>>.
5.
CAUTION: Do not allow the weight of the vertical link to hang on the brake hose. NOTE: Note the position of the shims before removing the fulcrum bolt.
Remove fulcrum bolt. 1. Remove nut. 2. Remove fulcrum bolt: collect washers and shims. 3. Secure wishbone.
6.
CAUTION: The total number of shims fitted to each fulcrum bolt must always remain the same, regardless of adjustment to the front and rear packs, i.e. no shims are to be added or removed from the fulcrum
1 2012-07-21

bolt. Caster angle is adjusted by interchanging the shims between the front and rear arm of each wishbone. See <<204-01>> specifications for settings. 7. Use the illustration and table below to calculate the required positioning of the shims needed to set the caster angle.
www.JagDocs.com
8. NOTE: Caster specification is subject to market variations, as shown in the following table, which is the result of differing road surfaces and market preferences. To increase positive caster, the shim thickness at the front of the wishbone 1 or 3 must be decreased, and the rear 2 or 4 increased by the same amount. 9. To decrease positive caster, the shim thickness at the front of the wishbone 1 or 3 must be increased and the rear 2 or 4 decreased by the same amount. N. America Thick x 2 Thin x 1 Pack 2 Left Side Rear Thin x 1 Thick x 1 Thin x 2 Pack 3 Right Side Front Pack 4 Right Side Rear Thin x 1 Thick x 2 Thin x 1 Thick x 1 Thin x 1 Thick x 1 Thin x 1 U.K. Thick x 1 R.O.W. Thick x 1 Thick x 1 Thick x 1 Thin x 1 Thick x 1 Thin x 1 Thick x 1 Thin x 1
Pack 1 Left Side Front
The thick shim is 1.6 mm thick, paint code blue, it will effect caster by 0.4 degrees. The thin shim is 0.9 mm thick, paint code red, it will effect caster by 0.2 degrees. The total number of shims allocated to each wishbone fulcrum bolt is 2 thick and 2 thin shims.
2012-07-21
10. Fit fulcrum bolt. 1. Align wishbone to crossbeam. 2. Fit fulcrum bolt, and shims and washers. 3. Fit and tighten nut. 11. Fit road wheels. Refer to section <<204-04>>. 12. Remove stands and lower vehicle. Refer to section <<100-02>>. 13. Remove paintwork protection covers. 14. Check caster setting is correct. 15. Check camber and toe settings and adjust if necessary. See specification section. 16. Road test vehicle.
2012-07-21
Front Camber and Caster Adjustment

1. The close tolerance machined alloy subframe installed on NA vehicles with VIN up to 031302, precludes the necessity for adjustment of front suspension geometry during vehicle manufacture. Eccentric lower wishbone fulcrum bolts are available as service items, but should only be fitted when directed by Jaguar Technical Support.On RHD and Japan market LH drive SC vehicles with VIN up to 031302, eccentric fulcrum bolts securing the lower wishbone to the front crossbeam, facilitate adjustment of wheel camber.All RH drive and Japan market LH drive vehicles from VIN 031302, incorporate a long upper wishbone on the RH side of the vehicle and a short upper wishbone on the LH side. There is a 2mm difference between the two wishbones, measured from the centers of the ball joint location and the fulcrum bolt location. The longer wishbone is identified by a countersunk hole in the upper surface adjacent to the ball joint location. All other LH drive vehicles from VIN 031302 onward are fitted with the shorter upper wishbone on both sides. These measures counter the effects of road camber on steering and eliminate the necessity for adjustment of suspension geometry.NOTE: The vehicle must be checked to establish that it conforms to the Jaguar original specification, e.g. wheels, tires, tire pressures, etc. NOTE: The 'space saver' wheel must not be installed on any of the hubs when measuring suspension geometry. NOTE: The vehicle must be unladen and the fuel tank full when measuring suspension geometry. Whilst fulcrum bolts remain available as service items, a suspected suspension problem must be reported to Jaguar Technical Support on the 'Suspension Geometry Record Form' provided and Technical Support consulted, before any adjustments are carried out. 2. Road test the vehicle to establish the exact nature of the complaint, e.g. pulling to one side, wander. 3. Measure the suspension geometry, fill in the 'Suspension Geometry Record Form', and contact Jaguar Technical Support for assistance. 4. Technical Support will give advice on the course of action to be taken to rectify the problem.
www.JagDocs.com
2012-07-21
Rear Toe Adjustment

1. NOTE: The vehicle should be unladen and at curb weight with a full fuel tank when checking and adjusting wheel alignment. NOTE: Wheel alignment must not be carried out with a space saver wheel installed on any of the hubs. NOTE: Before carrying out any checking or adjustment of wheel alignment, ensure that the vehicle wheels, tires and tire pressures are to Jaguar specification. NOTE: Before checking or adjusting rear wheel alignment, examine the vehicle for curb impact damage on wheels and subsequent damage to suspension components. Position alignment checking equipment on road wheels and following equipment manufacturer's instructions, check and if necessary adjust rear wheel alignment to Specifications in Section <<204-02>>.
2012-07-21
Wheel Bearing Circlip Inspection
www.JagDocs.com
1. When installing the bearing circlips in the vertical link ensure that the ears are located at the lowest position to permit water drainage.To achieve this, a perpendicular line drawn through the suspension upper ball-joint will indicate the position of the gap between the circlip ears. This procedure makes an allowance for the caster angle prior to installing the vertical link.
2012-07-21
Wheel Bearing Inspection
1. During use, a small amount of surplus grease may appear around the bearing seal, this does not indicate a failed bearing or seal. The grease should not be removed as this will act as an additional barrier to the ingress of water or foreign matter.Excessive end float or bearing rumble will indicate a failed bearing; for maximum permissible end float see specification section. Take care not to confuse suspension ball joint or upper or lower fulcrum bush movement for bearing end float.If the hub is removed for any reason, a new bearing assembly must be installed. Never attempt to re-use a bearing.
2012-07-21
Suspension System
Details of the Suspension System (including Wheels and Tires) can be found in Sections <<204-01>>, <<204-02>>, 204-03 and <<204-04>>.
www.JagDocs.com
2012-07-21
1999 XK RANGE - Front Suspension - 204-01
Press-In Loads Component Ball Joint-lower Ball Joint-upper Load 25 - 50 Kn 25 - 50 Kn
Torques CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used. See section <<100-00>> for information. Component Nut - ball joint-upper Nut - ball joint-lower Bolt - brake disc shield Bolt - crossbeam front mounting bracket to body Bolt - crossbeam rear mounting to body Bolt - crossbeam to rear mounting Bolt - crossbeam to engine mounting Nut - hub rotor nut Nut - shock absorber lower pivot Nut - shock absorber upper stud (non-adaptive damping) Nut - shock absorber upper stud (adaptive damping) Nut - spring and shock absorber upper-mounting to body Bolt - stabilizer bar bracket to crossbeam Nut - stabilizer bar to link Nut - stabilizer bar link to lower wishbone Bolt - wishbone lower front arm to rear arm Nut - wishbone upper fulcrum Bolt - wishbone lower front-fulcrum Bolt - wishbone lower rear-fulcrum Nm 60-80 60-80 9-11 77-103 77-103 26-34 34-46 270-330 60-80 30-40 16-18 26-34 22-28 60-80 39-55 128-172 98-132 113-153 113-153
2012-07-21
Front Suspension
Front Suspension Components
www.JagDocs.com
Item 1 2 3 4 5 6 7 8 9 10 11
Description Crossbeam Shock Absorber and Spring Assembly Upper Wishbone Vertical Link Lower Wishbone Stabilizer Bar Link Lower Ball Joint Upper Ball Joint Stabilizer Bar Hub Hub Rotor Nut
2012-07-21

Crossbeam
Item 1 2 3 4 5 6
Description Upper Wishbone Mounting Lower Wishbone Mounting Front Mounting Bush Location Engine Mounting Location Rear Mounting Location Power Steering Rack Mounting
CAUTION: Do not attempt to weld or repair the aluminum crossbeam. If it is damaged, a new one must be installed.
CAUTION: Do not use the crossbeam as a jacking point, as damage can occur to the crossbeam, steering rack and brake pipes. The crossbeam is a lightweight aluminum casting which is bolted at four points to the vehicle's longitudinal members, through metal-to-rubber bonded mountings. Bushes which are pressed into the crossbeam are used at the front, and mountings which are bolted to the crossbeam are used at the rear.
Wishbone Assemblies
Both upper and lower wishbone assemblies are attached to the crossbeam by fulcrum bolts. The upper wishbone is a single-piece steel forging, which is fitted with a press-fit ball joint, and two slipflex bushes to each arm. A single fulcrum bolt attaches the upper wishbone to the crossbeam. Shims installed with the upper fulcrum bolt are used to adjust the caster setting. The wide-base lower wishbone comprises two steel forged arms bolted together. The front wishbone arm is tapped to accept the two bolts which secure the two wishbone arms together. Additionally the two bolts also secure the shock absorber mounting brackets to the wishbone. Each lower wishbone arm is fitted with a metal-to-rubber bonded
2 2012-07-21

fulcrum bush which is attached to the crossbeam by an independent fulcrum bolt. The rear wishbone arm has a press fit ball joint installed. The camber setting is adjusted by rotating the lower-wishbone rear fulcrum bolt, which has an eccentric shaft. However, in some markets the eccentric bolt is not fitted and the original fulcrum bolt has to be substituted with an eccentric bolt to enable adjustment. The eccentric bolt is supplied by Jaguar Cars Ltd.
Stabilizer Bar
The stabilizer bar, is attached to the crossbeam in two positions by rubber bushes and clamps. The outer ends of the stabilizer bar are attached to links which are connected the lower wishbones. The stabilizer bar provides the required stiffness to prevent excessive body roll and fore-and-aft motion.
Vertical link
The vertical link swivels on the upper and lower wishbones via the ball joints, and carries the hub, cartridge wheel bearing - which is greased for life, has integral seals, and is non-adjustable, hub rotor nut (hub nut and ABS rotor combined), wheel speed sensor, brake caliper, and brake disc and shield. The position of the vertical link is determined by the movement of the steering rack, which is connected to the vertical link's integral steering arm by the tie-rod-end.
www.JagDocs.com
Shock absorber and spring assembly

The shock absorber and spring is a coaxial assembly, installed between the lower wishbone and vehicle body. The top spring mounting is attached to the vehicle's inner fender and the shock absorber is attached to a bracket on the lower wishbone. The spring is compressed between the upper mounting and the lower spring pan which is held in position by a circlip attached to the shock absorber. Springs come in various ratings depending on the vehicle's suspension specification The suspension specification also determines the number of packers fitted between the lower spring pan and the spring. Shock absorbers and CATS (adaptive damping): see section 204-03 Description and Operation.
2012-07-21
Ball Joint 60.15.02

Special Service tools
Ball Joint Taper Separator 204-192 (JD 219)
Upper wishbone ball joint installer. 204-199 (JD239)
Upper wishbone ball joint remover. 204-200 (JD240)
Removal CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the
2012-07-21

vehicle. These devices restrict the number of times a nut or bolt can be used. See section <<100-00>> for information.
CAUTION: The ball joint must be returned for warranty purposes, care must therefore be exercised to avoid damaging it during removal. Any damage incurred during removal must be noted and recorded.
1. Raise front of vehicle and support on stands. 2. Remove appropriate road wheel. Refer to Section <<204-04>>.
www.JagDocs.com
3. Position wheel speed sensor harness for access. Remove and discard tie straps securing wheel speed sensor harness to wishbone. Position harness clear of wishbone.
4. Remove nut securing upper wishbone ball joint to vertical link.
2012-07-21
5. Remove tool from ball joint.
6.
CAUTION: Do not use special tool 211-098 in the following procedure as this will damage the ball joint gaiter.
Release wishbone ball joint from vertical link. 1. Install special tool 204-192 on upper wishbone ball joint. 2. Tighten bolt of special tool to release ball joint taper from vertical link.
7. Raise upper wishbone to release ball joint pin from vertical link.
2012-07-21
8. To prevent damage to lower ball joint, secure vertical link to road spring using strong wire.
www.JagDocs.com
9. Remove upper wishbone fulcrum nut, washer and shaft.
2012-07-21
10.
CAUTION: When removing wishbone from suspension beam, retain and note positions of castor adjustment shims.
Remove upper wishbone from suspension beam and retain adjustment shims. 11. Position wishbone in a vise.
12. Using a hacksaw, partially cut through two diametrically opposite segments of ball joint flange.
2012-07-21
www.JagDocs.com
13. Carefully chisel through and remove the two ball joint flange segments to permit installation between press bed plates. 14. Remove wishbone from vise and thoroughly clean to remove swarf and road deposits.
15. For warranty purposes, paint positions of spring clip ends on ball joint housing and rubber gaiter.
2012-07-21
16. NOTE: Any gaiter damage incurred during removal must be recorded for warranty purposes. Remove retaining clips and gaiter. Exercising care to avoid splitting or otherwise damaging gaiter, remove retaining clips. Remove gaiter and retain for warranty purposes.
17. Invert wishbone and position on press with ball joint flange between press bed plates.
2012-07-21
18. Install special tool 204-200 on ball joint and operate press to release joint from wishbone. 19. Remove special tool from ball joint. 20. Remove ball joint and wishbone from press. 21. Ensuring that their relative positions are clearly marked, place ball joint, rubber gaiter and retaining clip in a clean plastic bag and return for warranty purposes. 22. Thoroughly clean wishbone paying particular attention to ball joint and pivot bolt locations.
www.JagDocs.com
Installation
1. Install ball joint in wishbone. Position support of special tool 204-199 on press bed and place wishbone on tool.
8 2012-07-21

Using ball joint plastic cover to align, position mandrel of special tool 204-199 on ball joint Align assembly with press ram and operate press to fully seat ball joint in wishbone. 2. Remove tools from ball joint. 3. Remove wishbone from press. 4. Remove and discard plastic cover from ball joint.
5. Installing castor shims in positions noted during removal, assemble wishbone to suspension beam.
6. Install upper wishbone. Install fulcrum shaft thread facing rearward. Install washer and nut and tighten nut to 98-132Nm.
2012-07-21
7. Remove wire/string temporarily securing vertical link to damper.
www.JagDocs.com
8. Position wishbone to facilitate engagement of ball joint taper pin in vertical link.
10
2012-07-21
9. Install nut securing ball joint to vertical link and tighten nut to 60-80Nm.
10. Position wheel speed sensor harness on wishbone and secure with new tie straps. 11. Install road wheel. Refer to Section <<204-04>>. 12. Raise front of vehicle remove stands and lower vehicle. 13. Check and as necessary adjust front wheel alignment. Refer to 57.65.01.
11
2012-07-21
Front Lower Arm and Rear Lower Arm Assembly 60.35.02

www.JagDocs.com
Ball joint splitter 204-293
Removal CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used. See section <<100-00>> for information.
1. Raise front of vehicle and support on stands. Refer to Section <<100-02>> 2. Remove appropriate front road wheel. Refer to Section <<204-04>>.
2012-07-21
3. Remove nut and bolt securing stabilizer bar link-rod to lower wishbone.
4. To prevent damage to upper ball joint, secure vertical link to road spring using strong wire.
2012-07-21
5. Remove nut securing lower ball joint to vertical link.
www.JagDocs.com
6.
CAUTION: Do not use special tool 211-098 in the following procedure as this will damage the ball joint gaiter.
Release lower ball joint from vertical link. 1. Install special tool 204-293 on ball joint. 2. Ensuring that rubber gaiter is not trapped, tighten tool bolt until ball joint taper pin is released from vertical link. 7. Remove special tool from ball joint.
2012-07-21
8. Remove shock absorber lower nut and bolt.
9. Remove nut and bolt securing lower wishbone front arm to cross-beam.
2012-07-21
10. Remove nut and bolt securing lower wishbone rear arm to cross-beam
www.JagDocs.com
11. Remove lower wishbone/ball joint assembly from cross-beam. 12. Thoroughly clean wishbone and ball joint. assembly 13. Check that ball joint gaiter is free from cuts or abrasions.
2012-07-21

Installation
1. Position lower wishbone on suspension cross-beam and vertical link.
2. Install but do not tighten wishbone rear arm to cross beam pivot nut and bolt.
2012-07-21
3. Install but do not tighten wishbone front arm to cross beam pivot nut and bolt.
www.JagDocs.com
4. Install nut securing lower ball joint to vertical link and tighten to 60-80Nm.
2012-07-21
5. Align lower end of shock absorber with wishbone, install nut and bolt and tighten to 60-80Nm.
6. Remove wire temporarily securing vertical link to road spring.
2012-07-21
7. Tighten wishbone rear arm pivot nut and bolt to 113-153Nm.
www.JagDocs.com
8. Tighten wishbone front arm pivot nut and bolt to 113-153Nm.
2012-07-21
9. Align stabilizer bar link rod with lower wishbone, install nut and bolt and tighten to 39-55Nm. 10. Install road wheel. Refer to Section <<204-04>>. 11. Raise vehicle, remove stands and lower vehicle. Refer to Section <<100-02>>.
10
2012-07-21
Lower Arm Bushing 60.35.45

www.JagDocs.com
Lower Wishbone - Bush Remover 204-214 (JD 244)
Ball joint splitter 204-293 Removal 1. CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used. See
1 2012-07-21

section <<100-00>> for information. Open engine compartment and fit paintwork protection covers to fenders. 2. Raise front of vehicle and support on stands. Refer to section <<100-02>>. 3. Remove front wheel. Refer to section <<204-04>>.
4. Release stabilizer-bar link from lower wishbone. Remove nut and bolt.
5.
CAUTION: Do not allow the weight of the vertical link to hang on the upper ball-joint. Support the weight of the vertical link through-out the procedure, to prevent damage to the upper ball-joint.
2012-07-21

Remove nut from lower ball joint.
www.JagDocs.com
6. Release lower ball joint from vertical link. 1. Fit special tool to ball joint. 2. Tighten tool bolt to release ball joint taper . Remove tool and release ball joint from vertical link.
7. Release shock absorber from lower mounting. Remove nut and bolt.
2012-07-21
2012-07-21
www.JagDocs.com
11.
CAUTION: Do not allow the weight of steering rack to hang on the PAS pipes.
Lower steering rack. 1. Remove bolts from brackets. 2. Carefully lower steering rack.
2012-07-21
12.
CAUTION: Note the position of the fulcrum bolts, as some vehicles are fitted with an eccentric bolt to the rear wishbone arm. See General Procedures section <<204-01>> for information.
Remove lower wishbone from crossbeam. 1. Remove nut and bolt from front wishbone and fulcrum tie. 2. Remove nut and bolt from rear wishbone arm. 3. Remove wishbone.
13. Disassemble lower wishbone. Position wishbone in a vice, with the front arm clamped in the jaws. 1. Remove bolts. 2. Remove rear arm. 3. Collect shock absorber mounting-brackets. Remove front arm from vice.
2012-07-21
www.JagDocs.com
14. NOTE: For assembly reference, note orientation of bush. Using a hydraulic press, remove bush from front wishbone arm. 1. Position arm on suitable supports on press bed. 2. Position special tool on top of bush. 3. Operate press to remove bush from arm. Initial press action will cause tool to shear through bush flange.
15. NOTE: For assembly reference, note orientation of bush. Using a hydraulic press, remove bush from rear wishbone arm. 1. Position arm on suitable supports on press bed. 2. Position special tool on top of bush. 3. Operate press to remove bush from arm. Initial press action will cause tool to shear through bush flange.
Installation
CAUTION:
7 2012-07-21

The front and rear wishbone bushes are different lengths, make sure the bushes are fitted to the correct arms.
1. NOTE: Fit bush into arm in the same orientation as noted in the removal section. Using a hydraulic press, fit bush into rear wishbone arm. 1. Position arm on suitable supports on press bed. 2. Align bush to arm. 3. Position suitable flat steel plate on top of bush. 4. Operate press to fit bush into arm.
2. NOTE: Fit bush into arm in the same orientation as noted in the removal section. Using a hydraulic press, fit bush into front wishbone arm. 1. Position arm on suitable supports on press bed. 2. Align bush to arm. 3. Position a suitable flat steel plate on top of bush.
2012-07-21

4. Operate press to fit bush into arm.
www.JagDocs.com
3. Assemble lower wishbone. Clamp front wishbone arm in a vice. 1. Align rear arm to front arm. 2. Align shock absorber mounting-brackets to arms. 3. Fit bolts: DO NOT tighten bolts at this stage.
4. Align wishbone arms and tighten bolts. 1. Temporarily fit link bolt to align shock absorber mounting-brackets. 2. Tighten bolts. Remove link bolt. 5. Remove wishbone from vice.
2012-07-21
6. Fit wishbone to vehicle. 1. Position wishbone to crossbeam and insert ball joint pin into vertical link. 2. Fit front and rear fulcrum bolts and nuts: DO NOT tighten at this stage. 3. Fit and tighten ball-joint nut.
7. Fit shock absorber to lower mounting bracket. Align shock absorber to mounting bracket and fit bolt. Fit and tighten nut.
10
2012-07-21
www.JagDocs.com
8.
CAUTION: Make sure the fulcrum bolts are fitted in their original positions as noted in removal.
Tighten lower wishbone fulcrum bolts.
9. Fit steering rack. Align steering rack to vehicle. Fit and tighten bolts.
11
2012-07-21
11. NOTE: Make sure steering wheel and road wheels are in the central position before fitting the steering column. Fit steering column to pinion shaft. Move column downwards onto pinion shaft. 1. Fit and tighten clamp bolt.
12
2012-07-21
www.JagDocs.com
13. Connect link to lower wishbone. 1. Align link to wishbone and fit bolt. 2. Fit and tighten nut. 14. Fit wheel. Refer to section <<204-04>>. 15. Remove stands and lower vehicle. Refer to section <<100-02>>. 16. Remove paintwork protection covers. 17. Check front suspension geometry. Refer to General Procedure <<57.65.02>>.
13
2012-07-21
Rear Lower Arm 60.35.54

1. Raise front of vehicle and support on stands. Refer to Section <<100-02>>. 2. Remove appropriate road wheel. Refer to Section <<204-04>>. 3. Remove lower wishbone. Refer to 60.35.02.90
4. Separate wishbone arms. 1. Clamp wishbone front arm in vise and remove bolts securing front arm to rear arm. 2. Remove and discard wishbone rear arm/lower ball joint assembly. 3. Remove and retain shock absorber lower mounting brackets. 5. Remove wishbone front arm from vise. 6. Thoroughly clean wishbone front arm and shock absorber lower mounting brackets.
2012-07-21

Installation
www.JagDocs.com
1. Fit bush to rear arm assembly. Position wishbone rear arm front uppermost on press bed. Position bush on rear arm. Place a steel plate on top of bush. Ensuring there is sufficient underside clearance for bush protrusion, operate press to fully seat bush. 2. Remove steel plate from bush. 3. Remove wishbone rear arm assembly from press.
4. Install wishbone rear arm and shock absorber mounting brackets to wishbone front arm. 1. Position shock absorber mounting brackets and wishbone securing bolts on rear arm. 2. Position wishbone front arm on bolts. Install but do not tighten bolts.
2012-07-21
5. Secure wishbone rear arm to front arm. 1. Install but do not tighten stabilizer bar link bolt and nut. 2. Tighten wishbone rear arm to front arm bolts to 128-172Nm.
6. Remove stabilizer bar link bolt. 7. Release wishbone assembly from vise and remove plastic transit cover from ball joint. 8. Install lower wishbone assembly. Refer to 60.35.02.90 9. Install road wheel. Refer Section <<204-04>>. 10. Raise front of vehicle, remove stands and lower vehicle. Refer to Section <<100-02>>.
2012-07-21
Shock Absorber and Spring Assembly 60.30.02

Removal 1. CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used. See section <<100-00>> for information.
Open engine compartment and fit paintwork protection covers to fenders. 2. Raise front of vehicle and support on stands. Refer to section <<100-02>>. 3. Remove front wheel. Refer to section <<204-04>>.
4.
www.JagDocs.com
CAUTION: The suspension must remain supported by the jack throughout this operation, to prevent damage to the upper and lower ball-joints.
Place a jack under the lower wishbone, raise the jack until the weight of the suspension is supported.
5. Remove shock absorber upper-mounting nuts. 1. Remove covers. 2. Vehicles fitted with adaptive damping: disconnect connector. 3. Remove nuts.
2012-07-21
6. Remove nut securing shock absorber to lower mounting, DO NOT remove bolt at this stage. 7. Carefully lower the jack supporting the suspension, while guiding the shock absorber, upper mounting studs through the body. Stop lowering the jack when the studs have passed through the body.
8.
CAUTION: For installation reference, note position of washers and shims before removing fulcrum shaft.
Release upper wishbone from crossbeam, to provide access for the removal of the shock absorber and spring assembly. 1. Remove nut. 2. Remove fulcrum shaft. 3. Collect washers and shims. 4. Release upper wishbone from crossbeam.
2012-07-21
www.JagDocs.com
9.
CAUTION: Do not stretch the brake hose when removing shock absorber and spring assembly.
With assistance, remove shock absorber and spring assembly. Remove bolt from shock absorber lower mounting. Remove shock absorber and spring assembly from vehicle.
10. Reposition upper wishbone. 1. Align upper wishbone to crossbeam. 2. Temporarily fit fulcrum shaft. 11. Clean relevant parts.
2012-07-21

Installation
1. Final alignment of shock absorber with upper mounting studs. 1. Fit jaw protectors to vice. 2. Secure assembly in the vice by clamping across two of the upper mounting studs. 3. Align the lower bush bore so that it is parallel with two of the upper mounting studs. Remove assembly from vice.
2012-07-21
www.JagDocs.com
2. Release upper wishbone to provide access for the fitting of the shock absorber and spring assembly. 1. Remove fulcrum shaft. 2. Release upper wishbone.
3.
CAUTION: Do not stretch brake-hose when fitting shock absorber and spring assembly.
With assistance, fit shock absorber and spring assembly. Position shock absorber to lower mounting. 1. Fit bolt to lower mounting, DO NOT fit nut at this stage.
2012-07-21
4. Fit upper wishbone. 1. Position wishbone to crossbeam. 2. Fit fulcrum shaft; washers and shims in the positions noted in removal. 3. Fit and tighten nut.
5.
CAUTION: Make sure the adaptive damping electrical connector is correctly aligned. Failure to follow these instructions may cause damage to the electrical connector.
Fit shock absorber and spring assembly upper-mounting to body. Raise suspension carefully on jack, and guide upper mounting studs into body stud-holes. Fit and tighten nuts. Vehicles fitted with adaptive damping: connect connector. Fit covers.
2012-07-21
www.JagDocs.com
6. Fit nut to shock absorber lower mounting. Fit and tighten nut. 7. Lower and remove jack supporting suspension. 8. Fit wheel. Refer to section <<204-04>>. 9. Remove stands and lower vehicle. 10. Remove paintwork protection covers.
2012-07-21
Stabilizer Bar 60.10.01

Engine Support Beam 303-021 (MS 53D) Rubber Suspension Insulator Lube Castrol NTR Removal 1. CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used. See section <<100-00>> for information.
Position vehicle on a four-post lift. 2. Open engine compartment to the service position. 3. Fit paintwork protection covers to fenders. 4. Disconnect battery ground cable. Refer to section <<414-01>>.
2012-07-21
www.JagDocs.com
5. Remove both engine covers. Release retaining pegs. Remove engine covers.
6. Support weight of engine. 1. Position special tool in RH and LH fender channels and tighten beam fixings. 2. Engage hooks into engine front lifting eyes. 3. Tighten hook adjustment nuts until weight of engine is supported. 7. Raise vehicle on a four-post ramp.
2012-07-21
8. Remove generator front cooling duct. Remove bolt. Move duct rearwards to release tang from undertray. Release front duct from rear vertical duct.
9. Remove undertray. 1. Remove and discard eight scrivets. 2. Remove screws. 3. Remove undertray.
2012-07-21
www.JagDocs.com
10. Remove cruciform strut (convertible vehicles only). Remove four bolts. Remove cruciform strut. 11. Raise front of vehicle and support on stands. Refer to section <<100-02>>. 12. Remove front wheels. Refer to section <<204-04>>.
13. Release both front wheel-arch liners to access stabilizer-bar brackets. Remove screw. Remove nut. Repeat procedure to release opposite-side wheel-arch liner.
14.
CAUTION: Place a wooden block between the jack and crossbeam, to prevent damage to the crossbeam.
2012-07-21
Using a suitable jack, support the weight of the front crossbeam.
15. Remove crossbeam front mounting-brackets. 1. Remove front bolts. 2. Remove rear bolt. 3. Remove mounting bracket. Repeat procedure to remove opposite-side mounting bracket.
16. Release both front engine mountings from crossbeam. Remove bolt. Repeat procedure to release opposite-side engine mounting.
2012-07-21
www.JagDocs.com
17. Release both front shock-absorbers from lower mountings. 1. Remove nut and bolt. 2. Repeat procedure to release opposite-side shock absorber.
18. Release both links from front stabilizer bar. Use an open-ended spanner on the ball-pin flats to prevent the dust cover from twisting. Remove nut. Release link. Repeat procedure to release opposite-side link.
2012-07-21
19. Release front crossbeam, rear-mountings from vehicle's body. Remove mounting center bolt. Repeat procedure to release opposite-side mounting. 20. Lower crossbeam sufficiently, to access stabilizer bar mounting-brackets.
21. Remove stabilizer bar mounting-brackets and bushes. 1. Remove bolts. 2. Remove bracket. 3. Remove bush. Repeat procedure to remove opposite-side mounting bracket and bush. 22. Remove stabilizer bar from vehicle. 23. Clean relevant parts.
2012-07-21
Installation 1. Position stabilizer bar to vehicle.
www.JagDocs.com
2.
CAUTION: Make sure the Casrol NTR grease is only applied to the inner surface of the mounting bush. Failure to follow this instruction may affect the retention of the bush in the retaining bracket. NOTE: Make sure bushes are seated correctly in the stabilizer bar's retaining bosses and crossbeam recesses.
Fit both mounting bushes to stabilizer bar. Apply a thin film of Castro NTR grease to the inner surface of the bush. Fit bush so that split is facing towards rear of vehicle. Repeat procedure to fit opposite-side bush.
2012-07-21

3. Fit both stabilizer bar mounting-brackets. Position bracket. Fit and tighten bolts. Repeat procedure to fit opposite-side bracket. 4. Raise crossbeam.
5. Secure crossbeam rear mountings to vehicle's body. Fit and tighten bolt. Repeat procedure to secure opposite-side mounting.
6. Secure links to stabilizer bar. 1. Position link to stabilizer bar. Use an open-ended spanner on the ball-pin flats to prevent the dust cover from twisting. 2. Fit and tighten nut. Repeat procedure to secure opposite-side link.
2012-07-21
www.JagDocs.com
7. Secure shock absorbers to lower mountings. 1. Align shock absorber to lower-mounting and fit bolt. 2. Fit and tighten nut. Repeat procedure to secure opposite-side shock absorber.
8. Fit front engine mounting bolts, but DO NOT tighten at this stage. Repeat procedure on opposite-side mounting.
10
2012-07-21
9. Fit both front mounting-brackets to crossbeam. 1. Align bracket. 2. Fit front bolts: do not tighten bolts at this stage. 3. Fit and tighten rear bolt. 4. Tighten front bolts. Repeat procedure to fit opposite-side mounting bracket. 10. Lower and remove the jack from beneath the crossbeam.
11. Secure both wheel-arch liners. Fit and tighten screw. Fit and tighten nut. Repeat procedure to secure opposite-side wheel arch liner.
11
2012-07-21
www.JagDocs.com
12. Fit cruciform strut (convertible models only). Position cruciform strut. Fit and tighten bolts.
13. Fit generator cooling duct deflector. Position deflector over rear vertical duct. Slide deflector forward to engage center tang over undertray. Fit bolt and tighten to 17-23Nm.
12
2012-07-21
14. Fit undertray. 1. Position undertray. 2. Fit screws. 3. Fit new scrivets. 15. Fit wheels. Refer to section <<204-04>>. 16. Remove stands and lower front of vehicle. 17. Lower four-post lift.
18. Release weight of engine. 1. Undo hook adjustment nuts. 2. Remove hooks from lifting eyes. 3. Remove special tool.
13
2012-07-21
www.JagDocs.com
19. Secure front engine mountings to crossbeam. Tighten bolt. Repeat procedure to secure opposite-side mounting.
20. Fit engine covers. Position covers to engine. Secure covers with retaining pegs. 21. Connect battery ground cable. Refer to section <<414-01>>, Battery Reconnection Procedure. 22. Remove paintwork protection covers.
14
2012-07-21
Stabilizer Bar Bushing 60.10.04

Rubber Suspension Insulator Lube Castrol NTR Removal 1. CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used. See section <<100-00>> for information.
Open engine compartment and fit paintwork protection covers to fenders. 2. Raise front of vehicle and support on stands. Refer to section <<100-02>>. 3. Remove front wheels. Refer to section <<204-04>>.
4. Release both front wheel-arch liners to access stabilizer-bar brackets. Remove screw. Remove nut. Repeat procedure to release opposite-side wheel-arch liner.
2012-07-21
www.JagDocs.com
5. Remove generator cooling duct. Remove bolts. Remove cooling duct.
6. Release both links from front stabilizer bar. Use an open-ended spanner on the ball-pin flats to prevent the dust cover from twisting. Remove nut. Release link. Repeat procedure to release opposite-side link.
2012-07-21
7. Remove stabilizer bar mounting-brackets and bushes. 1. Remove bolts. 2. Remove bracket. 3. Remove bush. Repeat procedure to remove opposite-side mounting-bracket and bush. 8. Clean relevant parts.
Installation
1.
CAUTION: Make sure the Castrol NTR grease is only applied to the inner surface of the mounting bush. Failure to follow this instruction may affect the retention of the bush in the retaining bracket. NOTE: Make sure bushes are seated correctly in the stabilizer bar's retaining bosses and crossbeam recesses.
2012-07-21
Fit both mounting bushes to stabilizer bar. Apply a thin film of Castrol NTR grease to the inner surface of the bush. Fit bush so that split is facing towards rear of vehicle. Repeat procedure to fit opposite-side bush.
www.JagDocs.com
2. Fit both stabilizer bar mounting-brackets. Position bracket. Fit and tighten bolts. Repeat procedure to fit opposite-side bracket.
3. Secure links to stabilizer bar. 1. Position link to stabilizer bar. Use an open-ended spanner on the ball-pin flats to prevent the dust cover from twisting. 2. Fit and tighten nut. Repeat procedure to secure opposite-side link.
2012-07-21
4. Fit generator cooling duct. 1. Align cooling duct. 2. Fit and tighten bolts.
5. Secure both wheel-arch liners. Fit and tighten screw. Fit and tighten nut. Repeat procedure to secure opposite-side wheel arch liner. 6. Fit wheels. Refer to section <<204-04>>. 7. Remove stands and lower vehicle. 8. Remove paintwork protection covers.
2012-07-21
Stabilizer Bar Link 60.10.02

www.JagDocs.com
4. Remove link. Use an open-ended spanner on the ball-pin flats to prevent the dust cover from twisting. 1. Remove nut. 2. Remove nut and bolt. 3. Remove link from stabilizer bar. 5. Clean relevant parts.
2012-07-21

Installation
1. Fit link . 1. Align link to lower wishbone and fit bolt. 2. Fit and tighten nut. Use an open-ended spanner on the ball-pin flats to prevent the dust cover from twisting. 3. Fit and tighten nut. 2. Fit front wheel. Refer to section <<204-04>>. 3. Remove stands and lower vehicle. 4. Remove paintwork protection covers.
2012-07-21
Upper Arm Bushing

Ball Joint Taper Separator 204-192 (JD 219) Removal 1. CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used. See section <<100-00>> for information.
www.JagDocs.com
4. Release ABS speed sensor harness from upper wishbone. Remove tie straps.
1 2012-07-21

Reposition harness.
5. Remove nut from upper ball joint.
6.
CAUTION: Do not allow the weight of the vertical link to hang on the brake hose.
Release upper ball-joint from vertical link. Using a strong length of wire secure the vertical link to the shock absorber. 1. Fit special tool to ball joint. 2. Tighten tool bolt to release ball joint pin-taper. Remove tool and disengage ball joint from vertical link.
2012-07-21
www.JagDocs.com
7.
CAUTION: For installation reference, note the position of washers and shims before removing fulcrum bolt.
Remove upper wishbone. 1. Remove nut. 2. Remove fulcrum bolt: collect washers and shims. 3. Remove wishbone. 8. Secure wishbone in a vice.
9. Remove fulcrum bushes from wishbone. 1. Using a suitable drift remove spacer tube from bush. 2. Prise out both sections of bush. Repeat procedure to remove remaining bush. 10. Clean relevant parts.
2012-07-21
Installation
1. Fit spacer tube into bush section. Apply a suitable lubricant to bush and spacer tube. Insert spacer tube into bush. 2. Fit jaw protectors to vice.
3. Using a vice, fit first section of bush into wishbone bore. Apply a suitable lubricant to bush. 1. Align first section of bush and spacer tube to bore. 2. Place wishbone and bush between vice jaws and tighten vice until bush is fully seated. Remove wishbone from vice.
2012-07-21
www.JagDocs.com
4. Fit second section of bush to wishbone. Apply a suitable lubricant to bush. 1. Align second section of bush to bore, make sure spacer tube engages bush. 2. Place wishbone and bush between vice jaws and tighten vice until bush is fully seated. Remove wishbone from vice. 5. Repeat the previous three pictorial-procedures to fit other bush into wishbone.
6. Fit wishbone to crossbeam. 1. Align wishbone to crossbeam. 2. Fit fulcrum bolt; shims and washers to their original positions as noted in the removal section. 3. Fit and tighten nut.
2012-07-21
7. Fit upper ball joint to vertical link. 1. Engage ball joint taper-pin into vertical link. 2. Fit and tighten nut. 8. Release vertical link from shock absorber.
9. Secure ABS harness to upper wishbone. Position harness and secure with tie clips. 10. Fit wheel. Refer to section <<204-04>>. 11. Remove stands and lower vehicle. 12. Remove paintwork protection covers.
2012-07-21
Wheel Bearing 60.25.40

Hub Remover 204-193 (JD 224)
www.JagDocs.com
Hub Removal Collets 204-194 (JD 225)
Hub Holding Tool 204-195 (JD 227)
2012-07-21
Hub Replacer 204-196 (JD 236)
Wheel Bearing Remover 204-197 (JD 237)
Wheel Bearing Replacer 204-198 (JD 238)
2012-07-21
ABS Rotor Nut Socket 206-066A
www.JagDocs.com
Circlip Pliers 18G 1004 Removal 1. CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used. See section <<100-00>> for information.
Remove vertical link and hub assembly. Refer to operation <<60.25.38.90>>.
2012-07-21
2. Remove brake-disc shield from vertical link. 1. Remove screws. 2. Remove disc shield.
3. Using special tool, secure vertical link and hub assembly in a vice. Secure special tool in a vice. Position hub in tool. Fit and tighten wheel nuts.
2012-07-21
4. Remove rotor nut spring-clip.
www.JagDocs.com
5. Remove rotor nut. Using special tool remove rotor nut. 6. Remove vertical link and hub assembly from special tool.
2012-07-21
7. Using a hydraulic press, remove hub from vertical link. 1. Place special tool on press bed. 2. Position vertical link and hub assembly into tool collets. 3. Make sure one of the disc shield screw-bosses is in the center of one of the tool collets. 4. Position special tool on top of hub. 5. Operate press to remove hub from vertical link.
8. Remove and discard the inboard circlip from the vertical link.
2012-07-21
9. Remove and discard outboard circlip from the vertical link.
www.JagDocs.com
10. Using a hydraulic press, remove wheel bearing from vertical link. NOTE: Make sure the vertical link is level, and the supports are situated as near to the bearing bore as possible. 1. Position the vertical link so that the inboard side of the bearing bore is resting on suitable supports on the press-bed. 2. Position special tool on top of bearing. 3. Operate press to remove bearing from vertical link, discard bearing. 11. Clean relevant parts.
2012-07-21

Installation
1. NOTE: The gap between the ears of the circlip must be positioned so that it is in the lowest position of the bore when the vertical link is fitted to the vehicle. Refer to General Procedures for further information. Fit outboard circlip to the vertical link.
2. Using a hydraulic press, fit wheel bearing into the vertical link. 1. Position vertical link on the press bed with outboard side of the vertical link face down. 2. Position wheel bearing to vertical link. 3. Position special tool on top of wheel bearing. 4. Operate press to fit bearing, make sure that the bearing is fully seated by applying a three-ton seating load.
2012-07-21
www.JagDocs.com
3.
CAUTION: To prevent damage to the integral wheel-bearing seal, select a set of ends for the circlip pliers which do not protrude through the circlip ears.
4. NOTE: The gap between the ears of the circlip must be positioned so that it is in the lowest position of the bore, when the vertical link is fitted to the vehicle. Refer to General Procedures for further information. Fit inboard circlip to the vertical link.
2012-07-21
5. Using a hydraulic press, fit hub into vertical link. 1. Position special tool onto press bed. 2. Position the vertical link, with the inboard-side face down, onto the tool. 3. Position hub to bearing. 4. Position a flat steel plate across the face of the hub, DO NOT place plate across wheel studs. 5. Operate press to fit the hub, make sure the hub is fully seated in the wheel bearing by applying a three-ton seating load.
10
2012-07-21
www.JagDocs.com
7. NOTE: The grease deflector ring was fitted to production vehicles at VIN number 018108 and on. Vehicles before this number must be fitted with a deflector ring when the rotor nut is removed for repair purposes. Deflector rings can be obtained from Jaguar Parts. Where necessary, fit a grease deflector ring to the rotor nut. Fit the grease deflector ring as shown. The distance at 'A' must be 0.5 mm.
8. Fit rotor nut to hub. 1. Fit rotor nut. 2. Using special tool tighten rotor nut.
11
2012-07-21
9.
CAUTION: Do not slacken the rotor nut to engage the spring clip.
Fit rotor nut spring-clip. Fit spring clip into the hub retaining holes and, if aligned, into the castellated slots of the rotor nut. If the castellated slots of the rotor nut are not aligned it will be necessary to tighten the rotor nut further until the spring clip engages the slots.
10. Fit disc shield to vertical link. 1. Position disc shield. 2. Fit and tighten bolts. 11. Fit vertical link and hub assembly to vehicle. Refer to operation <<60.25.38.90>>. 12. Check wheel alignment and adjust if necessary. Refer to operation 57.65.01.
12
2012-07-21
Wheel Hub
www.JagDocs.com
2012-07-21
2012-07-21
www.JagDocs.com
2012-07-21
2012-07-21
www.JagDocs.com
2012-07-21
7. Using a hydraulic press, remove hub from vertical link. 1. Place special tool on press bed. 2. Position vertical link and hub assembly into tool collets. 3. Make sure one of the disc shield screw-bosses is in the center of one of the tool collets. 4. Position special tool on top of hub. CAUTION: Removing the hub from the vertical link damages the wheel bearing. A new wheel bearing MUST be fitted to the vertical link. 5. Operate press to remove hub from vertical link.
2012-07-21
www.JagDocs.com
10. Using a hydraulic press, remove the wheel bearing from the vertical link. NOTE: Make sure the vertical link is level, and the supports are situated as near to the bearing bore as possible. 1. Position the vertical link so that the inboard side of the bearing bore is resting on suitable supports on the press-bed. 2. Position special tool on top of bearing. 3. Operate press to remove bearing from vertical link, discard bearing. 11. Clean relevant parts.
2012-07-21

Installation
2. Using a hydraulic press, fit the wheel bearing into the vertical link. 1. Position vertical link on the press bed with outboard side of the vertical link face down. 2. Position wheel bearing to vertical link. 3. Position special tool on top of wheel bearing. 4. Operate press to fit bearing, make sure that the bearing is fully seated by applying a three-ton seating load.
2012-07-21
www.JagDocs.com
3.
CAUTION: To prevent damage to the integral wheel-bearing seal, select a set of ends for the circlip pliers which do not protrude through the circlip ears.
2012-07-21
10
2012-07-21
www.JagDocs.com
11
2012-07-21
9.
12
2012-07-21
Wheel Knuckle 60.25.23

www.JagDocs.com
2012-07-21
2012-07-21
www.JagDocs.com
2012-07-21
2012-07-21
www.JagDocs.com
2012-07-21
7. Using a hydraulic press, remove hub from vertical link. 1. Place special tool on press bed. 2. Position vertical link and hub assembly into tool collets. 3. Make sure one of the disc shield screw-bosses is in the center of one of the tool collets. 4. Position special tool on top of hub. CAUTION: Removing the hub from the vertical link damages the wheel bearing. A new wheel bearing MUST be fitted to the vertical link. 5. Operate press to remove hub from vertical link.
2012-07-21
www.JagDocs.com
10. Using a hydraulic press, remove wheel bearing from vertical link. NOTE: Make sure the vertical link is level, and the supports are situated as near to the bearing bore as possible. 1. Position the vertical link so that the inboard side of the bearing bore is resting on suitable supports on the press-bed. 2. Position special tool on top of bearing. 3. Operate press to remove bearing from vertical link, discard bearing. 11. Clean relevant parts.
2012-07-21

Installation
2. Using a hydraulic press, fit wheel bearing into the vertical link. 1. Position vertical link on the press bed with outboard side of the vertical link face down. 2. Position wheel bearing to vertical link. 3. Position special tool on top of wheel bearing. 4. Operate press to fit bearing, make sure that the bearing is fully seated by applying a three-ton seating load.
2012-07-21
www.JagDocs.com
3.
CAUTION: To prevent damaging the integral wheel-bearing seal, select a set of ends for the circlip pliers which do not protrude through the circlip ears.
2012-07-21
10
2012-07-21
www.JagDocs.com
11
2012-07-21
9.
12
2012-07-21
Wheel Knuckle and Wheel Hub Assembly 60.25.38.90

Tie-Rod-End Taper Separator 211-098 (JD 100)
www.JagDocs.com
Ball joint splitter 204-293 Removal 1. CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used. See
1 2012-07-21

section <<100-00>> for information. Open engine compartment and fit paintwork protectors to fenders. 2. Raise front of vehicle and support on stands. Refer to section <<100-02>>. 3. Remove front wheel. Refer to section <<204-04>>.
4.
CAUTION: Do not allow the brake caliper to hang on the brake hose.
Remove front brake disc. Refer to operation 70.10.12.
5. Remove wheel speed-sensor from vertical link. Remove bolt.
2012-07-21
6. Remove nut securing tie-rod end to steering arm.
www.JagDocs.com
7. Release tie-rod end from steering arm. 1. Fit special tool to tie-rod end. 2. Tighten tool bolt to release tie-rod end, taper pin. 3. Remove tool and disengage tie-rod end from steering arm.
2012-07-21
8. Remove nut from upper-wishbone ball joint.
9.
CAUTION: Do not allow the weight of the vertical link to hang on the lower ball joint, after releasing the upper ball joint.
Release upper-wishbone ball joint from vertical link. 1. Fit special tool to ball joint. 2. Tighten tool bolt to release ball joint taper-pin. Remove tool and disengage ball joint from vertical link.
2012-07-21
10. Remove nut from lower-wishbone ball joint.
www.JagDocs.com
11. Release lower ball joint from vertical link. 1. Fit special tool to ball joint. 2. Tighten tool bolt to release ball joint taper-pin. Remove tool and disengage ball joint from vertical link. 12. Remove the vertical link and hub assembly from the vehicle. 13. Clean relevant parts.
Installation 1. Position vertical link and hub assembly to vehicle.
2012-07-21
2. Fit upper ball joint to vertical link. Position ball joint taper-pin into vertical link. Fit and tighten nut.
3. Fit lower ball joint to vertical link. Position ball joint taper-pin into vertical link. Fit and tighten nut.
2012-07-21
www.JagDocs.com
4. Fit tie-rod end to steering arm. Position tie-rod end, taper-pin into steering arm. Fit and tighten nut.
5. Fit wheel speed-sensor to vertical link. Align speed sensor. Fit and tighten bolt. 6. Fit brake disc. Refer to operation 70.10.12. 7. Fit wheel. Refer to section <<204-04>>. 8. Remove stands and lower vehicle. 9. Remove paintwork protection covers.
2012-07-21
Shock Absorber and Spring Assembly 60.30.21

Compressor, Coil Spring 204-476
Disassembly 1. CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used. <<100-00>>
Remove the front shock absorber and spring assembly.
2.
WARNING: MAKE SURE THE SHOCK ABSORBER IS SECURED BY FULLY INSERTING THE LOCKING PIN IN TO THE SPECIAL TOOL. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
Install the shock absorber and spring assembly to the special tool as shown.
2012-07-21
3.
WARNING: AS THE SPRING IS UNDER EXTREME TENSION CARE MUST BE TAKEN AT ALL TIMES. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
www.JagDocs.com
Clamp the road spring. Rotate the handle until spring pressure is released.
NOTATION GIF ENTITY SYSTEM "..\GRAPHIC\E43415.GIF" 4. Remove the shock absorber retaining nut. Remove and discard the retaining nut.
5. Release the road spring.
2012-07-21
6. Remove the shock absorber.
NOTATION GIF ENTITY SYSTEM "..\GRAPHIC\E33739.GIF" 7. Remove the gaiter assembly from the upper mounting. 1. Disengage the gaiter from the upper mounting. 2. Remove the spring assister from the gaiter. 8. Clean the relevant parts. Assembly NOTATION GIF ENTITY SYSTEM "..\GRAPHIC\E32295.GIF" 1. NOTE: To ease fitting apply a suitable lubricant to the spring assister and gaiter. NOTE: Make sure the gaiter assembly is seated securely and squarely into the upper mounting. Assemble the upper mounting. 1. Insert the spring assister fully into the gaiter. 2. Insert the gaiter into upper mounting location.
2012-07-21
2.
CAUTION: Make sure circlip on the shock absorber abuts with the lower spring pan.
CAUTION: Make sure the spring ends butt correctly against the spring seats. Install the shock absorber and spring assembly to the special tool.
www.JagDocs.com
3.
WARNING: AS THE SPRING IS UNDER EXTREME TENSION CARE MUST BE TAKEN AT ALL TIMES. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
Clamp the road spring.
NOTATION GIF ENTITY SYSTEM "..\GRAPHIC\E43415.GIF" 4. Vehicles without adaptive damping. Install a new retaining nut. Tighten to 40 Nm.
NOTATION GIF ENTITY SYSTEM "..\GRAPHIC\E43415.GIF" 5. Vehicles with adaptive damping. Install a new retaining nut. Tighten to 18 Nm.
2012-07-21
6. Release the road spring. 7. Remove the shock absorber and spring assembly from the special tool. 8. Install the front shock absorber and spring assembly.
2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
Torques CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used. See section <<100-00>> for information. Component Bolt - ABS Sensor to Hub Carrier Bolt - bump stop to body Nut - differential stud to pendulum Nut - hub Nut - link assembly to differential Bolt - link assembly to subframe mounting bracket Bolt - monostrut to body bracket Bolt - support plate to subframe mounting bracket Nut - shock absorber lower-pivot Nut - shock absorber upper-stud (non-adaptive damping) Nut - shock absorber upper-stud (adaptive damping) Nut - spring and shock absorber assembly, upper-mounting to body Stud - spring and shock absorber assembly, upper-mounting to body Bolt - stabilizer-bar bracket to wishbone-tie Nut - stabilizer bar to link Nut - stabilizer-bar link to wishbone Bolt - suspension subframe to differential Nut - suspension subframe front flange to subframe mounting bracket Bolt - suspension subframe to mounting-bush bracket (through bush) Bolt - suspension-subframe mounting-bush bracket to body Tie-stud (front) - to differential Nut - wishbone-tie to monostrut Nut - wishbone-tie to differential Nut - wishbone inner fulcrum Nut - wishbone outer fulcrum Nm 8-10 26-34 149-201 304-336 68-92 88-118 88-118 40-54 77-103 30-40 16-18 17-23 15-19 40-54 30-40 30-40 88-118 68-92 88-118 88-118 350-430 77-103 88-118 77-103 88-118
www.JagDocs.com
2012-07-21
Rear Suspension
Rear Suspension Components
Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Description Lower wishbone Suspension spring Damper Upper spring seat Hub carrier 'A' Frame Wide mounting frame Wishbone tie assembly Pendulum Wishbone fulcrum pin Stabilizer bar Bump stop Monostrut Upper link assembly
The independent rear suspension uses co-axial spring and damper units, an 'A' frame, wishbone tie, pendulum assembly, wide mounting frame, monostrut and cast wishbones. Positive location of the suspension is provided by the 'A' frame, wide mounting bracket and monostrut. Each wishbone inner is pivoted on a fulcrum bolt which passes through the wishbone tie and pendulum assembly. The wishbone tie and pendulum assemblies are installed at the front and rear of the final drive housing. The monostrut is also attached to wishbone tie assembly and two further tie rods are installed between the front of the 'A' frame and the top of the final drive housing.
2012-07-21
The outer end of the wishbone is bolted to the hub carrier assembly using a pivot bolt, allowing for toe-in adjustment. When the pivot bolt is correctly seated in a groove on the wishbone arm, it has small clearance at the sides but full clearance at the top and bottom. Rotation of the bolt, with the eccentric constrained between vertical faces, causes the bolt shank to be moved in the horizontal plane, thus moving the hub carrier and effecting wheel alignment adjustment. The axle-shaft acts as the the upper wishbone and the hub carrier as a vertical link. A snubber is installed above the hub carrier to prevent the carrier contacting the vehicle body. The suspension spring is co-axial with the damper unit and is installed between the wishbone integral spring seat and the upper spring seat mounted on the vehicle body. The damper lower end is attached to the wishbone by a bolt which forms the damper lower pivot. A stabilizer bar is mounted at the rear of the wishbone tie assembly and its outer ends are connected to the wishbones by short links. As the road wheel rises, the movement is transmitted through the hub carrier assembly to the wishbone and axle-shaft, which also rise. As the wishbone rises, it causes the suspension spring to be compressed and the damper to move through part of its travel. The spring absorbs the shock and the damper damps any unwanted spring frequencies. When cornering, weight is transferred to the outer wheel with a natural tendency for the inner wheel to lift. The stabilizer bar helps to minimise this by transferring some of the apparent rise of the outer wheel to the inner wheel through the links to the wishbones, helping to provide a more level ride. Adaptive damping may also be specified as an option.
www.JagDocs.com
2012-07-21
Axle Bump Stop 64.30.15

Removal 1. Raise rear of vehicle and support on stands. 2. Remove appropriate road wheel.
3. Remove bump stop bolts. 4. Remove bump stop from vehicle.
Installation 1. Position bump stop on vehicle. 2. Install bump stop bolts and tighten to 26-34 Nm. 3. Install road wheel. 4. Raise vehicle, remove stands and fully lower onto wheels.
2012-07-21
Rear Suspension and Axle Assembly 64.25.01

Removal 1. CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used. <<100-00>>
Raise the rear of the vehicle and support on axle stands. <<100-02>> 2. Remove the rear wheels. <<204-04>>
www.JagDocs.com
3.
CAUTION: Do not suspend the caliper from the brake hose as this will damage the hose. NOTE: Right-hand shown, left-hand similar
Remove the brake calipers from the carriers. 1. Remove the caliper spring clip. 2. Remove the guide pin dust caps. 3. Slacken and withdraw the guide pins. 4. Remove the caliper from the carrier and secure to the suspension mounting bracket using a tie strap.
2012-07-21
4. NOTE: Right-hand shown, left-hand similar Disconnect the wheel speed sensor electrical connectors.
5. NOTE: Right-hand shown, left-hand similar Remove and discard the tie straps securing the wheel speed sensor harnesses to the brake hose clips.
2012-07-21
www.JagDocs.com
6. On vehicles with adaptive damping: Remove the top cover from the shock absorbers. Disconnect the shock absorber electrical connectors by pressing the lugs down and pulling the connectors up.
7. NOTE: Right-hand shown, left-hand similar Remove shock absorber upper mounting plates to body nuts.
2012-07-21
8. Fully slacken but do not remove the parking brake cable adjuster nut.
9. Release the parking brake cable from the connecting clip.
2012-07-21
10. Withdraw the left-hand parking brake cable through the equalizer.
www.JagDocs.com
11. Mark the position of the drive shaft coupling to the flexible coupling.
2012-07-21
12. Remove the drive shaft from the differential drive coupling. Remove the drive shaft to differential drive coupling bolts. Carefully withdraw and lower the drive shaft from the differential coupling.
13.
CAUTION: Position a suitable piece of wood between the jack and the rear suspension and axle assembly. Failure to follow this instruction may result in damage to the vehicle.
Support the rear suspension and axle assembly. Position a trolley jack under the rear suspension and axle assembly. Position a suitable piece of wood between the jack and the rear suspension and axle assembly. Raise the jack to take the weight of the rear suspension and axle assembly.
2012-07-21
www.JagDocs.com
14. NOTE: Left-hand shown, right-hand similar Remove the exhaust mounting to suspension bracket bolts.
15. NOTE: Right-hand shown, left-hand similar Remove and discard the subframe front mounting brackets to body bolts.
2012-07-21
16. NOTE: Right-hand shown, left-hand similar Remove the subframe front mounting brackets. Remove and discard the mounting bracket to subframe bolts. Remove the front mounting bracket.
17. NOTE: Left-hand shown, right-hand similar Remove differential strut upper mounting to body bracket securing bolts.
2012-07-21
18.
WARNING: WITH ASSISTANCE, SUPPORT THE REAR SUSPENSION AND AXLE ASSEMBLY DURING REMOVAL. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN PERSONAL INJURY.
www.JagDocs.com
Remove the rear suspension and axle assembly. Ensure that the hydraulic pipes, brake calipers, harnesses and the drive shaft will not obstruct the rear suspension and axle assembly during removal. Carefully lower the rear suspension and axle assembly and traverse clear of vehicle.
19. Retrieve the subframe mounting bush shims. 20. With assistance, position the rear suspension and axle assembly on to a bench. 21. Clean the subframe mounting bushes and corresponding body locations.
2012-07-21

Installation
1. Apply a thin coat of grease to the subframe bushes and place the shims in position.
2.
WARNING: WITH ASSISTANCE, SUPPORT THE REAR SUSPENSION AND AXLE ASSEMBLY DURING INSTALLATION. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN PERSONAL INJURY. CAUTION: Position a suitable piece of wood between the jack and the rear suspension and axle assembly. Failure to follow this instruction may result in damage to the vehicle.
Position the rear suspension and axle assembly on to a trolley jack.
3.
WARNING: WITH ASSISTANCE, SUPPORT THE REAR SUSPENSION AND AXLE ASSEMBLY DURING INSTALLATION. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN PERSONAL INJURY.
Position the rear suspension and axle assembly under the vehicle.
10
2012-07-21
www.JagDocs.com
4.
WARNING: WITH ASSISTANCE, SUPPORT THE REAR SUSPENSION AND AXLE ASSEMBLY DURING INSTALLATION. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN PERSONAL INJURY.
Raise the trolley jack to position the rear suspension and axle assembly to the vehicle.
5. NOTE: Right-hand shown, left-hand similar Install the mounting brackets. Position the mounting brackets to the subframe. Install but do not tighten new bolts to the mounting bracket .
11
2012-07-21
6. NOTE: Right-hand shown, left-hand similar Install new outer bolts to the mounting bracket. Tighten to 41-54 Nm.
7. NOTE: Right-hand shown, left-hand similar Install new inner mounting bracket bolts. Tighten to 88-118 Nm.
12
2012-07-21
www.JagDocs.com
8. NOTE: Right-hand shown, left-hand similar Tighten to 88-118 Nm.
9. NOTE: Right-hand shown, left-hand similar Install new differential strut to body bracket bolts. Tighten to 68-92 Nm. 10. Lower and remove trolley jack.
13
2012-07-21
11. Attach the drive shaft to the flexible coupling. Align the marks previously painted on drive shaft and flexible coupling. Install new drive shaft coupling bolts and nuts.
12. Tighten to 76-88 Nm.
14
2012-07-21
www.JagDocs.com
13. Install the exhaust brackets. Position exhaust mounting bracket on subframe. Install bolts and nuts. Tighten to 22-28 Nm.
14. Route the left hand parking brake cable through the equalizer.
15
2012-07-21
15. Install the parking brake cable in to the connecting clip. 16. Adjust the parking brake cable. Refer to <<70.35.10>>.
17.
On vehicles with adaptive damping: Connect the shock absorber electrical connector, ensuring the electrical connector key locates in the socket keyway.
16
2012-07-21
www.JagDocs.com
18. Install the brake caliper on to the carrier. 1. Position the caliper assembly on to the carrier. 2. Install the guide pins and tighten to 25-30 Nm. 3. Install the dust caps. 4. Install the brake caliper spring clip.
19. Connect the wheel speed sensor electrical connector.
17
2012-07-21
20. Using a new tie strap, secure the wheel speed sensor harness to the brake hose clip. 21. Install the rear wheels. <<204-04>> 22. Remove the axle stands and lower the vehicle. <<100-02>> 23. Check and adjust the rear wheel alignment as necessary. <<204-00>>
18
2012-07-21
Shock Absorber 64.30.02

Spring Compressors 204-179 (JD 199)
www.JagDocs.com
Spring Retaining Straps 204-179-1 (JD 199-1) Removal 1. CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used. <<100-00>>
Raise the rear of the vehicle and support on axle stands. <<100-02>> 2. Remove the relevant rear wheel. <<204-04>>
2012-07-21
3.
CAUTION: Do not suspend the caliper from the brake hose as this will damage the hose.
Remove the brake caliper from the carrier. 1. Remove the caliper spring clip. 2. Remove the guide pin dust caps. 3. Slacken and withdraw the guide pins. 4. Remove the caliper from the carrier and secure to the suspension mounting bracket using a tie strap.
4. Disconnect the wheel speed sensor electrical connector.
2012-07-21
5. Remove and discard the tie strap securing the wheel speed sensor harness to the brake hose clip.
www.JagDocs.com
6. Mark the wishbone at the pivot pin eccentric flange marker to aid installation.
2012-07-21
7. Remove the pivot pin nut and washer.
8.
CAUTION: To prevent damage to the parking brake cable, the hub carrier must be supported on removal from the wishbone.
Remove the hub carrier from the wishbone. Remove the pivot pin from the hub carrier. Withdraw the hub carrier and support on a block of wood.
2012-07-21
9.
www.JagDocs.com
CAUTION: Note the position of the shims during removal. They must be returned to their original position during installation.
Noting their positions, remove the shim from each end of the pivot pin sleeve.
10.
WARNING: ENSURE THE SPECIAL TOOLS ARE POSITIONED DIAMETRICALLY OPPOSITE ON THE SPRING AND THE ARMS ARE CORRECTLY SEATED . WARNING: WHEN COMPRESSING THE SPRING, TIGHTEN THE SPECIAL-TOOL ADJUSTMENT BOLTS EVENLY.
Compress the spring. Install and align the special tools 204-179 diametrically opposite on the spring. Evenly tighten the special tool tensioning bolts to compress the spring.
2012-07-21
11. Remove the shock absorber to wishbone mounting nut and bolt.
12. Remove the nuts securing the shock absorber and spring upper mounting to the body.
2012-07-21
13. Using the special tools 204-179-1, secure the upper mounting to the spring.
www.JagDocs.com
14. Using a jack, retract the shock absorber through the wishbone aperture.
2012-07-21
15. Position a bolt through the spring coils and shock absorber lower-bush, to temporarily locate the shock absorber. 16. Partially lower the jack for access to the top of the shock absorber.
17. On vehicles with adaptive damping: Disconnect the shock absorber electrical connector by pressing the lugs down and pulling the connector up. 18. Lower and remove the jack. 19. Remove the shock absorber and spring assembly from the vehicle and place the assembly on a work bench. 20. Clean the upper mounting spring location.
2012-07-21
21. Remove the pigtail seat and clean the wishbone lower spring location.
www.JagDocs.com
22. With assistance, manually compress the shock absorber and withdraw the bolt from the spring coils.
2012-07-21
23. Remove the shock absorber from the upper mounting. Position a wrench on the shock absorber shaft flats to prevent rotation (wrench in socket on vehicles with adaptive damping). Remove the shock absorber upper retaining nut. Remove the upper washer and isolator.
24. Remove the special tools 204-179-1 and remove the upper mounting from the spring.
10
2012-07-21
www.JagDocs.com
25. Remove the shock upper mounting assembly from the spring. Remove the spring upper isolator. Remove the upper spring pan. Remove the packing ring.
Installation
1. Install the spring pigtail lower seat on to the wishbone.
11
2012-07-21
2. Install the spring in the upper mounting. Install the spring upper isolator. Install the upper spring pan. Install the packing ring.
3. Ensuring the correct orientation, secure the upper mounting to the spring using the special tools 204-179-1.
12
2012-07-21
www.JagDocs.com
4. Position the spring upper mounting assembly on to the shock absorber. Apply a thin coat of grease to the upper mounting bush. Ensure that the washer, lower isolator and bush are correctly positioned on the shock absorber shaft. Position the shock absorber shaft in the upper mounting.
5. Secure the top of the shock absorber to the upper mounting. Install the spring upper isolator. Install the upper washer. Install but do not tighten the locknut on to the shock absorber.
13
2012-07-21
6. Manually retract the shock absorber and place a bolt through the spring coils and the shock absorber lower-bush.
7. Secure the shock absorber to the upper mounting. Position a wrench on the shock absorber shaft flats to prevent rotation (wrench in socket on vehicles with adaptive damping). Tighten the shock absorber upper lock nut to 30-40 Nm (16-18 Nm on vehicles with adaptive damping). 8. Position the shock absorber and spring assembly to the vehicle.
14
2012-07-21
9. With assistance, manually retract the shock absorber and remove the temporary securing bolt.
www.JagDocs.com
10. Remove the special tools 204-179-1.
15
2012-07-21
11. Align the shock absorber lower bush to the wishbone and install the mounting bolt. 1. Install but do not tighten the nut.
12.
16
2012-07-21
www.JagDocs.com
13. Seat the upper mounting in the body location. 1. If adaptive damping is installed, ensure the harness is correctly positioned.
14. Ensuring that the spring is seated on the isolator and spring pan, position the upper spring pan on to the body studs.
17
2012-07-21
15. Release the spring tension. Ensuring that the spring is correctly located, evenly slacken the adjuster bolts on the special tools 204-179. 16. Remove the special tools 204-179.
17. Fully seat and secure the upper spring pan to the body. Ensure the spring pan is correctly seated in the body location. Install the nuts securing the spring pan to the body studs. Tighten to 17-23 Nm.
18
2012-07-21
www.JagDocs.com
19. Install the shims on the pivot pin sleeve in the positions noted during removal.
19
2012-07-21
20. Install the hub assembly to the wishbone assembly. Position the hub and carrier to the wishbone. Install the pivot pin ensuring that the eccentric flange correctly seats in the wishbone groove.
21. Install the pivot pin nut. Align the marker on the pivot pin flange with the mark made on wishbone. Install the nut on to the pivot pin and, ensuring the pin position is not disturbed, tighten the nut to 88-118 Nm. 22. Release the tie strap securing the brake caliper to the suspension mounting bracket.
20
2012-07-21
www.JagDocs.com
21
2012-07-21
25. Using a new tie strap, secure the wheel speed sensor harness to the brake hose clip. 26. Install the rear wheel. <<204-04>> 27. Remove the axle stands and lower the vehicle. <<100-02>> 28. Check and adjust the rear wheel alignment as necessary. <<204-00>>
22
2012-07-21
Spring 64.20.01
Spring Compressors 204-179 (JD 199)
www.JagDocs.com
Spring Retaining straps 204-179-1 (JD 199-1) Removal 1. CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used. <<100-00>>
Raise the rear of the vehicle and support on axle stands. <<100-02>> 2. Remove the relevant rear wheel. <<204-04>>
2012-07-21
3.
CAUTION: Do not suspend the caliper from the brake hose as this will damage the hose.
Remove the brake caliper from the carrier. 1. Remove the caliper spring clip. 2. Remove the guide pin dust caps. 3. Slacken and withdraw the guide pins. 4. Remove the caliper from the carrier and secure to the suspension mounting bracket using a tie strap.
4. Disconnect the wheel speed sensor electrical connector.
2012-07-21
5. Remove and discard the tie strap securing the wheel speed sensor harness to the brake hose clip.
www.JagDocs.com
6. Mark the wishbone at the pivot pin eccentric flange marker to aid installation.
2012-07-21
7. Remove the pivot pin nut and washer.
8.
CAUTION: To prevent damage to the parking brake cable, the hub carrier must be supported on removal from the wishbone.
Remove the hub carrier from the wishbone. Remove the pivot pin from the hub carrier. Withdraw the hub carrier and support on a block of wood.
2012-07-21
9.
www.JagDocs.com
CAUTION: Note the position of the shims during removal. They must be returned to their original position during installation.
Noting their positions, remove the shim from each end of the pivot pin sleeve.
10.
WARNING: ENSURE THE SPECIAL TOOLS ARE POSITIONED DIAMETRICALLY OPPOSITE ON THE SPRING AND THE ARMS ARE CORRECTLY SEATED . WARNING: WHEN COMPRESSING THE SPRING, TIGHTEN THE SPECIAL-TOOL ADJUSTMENT BOLTS EVENLY.
Compress the spring. Install and align the special tools 204-179 diametrically opposite on the spring. Evenly tighten the special tool tensioning bolts to compress the spring.
2012-07-21
11. Remove the shock absorber to wishbone mounting nut and bolt.
12. Remove the nuts securing the shock absorber and spring upper mounting to the body.
2012-07-21
13. Using the special tools 204-179-1, secure the upper mounting to the spring.
www.JagDocs.com
14. Using a jack, retract the shock absorber through the wishbone aperture.
2012-07-21
15. Position a bolt through the spring coils and shock absorber lower-bush, to temporarily locate the shock absorber. 16. Partially lower the jack for access to the top of the shock absorber.
17. On vehicles with adaptive damping: Disconnect the shock absorber electrical connector by pressing the lugs down and pulling the connector up. 18. Lower and remove the jack. 19. Remove the shock absorber and spring assembly from the vehicle and place the assembly on a work bench. 20. Clean the upper mounting spring location.
2012-07-21
21. Remove the pigtail seat and clean the wishbone lower spring location.
www.JagDocs.com
22. With assistance, manually compress the shock absorber and withdraw the bolt from the spring coils.
2012-07-21
23. Remove the shock absorber from the upper mounting. Position a wrench on the shock absorber shaft flats to prevent rotation (wrench in socket on vehicles with adaptive damping). Remove the shock absorber upper retaining nut. Remove the upper washer and isolator.
24. Remove the special tools 204-179-1 and remove the upper mounting from the spring.
10
2012-07-21
www.JagDocs.com
25. Remove the shock upper mounting assembly from the spring. Remove the spring upper isolator. Remove the upper spring pan. Remove the packing ring.
26. For installation purposes, mark position of tool arms on spring.
11
2012-07-21
27.
CAUTION: The type and number of packers fitted to rear springs is dependent upon spring rating. Some springs are fitted without any packers. The original packer(s) must therefore be retained on removal.
Remove the shock upper mounting assembly from the spring. Remove the spring upper isolator. Remove the upper spring pan. Remove the packing ring.
28.
WARNING: WHEN RELEASING THE SPRING TENSION, SLACKEN THE SPECIAL-TOOL ADJUSTMENT BOLTS EVENLY.
Evenly slacken the adjuster bolts on special tools 204-179 and remove the tools from the spring.
12
2012-07-21
Installation
www.JagDocs.com
1. Transfer reference marks from old spring to replacement spring.
2.
WARNING: ENSURE THE SPECIAL TOOLS ARE POSITIONED DIAMETRICALLY OPPOSITE ON THE SPRING AND THE ARMS ARE CORRECTLY SEATED . WARNING: TIGHTEN THE SPECIAL TOOL ADJUSTMENT BOLTS EVENLY WHEN COMPRESSING THE SPRING.
Using the special tools 204-179 compress the spring. 1. Fit and align the arms of the special-tools to the spring reference marks. 2. Tighten the special-tool adjustment bolts evenly to compress the spring.
13
2012-07-21
3. Install the spring pigtail lower seat on to the wishbone.
4. Install the spring in the upper mounting. Install the spring upper isolator. Install the upper spring pan. Install the packing ring.
14
2012-07-21
5. Ensuring the correct orientation, secure the upper mounting to the spring using the special tools 204-179-1.
www.JagDocs.com
6. Position the spring upper mounting assembly on to the shock absorber. Apply a thin coat of grease to the upper mounting bush. Ensure that the washer, lower isolator and bush are correctly positioned on the shock absorber shaft. Position the shock absorber shaft in the upper mounting.
15
2012-07-21
7. Secure the top of the shock absorber to the upper mounting. Install the spring upper isolator. Install the upper washer. Install but do not tighten the locknut on to the shock absorber.
8. Manually retract the shock absorber and place a bolt through the spring coils and the shock absorber lower-bush.
16
2012-07-21
www.JagDocs.com
9. Secure the shock absorber to the upper mounting. Position a wrench on the shock absorber shaft flats to prevent rotation (wrench in socket on vehicles with adaptive damping). Tighten the shock absorber upper lock nut to 30-40 Nm (16-18 Nm on vehicles with adaptive damping). 10. Position the shock absorber and spring assembly to the vehicle.
11. With assistance, manually retract the shock absorber and remove the temporary securing bolt.
17
2012-07-21
12. Remove the special tools 204-179-1.
13. Align the shock absorber lower bush to the wishbone and install the mounting bolt. 1. Install but do not tighten the nut.
18
2012-07-21
www.JagDocs.com
14.
15. Seat the upper mounting in the body location. 1. If adaptive damping is installed, ensure the harness is correctly positioned.
19
2012-07-21
16. Ensuring that the spring is seated on the isolator and spring pan, position the upper spring pan on to the body studs.
17. Release the spring tension. Ensuring that the spring is correctly located, evenly slacken the adjuster bolts on the special tools 204-179. 18. Remove the special tools 204-179.
20
2012-07-21
www.JagDocs.com
19. Fully seat and secure the upper spring pan to the body. Ensure the spring pan is correctly seated in the body location. Install the nuts securing the spring pan to the body studs. Tighten to 17-23 Nm.
21
2012-07-21
21. Install the shims on the pivot pin sleeve in the positions noted during removal.
22. Install the hub assembly to the wishbone assembly. Position the hub and carrier to the wishbone. Install the pivot pin ensuring that the eccentric flange correctly seats in the wishbone groove.
22
2012-07-21
www.JagDocs.com
23. Install the pivot pin nut. Align the marker on the pivot pin flange with the mark made on wishbone. Install the nut on to the pivot pin and, ensuring the pin position is not disturbed, tighten the nut to 88-118 Nm. 24. Release the tie strap securing the brake caliper to the suspension mounting bracket.
23
2012-07-21
27. Using a new tie strap, secure the wheel speed sensor harness to the brake hose clip. 28. Install the rear wheel. <<204-04>> 29. Remove the axle stands and lower the vehicle. <<100-02>> 30. Check and adjust the rear wheel alignment as necessary. <<204-00>>
24
2012-07-21
Stabilizer Bar 64.35.08

Raise vehicle on a four-post lift. Refer to section <<100-02>>.
www.JagDocs.com
2. Remove nuts and bolts securing stabilizer bar to links.
3. Remove stabilizer bar mounting-brackets. Remove bolts. Remove brackets.

1 2012-07-21
4. Remove stabilizer bar from vehicle. Remove bushes. 5. Clean relevant parts.
Installation
1.
CAUTION: Make sure the Castrol NTRgrease is only applied to the inner surface of the mounting bushes. Failure to follow this instruction may affect the retention of the bushes in the retaining brackets.
Fit bushes to stabilizer bar. Apply a thin film of Castrol NTR grease to the inner surface of the bushes.
2012-07-21
www.JagDocs.com
2. Position stabilizer bar to vehicle. Position stabilizer bar to links. Fit nuts and bolts, DO NOT tighten at this stage.
3. Fit mounting brackets to stabilizer bar. Align bushes and fit mounting brackets. Fit and tighten bolts.
2012-07-21
4. Tighten nuts securing stabilizer bar to links. 5. Lower four-post lift.
2012-07-21
Stabilizer Bar Bushing 64.35.18

www.JagDocs.com
2. Remove nuts and bolts securing stabilizer bar to links.
3. Remove stabilizer bar mounting-brackets. Remove bolts. Remove brackets.

1 2012-07-21
4. Remove stabilizer bar from vehicle. Remove bushes. 5. Clean relevant parts.
Installation
1.
CAUTION: Make sure the Castrol NTR grease is only applied to the inner surface of the mounting bushes. Failure to follow this instruction may affect the retention of the bushes in the retaining brackets.
Fit bushes to stabilizer bar. Apply a thin film of Castro NTR grease to the inner surface of the bushes.
2012-07-21
www.JagDocs.com
2. Position stabilizer bar to vehicle. Position stabilizer bar to links. Fit nuts and bolts, DO NOT tighten at this stage.
3. Fit mounting brackets to stabilizer bar. Align bushes and fit mounting brackets. Fit and tighten bolts.
2012-07-21
4. Tighten nuts securing stabilizer bar to links. 5. Lower four-post lift.
2012-07-21
Stabilizer Bar Link 64.35.24

www.JagDocs.com
2. Remove link. 1. Remove nut securing link to wishbone. 2. Remove lower bush. 3. Remove nut and bolt securing link to stabilizer bar. 4. Remove link from wishbone. 5. Remove upper-bush from link. 3. Clean relevant parts.
2012-07-21

Installation
1. Fit link. 1. Fit 2. Fit 3. Fit 4. Fit 5. Fit
upper bush to link. link to wishbone. and tighten nut and bolt securing link to stabilizer bar. lower bush to link. and tighten nut securing link to wishbone.
2. Lower four-post lift.
2012-07-21
Stabilizer Bar Link Bushing 64.35.25

www.JagDocs.com
2. Remove link. 1. Remove nut securing link to wishbone. 2. Remove lower bush. 3. Remove nut and bolt securing link to stabilizer bar. 4. Remove link from wishbone. 5. Remove upper-bush from link. 3. Clean relevant parts.
2012-07-21

Installation
1. Fit link. 1. Fit 2. Fit 3. Fit 4. Fit 5. Fit
upper bush to link. link to wishbone. and tighten nut and bolt securing link to stabilizer bar. lower bush to link. and tighten nut securing link to wishbone.
2. Lower four-post lift.
2012-07-21
Stabilizer Bar Mounting Frame Vehicles Without: Convertible Top 64.25.12

Raise vehicle on a two-post lift. Refer to section <<100-02>>. 2. Remove RH rear wheel. Refer to section <<204-04>>.
www.JagDocs.com
3. Disconnect driveshaft from the differential drive-coupling. 1. Reference-mark position of driveshaft coupling to differential coupling. 2. Remove nuts and bolts. Position driveshaft aside.
2012-07-21
4. Release both exhaust tail pipes from rear mountings.
5.
CAUTION: To prevent damage to the axle assembly, position a piece of wood between the jack and axle assembly.
Position a suitable jack under the suspension subframe, and support the weight of the axle assembly.
6. Remove nuts and bolts securing monostrut to wishbone-tie assembly.
2012-07-21
7. Remove bolts securing monostrut to body brackets.
www.JagDocs.com
8. Remove both mounting brackets from suspension subframe. 1. Remove bush center bolt from bracket. 2. Remove bolts securing bracket to body. Remove bracket. Repeat procedure to remove opposite-side bracket. 9. Lower axle assembly sufficiently (approximately 25mm), to allow for the removal of the monostrut. 10. Remove monostrut through RH wheel arch. 11. Clean relevant components and mating surfaces.
2012-07-21

Installation 1. Manoeuvre monostrut into position and align in body brackets.
2. Fit bolts securing monostrut to body brackets, DO NOT tighten bolts at this stage. 3. Raise axle assembly on jack, and guide monostrut into wishbone-tie assembly brackets.
4. Fit nuts and bolts securing monostrut to wishbone-tie assembly. Tighten nuts.
2012-07-21
5. Tighten bolts, securing monostrut to body brackets.
www.JagDocs.com
6. Fit suspension subframe mounting-brackets. 1. Position bracket to subframe. 2. Fit bush center bolt, DO NOT tighten bolt at this stage. 3. Fit bolts securing bracket to body, DO NOT tighten bolts at this stage. Repeat procedure on opposite-side mounting bracket.
2012-07-21
7. Tighten bolts securing mounting brackets to body. Repeat procedure on opposite-side mounting bracket.
8. Tighten mounting bracket, bush center bolts. Repeat procedure on opposite-side mounting bracket. 9. Remove jack from beneath axle assembly.
2012-07-21
10. Fit exhaust tail pipes to mountings.
www.JagDocs.com
11. Connect driveshaft to differential coupling. Align reference marks on couplings. Fit nuts and bolts. Tighten bolts. 12. Fit road wheel. Refer to section <<204-04>>. 13. Lower vehicle.
2012-07-21
Stabilizer Bar Mounting Frame Vehicles With: Convertible Top 64.25.12

Raise vehicle on a two-post lift. Refer to section <<100-02>>. 2. Remove RH rear wheel. Refer to section <<204-04>>.
3. Remove both rear struts. Remove ratchet straps securing drain tubes. Remove bolts. Remove struts.
2012-07-21
www.JagDocs.com
4. Disconnect driveshaft from the differential drive-coupling. 1. Reference-mark position of driveshaft coupling to differential coupling. 2. Remove nuts and bolts. Position driveshaft aside.
5. Release both exhaust tail pipes from rear mountings.
6.
CAUTION: To prevent damage to the axle assembly, position a piece of wood between the jack and the axle assembly.
Position a suitable jack under the suspension subframe, and support the weight of the axle assembly.
2012-07-21
7. Remove nuts and bolts securing monostrut to wishbone-tie assembly.
8. Remove bolts securing monostrut to body brackets.
2012-07-21
www.JagDocs.com
9. Remove both mounting brackets from suspension subframe. 1. Remove bush center bolt from bracket. 2. Remove bolts securing bracket to body. Remove bracket. Repeat procedure to remove opposite-side bracket. 10. Lower axle assembly sufficiently (approximately 25mm), to allow for the removal of the monostrut. 11. Remove monostrut through RH wheel arch. 12. Clean relevant components and mating surfaces.
Installation 1. Manoeuvre monostrut into position and align in body brackets.
2012-07-21
2. Fit bolts securing monostrut to body brackets, DO NOT tighten bolts at this stage. 3. Raise axle assembly on jack, and guide monostrut into wishbone-tie assembly brackets.
4. Fit nuts and bolts securing monostrut to wishbone-tie assembly. Tighten nuts.
2012-07-21
5. Tighten bolts, securing monostrut to body brackets.
www.JagDocs.com
2012-07-21
8. Tighten mounting bracket, bush center bolts. Repeat procedure on opposite-side mounting bracket. 9. Remove jack from beneath axle assembly.
2012-07-21
10. Fit exhaust tail pipes to mountings.
www.JagDocs.com
11. Connect driveshaft to differential coupling. Align reference marks on couplings. Fit nuts and bolts. Tighten bolts.
2012-07-21
12. Fit body struts. Align body struts. Fit and tighten bolts. Secure drain tubes to struts with tie straps. 13. Fit road wheel. Refer to section <<204-04>>. 14. Lower vehicle.
2012-07-21
Stabilizer Bar Mounting Frame Bushing Vehicles Without: Convertible Top 64.25.13
Adaptor Ring 204-116-01 (JD 143-1)
www.JagDocs.com
Anvil Adaptor 204-116-02 (JD 143-2)
Remover/Replacer Adaptor 204-116-08 (JD 143-8)
2012-07-21
Differential Strut - Bush Replacer 204-201 (JD 241) Removal 1. CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used. See section <<100-00>> for information.
Remove monostrut from vehicle. Refer to operation <<64.25.12>>.
2. Using a hydraulic press remove bush from monostrut. Using special tools, support monostrut on the press bed. Position special tool on top of bush and align tool with press ram. Press bush from monostrut. 3. Clean relevant parts.
2012-07-21

Installation
www.JagDocs.com
1. Using a hydraulic press, fit bush into monostrut. Support the bush-bore of the monostrut between plates on the press-bed. Position bush to bore. Position special tool on top of bush and align tool with press ram. Press bush into monostrut. 2. Fit monostrut to vehicle. Refer to operation <<64.25.12>> .
2012-07-21
Stabilizer Bar Mounting Frame Bushing Vehicles With: Convertible Top 64.25.13
Adaptor Ring 204-116-01 (JD 143-1)
Anvil Adaptor 204-116-02 (JD 143-2)
2012-07-21
Differential Strut - Bush Replacer 204-201 (JD 241) Removal 1. CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used. See section <<100-00>> for information.
www.JagDocs.com
Remove monostrut from vehicle. Refer to operation 64.25.12.70.
2. Using a hydraulic press remove bush from monostrut. Using special tools, support monostrut on the press bed. Position special tool on top of bush and align tool with press ram. Press bush from monostrut. 3. Clean relevant parts.
2012-07-21

Installation
1. Using a hydraulic press, fit bush into monostrut. Support the bush-bore of the monostrut between plates on the press-bed. Position bush to bore. Position special tool on top of bush and align tool with press ram. Press bush into monostrut. 2. Fit monostrut to vehicle. Refer to operation 64.25.12.70.
2012-07-21
Wheel Bearing 64.15.14

Hub Holding Tool 204-195 (JD227)
www.JagDocs.com
Hub Puller 204-011 (JD 1D)
Rear-Hub Remover 204-113 (JD 132)
2012-07-21
Bearing Cup Replacer Adaptor 204-118 (JD 550-4/1)
Bearing Cup Replacer Adaptor 204-118 (JD 550-4/2)
Driver Handle 100-013 (18G-134)
2012-07-21
Rear-hub spacer replacer 204-003 (JD 15)
www.JagDocs.com
Oil Seal Remover/Replacer 205-234 (JD 550-1)
1. Release handbrake. 2. Raise the vehicle on a four-post lift.
2012-07-21
3. Fully slacken but do not remove parking brake cable adjuster nut.
4. Release appropriate side parking brake cable from connecting clip.
2012-07-21
5. Withdraw parking brake cable through equalizer (LH side cable only). 6. Lower four-post lift. 7. Raise rear of vehicle to working height and support on stands. Refer to section <<100-02>>. 8. Remove rear wheel. Refer to section <<204-04>>.
www.JagDocs.com
9. Position special tool 204-195 on hub studs and install securing nuts.
2012-07-21
10. Slacken but do not remove hub to axle shaft securing nut. 11. Remove securing nuts and withdraw special tool (204-195) from hub. 12. Remove rear brake disc. Refer to 70.10.13. 13. Remove parking brake shoes. Refer to <<70.40.05>>.
14. Remove wheel speed sensor. Disconnect wheel speed sensor harness from sensor Remove wheel speed sensor securing bolt and withdraw sensor from hub carrier.
2012-07-21
15. Sever and discard wheel speed sensor harness tie strap and position harness for access.
www.JagDocs.com
16. Remove hub nut and collar. Remove nut. Remove locating collar.
2012-07-21
17. Install a thread protector on axle shaft.
18. Release hub from axle shaft. Position hub puller 204-011 on hub studs. Install securing nuts. Progressively tighten puller center bolt to release hub from axle shaft splines. 19. Remove hub puller and thread protector. Remove securing nuts and release puller from hub. Remove thread protector from axle shaft.
2012-07-21
www.JagDocs.com
20. Release parking brake cable from suspension mounting bracket. Remove cable retaining clip. Draw cable through suspension mounting bracket aperture.
21. Remove parking brake cable to hub carrier grommet.
2012-07-21
22. Remove back plate. Remove two bolts and two screws securing back plate to hub carrier. Withdraw back plate complete with parking brake cable.
23. Remove nut and washer from pivot pin.
10
2012-07-21
www.JagDocs.com
24. Remove hub and carrier from wishbone and axle shaft. Withdraw pivot pin and remove hub and carrier assembly.
25.
CAUTION: Note position of shims during removal. They must be returned to their original positions during installation.
Noting positions, remove shim from each end of pivot pin sleeve.
11
2012-07-21
26. Withdraw pivot pin sleeve from hub carrier.
27. Using a hydraulic press, remove hub from carrier. Place large section of special tool 204-113 on press bed, with recess in tool uppermost. Position hub carrier on tool, ensuring handbrake cable housing locates in tool recess. Position small section of special tool on hub. 204-113. Align tool to press-ram, and operate press to remove hub from hub carrier. 28. Place hub carrier on a work bench.
12
2012-07-21
29. Withdraw ABS rotor from hub carrier.
www.JagDocs.com
30. Remove outer seal and bearing assembly from hub carrier. Using a drift, remove and discard outer seal. Remove and discard outer bearing. Remove bearing spacer. Remove bearing shim.
13
2012-07-21
31. Remove inner seal and bearing from hub carrier. Using a drift, remove and discard inner seal. Remove and discard inner bearing.
32. Remove inner bearing cup from hub carrier. Position hub carrier on a block of wood. Using a drift, remove and discard inner bearing cup.
14
2012-07-21
www.JagDocs.com
33. Remove outer bearing cup from hub carrier. Position hub carrier on a block of wood. Using a drift, remove and discard outer bearing cup. 34. Clean hub and hub carrier.
Installation
1. Place hub carrier on press bed and insert inner bearing cup.
15
2012-07-21
2. Using a hydraulic press, install new inner bearing cup in hub carrier. Install special handle 18G134 to tool 204-118/2. Align special tool 204-118/2 to bearing cup. Align assembly to ram, and operate press to fully seat bearing cup.
3. Place hub carrier on press-bed and insert outer bearing cup.
16
2012-07-21
www.JagDocs.com
4. Using a hydraulic press, install outer bearing cup in hub carrier. 1. Install special handle 18G134 to tool 204-118/1 2. Align special tool 204-118/1 to bearing cup. Align assembly to ram, and operate press to fully seat bearing cup. 5. Place hub carrier on a work bench.
6. Install outer bearing in hub carrier.
17
2012-07-21
7. Install hub in outer bearing and carrier.
8. Install inner bearing in hub carrier. 1. Install bearing spacer to hub. 2. Install a 3.47 mm (maximum thickness) shim on hub. 3. Install inner bearing in hub carrier.
18
2012-07-21
9.
www.JagDocs.com
CAUTION: Do not allow press load to be directed on to hub studs.
Using a hydraulic press, install ABS-sensor rotor to hub. Place block of wood on press-bed. 1. Position hub carrier on block of wood. 2. Position ABS-rotor sensor to hub. Align assembly to press-ram, and operate press to install ABS-sensor rotor to hub.
10.
CAUTION: Do not use excessive force when levering hub.
Measure hub end-float. Secure hub carrier in vice. Install special tool JD15 to hub. 1. Install dial gauge JD 13A on hub carrier. 2. Using two levers, measure and record hub end-float.
19 2012-07-21

Remove special tools from hub carrier.
11. Using hydraulic press, remove hub and outer bearing assembly from carrier. 1. Position large section of special tool JD132 on press bed, with recess in tool upper most. 2. Position hub carrier on tool, ensuring parking brake cable housing locates in tool recess. 3. Position small section of special tool JD132 on hub. Align assembly to press-ram, and operate press to remove hub from hub carrier.
12. Remove ABS rotor and inner bearing from hub carrier. Remove ABS rotor. Remove inner bearing.
20
2012-07-21
www.JagDocs.com
13. Remove outer bearing assembly from hub. Remove bearing shim. Remove bearing spacer. Remove outer bearing. 14. Pack new inner and outer bearings with Shell Retinax 'A' grease.
15. Install outer bearing and using special tool 205-234, fully seat seal in hub carrier.
21
2012-07-21
16. Using a press, install hub in carrier/bearing assembly.
17. Install inner bearing assembly. 1. Install bearing spacer. 2. Install bearing shim. 3. Install inner bearing. 18. Determine hub end float. Measure and record end-float as a datum. Calculating from datum, select a shim that will achieve a 0.076 mm end-float.
22
2012-07-21
www.JagDocs.com
19. Install new bearing shim. 1. Install selected shim. 2. Install inner bearing. 3. Using special tool 205-234, install inner bearing seal. 20. Place block of wood on hydraulic press-bed and position hub carrier on block.
21.
CAUTION: Do not allow press load to be directed on to hub studs.
Align ABS rotor to hub and operate press to fully seat rotor on hub.
23
2012-07-21
22. Install pivot pin sleeve in carrier bearings.
23. Install shims on pivot pin sleeve in positions noted during removal.
24
2012-07-21
www.JagDocs.com
24. Position hub carrier assembly on wishbone. 1. Ensuring shims remain positioned on sleeve, position hub carrier assembly on wishbone.
25. Install hub assembly to wishbone and axle assembly. Position hub and carrier to wishbone and axle shaft. Install pivot pin in sleeve with threaded end at front.
25
2012-07-21
26. Install washer and nut on pivot pin, but DO NOT tighten nut.
27. Install hub on axle shaft . Route parking brake cable through hub carrier aperture and install grommet. Apply Loctite 270 to axle shaft splines and thread, and fully seat hub on shaft.
26
2012-07-21
28. Install locating collar and hub nut on axle shaft, but DO NOT tighten hub nut.
www.JagDocs.com
29. Tighten pivot pin nut to 90-110Nm .
27
2012-07-21
30. Install wheel speed sensor on hub carrier. Position sensor on hub carrier and install and tighten bolt to 7-10Nm. Connect wheel speed sensor harness to sensor.
31. Using new tie strap, secure wheel speed sensor harness to hub carrier. 32. Install handbrake shoes. Refer to operation <<70.40.05>>. 33. Install brake disc. Refer to operation 70.10.13.
28
2012-07-21
34. Position special tool 204-195 on hub studs and install nuts.
www.JagDocs.com
35. Tighten hub nut to 304-336Nm. 36. Remove securing nuts and withdraw special tool 204-195 from hub. 37. Install rear wheel. Refer to Section <<204-04>>. 38. Remove stands and lower vehicle onto wheels. Refer to section <<100-02>>. 39. Raise vehicle on four-post lift.
29
2012-07-21
40. Route parking brake cable through suspension mounting bracket and secure with clip.
41. Route parking brake LH cable through equalizer.
30
2012-07-21
42. Install LH cable in connecting clip. 43. Adjust parking brake cable. Refer to <<70.35.10>>. 44. Lower four-post lift 45. Apply parking brake.
www.JagDocs.com
31
2012-07-21
Wheel Hub Seal 64.15.15

Rear-Hub Remover 204-113 (JD 132)
2012-07-21
Oil Seal Remover/Replacer 205-234 (JD 550-1)
www.JagDocs.com
1. Release parking brake. 2. Raise the vehicle on a four-post lift.
2012-07-21
5. Withdraw parking brake cable through equalizer (LH side cable only). 6. Lower four-post lift. 7. Raise rear of vehicle to working height and support on stands. Refer to section <<100-02>>. 8. Remove rear wheel. Refer to section <<204-04>>.
2012-07-21
9. Position special tool (204-195) on hub studs and install securing nuts.
www.JagDocs.com
10. Slacken but do not remove hub to axle shaft securing nut. 11. Remove nuts and withdraw special tool (204-195) from hub. 12. Remove rear brake disc. Refer to 70.10.13. 13. Remove parking brake shoes. Refer to <<70.40.05>>.
2012-07-21
14. Remove wheel speed sensor. Disconnect wheel speed sensor harness connector. Remove sensor bolt and withdraw sensor from hub carrier.
15. Sever and discard wheel speed sensor harness tie strap and position harness for access.
2012-07-21
www.JagDocs.com
17. Install thread protector on axle shaft.
2012-07-21
18. Release hub from axle shaft. Position hub puller on hub studs. (204-011) Install nuts. Progressively tighten puller center bolt to release hub from axle shaft splines. 19. Remove hub puller and thread protector. Remove nuts and release puller from hub. Remove thread protector from axle shaft.
20. Release parking brake cable from suspension mounting bracket. Remove cable retaining clip. Draw cable through suspension mounting bracket aperture.
2012-07-21
www.JagDocs.com
22. Remove back plate. Remove two bolts and two screws securing back plate to hub carrier. Withdraw back plate complete with parking brake cable.
2012-07-21
24. Remove hub and carrier from wishbone and axle shaft. Withdraw pivot pin and remove hub and carrier assembly.
2012-07-21
25.
www.JagDocs.com
CAUTION: Note position of shims during removal. They must be returned to their original positions during installation.
Noting positions, remove shim from each end of pivot pin sleeve.
26. Withdraw pivot pin sleeve from hub carrier.
10
2012-07-21
27. Using a hydraulic press, remove hub from carrier. Place large section of special tool on press bed, with recess in tool uppermost. (204-113) Position hub carrier on tool, ensuring handbrake cable housing locates in tool recess. Position small section of special tool on hub. (204-113) Align tool to press-ram, and operate press to remove hub from hub carrier. 28. Place hub carrier on a work bench.
29. Withdraw ABS rotor from hub carrier.
11
2012-07-21
www.JagDocs.com
30. Remove outer seal and bearing assembly from hub carrier. Using a drift, remove and discard outer seal. Remove outer bearing. Remove bearing spacer. Remove bearing shim.
31. Remove inner seal and bearing from hub carrier. Using a drift, remove and discard inner seal. Remove inner bearing. 32. Using approved cleaning agents: Wash and thoroughly dry inner and outer bearings. Thoroughly clean hub carrier paying particular attention to bearing cups. Thoroughly clean hub.
12
2012-07-21

Installation 1. Grease bearings. Pack inner and outer bearing races with Shell Retinax 'A' grease: Apply a film of shell Retinax 'A' grease to bearing cups
2. Install outer bearing in hub carrier and fully seat new seal using special tool 205-234.
3. Apply a thin film of Shell Retinax 'A' grease to hub shaft and install hub in carrier/bearing assembly.
13
2012-07-21
www.JagDocs.com
4. Install inner bearing assembly and seal. 1. Install bearing spacer. 2. Install bearing shim. 3. Install inner bearing. 4. Install and fully seat new inner bearing seal using special tool 205-234. 5. Place block of wood on hydraulic press-bed and position hub carrier on block.
6.
CAUTION: Do not allow press load to be directed onto hub studs.
Align ABS rotor to hub and operate press to fully seat rotor on hub.
14
2012-07-21
7. Install pivot pin sleeve in carrier bearings.
8. Install shims on pivot pin sleeve in positions noted during removal.
15
2012-07-21
www.JagDocs.com
9. Install hub assembly to wishbone and axle assembly. Position hub and carrier to wishbone and axle shaft. Install pivot pin in sleeve with threaded end at front.
10. Install washer and nut on pivot pin, but DO NOT tighten nut.
16
2012-07-21
11. Install hub on axle shaft . Route parking brake cable through hub carrier aperture and install grommet. Apply Loctite 270 to axle shaft splines and thread, and fully seat hub on shaft.
17
2012-07-21
13. Tighten pivot pin nut to 90-110Nm .
www.JagDocs.com
18
2012-07-21
15. Using new tie strap, secure wheel speed sensor harness to hub carrier. 16. Install handbrake shoes. Refer to operation <<70.40.05>>. 17. Install brake disc. Refer to operation 70.10.13.
19
2012-07-21
19. Tighten hub nut to 304-336Nm. 20. Remove securing nuts and withdraw special tool (204-195) from hub. 21. Install rear wheel. Refer to Section <<204-04>>. 22. Raise rear of vehicle, remove stands and lower vehicle. Refer to section <<100-02>>. 23. Raise vehicle on four-post lift.
www.JagDocs.com
24. Route parking brake cable through suspension mounting bracket and secure with clip.
20
2012-07-21
25. Route parking brake cable through equalizer (LH side cable only).
26. Install parking brake cable in connecting clip. 27. Adjust parking brake cable. Refer to <<70.35.10>>. 28. Lower four-post lift 29. Apply parking brake.
21
2012-07-21
Wheel Knuckle Bushing 64.15.24

www.JagDocs.com
Driver Handle 100-013 (18G 134)
2012-07-21
Bearing Cup Replacer Adaptor 204-120 (JD 550-6)
1. Release parking brake. 2. Raise the vehicle on a four-post lift.
2012-07-21
www.JagDocs.com
5. Withdraw parking brake cable through equalizer (LH side cable only). 6. Lower four-post lift. 7. Raise rear of vehicle to working height and support on stands. Refer to section <<100-02>>. 8. Remove road wheel. Refer to section <<204-04>>.
2012-07-21
10. Slacken but do not remove hub to axle shaft securing nut. 11. Remove nuts from studs and withdraw special tool (204-195) from hub. 12. Remove rear brake disc. Refer to 70.10.13. 13. Remove handbrake shoes. Refer to <<70.40.05>>.
2012-07-21
www.JagDocs.com
14. Remove wheel speed sensor. Disconnect wheel speed sensor harness connector. Remove sensor bolt and withdraw sensor from hub carrier.
15. Remove wheel speed sensor harness tie strap and position harness for access.
2012-07-21
2012-07-21
18. Install thread protector on axle shaft.
www.JagDocs.com
19. Release hub from axle shaft. Position hub puller 204-011 on hub studs. Install securing nuts. Progressively tighten puller center bolt to release hub from axle shaft splines. 20. Remove nuts and release puller from hub. 21. Remove thread protector from axle shaft.
2012-07-21
22. Release handbrake cable from suspension mounting bracket. Remove cable retaining clip. Draw cable through suspension mounting bracket aperture.
2012-07-21
www.JagDocs.com
24. Remove back plate. Remove four screws securing back plate to hub carrier. Withdraw back plate complete with parking brake cable.
25. Remove hub and carrier. Withdraw pivot pin. Remove hub and carrier assembly from wishbone and axle shaft.
2012-07-21
26. Remove shim from each end of pivot pin sleeve.
27. Withdraw pivot pin sleeve from hub carrier. 28. Secure hub carrier in a vice.
10
2012-07-21
29. Remove and discard bearings from hub carrier.
www.JagDocs.com
30. Remove bearing cup from hub carrier. Position hub carrier on a piece of wood. Position a long tapered drift in housing bore recess. Remove bearing cup. 31. Repeat procedure to remove opposite end bearing cup and discard both cups. 32. Remove hub carrier from vice. 33. Thoroughly clean all components.
11
2012-07-21

Installation
1. Using a hydraulic press, install new bearing cups in hub carrier. Using special tool 100-013 and adapter 204-120, align bearing cup to hub carrier. Align assembly to ram, and operate press to fully seat bearing cup. Repeat procedure to fit other bearing cup. 2. Secure hub carrier in a vice.
3. Install pivot pin sleeve in hub carrier. 4. Pack new pivot bearings with Shell Retinax 'A' grease.
12
2012-07-21
www.JagDocs.com
5. Install pivot bearings in hub carrier. 1. Slide bearing over pivot sleeve and seat in bearing cup. 2. Install a 3.905 mm (minimum size) shim to sleeve. Repeat procedure to install opposite end bearing and shim.
6. Press pivot pin sleeve into hub carrier. 1. Install pivot pin in sleeve. 2. Position a piece of tube over part of pin thread. 3. Install pivot pin nut and tighten until shims fully seat on pivot sleeve. Remove nut and tube.
13
2012-07-21
7. Measure bearing pre-load. 1. Position a flat washer to abut shim. 2. Install pivot pin nut. 3. Using a feeler gauge measure and record gap between shim and washer.
8. Remove shims from hub carrier. 1. Remove nut. 2. Remove washer. 3. Remove pivot pin. 4. Remove both shims from pivot sleeve. 9. Using 3.905mm shim and pre-load measurements as a datum, select two new shims of equal thickness to provide a pre-load measurement of 0.076 mm.
14
2012-07-21
10. Position shims on pivot sleeve.
www.JagDocs.com
11. Press selected shims into hub carrier. 1. Install pivot pin in sleeve. 2. Position piece of tube over part of pivot pin thread. 3. Install nut to fully seat shims on sleeve. 12. Remove nut, tube and pivot pin from hub carrier.
15
2012-07-21
13. Position hub carrier assembly on wishbone. 1. Ensuring shims remain positioned on sleeve, position hub carrier assembly on wishbone.
14. Secure hub carrier to wishbone. Install pivot pin. Install pivot pin washer Install but do not tighten pivot pin nut.
16
2012-07-21
www.JagDocs.com
15. Install hub on axle shaft . Route handbrake cable through hub carrier. Apply Loctite 270 to axle shaft splines and thread, and fully seat hub on shaft.
17
2012-07-21
17. Tighten pivot pin nut to 90-110Nm.
18
2012-07-21
19. Using new tie strap, secure wheel speed sensor harness to hub carrier. 20. Install parking brake shoes. Refer to <<70.40.05>>. 21. Install brake disc. Refer to operation 70.10.13.
www.JagDocs.com
22. Install special tool (204-195) on studs and install nuts.
19
2012-07-21
23. Tighten hub nut to 304-336Nm. 24. Remove nuts and withdraw special tool (204-195) from hub studs. 25. Install rear wheel. Refer to section <<204-04>>. 26. Raise rear of vehicle, remove stands and lower vehicle. Refer to section <<100-02>>. 27. Raise vehicle on four-post lift.
28. Route parking brake cable through equalizer (LH side cable only).
20
2012-07-21
29. Install cable in connecting clip. 30. Adjust parking brake cable. Refer to <<70.35.10>>. 31. Lower four-post lift. 32. Apply parking brake.
www.JagDocs.com
21
2012-07-21
1999 XK RANGE - Wheels and Tires - 204-04
Torques Component Wheel nut - steel wheel Wheel nut - alloy wheel Spare wheel retainer - temporary or full size spare Nm 68 - 82 88 - 102 3
Inflation Pressures for Recommended Tires - Normal Tire Size 17 inch 18 inch Front 2.2 bar (32 lbf/in2) 2.2 bar (32 lbf/in2) Rear 2.3 bar (34 lbf/in2) 2.3 bar (34 lbf/in2)
Inflation Pressures for Recommended Tires - Maximum Comfort Speeds up to 160 km/h (100 mph) CAUTION: Only check tire pressures when the tires are cold, (when the tires have been operational wait until the tires have cooled to ambient temperature before checking the pressures). Tire Size 17 inch 18 inch Front 1.7 bar (26 lbf/in2) 1.7 bar (26 lbf/in2) Rear 1.9 bar (28 lbf/in2) 1.9 bar (28 lbf/in2)
Inflation Pressure for Temporary Spare (space saver) CAUTION: Do not exceed 80km/h (50mph) when the temporary spare wheel is installed. Tire Size 3.5' X 18' Front 4.1 bar (60 lbf/in2) Rear 4.1 bar (60 lbf/in2)
Tires without Jaguar approval Tires other than those recommended must be inflated to the following cold inflation pressure (front and Rear): 3.0 bar, 44lbf/in2 When using non-Jaguar approved winter tires, inflate to the recommended tire pressure and do not exceed the tire's speed capability.
Wheel Application NOTE: Refer to (<<204-04>>) Description and Operation Section for Wheel Designs. Wheel Standard cast alloy Optional cast alloy - Front Optional cast alloy - Rear Temporary spare Cast alloy - Front Cast alloy - Rear Size 8J X 17 8J X 18 9J X 18 3.5J X 18 8J X 18 9J X 18 Model Application XK8 XK8 XK8 XK8 XKR XKR
2012-07-21
Recommended Tires CAUTION: The 9J X 18 rear wheels and tires MUST NOT be installed to the front of the vehicle. Manufacturer Wheel Size: XK8 Standard - 8J X 17 Pirelli Wheel Size: XK8 Optional Front - 8J X 18 Pirelli Wheel Size: XK8 Optional Rear - 9J X 18 Pirelli Wheel Size: XK8 and XKR Temporary Spare - 3.5J X 18 Pirelli Wheel Size: XKR Front - 8J X 18 Pirelli Wheel Size: XKR Rear - 9j X 18 Pirelli P Zero 255 / 45 R 18 P Zero 245 / 45 R 18 135 / 80 R 18 P Zero 255 / 45 R 18 P Zero 245 / 45 R 18 Type P Zero Size 245 / 50 R 17
www.JagDocs.com
Recommended Winter Tires CAUTION: Only use winter tires in complete sets of the same type and size. Manufacturer Pirelli Pirelli Type Winter 210 M+S Winter 210 M+S Size 245 / 50 R 17 245 / 45 R 18
2012-07-21
Wheels and Tires
XK8 Wheel Designs
Item 1 2
Description Standard 8J X 17 Alloy Wheel Optional 8J X 18 Alloy Wheel - Front Optional 9J X 18 Alloy Wheel - Rear
XKR Wheel Designs
Item -
Description 8J X 18 Alloy Wheel - Front 9J X 18 Alloy Wheel - Rear
2012-07-21

Wheel Changing
CAUTION: Do not allow grease to contaminate the wheel stud threads and wheel nut to wheel mating surface, as this may cause the nuts to loosen. NOTE: When installing the wheel, smear a thin layer of grease onto the hub mounting face and spigot; and wheel mounting face and spigot hole, to prevent the wheel corroding on to the hub. For wheel changing procedure refer to <<74.20.05>>.
Locking Wheel Nuts
www.JagDocs.com
2012-07-21

Item 1 2 3 4 Description Locking wheel nut Cover Cover removal tool Wrench socket
Locking wheel nuts are fitted as standard to UK vehicles. One locking wheel nut is fitted to each road wheel and can only be removed by using the correctly coded socket. For road wheels with exposed wheel nuts, each locking wheel nut is provided with a cover, which is removed using the cover removal tool. Locking wheel nuts have different coded keyway combinations with corresponding coded sockets. The correct socket, and cover removal tool are supplied with the vehicle toolkit. Sets of sockets are available to Jaguar dealers.
Temporary Spare Wheel

In certain markets, the spare wheel supplied with the vehicle is of the temporary-use type, it is narrower than the normal road wheel and takes up less room in the luggage compartment. NOTE: When using this type of spare wheel note that: Speed must not exceed 80 km/h (50 mph). The normal road wheel must be reinstalled as soon as possible. Only one temporary wheel may be installed to the vehicle. Traction control (where fitted) must be switched OFF.
Tires
The radial ply tires shown in the <<204-04>> Specification Section are recommended by Jaguar to meet the high speed performance of the vehicle. Only tires of identical specification may be fitted as replacements. Under no circumstances must cross-ply tires be fitted.
Tire Inflation Pressures

All recommended tires, including winter tires, must be inflated to the pressures shown in the <<204-04>> Specification Section. Inflation pressures must only be checked when the tires are cold.
Tire Replacement and Wheel-Interchanging

When renewal of tires is necessary, it is preferable to fit a complete set. If two replacement tires are fitted (to one axle), they must be of the same manufacturer and type as those on the other axle. No attempt must be made to interchange wheels from the front to the rear or vice-versa, as wear produces a characteristic pattern on each tire depending upon its position on the vehicle. If this 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 before installing to the vehicle.
Winter Tires
NOTE: Speed must not exceed 210 km/h (131 mph) when winter tires are installed. Jaguar recommended winter tires as specified in <<204-04>> Specification Section must only be fitted in complete four-wheel sets of the same type and size.
2012-07-21
Snow Chains and Spike Spider Traction System

Jaguar recommended snow chains, must only be installed when using 17 inch wheels with 245/50 R17 winter tires. The Jaguar recommended spike spider traction system can be used on all wheel and tire sizes, except the temporary spare wheel. NOTE: When using snow chains or the spike spider traction system, note that: Snow chains and the spike spider traction system must only be fitted to the rear wheels. Only Jaguar recommended snow chains or spike spider traction system must be used. The maximum permissible speed with winter tires, and snow chains or spike spider traction system fitted is 48 km/h (30 mph). Traction control (where fitted) must be switched OFF when using snow chains or the spike spider traction system. Snow chains and the spike spider traction system must not be used on roads which are clear of snow.
Asymmetric Tires
Some tires recommended by Jaguar are asymmetric. Inner and outer markers embossed on the tire walls must be observed to ensure the correct installation of the tire to the wheel.
www.JagDocs.com
Rotational Indicators
Some tires recommended by Jaguar are directional, these tires have an embossed arrow on the tire wall to show the direction of rotation of the tire when installed.
Tread Wear Indicator

NOTE: Tire condition must comply with prevailing local legislation. Tread wear indicators are molded into the bottom of the tread grooves across the width of the tire. The tire must be renewed when tread wear indicators become visible at the surface of the tread.
2012-07-21
Wheels and Tires

General Notes
1. Factory installed tires and wheels are designed to provide optimum ride and handling characteristics when inflated to the recommended inflation pressures, with vehicle loads not exceeding the full-rated load capacity. 2. Correct tire pressures and driving technique have an important influence on tire life. Heavy cornering, excessively rapid acceleration and unnecessary sharp braking increase tire wear. 3. Replacement tires should follow the recommended: Size. Speed rating. Load range. Radial construction type. 4. The use of any other size or type of wheel / tire may seriously affect: Safety. Ride. Handling. Speedometer / odometer calibration. Vehicle ground clearance. Tire clearance between body and chassis. Wheel bearing life. Brake cooling. 5. Wheels must be renewed when: Impact damaged. Heavily corroded. Porous Wheel stud holes or seats become damaged. They have excessive radial or lateral runout.
Safety Notes
WARNING: DO NOT MIX DIFFERENT TYPES OF TIRES ON THE SAME VEHICLE, HANDLING MAY BE SERIOUSLY AFFECTED RESULTING IN LOSS OF CONTROL. WARNING: DO NOT MIX DIFFERENT TYPES OF TIRES ON THE SAME VEHICLE, HANDLING MAY BE SERIOUSLY AFFECTED RESULTING IN LOSS OF CONTROL. WARNING: CORRECT TIRE ROTATIONAL DIRECTION IS IMPORTANT, OBSERVE THE DIRECTION OF THE SIDEWALL MOLDED INDICATORS. WARNING: A TIRE AND WHEEL MUST ALWAYS BE CORRECTLY MATCHED. WIDER OR NARROWER TIRES THAN RECOMMENDED COULD CAUSE DANGER THROUGH SUDDEN DEFLATION. WARNING: WHEN USING THE TEMPORARY SPARE WHEEL, SPEED MUST NOT EXCEED 80 KM/H (50 MPH). DRIVE WITH CAUTION AND REPLACE WITH THE SPECIFIED WHEEL / TIRE ASSEMBLY AS SOON AS POSSIBLE. WARNING: TRACTION CONTROL (IF AVAILABLE) MUST NOT BE ENGAGED WITH THE TEMPORARY SPARE WHEEL
2012-07-21

FITTED. WARNING: WHEN CHANGING A WHEEL, ENSURE THAT THE VEHICLE CANNOT MOVE. ALWAYS APPLY THE PARK BRAKE AND SELECT TRANSMISSION 'P' POSITION. WARNING: NEVER RUN THE ENGINE WITH ONE WHEEL OFF THE GROUND, FOR EXAMPLE, WHEN CHANGING THE WHEEL. THE VEHICLE COULD MOVE. WARNING: TIGHTEN THE WHEEL NUTS TO SPECIFICATION. WHEELS MAY COME LOOSE IF OVER OR UNDER TIGHTENED. WARNING: USE WHEELS AND WHEEL NUTS DESIGNED FOR XK SERIES VEHICLES ONLY. AFTERMARKET WHEELS OR WHEEL NUTS MAY NOT FIT OR FUNCTION PROPERLY AND COULD CAUSE INJURY OR DAMAGE.
Inspection and Verification

To maximize tire performance, inspect the tires frequently for signs of: Uneven wear. Incorrect tire pressure. Wheel imbalance. Cuts. Abrasions. Bulges (blister). Ply separation. Embedded objects. Impact damage. Inspection should be more frequent when: Continuous high speed operation is required. Rapid or extreme temperatures changes occur. Road surfaces are rough. Roads are littered with debris.
www.JagDocs.com
Tread Wear Indicator

NOTE: Tire condition must comply with prevailing local legislation. New tires must be installed if the wear indicators are exposed or if there is severe shoulder wear. Shoulder wear is usually caused by either excessive camber or toe on tires.
Tire Vibration Diagnosis

A tire vibration diagnostic procedure always begins with a road test. The road test and the customer interview (if available) will provide much of the information needed to find the source of vibration. During the road test, drive the vehicle on a road that is smooth and free of undulations. If vibration is apparent, note and record the following:
2012-07-21
The speed at which the vibration occurs. What type of vibration occurs in each speed range - mechanical or audible. How the vibration is affected by changes in the following: -engine torque -vehicle speed -engine speed. Type of vibration - sensitivity: - torque sensitive, - vehicle speed sensitive, - or engine speed sensitive. The following explanations will help isolate the source of vibration.
Torque Sensitive
This means that the condition can be improved or made worse by accelerating, decelerating, coasting, maintaining a steady vehicle speed, or applying engine torque.
Vehicle Speed Sensitive

This means that the vibration always occurs at the same vehicle speed and is not affected by engine torque, engine speed or gear selection.
Engine Speed Sensitive

This means that the vibration occurs at varying vehicle speeds when a different gear is selected. It can sometimes be isolated by increasing or decreasing engine speed with the transmission in neutral or by stall testing with the transmission in gear. If the condition is engine speed sensitive, the cause is probably not related to tires. If the road test indicates that there is tire wine, but no shake or vibration, the noise originates with the contact between the tire and the road surface. A thumping noise usually means that the tire is flat or has soft spots making a noise as they slap the roadway. Tire whine can be distinguished from axle noise, as tire whine remains the same over a range of speeds.
Symptom Chart
Condition(s): Uneven tire wear. Possible Source(s): Incorrect tire inflation. Action(s) to take: Correct to specification. Possible Source(s): Excessive radial and lateral runout. Action(s) to take: Renew tire or wheel. Possible Source(s): Out of specification steering geometry.
2012-07-21
Action(s) to take: Realign steering geometry: Refer to Section <<204-00>>. Possible Source(s): Worn ball joint. Action(s) to take: Renew damaged component, realign steering geometry. Possible Source(s): Worn tie-rod end. Action(s) to take: Renew component, realign steering geometry. Possible Source(s): Incorrect tire / wheel usage. Action(s) to take: Install correct tire and wheel combination. Possible Source(s): Loose or leaking shock absorbers. Action(s) to take: Tighten or Renew as necessary: Refer to Section <<204-00>>. Possible Source(s): Suspension geometry out of alignment. Action(s) to take: Check and adjust: Refer to Section <<204-00>>. Possible Source(s): Loose, worn or damaged suspension components. Action(s) to take: Inspect, Repair or Renew as necessary. Possible Source(s): Wheel and tire assembly out of balance. Action(s) to take: Balance wheel and tire assembly. Possible Source(s): Excessive lateral or radial runout of wheel or tire. Action(s) to take: Check, Repair or Renew as required. Tires show excess wear on edge of treads. Possible Source(s): Tires under-inflated. Action(s) to take: Correct pressure to specification. Possible Source(s): Vehicle overloaded.
www.JagDocs.com
2012-07-21
Action(s) to take: Correct to specification. Tires show excess wear on edge of treads (with tire pressures correct). Possible Source(s): Incorrect toe setting. Action(s) to take: Set to specification: Refer to Section <<204-00>>. Tires show excess wear in center of tread. Possible Source(s): Tires over-inflated. Action(s) to take: Correct pressure to specification Wheel mounting is difficult. Possible Source(s): Incorrect application or mismatched parts, including wheel studs and wheel nuts. Corroded, worn or damaged parts. Action(s) to take: Follow the manufacturer's specifications. Clean or Renew. Wobble or shimmy affecting wheel runout. Possible Source(s): Damaged wheel (eventually damaging wheel bearings and causing uneven tire wear). Action(s) to take: Inspect wheel rims for damage and runout. Renew as required. Vehicle vibrations from wheels and tires. Possible Source(s): Tires / wheels mismatched. Action(s) to take: Install correct tire / wheel combination. Possible Source(s): Inflation pressure too high or low. Action(s) to take: Correct pressure to specification Possible Source(s): Uneven tire wear. Action(s) to take: Refer to Diagnosis and Testing in this section. Possible Source(s): Wheel and tire assembly imbalance. Action(s) to take:
2012-07-21

Balance wheel and tire assembly.
Possible Source(s): Brake disc imbalance. Action(s) to take: Check brake disc cooling fins for mud and foreign material. Check for damage or disc heavy spot. Refer to Section <<206-00>>. Possible Source(s): Damaged or distorted wheel. Action(s) to take: Renew wheel. Possible Source(s): Excessive radial run-out of wheel or tire. Excessive lateral run-out of wheel or tire. Action(s) to take: Renew wheel or tire. Possible Source(s): Incorrectly seated tire. Action(s) to take: Remount the tire. Possible Source(s): Loose wheel mountings: damaged wheel studs, wheel nuts, worn or broken wheel hub face or foreign material on mounting faces. Action(s) to take: Tighten or Renew worn or damaged parts. Clean mounting surfaces. Possible Source(s): Defective wheel bearings. Action(s) to take: Renew worn or damaged bearing sets: Refer to Section <<204-00>>. Possible Source(s): Water in tires. Action(s) to take: Remove water. Damaged wheel stud threads. Possible Source(s): Sliding wheel across the wheel studs during installation. Loose wheel nuts. Action(s) to take: Renew wheel studs. Broken wheel studs. Possible Source(s): Loose or overtightened wheel nuts. Action(s) to take: Renew wheel studs.
6 2012-07-21
www.JagDocs.com
Corrosion / contamination streaks from wheel stud holes. Possible Source(s): Loose wheel nuts. Action(s) to take: Check complete assembly. Renew damaged parts. Apply correct torque setting. Damaged wheel nuts. Possible Source(s): Loose wheel assembly. Over-tightened wheel nuts. Action(s) to take: Renew wheel nuts. Apply correct torque setting. Seized wheel nuts. Possible Source(s): Corrosion Action(s) to take: CAUTION: Do not permit lubricant to contaminate wheel hub stud holes or wheel nut seats. If corrosion is light, wire brush away corrosion. If corrosion is excessive renew wheel studs and wheel nuts. Lubricate the first three threads of wheel studs with a graphite based lubricant.
2012-07-21
Wheel and Tire 74.20.05

Removal CAUTION: Do not use heat to loosen a seized wheel nut: heat will change the metal's properties and damage wheel bearing and brake caliper seals.
www.JagDocs.com
1. Loosen, but do not remove wheel nuts. 2. Raise vehicle and support on stands. Refer to Section <<100-02>>.
3. Remove wheel and tire assembly. 1. Remove wheel nuts. 2. Remove wheel.
2012-07-21
Installation
1.
CAUTION: Do not allow grease to contaminate the wheel stud threads and wheel nut to wheel mating surface, as this may cause the nuts to loosen. NOTE: To prevent the wheel corroding on to the hub, smear a thin layer of grease onto the hub mounting face and spigot; and wheel mounting face and spigot hole.
Install the wheel and tire assembly. 1. Install wheel. 2. Install wheel nuts to secure wheel in position. 3. Lower vehicle. 4. Tighten wheel nuts in a diagonal sequence to: Steel wheel 68-82 Nm. Alloy wheel 88-102 Nm.
2012-07-21
1999 XK RANGE - Vehicle Dynamic Suspension - 204-05
Vehicle Dynamic Suspension

Damping System Description
Movement of each road spring is independently damped by a telescopic, hydraulically-controlled shock absorber. Each shock absorber is installed coaxially within the road spring. Front springs are located between spring seats on the shock absorber body and rod, rear springs are located between seats on the shock absorber and the lower wishbone.
Front Shock Absorber Arrangement
www.JagDocs.com
Item 1 2 3
Description Shock Absorber Road Spring Adaptive Damper Harness Connector
2012-07-21

Rear Shock Absorber Arrangement
Item 1 2 3 4
Description Shock Absorber Road Spring Lower Wishbone Spring Upper seat
Operation
As a shock absorber rod rises and falls in unison with road spring movement, that movement is damped by controlling the flow of fluid from one end of a chamber to the other within each shock absorber. Any increase in the restriction of fluid flow within a shock absorber results in a corresponding increase in damping action and a firmer ride.
Adaptive Damping System Description

The Adaptive Damping System available as an option, matches damping effect with vehicle driving forces, to provide optimum ride and handling performance. The system which is completely automatic and requires no drive input, comprises the following components: Four adaptive damping units installed in the normal shock absorber positions. These are identified by a harness connector incorporated in the top of each unit. An adaptive damping control module (ADCM) installed in the trunk adjacent to the battery.
2 2012-07-21
Two vertical movement sensors (accelerometers), one installed on the bulkhead below the air conditioning unit, the other in the trunk below the fuel tank. A lateral movement sensor (accelerometer) installed within the RH side false bulkhead.
Operation
The four adaptive damping units are simultaneously switched to either firm or soft setting to suit circumstances. When the vehicle is stationary, the system adopts the firm setting to minimize vehicle pitch during initial acceleration. From 8km/h (5mph) upwards, the system reverts to the soft setting until otherwise switched by the ADCM. On detecting cornering forces, the lateral sensor transits signals to the ADCM, which in turn switches the damping units to the firm setting, reducing vehicle roll-rate and improving wheel control. On detection of a bump or depression in the road, the vertical sensors transmit signals to the ADCM, which in turn switches the damping units to the firm setting to minimize vehicle body movement. Under braking conditions, the ACDM, on receipt of a signal, commences calculation of vehicle deceleration. When deceleration exceeds a pre-determined threshold, the ADCM switches the damping units to the firm setting, reducing vehicle pitch rate and improving wheel control. Following completion of a cornering manoeuvre, negotiation of road surface undulations, or heavy braking, that has necessitated switching to the firm setting, the ADCM always returns the damping units to the soft setting. In the event of failure of the Adaptive Damping System, the damping units automatically revert to the Firm setting, ensuring that the vehicle remains safe to drive under all circumstances. The driver will be alerted to such a failure by illumination of a 'SUSPENSION FAULT' warning on the fascia message center and the amber warning light in the instrument cluster.
www.JagDocs.com
Adaptive Damping Components
2012-07-21
Item 1 2 3 4 5 6 7 8
Description Adaptive Damper Unit Front-Right Hand Accelerometer-Lateral Accelerometer Vertical-Front Adaptive Damper Unit Rear-Right Hand Electronic Control Module (ADCM) Accelerometer Vertical-Rear Adaptive Damper Unit Rear-Left Hand Adaptive Damper Unit Front-Left Hand
ADCM / Component Relationship
2012-07-21
Item 1 2 3 4 5 6 7 8 9 10
Description Power Ignition Supply Ground Vertical Accelerometer - Front Vertical Accelerometer - Rear Lateral Accelerometer Brake Operation Signal Vehicle Speed Signal Output to Fascia Message Centre Damper Control Signals
Three accelerometers sense vehicle body movement and generate an analogue voltage (+5V max.) output, which is proportional to the vehicle body movement. These voltages are supplied to the Adaptive Damping Control Module (ADCM). At 0g. (no movement of the body) each vertical accelerometer outputs approximately 2.5V steady voltage. The lateral accelerometer outputs approximately 1.5V. The voltage output due to body movement is proportional to acceleration in the acceleration axis, up to approximately 4.5V and down to approximately 0.5V. The ADCM is hardwired to the Instrument Cluster. Should a fault occur, the ADCM grounds the System Error line which switches on the amber warning lamp and displays the message SUSPENSION FAILURE on the message centre.
www.JagDocs.com
Connector Pin Identity Chart for BT069
2012-07-21
Pin Number 1 2 3 10 11 13 14 15 18 20 21 22 24 25 26 27 28 30 31 32 33 34
Circuit
Circuit Function System Error Output, to Instrument Cluster Traction Over-ride, from ABS/TCCM Ground K-Line to Diagnostic Socket Ignition Supply +12V Control Signal (+ve) Output to Left Hand Rear Damper Control Signal (+ve) Output to Right Hand Front Damper Control Signal (+ve) Output to Right Hand Rear Damper Ground Lateral Accelerometer Input Front Vertical Accelerometer Input Rear Vertical Accelerometer Input Road Speed Input From Instrument Cluster Power Output +5V to Supply Accelerometers Brake Pedal Input Battery Supply +12V L-Line to Diagnostic Socket Control Signal (+ve) Output to Left Hand Front Damper Control Signal (-ve) Output to Left Hand Front Damper Control Signal (-ve) Output to Left Hand Rear Damper Control Signal (-ve) Output to Right Hand Front Damper Control Signal (-ve) Output to Right Hand Rear Damper
2012-07-21
Vehicle Dynamic Suspension

Refer to PDU User Guide
Refer to the PDU User Guide for details of diagnosing and testing the Adaptive Damping System. The PDU interrogates the ADCM directly via the K and L lines to the diagnostic socket. The PDU will give an indication of the integrity of each electronic and electrical component. It will indicate, for example, that the accelerometers are not broken, but not that they functioning correctly when the vehicle is in motion. However, it is exceptional for an accelerometer to function incorrectly in its dynamic mode if it is proved to be functioning when static.
Basic Checks
Before changing any component, refer to the circuit diagrams of the manual and check the continuity of relevant harness circuits; in some instances, the PDU will not differentiate between a faulty component and a damaged connection or wiring. Check the System Error line from the ADCM to the Instrument Cluster - Fascia Harness pin FC025/006. Check the Road Speed Output from the Instrument Cluster to the ADCM - Fascia Harness pin FC026/007. Check any relevant connections to confirm that the connection is electrically sound and that a terminal pin has not been pushed back into the connector shell, ie. not making a connection to its mating pin / socket. Check the following fuses in the luggage compartment fusebox: Fuse No. 2 (20A) and Fuse No. 4 (5A).
www.JagDocs.com
2012-07-21
Adaptive Damping Module 86.56.35

Removal 1. Remove trunk floor carpet. 2. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
3. Remove adaptive damping control module nuts.
4. Position control module for access and disconnect harness connector. 5. Remove control module from vehicle.
2012-07-21
Installation 1. Position control module in trunk and connect harness connector. 2. Finally position control module and install nuts. 3. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>. 4. Install trunk floor carpet.
www.JagDocs.com
2012-07-21
1999 XK RANGE - Driveline System - General Information - 205-00
Driveline System
Details of the Driveline System can be found in sections <<205-01>> and <<205-02>>.
2012-07-21
1999 XK RANGE - Driveshaft - 205-01
Torques Component Bolt M12 - Jurid flexible coupling to transmission flange Bolt M10 - Driveshaft to final drive unit flange Nm 75-88 51-69
www.JagDocs.com
2012-07-21
Driveshaft
Driveshaft Joint and Couplings
Item 1 2 3
Description Jurid flexible coupling Sliding joint Hookes joint
The one-piece aluminum driveshaft incorporates a flexible (Jurid) drive coupling at the transmission flange, a sliding joint aft of the transmission and a Hookes joint at the differential. The drive couplings and sliding joint allow for variations in the driveshaft alignment due to the relative movement of components.
2012-07-21
Driveshaft 47.15.01
Torque Adaptor Snap-on FRDHM13 (Re-worked) Removal 1. Special Tool Notes The depth of the adaptor ring end must be reduced to approximately 6,0mm. An allowance for the increase in leverage must be made when using the adaptor. 2. Torque wrench setting using may be achieved using one of the following methods: 1. Torque wrench calibration machine ; apply the specified torque at the calibrator (using the adaptor) and note the corresponding reading at the torque wrench 2. Formula to calculate the effect of the added length RS = (W x T) / (W + L)WhereRS = Torque wrench settingW = Effective length of the torque wrenchT = Torque specificationL = Length of adaptor 3. Using a torque wrench 330 mm (0,33 m) long and an adaptor 50mm (0,05 m) long, calculate as follows for a specified torque of 60Nm: RS = (0,33 x 60) / (0,33 + 0,05) = 52,1Nm
www.JagDocs.com
Removal CAUTION: To preserve 'drive line' refinement, individual parts, other than fixings, MUST NOT be renewed. In the event of any balance or driveshaft component related problem, the complete assembly must be renewed. Under no circumstances may the flexible coupling be removed from the driveshaft (or its fixings be loosened). Do not drop or subject the driveshaft to damage.
1. Remove the exhaust system center section, <<30.10.18>>
2012-07-21
2. Remove the parking brake relay lever mounting bracket,
3. Remove the driveshaft (Jurid coupling) from the transmission flange. If required, 'match mark' the transmission flange and coupling Unscrew the fixings (3)
2012-07-21
4. Move the sliding joint into the minimum length position.
www.JagDocs.com
5. Remove the driveshaft from the final drive flange If required, 'match mark' the final drive flange and coupling Unscrew the fixings (4)
Installation 1. Installation is the reverse of the removal procedure, noting that; Renew the driveshaft fixings and tighten to specification
2012-07-21
2. NOTE: See 'Special tool' notes Refer to the illustration
3. Refer to the illustration Renew the driveshaft fixings
2012-07-21
1999 XK RANGE - Rear Drive Axle/Differential - 205-02
Lubricants, Fluids, Sealants and Adhesives Unit Final Drive Hub spline to Axle shaft Specification Shell Spirax Super TS 90 Loctite 270 Studlock or equivalent
Capacities Unit Final Drive Liters 1,80
Torques Component Bolt - Final drive nose plate Bolt - 'A' frame to final drive Nut 'A' frame to rear mounting bracket Nut - Axle shaft to final drive flange Nut - Axle shaft to hub Nut - Damper lower fixing Bolt M12 - Jurid flexible coupling to transmission Bolt M10 - Driveshaft to final drive unit flange Nut - Lower fulcrum Nut - Pendulum to final drive Nut - Stabilizer to wishbone Nut - Tie rod to final drive Nut - Tie rod to wide mounting bracket Nut - Wishbone pivot Nut - Wishbone tie to final drive Nut 'A' frame to wide mounting bracket Nm 39 - 51 90 - 110 85 - 115 81 - 99 304 - 336 80 - 100 75 - 88 51 - 69 90 - 110 160 - 200 30 - 40 85 - 105 85 - 115 80 - 100 85 - 105 85 - 105
www.JagDocs.com
2012-07-21
Differential Output Shaft End Float Check
1. Disconnect the battery ground lead 2. Raise the vehicle for access
3. Mount a dial test indicator (DTI) to the differential housing with the probe resting on the axle shaft flange (the DTI probe must be parallel to the output shaft center line and NOT the axle shaft)
2012-07-21
www.JagDocs.com
4. Check the end float Push the wheel / shaft assembly INWARDS Zero the DTI Pull the wheel / shaft assembly OUTWARDS Note the reading 5. Check the specification 0 to 0,15 mm GOOD 0,15 mm + NOT GOOD; Renew the output shaft bearing
2012-07-21
Rear Drive Axle and Differential
Final Drive Mounting
Parts List Item 1 2 3 4 5 Description Final Drive Unit Wide Mounting Bracket Pendulum Assembly Wishbone Tie Assembly 'A' Frame
The type 14 HU final drive assembly is a hypoid unit with the pinion arranged on the cross-car cenerline. It utilizes a cassette type pinion oil seal and sealed output shaft bearings. The assembly is filled for life using a thermally stable lubricant. The differential unit is mounted between the wide mounting bracket, pendulum assembly and the wishbone tie assembly. Two tie rods are fitted between top rear of the final drive casing and the front of the wide mounting bracket.
2012-07-21
Axle Assembly 51.25.13

Suspension Spring Compressor Tool 204-179 Removal
www.JagDocs.com
1. Disconnect the battery ground lead 2. Raise the vehicle for access 3. Remove both rear roadwheels 4. Remove the rear suspension assembly, <<51.25.13>>
5.
CAUTION: Do not lift the assembly by the driveshafts, this may cause damage
2012-07-21
Using a suitable hoist, place the assembly onto a workbench
6. Locate the spring compressor 204 - 179 to the RH road spring
7. Tighten the spring compressor evenly to release the spring load on the damper
2012-07-21
www.JagDocs.com
8. Remove the damper assembly 1. Mark the tool position on the spring with adhesive tape 2. Remove the damper lower fixing 3. Remove the damper assembly 9. Repeat for the opposite hand spring / damper unit
10. Release the parking brake cable 1. Disconnect the cable in-line connector 2. Remove the outer cable to frame clips (2) 3. Clear the cable through the frame
2012-07-21
11. Remove the LH hub and axle shaft assembly 1. Remove the lower fulcrum shaft nut (1) 2. Remove the axle shaft to drive flange fixings (4) 3. Turn the axle-shaft for access to access the fixings for step 2 4. Support the axle shaft assembly and remove the hub fulcrum 5. Remove the hub and axle shaft assembly 6. Note the position of and remove the camber adjustment spacer 12. Repeat for the opposite hand
13. Remove the final drive nose plate. 1. Remove the final drive nose plate bolts (4) 2. Remove the final drive nose plate 14. Position the axle assembly on its LH side and support it on wooden blocks
2012-07-21
www.JagDocs.com
15. Remove the wishbone 1. Remove the fixing, stabilizer bar link to wishbone 2. Remove the pivot nut 3. Remove pivot 4. Note the position of and remove the front spacer and rear washers 5. Remove the wishbone 16. Repeat for the opposite hand
17. Remove the wishbone tie assembly 1. Remove the wishbone tie to final drive fixings (2) 2. Remove the washers (2) 3. Remove the wishbone tie assembly 4. Remove the washers (2)
2012-07-21
18. Remove the tie rods 1. Remove the tie rod to final drive fixings (2) 2. Remove the tie rods to wide mounting bracket fixings (2) 3. Remove the tie rods 4. Note the position of and remove the spacers 19. Position the assembly for access to the 'A' frame to final drive fixings, noting that oil may issue from the breather
20. Remove the 'A' frame assembly 1. Remove the 'A' frame to rear mounting bracket fixings (2) 2. Remove the 'A' frame to final drive fixings (2) 3. Remove the 'A' frame to wide mounting bracket fixings (2) 4. Remove the 'A' frame assembly
2012-07-21
21. Remove the 'A' frame rear mounting bracket
www.JagDocs.com
22. Remove the wide mounting bracket assembly 1. Remove the wide mounting bracket / pendulum assembly to final drive fixings (2) 2. Remove the wide mounting bracket assembly 3. Remove the washers (2)
2012-07-21
23. Remove the pendulum assembly
Installation 1. Installation is the reverse of the removal procedure noting the following
2. Locate the wide mounting bracket to the final drive. 1. Loose assemble the wide mounting bracket / pendulum to final drive fixings
2012-07-21
www.JagDocs.com
3. Locate the 'A' frame rear bracket and 'A' frame assembly 1. Fit the 'A' frame rear bracket 2. Fit the 'A' frame assembly 3. Loose assemble the 'A' frame to final drive fixings
4. Refer to the illustration
2012-07-21
10
2012-07-21
www.JagDocs.com
7. NOTE: Ensure the correct orientation of the flat sided washers Refer to the illustration
11
2012-07-21
12
2012-07-21
11. Refer to the illustration 12. Ensure that the spring pan and wishbone location reflects the original condition
www.JagDocs.com
13. Refer to the illustration 14. Check and adjust as required, the final drive unit oil level 15. Check and adjust as required, the rear wheel alignment, <<204-02>>.
13
2012-07-21
Axle Shaft 47.10.01

Hub remover 204-011
Thread protector JD 1D / 7
2012-07-21

Removal
1. Disconnect the battery ground lead 2. Support the vehicle at the rear and remove the appropriate rear road wheel 3. Remove and discard the hub nut, apply the brakes to prevent rotation 4. Remove the brake caliper in accordance with <<70.55.03>>, but do not disconnect the hydraulics
www.JagDocs.com
5. Prepare the hub carrier 1. 'Match mark' the hub carrier fulcrum bolt head and the carrier
2012-07-21
6. Prepare the hub carrier 1. Slacken the hub carrier fulcrum nut 2. Disconnect the ABS sensor multiplug at the hub carrier
7. Protect the driveshaft thread with sprcial tool JD 1D / 7
2012-07-21
8. Withdraw the hub from the axle shaft CAUTION: Take care not to introduce debris into the hub bearings, or damage the seal Using service tool 204 - 011, push the axle shaft through the hub
www.JagDocs.com
9. NOTE: In the wheel-free condition, the axle is in tension and the flanges will separate as the nuts are withdrawn Release the axle shaft 1. Remove and discard the (4) nuts axle shaft to differential output shaft 2. Clear the axle shaft from the output flange studs 3. Remove and keep safe the camber shim 10. NOTE: The axle shaft nuts may damage the studs upon removal; check the thread condition by engaging a new
2012-07-21
nut 2 or 3 threads by hand. Inspect the output flange studs and renew if there is evidence of damage / distortion 11. Clean all traces of thread locking agent from the hub splines (and axle shaft if it is to be re-used)
Installation 1. Installation is the reverse of the removal procedure, noting the following
2. Secure the axle shaft 1. Apply thread locking agent, to the SPLINE, as indicated 2. Refer to the illustration - do NOT re-use the original nut
2012-07-21
www.JagDocs.com
4. Refer to the illustration Ensure that the match marks are aligned prior to securing the fixing 5. Check and adjust as required, the final drive unit oil level 6. Check and adjust as required, the rear wheel alignment, <<204-02>>.
2012-07-21
Differential Output Shaft Bearing 51.10.22

Replacer hub bearing 204-083 Removal
1. Disconnect the battery ground lead 2. Raise the vehicle for access
2012-07-21
www.JagDocs.com
3. NOTE: In the wheel-free condition, the axle is in tension and the flanges will separate as the nuts are withdrawn Release the axle shaft 1. Match mark the output and axle shaft flanges (if the output shaft is to be re-used) 2. Remove and discard the (4) nuts axle shaft to differential output shaft 3. Remove and keep safe the camber shim 4. Thoroughly clean the area around the output shaft housing and differential case
5. Release the circlip and withdraw the output shaft assembly
2012-07-21
6. Prepare the retaining collar for removal 1. Mark the bearing retaining collar axially CAUTION: Do not drill into the output shaft, it is not necessary to break the inside diameter of the collar 2. Drill 3 off holes 4,0 mm dia equally spaced, to a MAXIMUM depth of 5,0 mm
7. Remove the retaining collar CAUTION: There is no need to split the collar when chiselling With a suitable chisel strike the collar across the three drilled holes (along the axis of the output shaft) to relieve tension within the steel
2012-07-21
8.
CAUTION: The original bearing must NOT be reused
Using a suitable press remove and discard the bearing, collar and circlip
Installation 1. Inspect the output shaft for damage and corrosion, replace as necessary
www.JagDocs.com
2. Identify the circlip cross section 1. This circlip is correct 2. This circlip MUST be discarded and the correct one used
2012-07-21
3. Fit the bearing using special tool 204 - 083 1. Position a new circlip 2. Locate the bearing 3. Locate the collar NOTE: It is strongly recommended that a press equipped with a pressure gauge is used, the assembly load MUST exceed 20Kn 4. Press the assembly
2012-07-21
www.JagDocs.com
4. Fit the output shaft assembly to the final drive Lubricate the 'O' ring and seat the shaft assembly Secure the assembly with the circlip
5. Ensure the correct circlip location Using a prybar, or similar, expand the circlip into its undercut by applying outward radial pressure. Start diametrically opposite to the circlip open ends and lever against the drive flange
2012-07-21
6. Verify the circlip location 1. The gap MUST be greater than 10,0 mm CAUTION: If the gap CANNOT be achieved, contact Jaguar Service 2. A gap smaller than specified will indicate an improperly fitted circlip. This may be rectified by refitting or by the application of radial pressure around the inner circumference of the circlip 7. Verify that the output shaft end-float is within specification
8. Refer to the illustration If appropriate realign the previously made match marks 9. Check the final drive oil level and adjust as required 10. Check and adjust rear wheel camber setting
7 2012-07-21
Drive Pinion Flange and Drive Pinion Seal 51.20.01

Wrench, Drive Pinion Flange 205-053
www.JagDocs.com
Remover, Drive Pinion Flange 303-588 Removal 1. Remove the driveshaft. For additional information, refer to<<205-01>>.
2012-07-21
2.
WARNING: MAKE SURE NO DAMAGE OCCURS TO THE INPUT SHAFT.
Release the peened collar of the drive pinion flange retaining nut.
3.
WARNING: MAKE SURE NO DAMAGE OCCURS TO THE INPUT SHAFT THREADS.
Using the special tool, remove and discard the drive pinion flange retaining nut.
2012-07-21
4. Using the special tool, remove and discard the drive pinion flange.
www.JagDocs.com
5. Remove and discard the ryton ring.
2012-07-21
6. Remove and discard the drive pinion oil seal.
Installation
1. Slide the drive pinion oil seal and ryton ring against the shoulder of the drive pinion flange. 1. Position the ryton ring to the drive pinion oil seal. 2. Slide the drive pinion oil seal and ryton ring against the shoulder of the drive pinion flange. 2. NOTE: Apply a suitable amount of clean differential oil to lubricate the outer diameter of the drive pinion oil seal. Loosely install the drive pinion flange assembly to the differential case.
2012-07-21
www.JagDocs.com
3. Slide the drive pinion flange assembly into position until the drive pinion oil seal is adjacent to the differential case.
4. NOTE: Install a new drive pinion flange retaining nut. NOTE: Make sure the ryton ring has remained correctly positioned to the drive pinion oil seal. Using the special tool, tighten the drive pinion flange retaining nut to 203 - 223 Nm.
2012-07-21
5. Peen the collar of the drive pinion flange retaining nut to the drive pinion. 6. Install the driveshaft. For additional information, refer to<<205-01>>. 7. Check the differential oil level, and if necessary, fill the differential with oil to the lower edge of the fill hole.
2012-07-21
1999 XK RANGE - Brake System - General Information - 206-00
Lubricants, Fluids, Sealants and Adhesives Unit Brake fluid Specification ITT Super Dot 4
Front Brake Dimensions NOTE: When a component reaches its maximum / minimum dimension limit the component must be replaced. Care must be taken when refinishing brake discs that the dimension limits are not exceeded. Component Brake disc - diameter Brake disc - thickness (new) Brake disc - minimum thickness Brake disc - minimum wall thickness Brake disc - maximum run-out Brake pad - minimum thickness Caliper piston diameter Dimension - Normally Aspirated Vehicle 305 mm 28 - 28.5 mm 26 mm 6.2 mm 0.1 mm 2 mm 60 mm Dimension - Super Charged Vehicle 325 mm 28 - 28.5 mm 26 mm 6.6 mm 0.1 mm 2 mm 60 mm
www.JagDocs.com
Rear Brake Dimensions NOTE: When a component reaches its maximum / minimum dimension limit the component must be replaced. Care must be taken when refinishing brake discs and drums that the dimension limits are not exceeded. Component Brake disc - diameter Brake disc - thickness (new) Brake disc - minimum thickness Brake disc - minimum wall thickness Brake disc - maximum run-out Caliper piston diameter Parking brake drum - maximum diameter Brake pad - minimum thickness Parking brake shoes - minimum thickness Dimension 305 mm 19.5 - 20 mm 18.5 mm 4.9 mm 0.15 mm 42 mm 181 mm 2 mm 2 mm
2012-07-21
Brake System Bleeding

WARNING: WASH HANDS AFTER HANDLING BRAKE FLUID. IF BRAKE FLUID COMES INTO CONTACT WITH THE EYES, FLUSH EYES WITH COLD RUNNING WATER. IF IRRITATION PERSISTS SEEK MEDICAL ATTENTION. IF BRAKE FLUID IS TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. CAUTION: Remove brake fluid spillage immediately from paint work with clean water.
1. Position vehicle on a four-post lift. 2. Open engine compartment and fit paint work protection covers to fenders.
3. NOTE: Make sure the brake-fluid level does not fall below the fluid reservoir 'MIN' (minimum) mark when bleeding the brake system. Fill fluid reservoir to the 'MAX' (maximum) mark.
2012-07-21
www.JagDocs.com
4. Prepare the left-hand front, brake-caliper for bleeding. Remove dust cap. Connect bleed pipe and fluid container to bleed nipple. 5. Bleed the brake. 1. Apply pressure to brake pedal 2. Open bleed nipple. 3. Fully depress brake pedal. 4. Close bleed nipple. 5. Release brake pedal. 6. Wait two seconds to allow system to prime. 7. Repeat procedure until air-free brake fluid is expelled from the caliper.
6. Tighten bleed nipple to: Front caliper bleed nipple: 4-6 Nm. Rear caliper bleed nipple: 8-11 Nm.
2012-07-21
7. Following the procedure above, bleed the brakes in the order shown: 1. Left-Hand Front, 2. Right-Hand Front, 3. Left- Hand Rear, 4. Right-Hand Rear.
8.
CAUTION: Remove brake fluid spillage immediately from paint work with clean water.
Fill fluid reservoir. Fill reservoir to the 'MAX' mark. Fit filler cap. 9. Start engine. 10. Check for correct brake-pedal travel and pressure.
2012-07-21
11. Apply brake pedal and check around vehicle for brake fluid leaks. 12. Make sure brake fluid level is at the 'MAX' mark.
www.JagDocs.com
2012-07-21
Front Brake Disc Runout Check

Dial Test Indicator Gauge and Stand.
1. Raise front of vehicle and support on stands. Refer to section <<100-02>>. 2. Remove wheel.
3.
CAUTION: Tie caliper housing aside. Do not allow the caliper housing to hang on the hydraulic hose, as this will damage the hose.
Remove caliper housing from caliper carrier. 1. Remove anti-rattle spring. 2. Remove dust covers. 3. Remove guide pins. Remove and tie caliper housing aside. 4. Make sure that wheel bearing end-float is correct. Refer to specification section <<204-01>>.
2012-07-21
www.JagDocs.com
5. Measure brake disc run-out. Install brake disc to hub and secure with all wheel nuts, tighten wheel nuts to 20 Nm in a diagonal sequence. Position the gauge so that the pointer contacts the disc, 10 mm from its outer edge. Slowly rotate the disc one revolution, the disc run-out must not exceed the specification. Refer to Specification Section <<206-03>>. 6. If the brake disc run-out exceeds specification, reposition the brake disc on the hub and repeat the above procedure. Continue repositioning the brake disc until the run-out is within specification. 7. If the brake disc run-out still exceeds specification, check the hub face run-out. 8. Remove brake disc. Refer to procedure 70.10.12.
9. Measure hub face run-out. Position the gauge so that the pointer contacts the hub face. Slowly rotate the hub one revolution, the hub run-out must not exceed the specification. Refer to
2012-07-21

Specification Section <<204-01>>. If the hub exceeds the maximum run-out specification replace the hub. Refer to procedure 60.25.01. 10. NOTE: Make sure the brake disc and hub mating surfaces are clean. If the hub run-out is within specification replace brake discs. Refer to procedure 70.10.12.
11. Install caliper housing to caliper carrier. Align housing to carrier. 1. Install and tighten guide pins to 25-30 Nm. 2. Install dust covers. 3. Install anti-rattle spring. 12. Install wheel. Refer to procedure <<74.20.05>>.
2012-07-21
Rear Brake Disc Runout Check

Dial Test Indicator Gauge and Stand.
1. Raise rear of vehicle and support on stands. Refer to section <<100-02>>. 2. Remove wheel.
www.JagDocs.com
3.
Remove caliper housing from caliper carrier. 1. Remove anti-rattle spring. 2. Remove dust covers. 3. Remove guide pins. 4. Remove housing from carrier. Tie caliper housing aside. 4. NOTE:
2012-07-21

Measurement of the brake disc run-out, must be carried-out with the disc and hub parking-brake adjuster-holes aligned. Make sure that wheel bearing end-float is correct. Refer to specification section <<204-02>>.
5. Measure brake disc run-out. Install brake disc to hub and secure with all wheel nuts, tighten wheel nuts to 20 Nm in a diagonal sequence. Position the gauge so that the pointer contacts the disc 10 mm from its outer edge. Slowly rotate the disc one revolution, the disc run-out must not exceed the specification. Refer to specifications in section <<206-04>>. 6. If the brake disc run-out exceeds specification, check the hub face run-out. 7. Remove brake discs. Refer to procedure 70.10.13.
8. Measure hub face run-out. Position the gauge so that the pointer contacts the hub face. Slowly rotate the hub one revolution, the hub run-out must not exceed the specification. Refer to
2012-07-21

Specification Section <<204-01>>. If the hub exceeds the maximum run-out specification replace the hub. Refer to Section <<204-01>>. 9. NOTE: Make sure the brake disc and hub mating surfaces are clean. If the hub run-out is within specification replace brake discs. Refer to procedure 70.10.13.
www.JagDocs.com
10. Install caliper housing to caliper carrier. 1. Align housing to carrier. 2. Install and tighten guide pins to 25-30 Nm. 3. Install dust covers. 4. Install anti-rattle spring. 11. Fit wheel. Refer to section <<204-04>>.
2012-07-21
Brake System
Principles of Operations
The brake system operates by transferring effort applied to the brake pedal, by the driver to the brakes at each wheel. The braking effort is distributed to each wheel, using a hydraulic system. The system is assisted using a vacuum brake booster that reduces pedal effort for a given hydraulic pressure. The parking brake operates on the rear wheels and is applied using a hand operated control.

NOTE: Prior to carrying out any diagnosis, make sure that the brake system warning indicator is functional. Visually examine the front and rear tire and wheel assemblies for damage such as uneven wear patterns, tread worn out or sidewall damage. Verify the tires are the same size, type and, where possible, same manufacture. Replace the damaged wheel or excessively worn tire. For additional information, refer to<<204-04>>. Wheels and tires must be cleared of any foreign matter and tire pressures adjusted to the correct specification. If the tires exhibit uneven wear or feathering, the cause must be corrected. Check the steering and suspension components for damage or wear and, if necessary, check and adjust front wheel alignment. For additional information, refer to<<204-00>>.
Road Test
Visual Inspection Chart Mechanical Brake master cylinder Brake caliper piston(s) Brake discs Wheel bearings Brake pads Power brake booster Brake pedal linkage Booster vacuum hose Tires Debris Carry out a road test to compare actual vehicle braking performance with the performance standards expected by the driver. The ability of the test driver to make valid comparisons and detect performance deficiencies will depend on experience. The driver should have a thorough knowledge of brake system operation and accepted general performance guidelines to make good comparisons and detect performance concerns. An experienced brake technician will always establish a route that will be used for all brake diagnosis road tests. The roads selected will be reasonably smooth and level. Gravel or bumpy roads are not suitable because the surface does not allow the tires to grip the road equally. Crowned roads should be avoided because of the large amount of weight shifted to the low set of wheels on this type of road. Once the route is established and consistently used, the road surface variable can be eliminated from the test results. Before a road test, obtain a complete description of the customer concerns or suspected condition. From the description, the technician's experience will allow the technician to match possible causes with symptoms. Certain Electrical Parking brake switch Damaged or corroded wiring harness Brake master cylinder fluid level switch
2012-07-21

components will be tagged as possible suspects while others will be eliminated by the evidence. More importantly, the customer description can reveal unsafe conditions which should be checked or corrected before the road test. The description will also help form the basic approach to the road test by narrowing the concern to specific components, vehicle speed or conditions. Begin the road test with a general brake performance check. Keeping the description of the concern in mind, test the brakes at different vehicle speeds using both light and heavy pedal pressure. To determine if the concern is in the front or rear braking system, use the brake pedal and then use the parking brake control. If the condition (pull, vibration, pulsation) occurs only with the parking brake, the concern is in the rear brake system. If the concern becomes evident during this check, verify it fits the description given before the road test. If the concern is not evident, attempt to duplicate the condition using the information from the description. If a concern exists, use the Symptom Chart in order to isolate it to a specific sub-system and condition description. From this description, a list of possible sources can be used to further narrow the cause to a specific component or condition.
Condition(s): Brakes noisy Possible Source(s): Brake pads. Brake discs. Action(s) to take: GO to <<Pinpoint Test A>>. Vibration when brakes are applied Possible Source(s): Wheels require balancing. Wheel hub nuts. Caliper mounting bolts. Brake pads. Foreign material/scratches/corrosion on brake disc contact surfaces. Excessive brake disc thickness variation. Excessive brake disc runout. Wheel bearing wear or failure. Suspension bush wear or failure. Steering bush wear or failure. Action(s) to take: Go to <<Pinpoint Test B>>. The brakes pull or drift Possible Source(s): Tire pressures/wear. Calipers. Brake pads. Brake discs. Wheel alignment adjustment. Wheel bearing.
www.JagDocs.com
2012-07-21

Suspension bushes and ball joints. Action(s) to take: GO to <<Pinpoint Test C>>. The pedal feels spongy Possible Source(s): Air in brake system. Leak in hydraulic system. Brake booster/master cylinder. Brake pads. Action(s) to take: GO to <<Pinpoint Test D>>. The pedal goes down fast Possible Source(s): Air in brake system. Leak in hydraulic system. Brake booster/master cylinder. Brake pads. Action(s) to take: GO to <<Pinpoint Test E>>. The pedal goes down slowly Possible Source(s): Air in brake system. Brake booster/master cylinder. Action(s) to take: Go to <<Pinpoint Test F>>. Excessive brake pedal effort Possible Source(s): Brake pads. Brake booster. Action(s) to take: GO to <<Pinpoint Test G>>. Brake lockup during light brake pedal force Possible Source(s): Brake pads. Calipers. Action(s) to take: GO to <<Pinpoint Test H>>.
2012-07-21

Brakes drag Possible Source(s): Parking brake control applied/malfunction. Seized parking brake cables. Seized caliper slide pins. Seized caliper. Brake booster. Pedal gear. Action(s) to take: GO to <<Pinpoint Test I>>. Excessive/Erratic brake pedal travel Possible Source(s): Hydraulic system. Brake pads. Brake discs. Hub and bearing assembly. Action(s) to take: GO to <<Pinpoint Test J>>. The red brake warning indicator is always on Possible Source(s): Fluid level. Action(s) to take: FILL the system to specification. CHECK for leaks. Possible Source(s): Brake fluid level sensor. Action(s) to take: INSTALL a new brake master cylinder fluid reservoir. For additional information, refer to<<206-06>>. Possible Source(s): Parking brake control. Action(s) to take: RELEASE and ADJUST the parking brake. For additional information, refer to<<206-05>>. Possible Source(s): Electrical circuit. Action(s) to take: For additional information, refer to PDU for analysis/rectification of the concern. Slow or incomplete brake pedal return Possible Source(s): Brake pedal binding. Brake booster/master cylinder. Action(s) to take: GO to <<Pinpoint Test K>>.
www.JagDocs.com
2012-07-21
A : BRAKES NOISY A1 : INSPECT BRAKE PADS

1. Inspect the condition of the front and rear brake pads. Check for damage to any anti-squeal shims. Are the brake pads OK? -> Yes Goto <<A2>> -> No CLEAN the front brake pads or INSTALL new front brake pads if necessary. For additional information, refer to<<206-03>>. CLEAN the rear brake pads or INSTALL new rear brake pads if necessary. For additional information, refer to<<206-04>>. Test vehicle for presence of brake squeal.
A2 : INSPECT BRAKE DISCS

1. Inspect the brake discs for excessive corrosion, wear or disc thickness variation. Does excessive corrosion, wear or disc thickness variation exist? -> Yes INSTALL new front brake discs and brake pads. For additional information, refer to<<206-03>>. INSTALL new rear brake discs and brake pads. For additional information, refer to<<206-04>>. TEST the system for normal operation. -> No Vehicle is OK.
B : VIBRATION WHEN BRAKES ARE APPLIED B1 : ROAD TEST VEHICLE

1. Road test the vehicle between 40-80 km/h (25-50 mph) without applying brakes. Is the vibration present? -> Yes TEST for noise vibration and harshness. REPEAT road test if necessary. -> No Goto <<B2>> .
B2 : CHECK FOR BRAKE VIBRATION

1. Road test the vehicle between 40-80 km/h (25-50 mph) with light and medium application on the brake pedal. Is a vibration present? -> Yes If the vibration is from the front of the vehicle Goto <<B3>> If the vibration is from the rear of the vehicle or can not be diagnosed between front or rear of the vehicle Goto <<B6>> -> No Vehicle is OK.
5 2012-07-21
B3 : CHECK THE SUSPENSION AND STEERING COMPONENTS

1. Check the condition of the front suspension bushes and ball joints <<204-01>> Check the condition of the steering linkage components <<211-02>><<211-03>> Do any of the front suspension components or steering components require replacement? -> Yes INSTALL new components as necessary <<204-01>><<211-02>><<211-03>> Road test the vehicle between 40-80 km/h (25-50 mph) with light and medium application on the brake pedal. If vibration still exists Goto <<B4>> -> No Goto <<B4>>
B4 : CHECK THE FRONT BRAKE PADS AND FRONT BRAKE DISCS

1. Check the condition of the front brake pads and front brake discs. Does excessive brake disc runout or brake disc thickness variation exist? -> Yes Goto <<B5>> -> No Goto <<B6>>
www.JagDocs.com
B5 : CHECK VEHICLE FOR A HISTORY OF BRAKE VIBRATION PROBLEMS

1. Check to see if the vehicle has recently been repaired for brake vibration problems by the installation of new front brake discs and pads. Has vehicle has recently been repaired for brake vibration problems by the installation of new front brake discs and pads. -> Yes INSTALL new front wheel hubs <<204-01>> INSTALL new front brake discs and front brake pads <<206-03>> TEST the system for normal operation. -> No INSTALL front brake discs and front brake pads <<206-03>> CHECK for excessive brake disc runout If excessive brake disc runout exists INSTALL new front wheel hubs <<204-01>> TEST the system for normal operation.
B6 : CHECK THE REAR BRAKE PADS AND REAR BRAKE DISCS

1. Check the condition of the rear brake pads and rear brake discs. Does excessive brake disc runout or brake disc thickness variation exist? -> Yes INSTALL rear brake discs and rear brake pads <<206-04>> CHECK for excessive brake disc runout. If excessive brake disc runout exists INSTALL new rear wheel hubs. TEST the system for normal operation. -> No REPEAT road test and re-check for a vibration concern. If vibration exists Goto <<B3>>
2012-07-21
C : THE BRAKES PULL OR DRIFT C1 : ROAD TEST VEHICLE

1. Road test the vehicle and apply the brake pedal. Does the vehicle pull or drift? -> Yes Goto <<C2>> -> No Vehicle is OK.
C2 : INSPECT TIRE PRESSURE

1. Check for excessive tire wear or incorrect pressures. Are the tires at the correct pressure and in good condition? -> Yes Goto <<C3>> -> No ADJUST the tire pressures or INSTALL new tires if excessively worn. TEST the system for normal operation.
C3 : CHECK CALIPERS
1. Check the front caliper pistons for binding, leaking or sticking. For additional information, refer to<<206-03>>. Check the rear caliper pistons for binding, leaking or sticking. For additional information, refer to<<206-04>>. Do the disc brake caliper pistons and pins bind, leak or stick? -> Yes INSTALL new calipers as necessary. TEST the system for normal operation. -> No Goto <<C4>>
C4 : INSPECT BRAKE DISCS

1. Check the brake discs for excessive damage, thickness variation or runout. For additional information, refer to General Procedures in this section. Does excessive damage or runout exist? -> Yes INSTALL new brake discs and brake pads as necessary. TEST the system for normal operation. -> No Goto <<C5>>
C5 : INSPECT THE FRONT HUB AND WHEEL BEARING ASSEMBLY

1. Check the front hub and wheel bearing assembly. For additional information, refer to<<204-00>>. Are the wheel bearings OK?
7 2012-07-21

-> Yes Goto <<C6>> -> No INSTALL new wheel bearings. For additional information, refer to<<204-01>>. TEST the system for normal operation.
C6 : CHECK SUSPENSION BUSHES AND BALL JOINTS.

1. Check all suspension bushes and ball joints. Are the suspension bushes and ball joints OK? -> Yes Vehicle is OK. -> No INSTALL new front suspension bushes and ball joints as required. For additional information, refer to<<204-01>>. INSTALL new rear suspension bushes and ball joints as required. For additional information, refer to<<204-02>>.
www.JagDocs.com
D : THE PEDAL FEELS SPONGY D1 : CHECK FOR SPONGY PEDAL (ENGINE OFF)
1. Check for a firm brake pedal. Is the brake pedal effort and brake pedal travel normal? -> Yes Vehicle is OK. -> No Goto <<D2>>
D2 : CHECK BRAKE PEDAL RESERVE (ENGINE OFF)

1. Pump the brake pedal 10 times and hold on the final application. Does the brake pedal feel firm on final application? -> Yes Goto <<D3>> -> No BLEED the brake system. For additional information, refer to General Procedures in this section. TEST the system for normal operation.
D3 : CHECK BRAKE PEDAL RESERVE (ENGINE ON)

1. Engine is idle. 2. Apply the brake pedal lightly three or four times. 3. Wait 15 seconds for the vacuum to recover. 4. Push down on the brake pedal until it stops moving downward or an increased resistance to the brake pedal travel occurs. 5. Hold the brake pedal in the applied position while increasing the engine speed to 2000 revs/min.
2012-07-21

6. Release the accelerator pedal. Does the brake pedal move downward as the engine speed returns to idle? -> Yes Goto <<D4>> -> No CHECK the vacuum to brake booster. For additional information, refer to<<206-07>>.
D4 : CHECK BRAKE FLUID LEVEL

1. Check the brake master cylinder reservoir fluid level. Is the fluid level OK? -> Yes BLEED the brake system. For additional information, refer to General Procedures in this section. TEST the system for normal operation. -> No CHECK brake master cylinder reservoir sealing points. For additional information, refer to Brake Master Cylinder in this section. ADD fluid and BLEED the brake system. For additional information, refer to General Procedures in this section. TEST the system for normal operation. REPEAT road test if necessary.
E : THE PEDAL GOES DOWN FAST E1 : ROAD TEST VEHICLE

1. Road test and apply the brake pedal. Is the brake pedal effort and brake pedal travel normal? -> Yes Vehicle is OK. -> No Goto <<E2>>
E2 : CHECK BRAKE FLUID LEVEL

1. Check the brake master cylinder reservoir fluid level. Is the fluid level within specification? -> Yes Goto <<E3>> -> No CHECK the brake master cylinder reservoir sealing points. For additional information, refer to Brake Master Cylinder Component Test in this section. ADD fluid and BLEED brake system. For additional information, refer to General Procedures in this section. TEST the system for normal operation. REPEAT road test if necessary.
E3 : CHECK BRAKE PEDAL TRAVEL-PRESSURIZE SYSTEM

1. Pump the brake pedal rapidly (five times). Does the brake pedal travel build up and then hold?
2012-07-21

-> Yes BLEED the brake system. For additional information, refer to General Procedures in this section. TEST the system for normal operation. REPEAT road test. -> No Goto <<E4>>
E4 : CHECK FOR BRAKE SYSTEM LEAKS

1. Check for external brake system leaks. For additional information, refer to Master Cylinder in this section. Are leaks found? -> Yes REPAIR as necessary, ADD fluid and BLEED brake system. For additional information, refer to General Procedures in this section. TEST the system for normal operation. REPEAT road test. -> No System is OK.
F : THE PEDAL GOES DOWN SLOWLY F1 : ROAD TEST VEHICLE - CHECK BRAKE PEDAL OPERATION
1. Check if the condition occurs during actual stopping application by applying the brake pedal while the vehicle is moving. Does the condition occur when the vehicle is moving? -> Yes Goto <<F2>> -> No Goto <<F3>>
www.JagDocs.com
F2 : CHECK FOR BRAKE SYSTEM LEAKS

1. Check for external brake system leaks. For additional information, refer to Master Cylinder in this section. Are there any external brake system leaks? -> Yes REPAIR as necessary. ADD fluid and BLEED the brake system. For additional information, refer to General Procedures in this section. TEST the system for normal operation. -> No Goto <<F3>>
F3 : CARRY OUT A BRAKE MASTER CYLINDER BYPASS TEST

1. Test for brake master cylinder bypass condition. Refer to Brake Master Cylinder Component Test in this section. Are any concerns found? -> Yes INSTALL a new brake master cylinder, ADD fluid and BLEED the brake system. For additional information, refer to General Procedures in this section. TEST the system for normal operation. -> No
10
2012-07-21

System is OK.
G : EXCESSIVE BRAKE PEDAL EFFORT G1 : CHECK BRAKE PADS

1. Check the brake pads for wear, contamination, correct installation, damage and type. Are any concerns found? -> Yes INSTALL the front brake pads correctly or INSTALL new front brake pads if necessary. For additional information, refer to<<206-03>>. INSTALL the rear brake pads correctly or INSTALL new rear brake pads if necessary. For additional information, refer to<<206-04>>. REPEAT road test. -> No Goto <<G2>>
G2 : CHECK VACUUM
1. Disconnect the vacuum booster hose from the booster. 2. Connect a vacuum/pressure tester to the vacuum hose. 3. Run the engine at normal operating temperature. 4. Record the vacuum reading. Is the reading 40.5kPa (12 in-Hg) or greater? -> Yes Goto <<G3>> -> No LOCATE and REPAIR the source of low vacuum. TEST the system for normal operation.
G3 : INSPECT SYSTEM
1. Switch the engine off. 2. Reconnect the vacuum hose. 3. Inspect the brake booster, rubber grommet, and all vacuum plumbing for cracks, holes, damaged connections, or missing clamps. 4. Pump the brake pedal several times to exhaust the vacuum. Push down on the brake pedal and hold. Does the brake pedal move down when the engine is started? -> Yes Vacuum system is OK. -> No Goto <<G4>>
G4 : CHECK POWER BRAKE BOOSTER VALVE

1. Check the brake booster valve. For additional information, refer to Brake Booster in this section. Is the power brake booster valve OK? -> Yes
11
2012-07-21

CHECK the brake booster. For additional information, refer to Brake Booster in this section. INSTALL a new brake booster if necessary. TEST the system for normal operation. -> No INSTALL a new brake booster valve. TEST the system for normal operation.
H : BRAKE LOCKUP DURING LIGHT BRAKE PEDAL FORCE H1 : TEST BRAKE LOCKUP
1. Road test the vehicle and apply the brake pedal lightly. Do the brakes lockup? -> Yes Goto <<H2>> -> No Vehicle is OK.
www.JagDocs.com
H2 : INSPECT BRAKE PADS

1. Inspect brake pads for contamination, correct installation, damage and type. Are any concerns found? -> Yes CHECK the front brake pads. For additional information, refer to<<206-03>>. CHECK the rear brake pads. For additional information, refer to<<206-04>>. INSTALL new brake pads as necessary. REPEAT road test. -> No Goto <<H3>>
H3 : INSPECT BRAKE CALIPERS

1. Inspect brake calipers for binding, leaking or sticking. Are any concerns found? -> Yes CHECK the front brake calipers. For additional information, refer to<<206-03>>. CHECK the rear brake calipers. For additional information, refer to<<206-04>>. INSTALL the brake calipers correctly or INSTALL new brake calipers as necessary. TEST the system for normal operation. REPEAT road test if necessary. -> No Vehicle is OK.
I : BRAKES DRAG I1 : ROAD TEST VEHICLE

1. Road test the vehicle and apply the brakes. Are the brakes functioning correctly? -> Yes Vehicle is OK. -> No
12
2012-07-21

Goto <<I2>>
I2 : CHECK CALIPERS
1. Check the front caliper pistons for binding, leaking or sticking. For additional information, refer to<<206-03>>. Check the rear caliper pistons for binding, leaking or sticking. For additional information, refer to<<206-04>>. Do the disc brake caliper pistons and pins bind, leak or stick? -> Yes INSPECT the brake calipers and parking brake cables. INSTALL new components as necessary. Road test vehicle. -> No Goto <<I3>>
I3 : CHECK BRAKE BOOSTER

1. Check the brake booster connecting rod alignment and travel. For additional information, refer to<<206-07>>. Is the connecting rod OK? -> Yes Vehicle is OK. -> No INSTALL a new brake booster. For additional information, refer to<<206-07>>. TEST the system for normal operation.
J : EXCESSIVE/ERRATIC BRAKE PEDAL TRAVEL J1 : TEST ON ROUGH ROAD

1. Road test the vehicle on rough road conditions. 2. Apply the brakes slowly. Is the brake pedal effort and brake pedal travel normal? -> Yes Vehicle is OK. -> No Goto <<J2>>
J2 : CHECK BRAKE FLUID LEVEL

1. Check the brake master cylinder reservoir fluid level. Is the fluid level OK? -> Yes Goto <<J3>> -> No CHECK brake master cylinder reservoir sealing points. For additional information, refer to Brake Master Cylinder in this section. ADD brake fluid and BLEED the brake system. For additional information, refer to General Procedures in this section. TEST the system for normal operation. REPEAT road test if necessary.
13
2012-07-21
J3 : CHECK BRAKE PEDAL RESERVE

1. Engine is idle. 2. Apply the brake pedal lightly three or four times. 3. Wait 15 seconds for the vacuum to replenish. 4. Push down on the brake pedal until it stops moving downward or an increased resistance to the brake pedal travel occurs. 5. Hold the brake pedal in the applied position while increasing the engine speed to 2000 revs/min. 6. Release the accelerator pedal. Does the brake pedal move downward as the engine speed returns to idle? -> Yes Goto <<J4>> -> No CHECK the vacuum to the brake booster. For additional information, refer to<<206-07>>.
www.JagDocs.com
J4 : CHECK THE FRONT HUB AND BEARING ASSEMBLY

1. Check the front hub and bearing assembly. For additional information, refer to<<204-01>>. Are the front wheel bearings loose? -> Yes INSTALL a new front wheel bearing if damaged. For additional information, refer to<<204-01>>. TEST the system for normal operation. -> No CHECK the front brake discs for thickness variances. For additional information, refer to General Procedures in this section.
K : SLOW OR INCOMPLETE BRAKE PEDAL RETURN K1 : CHECK FOR BRAKE PEDAL RETURN
1. Run the engine at fast idle while making several brake applications. 2. Pull the brake pedal rearward with approximately 44.5 N (10lb) force. 3. Release the brake pedal and measure the distance to the toe board. 4. Make a hard brake application. 5. Release the brake pedal and measure the brake pedal to toe board distance. The brake pedal should return to its original position. Does the brake pedal return to its original position? -> Yes Vehicle is OK. -> No Goto <<K2>>
K2 : CHECK FOR BRAKE PEDAL BINDING
14
2012-07-21
1. Check the brake pedal to make sure it is operating freely. Is the brake pedal operating freely? -> Yes INSTALL a new brake booster. For additional information, refer to<<206-07>>. TEST the system for normal operation. -> No REPAIR or INSTALL new brake pedal. TEST the system for normal operation.
Component Tests Brake Booster

1. Check all hoses and connections. All unused vacuum connectors should be capped. Hoses and their connections should be correctly secured and in good condition with no holes and no collapsed areas. Inspect the valve on the brake booster for damage. 2. Check the hydraulic brake system for leaks or low fluid. 3. With the transmission in PARK, stop the engine and apply the parking brake. Pump the brake pedal several times to exhaust all vacuum in the system. 4. With the engine switched off and all vacuum in the system exhausted, apply the brake pedal and hold it down. Start the engine. If the vacuum system is operating, the brake pedal will tend to move downward under constant foot pressure. If no motion is felt, the vacuum booster system is not functioning. 5. Remove the vacuum hose from the brake booster. Manifold vacuum should be available at the brake booster end of the hose with the engine at idle speed and the transmission in PARK or NEUTRAL. Make sure that all unused vacuum outlets are correctly capped, hose connectors are correctly secured and vacuum hoses are in good condition. When it is established that manifold vacuum is available to the brake booster, connect the vacuum hose to the brake booster and repeat Step 3. If no downward movement of the brake pedal is felt, install a new brake booster. 6. Operate the engine for a minimum of 10 seconds at a fast idle. Stop the engine and allow the vehicle to stand for 10 minutes. Then, apply the brake pedal with approximately 89 N (20lb) of force. The pedal feel (brake application) should be the same as that noted with the engine running. If the brake pedal feels hard (no power assist), install a new valve and then repeat the test. If the brake pedal still feels hard, install a new brake booster. If the brake pedal movement feels spongy, bleed the brake system. For additional information, refer to General Procedures in this section.
Brake Master Cylinder

Usually, the first and strongest indicator of anything wrong in the brake system is a feeling through the brake pedal. In diagnosing the condition of the brake master cylinder, check pedal feel as evidence of a brake concern. Check for brake warning lamp illumination and the brake fluid level in the brake master cylinder reservoir.
Normal Conditions
The following conditions are considered normal and are not indications that the brake master cylinder is in need of repair. New brake systems are designed to produce a pedal effort that is not as hard as in the past. Complaints of light pedal efforts should be compared to the pedal efforts of another vehicle of the same model and year. The fluid level will fall with brake pad wear.
15
2012-07-21

Abnormal Conditions
NOTE: Prior to carrying out any diagnosis, make sure the brake system warning indicator is functional. Changes in the brake pedal feel or brake pedal travel are indicators that something could be wrong in the brake system. The diagnostic procedure and techniques use brake pedal feel, warning indicator illumination and low brake fluid level as indicators to diagnosing brake system concerns. The following conditions are considered abnormal and indicate that the brake master cylinder is in need of repair: Brake pedal goes down fast. This could be caused by an external or internal leak. Brake pedal goes down slowly. This could be caused by an internal or external leak. Brake pedal is low or feels spongy. This condition may be caused by no fluid in the brake master cylinder, reservoir cap vent holes clogged or air in the hydraulic system. Brake pedal effort is excessive. This may be caused by a bind or obstruction in the pedal/linkage, a faulty non return valve, booster or insufficient booster vacuum. Rear brakes lock up during light pedal force. This may be caused by damaged brake pads, an incorrectly adjusted parking brake, a partially applied parking brake, a damaged ABS sensor or bearing failure. Brake pedal effort erratic. This condition could be caused by the brake booster or incorrectly installed brake pads. Brake warning indicator is on. This may be caused by low fluid level or float assembly damaged.
www.JagDocs.com
Non Pressure Leaks

Any reduced fluid volume in the brake master cylinder reservoir condition may be caused by two types of none pressure external leaks. Type 1: An external leak may be occur at the master cylinder reservoir cap because of incorrect positioning of gasket and cap. Reposition cap and gasket. Type 2: An external leak may occur at the reservoir mounting seals. Repair such a leak by installing new seals and make sure that the reservoir retaining bolt is correctly installed.
16
2012-07-21
1999 XK RANGE - Front Disc Brake - 206-03
Torques Component Bolt - caliper carrier to vertical link Guide Pin - caliper housing to caliper carrier Nm 120-160 25-30
Brake Tube, Hoses and Bracket Torques CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used. See section <<100-00>> for information. Component Bleed nipple - front Bleed nipple - rear Hose to front caliper Hose banjo to rear caliper M10 hose locknut M10 brake tube female-nut M10 brake tube male-nut M12 brake tube male-nut Bolt - 3-way tube connector to body Nm 4-6 8-11 10-14 30-40 15-20 13-17 13-17 15-20 9-12
2012-07-21
Front Disc Brake
Components
www.JagDocs.com
Item 1 2 3 4 5 6 7 8 9 10
Description Brake Disc Caliper Housing Caliper Carrier Brake Pads Guide Pins Dust Covers Anti-rattle Spring Dust Shield Brake Hose Bleed Nipple
Description and Operation

The brake disc is mounted on the wheel studs and is clamped between the wheel and hub. Cooling ducts run through the center of the brake disc to provide the required ventilation to keep the disc cool under operating conditions. The caliper carrier, which is secured to the vertical link by two bolts, carries the single-piston caliper housing. The caliper housing is secured to the caliper carrier by two guide-pins and an anti-rattle spring. When the brakes are applied the caliper-housing piston pushes the brake pad in front of it, towards the brake disc. This movement forces the caliper housing to move along the guide-pins, in the opposite direction of the piston, to apply the second brake pad. The brake disc is therefore gripped between the two pads. As brake pressure is increased the grip on the brake disc is increased to slow-down the rotation of the road wheel. The disc brakes require no adjustment.
2012-07-21
Brake Caliper 70.55.02

Brake Pedal Hold Tool JDS 9013
Removal WARNING: BRAKE DUST, IF INHALED CAN DAMAGE YOUR HEALTH. ALWAYS REMOVE BRAKE DUST USING A VACUUM BRUSH. DO NOT USE A COMPRESSED-AIR LINE TO DISPERSE BRAKE DUST INTO THE ATMOSPHERE. CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used. See section <<100-00>> for information.
CAUTION: Remove brake fluid spillage immediately from paint work, with clean water.
CAUTION: A new brake hose must be installed when replacing a front brake caliper.
CAUTION: The brake pad adhesive backing must not be reused, therefore always install new brake pads, irrespective of the condition of the original pads when replacing a brake caliper. Always replace brake pads as an axle set.
1. Open engine compartment and fit paint work protection covers to fenders. 2. Raise vehicle on a four-post lift. 3. Raise front of vehicle and support on stands. Refer to Section <<100-02>>. 4. Remove front wheels. See Section <<204-04>>.
2012-07-21
www.JagDocs.com
5. NOTE: The following three pictorial procedures must be carried-out to minimize brake fluid loss when disconnecting the brake hose. Open Left-Hand-Front and Left-Hand-Rear caliper bleed nipples. Connect a bleed tube and container to the calipers. Open bleed nipples.
6. Depress and hold down brake pedal at the specified measurement using the special tool. 1. Position tool between brake pedal and seat frame. 2. Turn the tool wheel until the brake pedal is held 60mm down from its released position.
2012-07-21
7. Close bleed nipples on both calipers. Remove bleed tubes and containers. Tighten front bleed nipple to 4-6 Nm. Tighten rear bleed nipple to 8-11 Nm.
8.
CAUTION: A new brake hose must be installed when replacing a front brake caliper.
Disconnect brake hose from brake tube. 1. Unscrew brake tube union nut. 2. Remove nut from hose. 3. Remove hose from bracket. Fit plug to brake tube.
2012-07-21
www.JagDocs.com
9. Remove brake hose from caliper. Unscrew brake hose. Fit plugs to caliper port. Discard brake hose.
10. Remove caliper housing from caliper carrier. 1. Remove anti-rattle spring. 2. Remove dust covers. 3. Remove guide pins. Remove housing from carrier.
2012-07-21
11. NOTE: The inner brake pad is fitted with a clip which secures the pad into the caliper piston. Remove and discard brake pads. (See Caution above).
12. Remove brake carrier from vertical link. Remove bolts. Remove carrier. 13. Remove brake dust and clean caliper mating surfaces. See Warning above.
2012-07-21

Installation
www.JagDocs.com
1. Install caliper carrier to vertical link. Align carrier to vertical link . Install and tighten bolts to 120-160 Nm.
2. NOTE: Clean caliper piston to pad mating surface . Install brake pads into caliper housing. (See Caution above). 1. Remove plug from port and slowly retract piston into caliper housing. 2. Remove paper backing from pads to reveal adhesive shim. Install brake pads, insert clip located on back of inner pad into caliper piston.
2012-07-21
3. Install caliper housing to caliper carrier. Align housing to carrier. 1. Install and tighten guide pins to 25-30 Nm. 2. Install dust covers. 3. Install anti-rattle spring.
4. NOTE: The brake hose must only be installed with the vehicle's body supported and the suspension hanging in the straight ahead position. Install and tighten brake hose to caliper housing to 10-14 Nm.
2012-07-21
www.JagDocs.com
5. NOTE: Make sure the brake hose does not twist when tightening the hose lock-nut. Connect brake hose to brake tube. 1. Position hose thread through bracket. 2. Install and tighten locking nut to 15-20 Nm. 3. Install and tighten brake-tube union nut. Refer to Specifications, section <<206-03>>. 6. Remove special tool from brake pedal. 7. Fit wheels. Refer to section <<204-04>>. 8. NOTE: Make sure the brake hose is routed correctly. Remove stands and lower vehicle. Refer to section <<100-02>>. 9. Bleed brake hydraulic system. See operation <<70.25.03>>.
2012-07-21
Brake Disc 70.10.10

Removal WARNING: BRAKE DISCS MUST ALWAYS BE REPLACED IN PAIRS. WARNING: BRAKE DUST, IF INHALED CAN DAMAGE YOUR HEALTH. ALWAYS REMOVE BRAKE DUST USING A VACUUM BRUSH. DO NOT USE A COMPRESSED-AIR LINE TO DISPERSE BRAKE DUST INTO THE ATMOSPHERE. CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used. See section <<100-00>> for information.
1. Open engine compartment and install paint work protection covers to fenders. 2. Raise front of vehicle and support on stands. See Section <<100-02>>. 3. Remove front wheels. Refer to Section <<204-04>>.
4.
Loosen brake fluid reservoir-cap. Position a cloth around the reservoir to collect any fluid spillage.
2012-07-21
www.JagDocs.com
5.
Remove caliper housing from caliper carrier. 1. Remove anti-rattle spring. 2. Remove dust covers. 3. Remove guide pins. Remove and tie caliper housing aside.
6.
CAUTION: Always install new brake pads, irrespective of the condition of the original pads, when renewing brake discs.
2012-07-21
NOTE: The inner brake pad is fitted with a clip which secures the pad into the caliper piston. Remove brake pads from caliper housing. Discard brake pads.
7. Remove brake carrier from vertical link. Remove bolts. Remove carrier.
8. Withdraw brake disc from hub. 9. Repeat above procedure to remove opposite side brake disc. 10. Remove brake dust from calipers and clean mating surfaces, see WARNING above.
2012-07-21
11. Thoroughly clean the area of the hubs where they mate against the brake discs.
Installation
www.JagDocs.com
1. Install brake disc to hub. 2. Check brake disc run-out. Refer to General Procedures section <<206-03>>.
3. Install caliper carrier to vertical link. Align carrier to vertical link . Install and tighten bolts to 120-160 Nm.
2012-07-21
4.
CAUTION: Always install new brake pads, irrespective of the condition of the original pads, when renewing brake discs.
CAUTION: Retracting the caliper piston may cause the fluid reservoir to over-flow. Remove brake fluid spillage immediately from paint work, with clean water. NOTE: Clean caliper piston to pad mating surface. Install brake pads into caliper housing. 1. Slowly retract piston into caliper housing. 2. Remove paper backing from pads to reveal adhesive shim. Install brake pads, insert clip located on back of inner pad into caliper piston.
5. Install caliper housing to caliper carrier. Align housing to carrier.

5 2012-07-21

1. Install and tighten guide pins to 25-30 Nm. 2. Install dust covers. 3. Install anti-rattle spring. 6. Repeat above procedure to install opposite side brake disc. 7. Fit wheels. Refer to operation <<74.20.05>>. 8. Remove stands and lower vehicle. Refer to section <<100-02>>.
www.JagDocs.com
9.
Check brake fluid level. Check brake fluid level is at the maximum mark. Remove cloth. Fit cap. 10. Remove paint work protection covers, and close engine compartment. 11. Start the engine and repeatedly press the brake pedal until brake pressure is evident.
2012-07-21
Brake Pads 70.40.02

1. Open engine compartment and fit paint work protection covers to fenders. 2. Raise front of vehicle and support on stands. See Section <<100-02>>. 3. Remove front wheels. See Section <<204-04>>.
4.
2012-07-21
www.JagDocs.com
5.
Remove caliper housing from caliper carrier. 1. Remove anti-rattle spring. 2. Remove dust covers. 3. Remove guide pins. Remove and tie caliper housing aside.
6. NOTE: The inner brake pad is fitted with a clip which secures the pad into the caliper piston. Remove brake pads from caliper housing. Discard brake pads.
2012-07-21
7. Clean all mating surfaces and remove brake dust, see WARNING above. 8. Repeat above procedure to remove opposite side brake pads.
Installation
1.
CAUTION: Retracting the caliper piston may cause the fluid reservoir to over-flow. Remove brake fluid spillage immediately from paint work, with clean water. NOTE: Clean caliper piston to pad mating surface.
Install brake pads into caliper housing. 1. Slowly retract piston into caliper housing. 2. Remove paper backing from pads to reveal adhesive shim. Install brake pads, insert clip located on back of inner pad into caliper piston.
2012-07-21
www.JagDocs.com
2. Install caliper housing to caliper carrier. Align housing to carrier. 1. Install and tighten guide pins to 25-30 Nm. 2. Install dust covers. 3. Install anti-rattle spring. 3. Repeat above procedure to install opposite side brake pads. 4. Fit wheels. Refer to section <<204-04>>. 5. Remove stands and lower vehicle. Refer to section <<100-02>>.
6.
Check brake fluid level.
2012-07-21

Check brake fluid level is at the maximum mark. Remove cloth. Fit cap. 7. Remove paint work protection covers, and close engine compartment. 8. Start the engine and repeatedly press the brake pedal until brake pressure is evident.
2012-07-21
1999 XK RANGE - Rear Disc Brake - 206-04
Torques Component Bolt - caliper carrier to hub carrier Guide Pin - caliper housing to caliper carrier Nm 54-66 25-30
Brake Tube, Hoses and Bracket Torques CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used. See section <<100-00>> for information. Component Bleed nipple - front Bleed nipple - rear Hose to front caliper Hose banjo to rear caliper - bolt M10 hose locknut M10 brake tube female-nut M10 brake tube male-nut M12 brake tube male-nut 3-way tube connector to body Nm 4-6 8-11 10-14 30-40 15-20 13-17 13-17 15-20 9-12
www.JagDocs.com
2012-07-21
Rear Disc Brake
Components
Item 1 2 3 4 5 6 7 8 9 10
Description Brake Disc Caliper Housing Caliper Carrier Brake Pads Guide Pins Dust Covers Anti-rattle Spring Dust Shield Brake Hose Bleed Nipple and Cap

The brake disc is mounted on the wheel studs and is clamped between the wheel and hub. Cooling ducts run through the center of the brake disc to provide the required ventilation to keep the disc cool under operating conditions. The caliper carrier, which is secured to the hub carrier by two bolts, carries the single-piston caliper housing. The caliper housing is secured to the caliper carrier by two guide-pins and an anti-rattle spring. When the brakes are applied the caliper-housing piston pushes the brake pad in front of it, towards the brake disc. This movement forces the caliper housing to move along the guide-pins, in the opposite direction of the piston, to apply the second brake pad. The brake disc is therefore gripped between the two pads. As brake pressure is increased the grip on the brake disc is increased to slow-down the rotation of the road wheel. The disc brakes require no adjustment.
2012-07-21
Brake Caliper 70.55.03

www.JagDocs.com
CAUTION: The brake pad adhesive backing must not be reused, therefore always install new brake pads, irrespective of the condition of the original pads when replacing a brake caliper. Always replace brake pads as an axle set.
1. Open luggage compartment lid and fit suitable paintwork protection equipment. 2. Raise vehicle on a four-post lift. 3. Raise rear of vehicle and support on stands. See Section <<100-02>>. 4. Remove rear wheel. See Section <<204-04>>.
2012-07-21
5. NOTE: The following three pictorial procedures must be carried-out to minimize brake fluid loss when disconnecting the brake hose. Open Left-Hand-Front and Left-Hand-Rear caliper bleed nipples. Connect a bleed tube and container to the calipers. Open bleed nipples.
6. Depress and hold down brake pedal at the specified measurement using the special tool. 1. Position tool between brake pedal and seat frame. 2. Turn the tool wheel until the brake pedal is held 60mm down from its released position.
2012-07-21
www.JagDocs.com
7. Close bleed nipples on both calipers. Remove bleed tubes and containers. Tighten front bleed nipple to 4-6 Nm. Tighten rear bleed nipple to 8-11 Nm.
8. Disconnect brake hose from rear caliper housing. Install plugs to caliper and brake hose.
2012-07-21
9. Remove caliper housing from caliper carrier. 1. Remove anti-rattle spring. 2. Remove dust covers. 3. Remove guide pins. 4. Remove housing from carrier.
10. NOTE: The inner brake pad is fitted with a clip which secures the pad into the caliper piston. Remove and discard brake pads. (See Caution above).
2012-07-21
www.JagDocs.com
11. Remove caliper carrier from hub carrier. Remove bolts. Remove carrier. 12. Clean all mating surfaces and remove brake dust. See Warning above.
Installation
1. Install caliper carrier to hub carrier. Align carrier to hub carrier. Install and tighten bolts to 54-66 Nm.
2012-07-21
2. Make sure piston is fully retracted into caliper housing. Remove plug from caliper housing. Retract piston.
3. Install brake pads into caliper housing. (See Caution above). Remove paper backing from pads to reveal adhesive shim. Install brake pads, insert clip located on back of inner pad into caliper piston.
2012-07-21
www.JagDocs.com
4. Install caliper housing to caliper carrier. 1. Align housing to carrier. 2. Install and tighten guide pins to 25-30 Nm. 3. Install dust covers. 4. Install anti-rattle spring.
5. Connect brake hose to caliper housing. Remove plugs. Install and tighten bolt to 30-40 Nm. 6. Remove special tool from brake pedal. 7. Fit wheels. See Section <<204-04>>. 8. Remove stands and lower vehicle. See Section <<100-02>>. 9. Bleed brake hydraulic system. Refer to operation <<70.25.03>>.
7 2012-07-21
Brake Disc 70.10.11

Removal WARNING: BRAKE DISCS MUST ALWAYS BE REPLACED IN PAIRS. WARNING: BRAKE DUST, IF INHALED CAN DAMAGE YOUR HEALTH. ALWAYS REMOVE BRAKE DUST USING A VACUUM BRUSH. DO NOT USE A COMPRESSED-AIR LINE TO DISPERSE BRAKE DUST INTO THE ATMOSPHERE. CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used. See section <<100-00>> for information.
1. Open engine compartment and fit paint work protection covers to fenders. 2. Raise rear of vehicle and support on stands. Refer to section <<100-02>>. 3. Remove rear wheels. Refer to section <<204-04>>.
4.
2012-07-21
www.JagDocs.com
5.
Remove caliper housing from caliper carrier. 1. Remove anti-rattle spring. 2. Remove dust covers. 3. Remove guide pins. 4. Remove housing from carrier. Tie caliper housing aside.
6.
CAUTION: Always install new brake pads, irrespective of the condition of the original pads, when renewing a brake disc. NOTE:
2012-07-21

The inner brake pad is fitted with a clip which secures the pad into the caliper piston. Remove brake pads from caliper housing. Discard brake pads.
7. Remove caliper carrier from hub carrier. Remove bolts. Remove carrier.
8. Align brake disc access hole with parking brake adjuster. Remove plug from access hole. Rotate brake disc until access hole is aligned with adjuster.
2012-07-21
www.JagDocs.com
9. Slacken parking brake adjuster. Rotate adjuster clockwise.
10. Remove brake disc from wheel studs. 11. Remove brake dust from calipers, and from area of parking brake shoes, see WARNING above. 12. Repeat above procedure to remove opposite side brake disc. 13. Thoroughly clean the area of both hubs where they mate against the brake discs.
2012-07-21

Installation
1. Install brake disc to wheel studs. Make sure hub and brake disc access holes are aligned. 2. Set the parking brake, refer to operation <<70.35.37>>. 3. Check brake disc run-out. Refer to General Procedures section <<206-04>>.
4. Install caliper carrier to hub carrier. Position carrier. Install and tighten bolts to 54-66 Nm.
2012-07-21
www.JagDocs.com
5.
CAUTION: Retracting the caliper piston may cause the fluid reservoir to over-flow. Remove brake fluid spillage immediately from paint work, with clean water.
Slowly retract piston into caliper housing.
6.
CAUTION: Always install new brake pads, irrespective of the condition of the original pads, when renewing a brake disc. NOTE: Clean caliper piston to pad mating surface.
Install brake pads to caliper housing. Remove paper backing from pads to reveal adhesive shim. Install brake pads, insert clip located on back of inner pad into caliper piston.
2012-07-21
7. Install caliper housing to caliper carrier. 1. Align housing to carrier. 2. Install and tighten guide pins to 25-30 Nm. 3. Install dust covers. 4. Install anti-rattle spring. 8. Repeat above procedure to install opposite side brake disc. 9. Fit wheels. Refer to section <<204-04>>. 10. Remove stands and lower vehicle. Refer to section <<100-02>>.
11.
2012-07-21
Check brake fluid level. Check brake fluid level is at the maximum mark. Remove cloth. Fit cap. 12. Remove paint work protection covers, and close engine compartment. 13. Start the engine and repeatedly press the brake pedal until brake pressure is evident.
www.JagDocs.com
2012-07-21
Brake Pads 70.40.03

1. Open engine compartment and fit paint work protection covers to fenders. 2. Raise rear of vehicle and support on stands. See Section <<100-02>>. 3. Remove both rear wheels. See Section <<204-04>>.
4.
2012-07-21
www.JagDocs.com
5.
Remove caliper housing from caliper carrier. 1. Remove anti-rattle spring. 2. Remove dust covers. 3. Remove guide pins. 4. Remove housing from carrier. Tie caliper housing aside.
6. NOTE: The inner brake pad is fitted with a clip which secures the pad into the caliper piston. Remove brake pads from caliper housing. Discard brake pads.
2012-07-21
7. Clean all mating surfaces and remove brake dust. See Warning above. 8. Repeat above procedure to remove opposite side brake pads.
Installation
1.
CAUTION: Retracting the caliper piston may cause the fluid reservoir to over-flow. Remove brake fluid spillage immediately from paint work, with clean water.
Slowly retract piston into caliper housing.
2. NOTE: Clean caliper piston to pad mating surface. Install brake pads to caliper housing.
3 2012-07-21

Remove paper backing from pads to reveal adhesive shim. Install brake pads, insert clip located on back of inner pad into caliper piston.
www.JagDocs.com
3. Install caliper housing to caliper carrier. 1. Align housing to carrier. 2. Install and tighten guide pins to 25-30 Nm. 3. Install dust covers. 4. Install anti-rattle spring. 4. Repeat above procedure to install opposite side brake pads. 5. Fit wheels. Refer to Section <<204-04>>. 6. Remove stands and lower vehicle. Refer to Section <<100-02>>.
7.
CAUTION:
2012-07-21

Remove brake fluid spillage immediately from paint work, with clean water. Check brake fluid level. Check brake fluid level is at the maximum mark. Remove cloth. Fit cap. 8. Remove paint work protection covers, and close engine compartment. 9. Start the engine and repeatedly press the brake pedal until brake pressure is evident.
2012-07-21
1999 XK RANGE - Parking Brake and Actuation - 206-05
Dimensions NOTE: When a component reaches its maximum / minimum limit the component must be replaced. Care must be taken when refinishing brake drums that the limits are not exceeded. Component Parking brake drum - maximum diameter Parking brake shoes - minimum thickness Dimension 181 mm 2 mm
Torques CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used. See section <<100-00>> for information. Component Bolt - parking brake lever to body Bolt - pivot to body Bolt - relay lever mounting plate to body Bolt - relay lever to mounting plate Nm 22-28 22-28 22-28 22-28
www.JagDocs.com
2012-07-21
Parking Brake Cable Adjustment

1. Raise rear of vehicle and support on stands. See section <<100-02>>. 2. Make sure gear selector is in the neutral (N) position.
3. Adjust parking brake cable. Rotate adjusting nut, until the parking brake can be applied by raising the parking brake lever 3 to 5 clicks.
4.
CAUTION: Make sure that the rear wheels rotate freely when the parking brake lever is released.
Remove stands and lower vehicle.
2012-07-21
Parking Brake Shoe and Lining Adjustment

1. Raise rear of vehicle and support on stands. See section <<100-02>>. 2. Remove both rear wheels. 3. Make sure that the parking brake lever is released, and the gear selector lever is in the neutral (N) position.
www.JagDocs.com
4. Align brake disc access hole with parking brake adjuster. Install three wheel nuts to secure brake disc to hub. Tighten nuts to 20 Nm. Remove plug from access hole. Rotate brake disc until access hole is aligned with adjuster.
5. Using a flat-bladed screwdriver rotate the adjuster counter-clockwise until the brake disc cannot be rotated.
2012-07-21
6. NOTE: The brake shoe return-spring next to the adjuster prevents the adjuster from rotating under normal operating conditions. Make sure that the spring is seated between the adjuster spokes, when brake adjustment is complete. Rotate the adjuster gradually clockwise until the brake disc rotates freely. Install plug to access hole. 7. Repeat parking brake setting procedure on opposite-side of vehicle.
8.
CAUTION: Make sure that the rear wheels rotate freely when the parking brake lever is released.
Adjust parking brake cable. Rotate adjusting nut, until the parking brake can be applied by raising the parking brake lever 3 to 5 clicks.
2012-07-21
9. Remove wheel nuts. 10. Fit rear wheels. See section <<204-04>>. 11. Remove stands and lower vehicle.
www.JagDocs.com
2012-07-21
Parking Brake
Parking Brake Components
Item 1 2 3 4 5 6 7 8 9
Description Hand Lever Front Cable Relay Lever Mounting Plate Relay Lever Cable Adjuster Rod Equalizer Rear Cable RH Rear Cable LH Warning-Light Switch

The parking-brake hand lever is mounted on the inner sill and incorporates the ratchet mechanism and release button. The front cable is routed from the hand lever, under the carpet through to an abutment bracket adjacent to the transmission tunnel, and then connected to the relay lever. The relay lever is attached to a mounting plate by a center bolt on which it rotates The relay lever mounting plate straddles the transmission tunnel, the plate is secured by four bolts on the coupe, and eight bolts on the convertible which has a longer plate. The relay lever acts as a center pull system to transmit the force from the hand lever to the rear brakes shoes. The equalizer which is positioned in the center of the rear brake cables balances the force that is applied to the rear brakes. The rear brake cables are linked together: each cable passes through the suspension subframe and rear hub carrier and connects to a brake shoe expander lever. Application of the parking brake causes the rear cables to pull on the expander levers, the expander lever mechanism rotates on a pivot pin to force the brake shoes outwards to contact
2012-07-21

the brake drums. The parking brake cables are adjusted by the rotation of a nut on the adjuster rod. The parking brake shoes are adjusted by means of a manual adjustment mechanism at each set of shoes. Refer to General Procedures in section <<206-05>>. If the vehicle is driven above 5 km/h with the parking brake applied, a warning lamp and text message will appear on the message center. The message clears when the brake is released or the speed drops below 3 km/h.
Parking Brake Shoe Arrangement
www.JagDocs.com
Item 1 2 3 4 5 6
Description Adjuster Mechanism Retaining Pins Brake Shoes Upper Return Spring Lower Return Spring Expander Lever Mechanism
The adjuster mechanism enables manual adjustment of the brake shoes. Retaining pins keep the shoes in contact with the dust shield. The brake shoes locate into the expander lever and the adjuster mechanism. Return springs retract the brake shoes when the parking brake is released. The expander lever mechanism moves the brake shoes outwards, in contact with the brake drum when the parking brake is applied.
2012-07-21
Parking Brake Control 70.35.08

1. Remove driver seat for access. Refer to operation 76.70.01.90. 2. Remove trim from hand lever. Refer to operation <<76.13.63>>. 3. Raise rear of vehicle and support on stands. Refer to section <<100-02>>.
4. Slacken brake cable, adjustment nut.
2012-07-21
www.JagDocs.com
5. NOTE: Spacers and washers (if installed) are used to seat the hand lever. For installation purposes note the number and position of the washers that are removed from each bolt. Remove bolts securing hand lever to body. 1. Remove bolts. 2. Collect spacers and washers (if installed).
6. NOTE: For installation purposes note the number of washers (if installed) that are removed from the bolt. Release hand lever from body. Undo pivot bolt (the pivot bolt remains captive in lever). Collect washers (if installed).
2012-07-21
7. Disconnect parking-brake, warning-light switch connector.
8. Release brake cable from hand lever. 1. Remove spring clip. 2. Release cable from trunnion. 3. Remove trunnion. Release cable from lever. 9. Remove hand lever from vehicle.
2012-07-21
www.JagDocs.com
10. Remove warning-light switch from lever. Remove screws.
Installation
1. Install warning-light switch to hand lever. Install and tighten screws.
2012-07-21
2. Install brake cable to hand lever. Position cable into hand lever. 1. Install trunnion into hand lever. 2. Install cable into trunnion. 3. Install spring clip.
3. Connect warning-light switch connector.
2012-07-21
www.JagDocs.com
4. Install parking-brake lever to body. 1. Position spacers, and washers (if installed). 2. Install bolts: do not tighten bolts at this stage. 3. Tighten pivot bolt to 22-28 Nm. 4. Tighten remaining bolts to 22-28 Nm. 5. Adjust parking brake. Refer to operation <<70.35.10>>. 6. Remove stands and lower vehicle. 7. Install trim to hand lever. Refer to operation <<76.13.63>>. 8. Install driver seat. Refer to operation 76.70.01.90.
2012-07-21
Parking Brake Control Shroud 76.13.63

Removal 1. Position parking brake lever fully fully upright.
2. Release brake lever trim press stud.
3. Release cover trim securing clip from brake lever and remove cover trim.
Installation 1. With parking brake lever in the fully up position, install cover trim on lever.
2012-07-21
2. Secure cover trim clip to brake lever. 3. Fasten cover trim press stud. 4. Return brake lever to down position.
www.JagDocs.com
2012-07-21
Parking Brake Front Cable 70.35.14

1. Position vehicle on a four-post lift. 2. Remove driver's seat. Refer to operation 76.70.01.90. 3. Remove parking-brake lever trim. Refer to operation <<76.13.63>>.
4. Remove the lower slider bar of the driver side seat belt. 1. Remove bolt. 2. Remove slider bar from body grommet and seat belt loop. 3. Collect spacer and card washer.
2012-07-21
www.JagDocs.com
5. Raise rear seat cushion on driver's side of vehicle for access to carpet. Remove nuts securing seat cushion to body Raise seat cushion. 6. Reposition carpet to gain access to parking brake cable. 7. Raise vehicle.
8. Loosen parking brake cable, adjustment nut.
2012-07-21
9. Release parking brake cable from relay-lever fork.
10. Remove body grommet from cable. Remove grommet from body. Remove grommet from cable. 11. Lower vehicle.
2012-07-21
www.JagDocs.com
12. Release cable form abutment bracket. Remove retaining clip. Pull cable into vehicle.
13. Release brake cable from hand lever. 1. Remove spring clip. 2. Release cable from trunnion. 3. Remove trunnion. Release cable. 14. Clean components and mating surfaces.
Installation 1. Lay cable in vehicle in its installed position.
2012-07-21
2. Install brake cable to hand lever. Position cable into hand lever. 1. Install trunnion into hand lever. 2. Install cable into trunnion. 3. Install spring clip.
3. Install cable into abutment bracket. Install retaining clip. 4. Raise vehicle.
2012-07-21
www.JagDocs.com
5. Install body grommet. Install grommet to cable. Install grommet to body.
6. Connect cable to relay-lever fork. 7. Set parking brake. Refer to operation <<70.35.37>>. 8. Lower vehicle. 9. Reposition carpet under rear seat cushion.
2012-07-21
10. Reposition rear seat cushion. Install nuts and tighten to 5-7 Nm.
11. Install the lower slider bar of the driver side seat belt. 1. Insert slider bar through seat belt loop and body grommet. 2. Position spacer and card washer. 3. Install bolt and tighten to 34-46 Nm. 12. Install parking brake lever trim. Refer to operation <<76.13.63>>. 13. Install driver seat. Refer to operation 76.70.01.90.
2012-07-21
Parking Brake Linkage Lever 70.35.22

1. Position vehicle on a four-post lift. 2. Make sure parking brake is fully released.
www.JagDocs.com
3. Remove equalizer. 1. Remove adjustment nut. 2. Remove equalizer from adjustment rod and cable. 3. Remove damper.
2012-07-21
4. Release front parking-brake cable from relay-lever fork.
5.
CAUTION: Be aware of the spring torsion when removing components from the relay lever.
Remove components to access relay lever. 1. Remove bolts. 2. Unhook return spring and remove tie strap. 3. Collect bush from relay lever. 4. Remove lower return spring. 5. Remove relay lever. 6. Remove upper return spring.
2012-07-21
www.JagDocs.com
6. Remove components from relay lever. 1. Remove clip and clevis pin. 2. Remove adjuster -mechanism fork. 3. Remove clip and clevis pin. 4. Remove front-cable fork. 7. Clean components and mating surfaces.
Installation 1. NOTE: Make sure return-spring legs are located correctly after installation. NOTE: Apply grease to clevis pins and relay lever. Installation is reversal of the removal procedure.
2012-07-21

2. Tighten bolts. 1. Tighten bolts to 22-28 Nm. 3. Adjust parking-brake cable. Refer to operation <<70.35.10>>.
2012-07-21
Parking Brake Linkage Lever Mounting Plate Vehicles Without: Convertible Top 70.35.42
www.JagDocs.com
3. Slacken parking-brake cable, adjustment nut.
2012-07-21
4.
CAUTION: Be aware of the spring torsion when removing components.
Remove components to access mounting plate. 1. Remove bolts. 2. Unhook return spring and remove tie strap. 3. Collect bush from relay lever. 4. Remove lower return spring. 5. Lower relay lever. 6. Remove upper return spring.
5. Remove mounting plate. Remove remaining bolts. Remove plate. 6. Clean components and mating surfaces.
Installation 1. NOTE: Make sure return-spring legs are located correctly after installation. Installation is reverse of removal procedure.
2012-07-21
www.JagDocs.com
2. Tighten bolts. 1. Tighten bolts to 22-28 Nm. 3. Adjust parking-brake cable. Refer to operation <<70.35.10>>.
2012-07-21
Parking Brake Linkage Return Springs 70.35.41

3. Slacken parking-brake cable, adjustment nut.
2012-07-21
4.
CAUTION: Be aware of the spring torsion when removing components.
Remove components to access return springs.. 1. Remove bolts. 2. Unhook return spring and remove tie strap. 3. Collect bush from relay lever. 4. Remove lower return spring. 5. Lower relay lever. 6. Remove upper return spring. 5. Clean components and mating surfaces.
Installation 1. NOTE: Make sure return-spring legs are located correctly after installation. Installation is reverse of removal procedure.
www.JagDocs.com
2. Tighten bolts. 1. Tighten bolt to 22-28 Nm. 3. Adjust parking-brake cable. Refer to operation <<70.35.10>>.
2012-07-21
Parking Brake Linkage Rod 70.35.40

3. Remove equalizer from rear parking-brake cable. 1. Remove adjustment nut. 2. Remove equalizer from adjustment rod and cable. 3. Remove damper.
2012-07-21
www.JagDocs.com
4. Remove adjuster assembly from relay. 1. Remove clip and clevis pin. 2. Remove adjustment rod. 3. Remove fork-end from adjustment rod.
Installation 1. Installation is the reverse of the removal procedure. 2. Adjust parking-brake cable. Refer to operation <<70.35.10>>.
2012-07-21
Parking Brake Shoes 70.40.05

1. Open engine compartment and fit paint work protection covers to fenders. 2. Raise rear of vehicle and support on stands. <<100-02>> 3. Remove both rear wheels. <<204-04>> 4. Remove both rear brake discs. <<206-04>>
5. Loosen parking brake cable adjustment nut.
2012-07-21
www.JagDocs.com
6. Remove front shoe retaining pin. Align hub access hole with retaining pin. Turn pin until it releases from backing plate.
7. Remove adjuster assembly. Move front shoe forwards. Remove adjuster assembly.
2012-07-21
8. Remove the parking brake shoes upper return spring.
9. Remove rear shoe retaining pin. Align hub access hole with retaining pin. Turn pin until it releases from backing plate. 10. Remove brake shoes from parking brake lever-mechanism and remove shoes from vehicle.
2012-07-21
11. Remove the parking brake lower return spring. 12. Remove brake dust and clean components, see WARNING above. 13. Repeat procedure to remove parking brake shoes on opposite side of vehicle.
www.JagDocs.com
Installation
1. Install the parking brake lower return spring.
2012-07-21
2. Install brake shoes to vehicle. Install brake shoes to parking brake lever-mechanism in the arrangement shown.
3. NOTE: Make sure retaining pin is seated correctly in backing plate. Install rear shoe retaining pin. Align hub access hole. Install retaining pin.
2012-07-21
4. Install the parking brake shoes upper return spring.
www.JagDocs.com
5. Install adjuster assembly. Lubricate adjuster mechanism with appropriate grease. Move front shoe forwards. Install adjuster assembly.
2012-07-21
6. NOTE: Make sure retaining pin is seated correctly in backing plate. Install front shoe retaining pin. Align hub access hole. Install retaining pin. 7. Make sure brake shoes are seated correctly in adjuster and lever mechanism. 8. Repeat procedure to install parking brake shoes on opposite side of vehicle. 9. Install both rear brake discs. <<206-04>> 10. Adjust parking brake. <<Parking Brake Cable Adjustment - >> 11. Fit rear wheels. <<206-04>> 12. Remove stands and lower vehicle.
2012-07-21
1999 XK RANGE - Hydraulic Brake Actuation - 206-06
Torques Component Nut - master cylinder to brake booster Nut - brake pedal pivot-pin to pedal housing Nut - brake switch to pedal housing Bolt - pedal housing to body Nut - pedal housing to body Nut - brake booster to pedal housing Nm 21-29 15-20 3 15-20 15-20 22-28
Brake Tube, Hoses and Bracket Torques CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used. See section <<100-00>> for information. Component Bleed nipple - front Bleed nipple - rear Hose to front caliper Hose banjo to rear caliper - bolt M10 hose locknut M10 brake tube female-nut M10 brake tube male-nut M12 brake tube male-nut Bolt - 3-way tube connector to body Nm 4-6 8-11 10-14 30-40 15-20 13-17 13-17 15-20 9-12
www.JagDocs.com
2012-07-21
Hydraulic Brake Actuation

The hydraulic brake system is split in to two independent circuits: the primary circuit operates the front brakes and the secondary circuit operates the rear brakes. This type of system prevents complete brake failure in the event of a brake tube fracture. The hydraulic brake system consists of the following components:
Item 1 2 3 4 5 6 7 8 6/7/8 9 10 11 12 13
Description Pedal Housing / Booster - refer to <<206-07>> Vacuum Hose - refer to <<206-07>> Master Cylinder / Reservoir Primary Brake Circuit Secondary Brake Circuit Hydraulic Pump / Motor Unit - refer to <<206-09>> Valve Block - refer to <<206-09>> ABS/Traction Control Control Module (ABS/TCCM) - refer to <<206-09>> Brake Control Modulator Brake Disc - refer to <<206-03>> or <<206-04>> Brake Caliper: refer to <<206-03>> / <<206-04>> Wheel Speed Sensor - refer to <<206-09>> ABS Warning Lamp - refer to <<206-09>> Brake Fluid Level Warning-Lamp
2012-07-21
Master Cylinder and Reservoir
www.JagDocs.com
The tandem master cylinder contains two independent pistons, fluid pressure to each brake circuit is controlled by its own individual piston. Brake fluid is supplied to the master cylinder by the reservoir, which is divided into two sections to prevent total fluid loss should one of the circuits fail. A port situated at the bottom of each section of the reservoir supplies the fluid to each piston. The fluid reservoir has a fluid-level indicator switch installed, which operates when the fluid level is low, causing the brake fluid level warning-lamp to illuminate.
Brake Calipers
The brake calipers are of the single piston type. The caliper carrier, which is secured to the vertical link by two bolts, carries the single-piston caliper housing. The caliper housing is secured to the caliper carrier by two guide-pins and a anti-rattle spring. When the brakes are applied, the caliper-housing piston pushes the brake pad in front of it, towards the brake disc. This movement forces the caliper housing to move along the guide-pins, in the opposite direction of the piston, to apply the second brake pad.
2012-07-21
Brake Fluid Reservoir 70.30.16

1. Position vehicle on a four-post lift. 2. Open engine compartment and fit paint work protection covers to fenders. 3. Disconnect battery ground cable (IMPORTANT, see operation <<86.15.19>> for further information). 4. Remove windshield wiper arm and blade assembly for access. Refer to operation 84.15.44.90. 5. Remove plenum cover for access. Refer to operation <<76.10.01>>. 6. Remove pedal housing, brake booster and master cylinder assembly. Refer to operation <<70.35.39>>. 7. Remove reservoir filler cap and empty residual brake fluid into a container. Refit cap.
8. Remove fluid reservoir from master cylinder. Remove locating pin. Pull reservoir from master cylinder.
2012-07-21
9. Install plugs into fluid reservoir ports.
www.JagDocs.com
10. Remove and discard seals from master cylinder.
2012-07-21
11. Install plugs into master cylinder ports. 12. Clean components and mating surfaces.
Installation
1. Install seals into master cylinder. Remove plugs. Lubricate seals with clean brake fluid. Install seals.
2012-07-21
www.JagDocs.com
2. Install reservoir to master cylinder. Remove plugs. Install reservoir, making sure reservoir is fully seated. Install locating pin. 3. Install pedal housing, brake booster and master cylinder assembly. Refer to operation <<70.35.39>>. 4. Install plenum cover. Refer to operation <<76.10.01>>. 5. Install windshield wiper arm and blade assembly. Refer to operation 84.15.44.90. 6. Reconnect battery ground cable (IMPORTANT, see operation <<86.15.15>> for further information). 7. Bleed brake system. Refer to operation <<70.25.03>>. 8. Remove paint-work protection covers and close engine compartment.
2012-07-21
Brake Master Cylinder 70.30.08

1. Position vehicle on a four-post lift. 2. Open engine compartment and fit paint work protection covers to fenders. 3. Disconnect battery ground cable (IMPORTANT, refer to operation <<86.15.19>> for further information). 4. Remove windshield wiper arm and blade assembly for access. Refer to operation 84.15.44.90. 5. Remove plenum cover for access. Refer to operation <<76.10.01>>. 6. Remove pedal housing, brake booster and master cylinder assembly. Refer to operation <<70.35.39>>.
7. Remove nuts securing master cylinder to brake booster.
2012-07-21
www.JagDocs.com
8. Remove master cylinder from brake booster. Remove master cylinder. Remove and discard seal. Remove filler cap and empty residual brake fluid into a container.
9. Remove fluid reservoir from master cylinder. Remove locating pin. Pull reservoir from master cylinder.
2012-07-21
10. Install plugs into reservoir ports.
11. Remove and discard seals from master cylinder.
2012-07-21
12. Install plugs into master cylinder ports. 13. Clean components and mating surfaces.
www.JagDocs.com
Installation
1. Install seals into master cylinder. Remove plugs. Lubricate seals with clean brake fluid. Install seals.
2012-07-21
2. Install fluid reservoir to master cylinder. Remove plugs from reservoir Install reservoir, making sure reservoir is fully seated. Install locating pin.
3. Install master cylinder to brake booster. Install seal. Install master cylinder, make sure master cylinder rod locates brake booster rod.
2012-07-21
4. Install and tighten nuts to 21-29 Nm. 5. Install pedal housing, brake booster and master cylinder assembly. Refer to operation <<70.35.39>>. 6. Install plenum cover. Refer to operation <<76.10.01>>. 7. Install windshield wiper arm and blade assembly. Refer to operation 84.15.44.90. 8. Connect battery ground cable (IMPORTANT, see operation <<86.15.15>> for further information). 9. Bleed brake system. Refer to operation <<70.25.03>>. 10. Remove paint-work protection covers and close engine compartment.
www.JagDocs.com
2012-07-21
Brake Pedal
Removal 1. Remove the brake booster and brake master cylinder. <<206-07>>
2. Remove the brake pedal position (BPP) switch.
3. Remove brake pedal from pedal housing. Remove nut. Remove pivot pin. Remove brake pedal. 4. Clean components.
2012-07-21
Installation
www.JagDocs.com
1. Install brake pedal to pedal housing. Apply grease to pivot bush and pivot pin. Align brake pedal in pedal housing. Install pivot pin. Install nut and tighten to 15-20 Nm. CAUTION: Make sure the BPP switch ratchet adjuster is fully released before installing.
2. Install the BPP switch. Tighten to 3 Nm. 3. Install the brake booster and brake master cylinder assembly. <<206-07>>
2012-07-21
Brake Pedal and Bracket 70.35.03

1. Position vehicle on a four-post lift. 2. Open engine compartment and fit paint work protection covers to fenders. 3. Disconnect battery ground cable (IMPORTANT, see operation <<86.15.19>> for further information). 4. Remove windshield wiper arm and blade assembly for access. Refer to operation 84.15.44.90. 5. Remove plenum cover for access. Refer to operation <<76.10.01>>. 6. Remove pedal housing, brake booster and master cylinder assembly. Refer to operation <<70.35.39>>. 7. Remove brake booster and master cylinder assembly. Refer to operation <<70.50.18>>.
8. Remove stoplamp switch from pedal housing. Remove nuts.
2012-07-21
www.JagDocs.com
9. Remove brake pedal from pedal housing. Remove nut. Remove pivot pin. Remove brake pedal. 10. Clean components.
Installation
1. Install brake pedal to pedal housing. Apply grease to pivot bush and pivot pin. Align brake pedal in pedal housing. Install pivot pin. Install nut and tighten to 15-20 Nm.
2012-07-21
2. Install stoplamp switch to pedal housing. Install nuts and tighten to 3 Nm. 3. Install brake booster and master cylinder assembly. Refer to operation <<70.50.18>>. 4. Install pedal housing, brake booster and master cylinder assembly. Refer to operation <<70.35.39>>. 5. Install plenum cover. Refer to operation <<76.10.01>>. 6. Install windshield wiper arm and blade assembly. Refer to operation 84.15.44.90. 7. Reconnect battery ground cable (IMPORTANT, see operation <<86.15.15>> for further information). 8. Bleed brake system. Refer to operation <<70.25.03>>. 9. Remove paint-work protection covers and close engine compartment.
2012-07-21
Brake Pedal and Bracket, Brake Booster and Brake Master Cylinder 70.35.39
1. Position vehicle on a four-post lift. 2. Open engine compartment and fit paint work protection covers to fenders. 3. Disconnect battery ground cable (IMPORTANT, see operation <<86.15.19>> for further information).
www.JagDocs.com
4. Disconnect stop lamp switch connector. Move carpet. Disconnect electrical connector.
2012-07-21
5. Disconnect low-level warning connector from master cylinder.
6. Disconnect vacuum pipe from brake booster. 1. Disconnect pipe. 2. Remove and discard seal. 7. Position absorbent cloth underneath master cylinder to collect brake fluid spillage.
2012-07-21
www.JagDocs.com
8. Disconnect brake tubes from master cylinder. Install plugs to brake tubes and master cylinder ports. 9. Remove windshield wiper arm and blade assembly for access. Refer to operation 84.15.44.90. 10. Remove plenum cover for access. Refer to operation <<76.10.01>>.
11. Remove pedal housing, brake booster and master cylinder assembly from vehicle. Remove nuts and bolts. Remove assembly from vehicle.
2012-07-21
12. Remove and discard gasket from pedal housing. 13. Clean components and mating surfaces.
Installation
1. Install gasket to pedal housing assembly.
2012-07-21
www.JagDocs.com
2.
CAUTION: Make sure no pipes or cables become trapped when fitting the pedal housing assembly.
Install pedal housing to vehicle. Install nuts and bolts. Tighten bolts to 15-20 Nm. Tighten nuts to 15-20 Nm. 3. Position cloth underneath master cylinder to collect brake fluid spillage.
4. Install brake tubes to master cylinder. Remove plugs. Connect brake tubes and tighten unions to specification. Refer to Specification section <<206-03>>. Remove cloth from underneath master cylinder.
2012-07-21
5. Connect low-level warning connector to master cylinder.
6. Connect vacuum pipe elbow to brake booster. 1. Install new seal. 2. Connect pipe. 7. Install plenum cover. Refer to operation <<76.10.01>>. 8. Install windshield wiper arm and blade assembly. Refer to operation 84.15.44.90.
2012-07-21
www.JagDocs.com
9. Connect stop lamp switch connector. Connect electrical connector. Reposition carpet. 10. Reconnect battery ground cable (IMPORTANT, see operation <<86.15.15>> for further information). 11. Bleed brake system. Refer to operation <<70.25.03>>. 12. Remove paint-work protection covers and close engine compartment.
2012-07-21
1999 XK RANGE - Power Brake Actuation - 206-07
Torques CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used. See section <<100-00>> for information. Component Nut - master cylinder to brake booster Nut - brake pedal pivot-pin to pedal housing Nut - brake switch to pedal housing Bolt - pedal housing to body Nut - pedal housing to body Nut - brake booster to pedal housing Nm 21-29 15-20 3 15-20 15-20 21-29
2012-07-21
Brake Booster
www.JagDocs.com
Item 1 2 3 4 5
Description Master Cylinder / Reservoir - refer to <<206-06>> Booster Pedal Box - refer to <<206-06>> Vacuum Hose Non-Return Valve
The brake booster provides assistance by reinforcing the driver's effort when braking. The reinforced assistance provided by the booster is proportional to the driver's effort applied to the brake pedal. The brake force applied by the driver is increased by the booster in a ratio of 6.5:1. The vacuum used to operate the booster is formed in the engine's intake manifold. The booster is connected to the intake manifold by a hose. The booster is fail-safe therefore, if a fault develops in the vacuum unit, the braking system will still function. However, the driver will have to apply a greater force to the brake pedal to slow down the vehicle.
2012-07-21
Brake Booster 70.50.17

1. Position vehicle on a four-post lift. 2. Open engine compartment and fit paint work protection covers to fenders. 3. Disconnect battery ground cable (IMPORTANT, see operation <<86.15.19>> for further information). 4. Remove windshield wiper arm and blade assembly for access. Refer to operation 84.15.44.90. 5. Remove plenum cover for access. Refer to operation <<76.10.01>>. 6. Remove pedal housing, brake booster and master cylinder assembly. Refer to operation <<70.35.39>>. 7. Remove brake booster and master cylinder assembly. Refer to operation <<70.50.18>>.
8. Remove nuts securing master cylinder to brake booster.
2012-07-21
www.JagDocs.com
9. Remove master cylinder from brake booster. Remove master cylinder. Remove and discard seal. Remove filler cap and empty residual brake fluid into a container. 10. Clean components and mating surfaces.
Installation
1. Install master cylinder to brake booster. Install seal. Install master cylinder, make sure master cylinder rod locates brake booster rod.
2012-07-21
2. Install and tighten nuts to 21-29 Nm. 3. Install brake booster and master cylinder assembly. Refer to operation <<70.50.18>>. 4. Install pedal housing, brake booster and master cylinder assembly. Refer to operation <<70.35.39>>. 5. Install plenum cover. Refer to operation <<76.10.01>>. 6. Install windshield wiper arm and blade assembly. Refer operation 84.15.44.90. 7. Reconnect battery ground cable (IMPORTANT, see operation <<86.15.15>> for further information). 8. Bleed brake system. Refer to operation <<70.25.03>>. 9. Remove paint-work protection covers and close engine compartment.
2012-07-21
Brake Booster and Brake Master Cylinder 70.50.18

1. Position vehicle on a four-post lift. 2. Open engine compartment and fit paint work protection covers to fenders. 3. Disconnect battery ground cable (IMPORTANT, see operation <<86.15.19>> for further information). 4. Remove windshield wiper arm and blade assembly for access. Refer to operation 84.15.44.90. 5. Remove plenum cover for access. Refer to operation <<76.10.01>>. 6. Remove pedal housing, brake booster and master cylinder assembly. Refer to operation <<70.35.39>>. 7. Remove reservoir filler cap and pour residual brake fluid into a container. Refit cap.
www.JagDocs.com
8. Remove stoplamp switch from pedal housing. Remove nuts.
2012-07-21
9. Release brake pedal from brake booster push-rod. Remove clip from clevis pin. Remove clevis pin.
10. Separate brake booster and master cylinder assembly from pedal housing. Remove nuts.
2012-07-21
11. Remove and discard gasket. 12. Clean components and mating surfaces.
www.JagDocs.com
Installation
1. Install brake booster and master cylinder assembly to pedal housing. Apply grease to forked end of brake booster push-rod. Install gasket to brake booster.
2012-07-21
2. Align brake booster assembly to pedal housing, make sure push-rod fork straddles brake pedal. Install nuts and tighten to 22-28 Nm.
3. Connect brake pedal to brake booster push-rod. Apply grease and install clevis pin. Install clevis-pin clip
2012-07-21
www.JagDocs.com
4. Install stoplamp switch to pedal housing. Install nuts and tighten to 3 Nm. 5. Install pedal housing, brake booster and master cylinder assembly. Refer to operation <<70.35.39>>. 6. Install plenum cover. Refer to operation <<76.10.01>>. 7. Install windshield wiper arm and blade assembly. Refer to operation 84.15.44.90. 8. Reconnect battery ground cable (IMPORTANT, see operation <<86.15.15>> for further information). 9. Bleed brake system. Refer to operation <<70.25.03>>. 10. Remove paint-work protection covers and close engine compartment.
2012-07-21
1999 XK RANGE - Anti-Lock Control - 206-09
Torques Component Bolt - front wheel speed sensor Bolt - rear wheel speed sensor Bolt - hydraulic control unit to bracket Hub rotor nut Nm 8-10 8-10 8-10 270-330
2012-07-21
Anti-Lock Control
Component Location
www.JagDocs.com
Item 1 2 3 4 5 6 7 8 6/7/8 9 10 11 12 13
Description Pedal Housing / Booster - refer to <<206-07>> Vacuum Hose - refer to <<206-07>> Master Cylinder / Reservoir - refer to <<206-06>> Primary Brake Circuit - refer to <<206-06>> Secondary Brake Circuit - refer to <<206-06>> Hydraulic Pump / Motor Unit ABS/Traction Control Control Module (ABS/TCCM) Hydraulic Control Unit (HCU) Brake Control Modulator Brake Disc - refer to <<206-03>> or <<206-04>> Brake Caliper - refer to <<206-03>>/<<206-04>> Wheel Speed Sensor ABS Warning Lamp Brake Fluid Level Warning-Lamp - refer to <<206-06>>
2012-07-21
Wheel Speed Sensors

Each wheel is monitored by a wheel speed sensor, to detect the speed of movement of a toothed gear that is driven by the wheel. Signal's generated by the toothed gear passing the sensor are sent to the ABS/TCCM to communicate the speed of wheel rotation and any rapid change of wheel speed. The frequency of the sinusoidal output voltage signal from the sensor, is proportional to road wheel rotational speed and the number of teeth on the toothed gear. The amplitude of the voltage is dependent upon the 'air gap' between the sensor and toothed wheel, therefore it is important that this preset gap remains clear and undisturbed.
Brake Control Modulator
The brake control modulator comprises: a ABS/TCCM a hydraulic control unit, an electrically driven hydraulic pump, two low pressure accumulators and damping chambers.
ABS/TCCM
The ABS/TCCM is integrated with the hydraulic control unit. It houses the solenoids that operate the hydraulic control unit's input and return valves; the valve stems locate into the ABS/TCCM's solenoids. There is no electrical connection between the ABS/TCCM and the hydraulic control unit. The ABS/TCCM constantly monitors the brake electronic system by passing self-checking electrical pulses around the circuit. The self check procedures carried-out by the ABS/TCCM are listed below: 1. Monitoring of the operating voltage: the control module will shut-down should the voltages not be (approximately) in the range of 9 to 19V. 2. The pump is monitored for voltage supply and voltage feedback. 3. Monitoring for disturbance, where a failure may be caused by external radio frequency interference, internal leakage current, defective valve transistor or a faulty valve. 4. Internal controller failure, detected by a RAM and ROM test.
2012-07-21
5. The controller area network (CAN) micro-controller checks for correct operation of the communication network and performs a RAM self-check. CAUTION: Disconnection of ABS/TCCM connectors may introduce other fault codes. Following rectification and reconnection, ensure that no induced codes exist. Signals processed by the ABS/TCCM are also sent to the CAN for vehicle use, such as the instrument cluster speed display, cruise control and stability/traction control.
Hydraulic Control Unit

Control of the fluid pressure to the front and rear brakes is by means of the valves contained in the hydraulic control unit. The valves are operated by solenoids housed in the ABS/TCCM.
Hydraulic Pump
The hydraulic pump is integrated with the hydraulic control unit. It is a reciprocating two-circuit pump in which one brake circuit is assigned to each pump circuit. It supplies the fluid pressure and volume to supply the brake circuits under ABS and Traction control. The pump is driven by an electric motor, with the pump housing incorporating two low pressure accumulators and damping chambers for each brake circuit. The accumulator stores the pressure and smooths out the output pulses from the pump.
www.JagDocs.com
ABS Warning Lamp

The system will be set in a fail-safe mode if a problem is detected; a warning lamp on the instrument panel will notify the driver there is a problem.
Anti-Lock Braking System (ABS)

The ABS components are combined with an hydraulic booster and a tandem master cylinder to provide a two circuit braking system. The system comprises, four wheel speed sensors, a brake control modulator and an ABS warning lamp. Should a wheel start to lock-up during braking a signal transmitted from the wheel speed sensor to the brake control modulator will start the hydraulic pump. The brake control modulator will close the input valve of the line connected to the locked-wheel to stop any increase in fluid pressure to the brake caliper. If this fails to prevent the wheel locking, the pressure in the caliper will be decreased by opening the return valve until the wheel starts accelerating again. The fluid pressure from the return valve is directed into the low pressure accumulator, housed in the pump. From the low pressure accumulator, fluid is pumped through the damping chamber to the brake master cylinder. The pressure to the brake caliper will then be increased in small steps to maintain maximum adhesion between the tire and road surface. This is achieved by closing the return valve, and opening the input valve and using the hydraulic pump to increase the pressure. Although the system senses all four wheels independently, the rear wheels are regulated as a pair. If a sensor on a rear wheel detects a wheel decelerating rapidly, then the fluid pressure to both wheels is reduced. The fluid pressure is then dictated by the wheel having the lowest adhesion with the road surface. The ABS system will be set in a fail-safe mode if a problem is detected; a warning lamp on the instrument panel will notify the driver there is a problem. The brake system will still operate conventionally and with the same standard of performance as a vehicle not equipped with ABS.
2012-07-21

Automatic Stability Control (ASC)
The ASC utilizes the ABS sensing arrangement to provide the maximum traction force to propel the vehicle. The ASC is switched on when the engine is started. The system can be switched off by pressing the 'ASC OFF' (the switched is marked 'TRAC OFF' on vehicles fitted with traction control). The switch, which is situated in the center console switchpack, lights up to warn that the system is switched off. An 'ASC' amber warning light flashes on the instrument panel when the system detects a spinning wheel. The ASC system uses engine intervention to reduce the torque delivered to the drive wheels to prevent them spinning. Engine torque is reduced in three ways: The throttle is moved towards the closed position. The ignition is retarded. Fuel is cut-off at the cylinder injectors. Wheel spin is detected by the wheel speed sensors and communicated to the ABS/TCCM. The ABS/TCCM uses information from the controller area network (CAN) to calculate the torque that the engine should produce to stop the wheel spinning. Torque reductions are then requested from the engine control module (ECM) through the CAN. The throttle is then positioned to provide the target torque, which has been calculated to prevent wheel spin. During the transient phase of torque reduction the fuel is cut-off and the ignition retarded Both the fuel cut-off and ignition retard will be restored to normal when the throttle is set to its new position. The ASC uses a brake control modulator with six solenoid valves: three normally open inlet valves and three normally closed outlet valves.
Traction Control
Traction control has the same capabilities as ASC but with the added ability to actuate the brakes of the spinning wheel. This enhances ASC by improving acceleration particularly on surfaces with uneven friction , e.g. one wheel on ice the other on tarmac. When wheelspin occurs, brake line pressure to the slipping wheel is generated, to operate that wheel's brake. The BCM achieves this by closing the cut-off solenoid valve and operating the hydraulic pump. Brake fluid is then drawn from the reservoir through the non-actuated master cylinder to the brake caliper. A 'TRAC' amber warning light flashes on the instrument panel when the system detects a spinning wheel. The traction control system uses a brake control modulator with nine solenoid valves: four normally open inlet valves and four normally closed outlet valves and one special isolating valve. The outlet valves control the brakes of each each rear wheel individually on the traction control system.
2012-07-21

Rear Wheel Speed Sensors and ABS/TCCM Circuit Diagram
www.JagDocs.com
Item 1 2 3 4 5 6 7
Description ABS / TCCM Engine compartment fuse-box TCM (supercharged) ECM TCM (normally aspirated) Left rear wheel speed sensor Right rear wheel speed sensor
2012-07-21
Anti-Lock Control
Principle of operation
The ABS components are combined with a hydraulic booster and a tandem master cylinder to provide a two circuit braking system. The system consists of; four wheel speed sensors, a brake control modulator, and an ABS warning lamp. Should a wheel start to lock up during braking, a signal transmitted from the wheel speed sensor to the brake control modulator will start the hydraulic pump. The brake control modulator will close the input valve of the line connected to the locked-up wheel to stop any increase in fluid pressure to the brake caliper. If this fails to prevent the wheel locking, the pressure in the caliper will be decreased by opening the return valve until the wheel starts accelerating again. The fluid pressure from the return valve is directed into the low pressure accumulator, housed in the modulator body. From the low pressure accumulator, fluid is pumped through the damping chamber to the brake master cylinder. The pressure to the brake caliper will then be increased in small steps to maintain maximum adhesion between the tire and the road surface. This is achieved by closing the return valve, and opening the inlet valve for short periods to increase the pressure. Although the system senses all four wheels independently, the rear wheels are regulated as a pair. If a sensor on a rear wheel detects a wheel decelerating rapidly, the fluid pressure to both rear wheels is reduced. The fluid pressure is then dictated by the wheel having the least adhesion to the road surface. The system will adopt a fail-safe mode if a fault is detected, and a warning light on the instrument panel will notify the driver. The brake system will still operate conventionally, with the same level of performance as a vehicle not equipped with ABS.

1. Verify the customer concern. 2. Confirm if the ABS warning light was illuminated, or still is. NOTE: An intermittent fault may allow the warning light to go off. This does not necessarily mean the fault is not present. Some warnings will appear to clear when the ignition is cycled. This is often because the warning has flagged as a result of one of the vehicle's on-board diagnostic routines having run to detect the fault. If the same routine is not run when the ignition is switched ON, the warning will not reflag until the routine does run. 3. In order to confirm the customer concern, it may be necessary to follow a drive cycle which will enable the system to perform it's diagnostic routine (see below),
Diagnostic Drive Cycles

NOTE: See DTC index for details of codes and possible sources/actions.
2012-07-21

DTC C1095 C1137 C1145/C1155/C1165/C1175 C1233/C1234/C1235/C1236 C1267 B1342 B1676 Cycle to detect fault Drive vehicle to activate ABS Ignition ON for more than 8 minutes Drive vehicle at more than 20 km/h (12.5 mph) for more than 2 minutes Drive vehicle at more than 40 km/h (25 mph) for more than 2 minutes Drive vehicle at more than 40 km/h (25 mph) Drive vehicle at more than 20 km/h (12.5 mph) Turn the ignition switch to the ON position Cycle to clear fault Drive vehicle at more than 40 km/h (25 mph) for more than 2 minutes Turn the ignition switch to the ON position Drive vehicle at more than 20 km/h (12.5 mph) Drive vehicle at more than 20 km/h (12.5 mph) Turn the ignition switch to the ON position Turn the ignition switch to the ON position Turn the ignition switch to the ON position System response to fault detection ABS shut-down, ABS light ON, TCS shut-down, TCS light ON ABS shut-down, ABS light ON, TCS shut-down, TCS light ON ABS shut-down, ABS light ON, TCS shut-down, TCS light ON ABS shut-down, ABS light ON, TCS shut-down, TCS light ON ABS shut-down, ABS light ON, TCS shut-down, TCS light ON Traction control switches off System functions between 9 and 19 volts
www.JagDocs.com
Visual Inspection
1. Visually inspect for obvious signs of mechanical or electrical damage. Mechanical Check the tire sizes, condition, and inflation Brake fluid level Wheel speed sensor fitment Wheel speed sensor air gap Wheel speed sensor toothed wheels (missing teeth/contamination) Electrical Warning light operation Fuses (see table) ABS/Traction control control unit Wheel speed sensors Connectors/pins Harnesses
2012-07-21

Fuse Identification Table
Location Engine bay fuse box Engine bay fuse box Engine bay fuse box Fuse Number 18 16 04 Rating 30 Amp 30 Amp 5 Amp Circuit ABS/Traction control control module battery supply ABS/Traction control control module battery supply ABS/Traction control control module ignition supply
1. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 2. If the cause is not visually evident and the Jaguar approved diagnostic system is not available, use a fault code reader to retrieve the fault codes before proceeding to the Diagnostic Trouble Code (DTC) Index Chart.
Diagnostic Trouble Code (DTC) Index

DTC C1095 Description Pump motor circuit fault Possible Source Pump motor to control module circuit; high resistance, open circuit, short circuit to ground, short circuit to B+ Pump motor supply circuit open circuit Pump motor failure C1137 Control module circuit failure Control module ground circuits; high resistance, open circuit, short circuit to B+ Control module power circuits; high resistance, open circuit, short circuit to ground Control module failure C1145 Right-hand front wheel speed sensor (WSS) circuit failure Wheel speed sensor circuit; open circuit, short circuit Wheel speed sensor to control module circuit; high resistance, open circuit, short circuit to ground Wheel speed sensor failure Control module failure For right-hand front WSS circuit tests, Goto <<C>> . For control module circuit tests, Goto <<B>> . Action For control module circuit tests, Goto <<A>> .
2012-07-21

C1155 Left-hand front wheel speed sensor (WSS) circuit failure Wheel speed sensor circuit; open circuit, short circuit Wheel speed sensor to control module circuit; high resistance, open circuit, short circuit to ground Wheel speed sensor failure Control module failure C1165 Right-hand rear wheel speed sensor (WSS) circuit failure Wheel speed sensor circuit; open circuit, short circuit Wheel speed sensor to control module circuit; high resistance, open circuit, short circuit to ground Wheel speed sensor failure Control module failure C1175 Left-hand rear wheel speed sensor (WSS) circuit failure Wheel speed sensor circuit; open circuit, short circuit Wheel speed sensor to control module circuit; high resistance, open circuit, short circuit to ground Wheel speed sensor failure Control module failure For left-hand rear WSS circuit tests, Goto <<F>> . For right-hand rear WSS circuit tests, Goto <<E>> . For left-hand front WSS circuit tests, Goto <<D>> .
www.JagDocs.com
2012-07-21

C1233 Left-hand front wheel speed sensor signal failure Wheel speed sensor gap incorrect Foreign matter on sensor face Missing tooth on sensor wheel Wheel speed sensor circuit; open circuit, short circuit Wheel speed sensor to control module circuit; high resistance, open circuit, short circuit to ground Wheel speed sensor failure Control module failure C1234 Right-hand front wheel speed sensor signal failure Wheel speed sensor gap incorrect Foreign matter on sensor face Missing tooth on sensor wheel Wheel speed sensor circuit; open circuit, short circuit Wheel speed sensor to control module circuit; high resistance, open circuit, short circuit to ground Wheel speed sensor failure Control module failure For right-hand front WSS circuit tests, Goto <<C>> . For sensor and wheel information, REFER to wheel speed sensor and wheel speed sensor ring in this section. For left-hand front WSS circuit tests, Goto <<D>> . For sensor and wheel information, REFER to wheel speed sensor and wheel speed sensor ring in this section.
2012-07-21

C1235 Right-hand rear wheel speed sensor signal failure Wheel speed sensor gap incorrect Foreign matter on sensor face Missing tooth on sensor wheel Wheel speed sensor circuit; open circuit, short circuit Wheel speed sensor to control module circuit; high resistance, open circuit, short circuit to ground Wheel speed sensor failure Control module failure C1236 Left-hand rear wheel speed sensor signal failure Wheel speed sensor gap incorrect Foreign matter on sensor face Missing tooth on sensor wheel Wheel speed sensor circuit; open circuit, short circuit Wheel speed sensor to control module circuit; high resistance, open circuit, short circuit to ground Wheel speed sensor failure Control module failure C1267 Modulator valve fault Modulator valve failure Supply circuit fault (fuse, etc) Control module failure B1342 CAN circuit malfunction CAN open circuit fault CAN short circuit fault Control module failure B1676 Supply voltage out of range Battery to control module B+ supply circuit; open circuit, high resistance Battery failure, loose connections Charging system failure Control module failure Check the battery condition and charging system, REFER to sections <<414-00>> and <<414-01>>. For CAN circuit tests, REFER to section <<418-00>>. For module supply circuit tests, REFER to section <<418-00>>. For left-hand rear WSS circuit tests, Goto <<F>> . For sensor and wheel information, REFER to wheel speed sensor and wheel speed sensor ring in this section. For right-hand rear WSS circuit tests, Goto <<E>> . For sensor and wheel information, REFER to wheel speed sensor and wheel speed sensor ring in this section.
www.JagDocs.com
2012-07-21
Pinpoint Tests
CAUTION: When probing connectors to take measurements in the course of the pinpoint tests, use the adaptor kit, part number 3548-1358-00. NOTE: When performing electrical voltage or resistance tests, always use a digital multimeter (DMM) accurate to 3 decimal places, and with an up-to-date calibration certificate. When testing resistance, always take the resistance of the DMM leads into account. NOTE: Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.
A : C1095; PUMP MOTOR FAULT

NOTE: Check connectors and pins for damage/corrosion. (See visual inspection).
A1 : CHECK THE BATTERY POWER SUPPLIES TO THE ABS/TRACTION CONTROL CONTROL MODULE
1. Turn the ignition switch to the OFF position. 2. Disconnect the ABS/traction control control module electrical connector, LF37. 3. Measure the voltage between LF37, pin 09 (NR) and GROUND. Is the voltage greater than 10 volts? -> Yes Goto <<A2>> -> No REPAIR the circuit. This circuit includes the engine compartment fuse box (fuse 18). For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
A2 : CHECK THE BATTERY POWER SUPPLIES TO THE ABS/TRACTION CONTROL CONTROL MODULE FOR SHORT TO BATTERY
1. Remove fuse 18 from the engine compartment fuse box.
2012-07-21

2. Measure the voltage between LF37, pin 09 (NR) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<A3>>
A3 : CHECK THE BATTERY POWER SUPPLIES TO THE ABS/TRACTION CONTROL CONTROL MODULE
1. Measure the voltage between LF37, pin 25 (NW) and GROUND. Is the voltage greater than 10 volts? -> Yes Goto <<A4>> -> No REPAIR the circuit. This circuit includes the engine compartment fuse box (fuse 16). For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
www.JagDocs.com
A4 : CHECK THE BATTERY POWER SUPPLIES TO THE ABS/TRACTION CONTROL CONTROL MODULE FOR SHORT TO BATTERY
1. Remove fuse 16 from the engine compartment fuse box. 2. Measure the voltage between LF37, pin 25 (NW) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<A5>>
A5 : CHECK THE GROUND TO THE ABS/TRACTION CONTROL CONTROL MODULE

1. Measure the resistance between LF37, pins 08 and 24 (B) and GROUND.
2012-07-21

Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<A6>>
A6 : CHECK THE PUMP FLY LEAD CONNECTOR

1.
2. Disconnect the pump fly lead electrical connector. 3. Inspect the connector and pins for corrosion/damage. 4. Inspect the harness for damage. Does the connector or harness show any indication of corrosion or damage? -> Yes REPAIR the connector pins or harness, using the harness repair kit, if possible. CLEAR the DTC. TEST the system for normal operation. -> No
2012-07-21

Contact dealer technical support for advice on possible control module failure.
B : C1137; CONTROL MODULE CIRCUIT FAILURE

NOTE: Check connectors and pins for damage/corrosion. (See visual inspection).
B1 : CHECK THE IGNITION SWITCHED POWER SUPPLIES TO THE ABS/TRACTION CONTROL CONTROL MODULE
1. Turn the ignition switch to the OFF position. 2. Disconnect the ABS/traction control control module electrical connector, LF37. 3. Turn the ignition switch to the ON position. 4. Measure the voltage between LF37, pin 20 (WU) and GROUND. Is the voltage greater than 10 volts? -> Yes Goto <<B2>> -> No REPAIR the circuit. This circuit includes the engine compartment fuse box (fuse 04) and the ignition relay. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
www.JagDocs.com
B2 : CHECK THE IGNITION SWITCHED POWER SUPPLIES TO THE ABS/TRACTION CONTROL CONTROL MODULE FOR SHORT TO BATTERY
1. Turn the ignition switch to the OFF position. 2. Measure the voltage between LF37, pin 20 (WU) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<B3>>
10
2012-07-21
B3 : CHECK THE GROUND TO THE ABS/TRACTION CONTROL CONTROL MODULE

1. Measure the resistance between LF37, pins 08 and 24 (B) and GROUND. Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Contact dealer technical support for advice on possible control module failure.
C : C1145, C1234; RIGHT-HAND FRONT WHEEL SPEED SENSOR (WSS) ELECTRICAL FAILURE
NOTE: Check connectors and pins for damage/corrosion. (See visual inspection). NOTE: Sensor resistances should be measured using a +/- of 60 ohms.
C1 : CHECK THE RESISTANCE OF THE SENSOR

1. Disconnect the WSS electrical connector, FR01. 2. Measure the resistance between FR01, pins 01 and 02. Is the resistance 1100 ohms? -> Yes Goto <<C2>> -> No INSTALL a new Right-hand front wheel speed sensor,
C2 : CHECK THE VOTAGE OUTPUT FROM THE SENSOR

1. Connect a voltmeter between FR01, pins 01 and 02. 2. Spin the wheel by hand.
11 2012-07-21

Is the voltage greater than 0 volts, but less than 5 volts? (The voltage will fluctuate, and be proportional to wheel speed). -> Yes Goto <<C4>> -> No Goto <<C3>>
C3 : CHECK THE SENSOR AIR GAP

NOTE: In the course of this test, it will be possible to check for contamination of the sensor face and/or toothed wheel, and to check the wheel for damage. Should any of these conditions be found, repair as necessary. NOTE: The air gap should be measured using a +/- of 0.75 mm. 1. Measure the gap between the WSS face and the toothed wheel. Is the air gap 0.90 mm? -> Yes Goto <<C5>> -> No Reset the air gap. CLEAR the DTC. TEST the system for normal operation.
www.JagDocs.com
C4 : CHECK THE SENSOR TO HCU CIRCUIT FOR HIGH RESISTANCE

1. Reconnect the WSS electrical connector, FR01. 2. Disconnect the battery negative terminal. 3. Disconnect the HCU electrical connector, LF37. 4. Measure the resistance between LF37, pins 03 (Y) and 04 (G). Is the resistance greater than 1100 ohms? -> Yes Goto <<C5>> -> No Contact dealer technical support for advice on possible control module failure.
12 2012-07-21
C5 : CHECK THE WSS TO HCU SIGNAL CIRCUIT FOR HIGH RESISTANCE

1. Disconnect the WSS electrical connector, FR01. 2. Measure the resistance between LF37, pin 03 (Y) and FR01, pin 02 (Y). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<C6>>
C6 : CHECK THE WSS TO HCU SIGNAL CIRCUIT FOR SHORT TO GROUND

1. Measure the resistance between LF37, pin 03 (Y) and GROUND Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<C7>>
C7 : CHECK THE WSS TO HCU - CIRCUIT FOR HIGH RESISTANCE

1. Measure the resistance between LF37, pin 04 (G) and FR01, pin 01 (G). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Carry out mechanical checks on the WSS. if no fault is found, install a new Right front wheel speed sensor. CLEAR the DTC. TEST the system for normal operation. If the DTC is repeated, contact dealer technical support for advice on possible control module failure.
13
2012-07-21
D : C1155, C1233; LEFT-HAND FRONT WHEEL SPEED SENSOR (WSS) ELECTRICAL FAILURE
D1 : CHECK THE RESISTANCE OF THE SENSOR

1. Disconnect the WSS electrical connector, FL01. 2. Measure the resistance between FL01, pins 01 and 02. Is the resistance 1100 ohms? -> Yes Goto <<D2>> -> No INSTALL a new Left-hand front wheel speed sensor,
www.JagDocs.com
D2 : CHECK THE VOTAGE OUTPUT FROM THE SENSOR

1. Connect a voltmeter between FL01, pins 01 and 02. 2. Spin the wheel by hand. Is the voltage greater than 0 volts, but less than 5 volts? (The voltage will fluctuate, and be proportional to wheel speed). -> Yes Goto <<D4>> -> No Goto <<D3>>
D3 : CHECK THE SENSOR AIR GAP

NOTE:
14 2012-07-21

In the course of this test, it will be possible to check for contamination of the sensor face and/or toothed wheel, and to check the wheel for damage. Should any of these conditions be found, repair as necessary. NOTE: The air gap should be measured using a +/- of 0.75 mm. 1. Measure the gap between the WSS face and the toothed wheel. Is the air gap 0.90 mm? -> Yes Goto <<D4>> -> No Reset the air gap. CLEAR the DTC. TEST the system for normal operation.
D4 : CHECK THE SENSOR TO HCU CIRCUIT FOR HIGH RESISTANCE

1. Reconnect the WSS electrical connector, FL01. 2. Disconnect the battery negative terminal. 3. Disconnect the HCU electrical connector, LF37. 4. Measure the resistance between LF37, pins 17 (W) and 18 (R). Is the resistance greater than 1100 ohms? -> Yes Goto <<D5>> -> No Contact dealer technical support for advice on possible control module failure.
D5 : CHECK THE WSS TO HCU SIGNAL CIRCUIT FOR HIGH RESISTANCE

1. Disconnect the WSS electrical connector, FL01. 2. Measure the resistance between LF37, pin 17 (W) and FL01, pin 02 (W). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
15
2012-07-21

-> No Goto <<D6>>
D6 : CHECK THE WSS TO HCU SIGNAL CIRCUIT FOR SHORT TO GROUND

1. Measure the resistance between LF37, pin 17 (W) and GROUND Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<D7>>
www.JagDocs.com
D7 : CHECK THE WSS TO HCU - CIRCUIT FOR HIGH RESISTANCE

1. Measure the resistance between LF37, pin 18 (R) and FL01, pin 01 (R). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Carry out mechanical checks on the WSS. if no fault is found, install a new Left front wheel speed sensor. CLEAR the DTC. TEST the system for normal operation. If the DTC is repeated, contact dealer technical support for advice on possible control module failure.
E : C1165, C1235; RIGHT-HAND REAR WHEEL SPEED SENSOR (WSS) ELECTRICAL FAILURE
E1 : CHECK THE RESISTANCE OF THE SENSOR
16
2012-07-21

1. Disconnect the WSS electrical connector, RR01. 2. Measure the resistance between RR01, pins 01 and 02. Is the resistance 1100 ohms? -> Yes Goto <<E2>> -> No INSTALL a new Right-hand rear wheel speed sensor,
E2 : CHECK THE VOTAGE OUTPUT FROM THE SENSOR

1. Connect a voltmeter between RR01, pins 01 and 02. 2. Spin the wheel by hand. Is the voltage greater than 0 volts, but less than 5 volts? (The voltage will fluctuate, and be proportional to wheel speed). -> Yes Goto <<E4>> -> No Goto <<E3>>
E3 : CHECK THE SENSOR AIR GAP

NOTE: In the course of this test, it will be possible to check for contamination of the sensor face and/or toothed wheel, and to check the wheel for damage. Should any of these conditions be found, repair as necessary. NOTE: The air gap should be measured using a +/- of 0.75 mm. 1. Measure the gap between the WSS face and the toothed wheel. Is the air gap 0.90 mm? -> Yes Goto <<E4>> -> No
17
2012-07-21

Reset the air gap. CLEAR the DTC. TEST the system for normal operation.
E4 : CHECK THE SENSOR TO HCU CIRCUIT FOR HIGH RESISTANCE

1. Reconnect the WSS electrical connector, RR01. 2. Disconnect the battery negative terminal. 3. Disconnect the HCU electrical connector, LF37. 4. Measure the resistance between LF37, pins 07 (O) and 06 (Y). Is the resistance greater than 1100 ohms? -> Yes Goto <<E5>> -> No Contact dealer technical support for advice on possible control module failure.
www.JagDocs.com
E5 : CHECK THE WSS TO HCU SIGNAL CIRCUIT FOR HIGH RESISTANCE

1. Disconnect the WSS electrical connector, RR01. 2. Measure the resistance between LF37, pin 07 (O) and RR01, pin 02 (O). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<E6>>
E6 : CHECK THE WSS TO HCU SIGNAL CIRCUIT FOR SHORT TO GROUND

1. Measure the resistance between LF37, pin 07 (O) and GROUND Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
18
2012-07-21

-> No Goto <<E7>>
E7 : CHECK THE WSS TO HCU - CIRCUIT FOR HIGH RESISTANCE

1. Measure the resistance between LF37, pin 06 (Y) and RR01, pin 01 (Y). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Carry out mechanical checks on the WSS. if no fault is found, install a new Right front wheel speed sensor. CLEAR the DTC. TEST the system for normal operation. If the DTC is repeated, contact dealer technical support for advice on possible control module failure.
F : C1175, C1236; LEFT-HAND REAR WHEEL SPEED SENSOR (WSS) ELECTRICAL FAILURE
F1 : CHECK THE RESISTANCE OF THE SENSOR

1. Disconnect the WSS electrical connector, RL01. 2. Measure the resistance between RL01, pins 01 and 02. Is the resistance 1100 ohms? -> Yes Goto <<F2>> -> No INSTALL a new Left-hand rear wheel speed sensor,
19
2012-07-21
F2 : CHECK THE VOTAGE OUTPUT FROM THE SENSOR

1. Connect a voltmeter between RL01, pins 01 and 02. 2. Spin the wheel by hand. Is the voltage greater than 0 volts, but less than 5 volts? (The voltage will fluctuate, and be proportional to wheel speed). -> Yes Goto <<F4>> -> No Goto <<F3>>
www.JagDocs.com
F3 : CHECK THE SENSOR AIR GAP

NOTE: In the course of this test, it will be possible to check for contamination of the sensor face and/or toothed wheel, and to check the wheel for damage. Should any of these conditions be found, repair as necessary. NOTE: The air gap should be measured using a +/- of 0.75 mm. 1. Measure the gap between the WSS face and the toothed wheel. Is the air gap 0.90 mm? -> Yes Goto <<F4>> -> No Reset the air gap. CLEAR the DTC. TEST the system for normal operation.
F4 : CHECK THE SENSOR TO HCU CIRCUIT FOR HIGH RESISTANCE

1. Reconnect the WSS electrical connector, RL01. 2. Disconnect the battery negative terminal. 3. Disconnect the HCU electrical connector, LF37.
20
2012-07-21

4. Measure the resistance between LF37, pins 21 (W) and 22 (U). Is the resistance greater than 1100 ohms? -> Yes Goto <<F5>> -> No Contact dealer technical support for advice on possible control module failure.
F5 : CHECK THE WSS TO HCU SIGNAL CIRCUIT FOR HIGH RESISTANCE

1. Disconnect the WSS electrical connector, RL01. 2. Measure the resistance between LF37, pin 21 (W) and RL01, pin 02 (W). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<F6>>
F6 : CHECK THE WSS TO HCU SIGNAL CIRCUIT FOR SHORT TO GROUND

1. Measure the resistance between LF37, pin 21 (W) and GROUND Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<F7>>
F7 : CHECK THE WSS TO HCU - CIRCUIT FOR HIGH RESISTANCE

1. Measure the resistance between LF37, pin 22 (U) and RL01, pin 01 (U). Is the resistance greater than 5 ohms?
21
2012-07-21

-> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Carry out mechanical checks on the WSS. if no fault is found, install a new Right rear wheel speed sensor. CLEAR the DTC. TEST the system for normal operation. If the DTC is repeated, contact dealer technical support for advice on possible control module failure.
www.JagDocs.com
22
2012-07-21
Anti-Lock Brake System (ABS) Module 70.60.02

1. Disconnect battery ground cable (IMPORTANT, see operation <<86.15.19>> for further information). 2. Position vehicle on a four-post lift. 3. Open engine compartment and fit paint work protection covers to fenders.
2012-07-21
www.JagDocs.com
4. NOTE: The following three pictorial procedures must be carried-out to minimize brake fluid loss when disconnecting brake tubes. Open Left-Hand-Front and Left-Hand-Rear caliper bleed nipples. Connect a bleed tube and container to the calipers. Open bleed nipples.
5. Depress and hold down brake pedal to specified position using special tool. 1. Position tool between brake pedal and seat frame. 2. Turn the tool wheel until the brake pedal is held 60mm down from its released position.
2012-07-21
6. Tighten bleed nipples to: Front caliper bleed nipple 4-6 Nm. Rear caliper bleed nipple 8-11 Nm. Remove bleed tubes and containers.
7. Remove elbow from washer bottle filler-neck . Remove and discard 'O'-ring seal.
2012-07-21
8. Disconnect electrical connector from bottom of control module.
www.JagDocs.com
9. Disconnect electrical connector from top of control module. Pull plunger upwards. Release connector. 10. Position an absorbent cloth underneath the HCU to absorb brake fluid spillage.
2012-07-21
11.
Release brake outlet tubes from HCU. Undo brake tube union nuts. Install plugs to HCU ports and brake tubes.
12. Remove control module from HCU, take care not to damage brake tubes. Remove bolts. Remove control module. 13. Clean components and mating surfaces.
2012-07-21

Installation
www.JagDocs.com
1. Install control Module to HCU. Align control module. Install and tighten bolts.
2. Install brake tubes to HCU. Remove plugs from HCU and brake tubes. Install and tighten brake tube union nuts. See Specification section <<206-09>> for torque setting.
2012-07-21
3. Connect electrical connector to top of control module. Push plunger down to secure connector.
4. Connect lower electrical connector to control module.
2012-07-21
www.JagDocs.com
5. Install elbow to washer bottle filler neck. Install 'O'-ring seal. Install elbow. 6. Remove special tool from brake pedal. 7. Reconnect battery ground cable (IMPORTANT, see SRO <<86.15.15>> for further information). 8. Bleed brake system. Refer to operation <<70.25.03>>.
2012-07-21
Front Wheel Speed Sensor 70.60.03

Removal 1. Raise front of vehicle and support on stands. Refer to section <<100-02>>.
2. Remove wheel speed sensor. Disconnect harness connector. Remove bolt. 3. Clean components and mating surfaces.
Installation
1. Install wheel speed sensor. Position sensor.

1 2012-07-21

Install and tighten bolt to 8-10 Nm. Connect harness connector. 2. Remove stands and lower vehicle.
www.JagDocs.com
2012-07-21
Hydraulic Control Unit (HCU) 70.60.18

1. Disconnect battery ground cable (IMPORTANT, see operation <<86.15.19>> for further information). 2. Position vehicle on a four-post lift. 3. Open engine compartment and fit paint work protection covers to fenders.
2012-07-21
www.JagDocs.com
4. NOTE: The following three pictorial procedures must be carried-out to minimize brake fluid loss when disconnecting the brake tubes. Open Left-Hand-Front and Left-Hand-Rear caliper bleed nipples. Connect a bleed tube and container to the calipers. Open bleed nipples.
5. Depress and hold down brake pedal to the specified position using special tool 1. Position tool between brake pedal and seat frame. 2. Turn the tool wheel until the brake pedal is held 60mm down from its released position.
2012-07-21
6. Tighten bleed nipples to: Front caliper bleed nipple 4-6 Nm. Rear caliper bleed nipple 8-11 Nm. Remove bleed tubes and containers.
7. Disconnect the upper electrical connector. Pull plunger upwards. Release connector. 8. Position an absorbent cloth underneath the brake control modulator to collect brake fluid spillage.
2012-07-21
www.JagDocs.com
9.
CAUTION: Remove brake fluid spillage immediately from paint work, with clean water. NOTE: To minimize brake fluid loss, release the brake tubes in the order shown.
Release brake tubes. 1. Undo union nuts and release inlet brake tubes. Install plugs to inlet ports and brake tubes. 2. Undo union nuts and release outlet brake tubes. Install plugs to outlet ports and brake tubes.
10. Remove brake control modulator from bracket. Remove bolts. 11. Clean components and mating surfaces.
2012-07-21
Installation
1. NOTE: The replacement brake control modulator is pre-filled with brake fluid. Install brake control modulator to bracket. Install bolts and tighten to 8-10 Nm.
2. NOTE: To minimize brake fluid loss, install the brake tubes in the order shown. Install brake tubes. Remove plugs from outlet ports and brake tubes. 1. Install and tighten outlet brake-tube union nuts. Refer to Specification section <<206-09>> for torque setting. Remove plugs from inlet ports and brake tubes. 2. Install and tighten inlet brake-tube union nuts. Refer to Specification section <<206-09>> for torque
2012-07-21

setting.
www.JagDocs.com
3. Connect upper electrical connector. Push plunger down to secure connector. 4. Remove special tool from brake pedal. 5. Reconnect battery ground cable (IMPORTANT, see SRO <<86.15.15>> for further information). 6. Bleed brake system. Refer to operation <<70.25.03>>.
2012-07-21
Rear Wheel Speed Sensor 70.60.04

Removal 1. Raise rear of vehicle and support on stands. Refer to section <<100-02>>.
2. Remove wheel speed sensor. Disconnect harness connector. Remove bolt. 3. Clean components and mating surfaces.
Installation
1. Install wheel speed sensor. Position sensor.

1 2012-07-21

Install and tighten bolt to 8-10 Nm. Connect harness connector. 2. Remove stands and lower vehicle.
www.JagDocs.com
2012-07-21
Wheel Speed Sensor Ring 70.60.25

1. Open engine compartment and install paintwork protectors to fenders. 2. Raise front of vehicle and support on stands. Refer to section <<100-02>>. 3. Remove front wheel. Refer to section <<204-04>>. 4. Remove front brake disc. Refer to operation 70.10.12. 5. Remove vertical link and hub assembly. Refer to operation <<60.25.38.90>>.
2012-07-21
www.JagDocs.com
7. Using special tool, secure vertical link and hub assembly in a vice. Secure special tool in a vice. Position hub in tool. Install and tighten wheel nuts.
2012-07-21
9. Using special tool remove rotor nut.
Installation 1. If necessary, install a grease deflector ring to the rotor nut. Refer to <<70.60.26>>.
2012-07-21
www.JagDocs.com
2. Install rotor nut to hub. 1. Install rotor nut. 2. Using special tool tighten rotor nut.
3.
Install rotor nut spring-clip. Install spring clip into the hub retaining holes and, if aligned, into the castellated slots of the rotor nut. If the castellated slots of the rotor nut are not aligned it will be necessary to tighten the rotor nut further until the spring clip engages the slots. 4. Remove vertical link and hub assembly from special tool.
2012-07-21
5. Install disc shield to vertical link. 1. Position disc shield. 2. Install and tighten bolts. 6. Install vertical link and hub assembly to vehicle. Refer to operation <<60.25.38.90>>. 7. Install brake disc. Refer to operation 70.10.12. 8. Install wheel. Refer to section <<204-04>>. 9. Remove stands and lower vehicle.
2012-07-21
Wheel Speed Sensor Ring Grease Deflector 70.60.26

Removal CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used. See section <<100-00>> for information. NOTE: The grease deflector ring was fitted to production vehicles at VIN number 018108 and on. Vehicles before this number must be fitted with a deflector ring when the rotor nut is removed for repair purposes. 1. Open engine compartment and fit paintwork protectors to fenders. 2. Raise front of vehicle and support on stands. Refer to section <<100-02>>. 3. Remove front wheel. Refer to section <<204-04>>. 4. Remove front brake disc. Refer to operation 70.10.12. 5. Remove vertical link and hub assembly. Refer to operation <<60.25.38.90>>.
www.JagDocs.com
6. Remove brake-disc shield from vertical link. 1. Remove screws. 2. Remove disc shield. 7. Remove ABS hub rotor nut from vertical link and hub assembly. Refer to operation <<70.60.25>>. 8. Remove grease deflector from rotor nut. 9. Clean components.
2012-07-21
Installation
1. Install grease deflector to rotor nut. Install the grease deflector ring as shown with deflectors towards rotor teeth. The distance at 'A' must be 0.5 mm. 2. Install ABS hub rotor nut to vertical link and hub assembly. Refer to operation <<70.60.25>>.
3. Install disc shield to vertical link. 1. Position disc shield. 2. Install and tighten bolts. 4. Install vertical link and hub assembly to vehicle. Refer to operation <<60.25.38.90>>. 5. Install brake disc. Refer to operation 70.10.12.
2012-07-21
6. Install wheel. Refer to section <<204-04>>. 7. Remove stands and lower vehicle.
www.JagDocs.com
2012-07-21
1999 XK RANGE - Steering System - General Information - 211-00
Steering Linkage Specifications Steering Linkage Free Play Free play (measured at the steering wheel rim) Measurement (mm) 0-6 Measurement (in) 0-0.24
Power Steering Pump Specifications Item Power steering pump relief pressure Specification 106-114 bar
Lubricants, Fluids, Sealers and Adhesives Item Power steering fluid Specification Dextron 3
2012-07-21
Power Steering System Filling and Bleeding
Fluid Level Indicator
www.JagDocs.com
1. Fill the reservoir to the bottom of the filler neck. Wait for any air to escape and top up again. Without the engine running, turn from lock to lock two or three times, topping up to the maximum level on the dip reservoir stick. Start the engine and immediately top up as air is vented. With the engine idling, turn lock to lock two or three times, topping up to the maximum level on the reservoir dip stick. When no further change of fluid level occurs, run the engine for twenty minutes to vent any remaining air. NOTE: Air in the fluid can temporarily result in PAS pump noise, but this will not cause damage. The time allowances mentioned in the above procedures are to reduce the possibility of a customer collecting a vehicle while still subject to excessive pump noise. If possible, allow the vehicle to stand for thirty minutes before restarting the engine to vent any further air.
2012-07-21
Power Steering System Vacuum Filling and Bleeding
Fluid Hoses
1. Parts List Item 1 2 Description Return Hose High Pressure Hose
2. If vacuum filling equipment is available, proceed as follows: Disconnect both the high pressure hose (2) and return hose (1) from the PAS pump and the return hose from the steering rack. Drain as much fluid as possible from the system by turning the steering from lock to lock two or three times. Reconnect all hoses. Fill the system using the vacuum equipment according to the manufacturers instructions. Start the engine and top up the fluid as necessary. Turn the steering from lock to lock two or three times with the engine running, topping up with fluid as necessary. If possible, run the engine for twenty minutes to expel any remaining air.
2012-07-21
Steering Gear Centralizing
Steering Gear Alignment Markers
www.JagDocs.com
1. The steering gear should always be centralized prior to steering column or suspension geometry adjustment. Centralization of the steering gear is achieved by aligning the marker on the centralizing cap with a locator on the pinion housing.
2012-07-21
Steering Wheel Centralizing

1. Remove the battery cover.
2.
WARNING: WAIT AT LEAST ONE MINUTE BEFORE STARTING WORK, BECAUSE THE AIR BAG IS EQUIPPED WITH A BACK-UP POWER SOURCE AND MAY BE INADVERTENTLY DEPLOYED.
Disconnect the battery ground cable. 3. Remove the driver's air bag module; refer to Section 501-20.
4. Release the horn harness multiplug from its secured position. 5. Align the steering to the straight ahead position.
2012-07-21
6. Remove the steering wheel. 1. Unscrew and remove the securing bolt. 2. Remove the steering wheel from the steering column. 7. Install the steering wheel. 1. Align the steering wheel in the straight ahead position. 2. Install the steering wheel on the steering column. 3. Install the securing bolt and tighten to specification.
www.JagDocs.com
8. Install the horn harness multiplug. 9. Install the air bag module; refer to Section 501-20.
10. Reconnect the battery. 11. Install the battery cover.
2012-07-21
Steering System
Details of the Steering System can be found in sections <<211-02>>, <<211-03>>, <<211-04>> and <<211-05>>.
2012-07-21
Steering System
1. Verify the customer concern by driving the vehicle. 2. Visually inspect for obvious signs of mechanical or electrical damage. Mechanical Inspection Chart Mechanical Checks Incorrect tire pressure, loose wheel nuts, incorrect wheel alignment Loose tie-rods Loose damper and spring assemblies or ball joint Loose steering column shaft universal joints Loose pinch bolts on steering column shaft Loose steering gear assembly Check for external damage to the steering gear. Damaged tie-rods CAUTION: If a steering gear assembly is returned under warranty with leaking seals, but there is also damage to the steering gear boot/boots the steering gear warranty will be invalid. This is due to the steering gear seals being damaged due to foreign materials entering the steering gear boot and damaging the steering gear seals thereafter. Damaged steering gear boot Damaged accessory drive belt Binding or misaligned steering column, pump or steering gear Incorrect fluid level Hose leaks or line restrictions Hose fouling bodywork
www.JagDocs.com
Electrical Inspection Chart Electrical Checks/Tests Make sure all connectors are in place (steering gear Servotronic solenoid and steering control module (SCM) - if applicable) Make sure all the fuses are in place and not blown DISCONNECT the steering gear transducer and the steering should become heavy TEST electrical values: Power Supply to the SCM = 12 Volts Steering gear transducer resistance 7.0 to 7.5 Ohms is normal Steering gear transducer voltage = 6 Volts Steering gear transducer current = 840 mA at 0 mph reducing to 0 mA at maximum speed RECONNECT all electrical items disturbed during testing
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before
2012-07-21

proceeding to the next step. 4. Check the power steering fluid condition. For additional information, REFER to Power Steering Fluid Condition Check in this section. 5. If the concern is not visually evident, verify the symptom and REFER to Steering Fault Diagnosis by Symptom Charts in this section.
Steering Relay Harness Connector
Item 1 2 3 4 5 6
Description Steering transducer ground Ignition feed Steering transducer feed Ground Speed sensor signal Serial interface
Steering Linkage Inspection and Backlash (Freeplay) Check

CAUTION: Steering gear boots must be handled carefully to avoid damage. Use new clamps when installing steering gear boots. Inspect the boots for cuts, deterioration, twisting or distortion. Check the steering gear boots to make sure they are tight. Install new boots or clamps as necessary.
2012-07-21
NOTE: The following steps must be carried out with assistance. 1. With the wheels in the straight ahead position, gently turn the steering wheel to the left and the right to check for free play. 2. Free play should be between 0 and 6 mm (0 and 0.24 in) at the steering wheel rim. If the free play exceeds this limit, either the ball joints are worn, the lower steering column joints are worn or the backlash of the steering gear is excessive. CAUTION: DO NOT attempt to adjust the steering gear yoke. Failure to follow this instruction will result in the steering gear warranty to become invalid. 3. The backlash of the steering gear cannot be adjusted, install a new steering gear. For additional information, <<211-02>> 4. Grasp the steering wheel firmly and move it up and down and to the left and right without turning the wheel to check for column bearing wear, steering wheel or steering column. For additional information, <<211-04>>
Power Steering Fluid Condition Check

1. Run the engine for 2 minutes. 2. Check the power steering fluid system level. 3. Observe the color and the odor. The color under normal circumstances should be dark reddish, not brown or black. 4. Allow the fluid to drip onto a facial tissue and examine the stain. 5. If evidence of solid material is found, the power steering fluid system should be drained for further inspection. 6. If fluid contamination or steering component failure is confirmed by the sediment in the power steering fluid system, REFER to Steering Fault Diagnosis by Symptom Charts in this section.
www.JagDocs.com
2012-07-21

Power Steering Pressure Test Test Equipment
Item 1 2 3 4 5 6 7 8 9
Special Tool Number 211-011 211-011-08 211-011-07 211-011-03/2 211-011-03/1 211-011-02 211-011-01 211-011 -
Description Pressure Gauge Hose Pump Return Hose Pump Return Hose Connector Test Equipment to High Pressure Hose Adaptor Pump High Pressure Outlet to Hose Adaptor Pump Adaptor to Control Valve Hose Control Valve Pressure Gauge 'O' Ring Seal
The measurement of the maximum system pressure, (which is governed by the pressure relief valve) is achieved by inserting the Service Tool (pressure gauge and adaptors) into the fluid circuit of the power steering system. Run the engine at idle speed, turn the steering from lock to lock and read the maximum pressure recorded on the gauge.
Installing Test Equipment

To install the pressure test equipment: Place a suitable drain tray below the power steering pump. Install a hose clamp on the reservoir to pump hose prior to disconnecting any hoses, to avoid unnecessary loss of fluid. Disconnect the hose from the power steering pump high pressure outlet. Install the pump outlet to hose adaptor (5). Do not omit the 'O' ring seal (9). Connect the power steering pump adaptor to control valve hose (6) of the test equipment. Install the adaptor (4) in the high pressure hose previously removed from the power steering pump outlet. Connect the connector (3) of the test equipment hose (2) to the adaptor (4). Remove the hose clamp from the reservoir hose. Start the engine.
4 2012-07-21

With the control valve (7) OPEN and the engine idling, the following system pressures may be checked: During turning. When the steering is held on full lock. With the steering at rest. CAUTION: To avoid excessive heating of the power steering pump, do not close the valve for longer than 5 seconds maximum.
CAUTION: Do not drive the vehicle with the test equipment installed. With the control valve (7) CLOSED the power steering pump maximum output pressure can be checked.
Removing Test Equipment

To remove the test equipment: Install a hose clamp on the reservoir to power steering pump hose. Removing the test equipment is a reversal of the installation instructions. Install a new 'O' ring seal (9) to the power steering pump high pressure outlet to hose connection. Install the original hose to the power steering pump. Remove the clamp from the reservoir to the power steering pump hose. Top-up the reservoir fluid. Bleed the power steering system. For additional information,
www.JagDocs.com
2012-07-21

Steering Fault Diagnosis by Symptom Charts Leakage
Condition Fluid leakage Possible Sources Confirm the position of the fluid leak. Action CLEAN the area of the leak. Inspect the area and confirm the exact position of leak. Make sure the fluid is not from another system on the vehicle. ' ' Overfilled system. Component leak. CORRECT the fluid level as necessary. NOTE: Record the position of the leak and some indication of the rate of the leak on the Warranty Return Record Sheet. LOCATE the suspect component or CHECK hose connections and repair as necessary. ' ' ' Fluid leakage ' Damaged fluid cap. Loose or damaged hose fittings. Leakage at power steering pump. Leakage at steering hose to steering gear connection. Power steering fluid leakage at O-ring seals. INSTALL a new fluid cap. TIGHTEN or INSTALL a new hose as necessary. INSTALL a new power steering pump as necessary. For additional information, <<211-02>> CHECK steering hose to steering gear connection for leakage. CHECK and TIGHTEN the steering hose to steering gear connection retaining bolts/bolts as necessary. CHECK the power steering system for signs of steering fluid loss from O-ring seals. INSTALL new O-ring seals as necessary. BLEED the power steering system. For additional information, <<211-00>> ' Power steering fluid leakage from transfer pipes. CHECK the power steering system for signs of steering fluid loss from the transfer pipes. CHECK and TIGHTEN the transfer pipes if required, INSTALL new transfer pipes as necessary. BLEED the power steering system. For additional information, <<211-00>> ' Power steering fluid leakage from the steering gear. Power steering fluid leakage from steering gear boot. CHECK the power steering gear for signs of fluid loss. INSTALL a new steering gear as necessary. For additional information, <<211-02>> CHECK the power steering gear for signs of fluid loss. INSTALL a new steering gear as necessary. For additional information, <<211-02>>
'
2012-07-21

Functional
Condition Free play at steering wheel Possible Sources Excess play in the steering linkage. Action CHECK the steering linkage for excess play. For additional information, REFER to the Steering Linkage Inspection and Backlash (Freeplay) Check in this section. CHECK and TIGHTEN the steering wheel retaining bolt/bolts as necessary. For additional information, <<211-04>> CHECK and TIGHTEN the lower steering column pinch bolts as necessary. For additional information, <<211-04>> CHECK for lower steering column for wear in the universal joints. If wear is present, INSTALL a new lower steering column as necessary. CAUTION: DO NOT attempt to adjust the steering gear yoke. Failure to follow this instruction will result in the steering gear warranty to become invalid. CHECK for excess wear in the front suspension joints. For additional information, <<204-00>> Vehicle wanders from side to side on the road, when the vehicle is driven straight ahead and the steering wheel is held in a firm position ' ' ' ' ' ' ' Incorrect tire pressure or tire size. CHECK and ADJUST the tire pressure. For additional information, <<204-04>> INSTALL a new tire as necessary. For additional information, <<204-04>> Vehicle is unevenly or excessively loaded. Loose/worn tie-rods. Steering gear bolts loose or damaged. Loose or worn suspension ball joint(s). Steering column universal joint pinch bolt loose. Incorrect toe adjustment. Loose or worn rear suspension. Incorrect tire pressure. Incorrect tire size or different tire/tread type. Uneven tire wear ' ' ' Vehicle is unevenly loaded or overloaded. Incorrect toe adjustment. Damaged front suspension components. ADJUST the load evenly. INSTALL a new tie-rod end. For additional information, <<211-03>> TIGHTEN or INSTALL new bolts. INSTALL a new suspension ball joint assembly. For additional information, <<204-01>> TIGHTEN the steering column universal joint pinch bolt. For additional information, <<211-04>> ADJUST as necessary. For additional information, <<204-00>> TIGHTEN loose, or INSTALL new rear suspension components. For additional information, <<204-02>> CHECK and ADJUST the tire pressure. For additional information, <<204-04>> INSTALL a new tire as necessary. For additional information, <<204-04>> Adjust the load. ADJUST as necessary. For additional information, <<204-00>> INSTALL new front suspension components as necessary. For additional information, <<204-01>>
'
Steering wheel loose.
'
Lower steering column pinch bolt loose. Excessive wear in lower steering column. Wear in suspension joints.
'
'
www.JagDocs.com
Vehicle tends to pull to one side when driven on a level surface
2012-07-21

' ' Damaged rear suspension components. Steering gear valve effort out of balance. INSTALL new rear suspension components as necessary. For additional information, <<204-02>> SHIFT the transmission into NEUTRAL while driving at no more than 30 miles/hour (50 km/h) and turn the ignition to position I (engine OFF-coasting). If the vehicle does not pull with the engine off, INSTALL a new steering gear. For additional information, <<211-02>> If the vehicle does drift with the engine off, CROSS SWITCH front wheel assemblies. If the vehicle pulls to the opposite side, SWITCH wheels that were on the rear to the same side on the front. If the vehicle pull direction is not changed, CHECK the front suspension components and toe adjustments. For additional information, <<204-01>> ' ' Check the front and rear brakes for correct operation. Check for bent rear suspension components and for damaged coil springs in the front suspension. Check the rear suspension for loose or worn suspension components. Incorrect underbody alignment. Lower steering column interference. Incorrect tire pressure. Incorrect tire size or type. Steering column upper shroud fouling on the steering wheel. Steering column universal joints binding. Steering column shaft floor seal binding. Steering column shaft floor seal may be torn. Binding or damaged tie-rods. Damaged or worn front suspension components. ADJUST as necessary. For additional information, <<206-00>> INSTALL new rear suspension components as necessary. For additional information, <<204-02>> INSTALL new front suspension components as necessary. For additional information, <<204-01>> TIGHTEN or INSTALL new components as necessary. For additional information, <<204-02>> CHECK underbody alignment. For additional information, <<502-00>> CHECK the steering column is free from interference from the engine harness, sound proofing or the floor covering. CHECK and ADJUST the tire pressure. For additional information, <<204-04>> INSTALL a new tire as necessary. For additional information, <<204-04>> CHECK steering column upper shroud for fouling. ADJUST as necessary. INSTALL a new steering column. For additional information, <<211-04>> CHECK the steering column shaft floor seal for correct fitment and REFIT as necessary. INSTALL a new steering column shaft floor seal as necessary. CHECK tie-rod end for excessive wear or tightness in ball joint. INSTALL a new tie-rod end. For additional information, <<211-03>> INSTALL new front suspension components as necessary. For additional information, <<204-01>>
'
' Poor returnability of the steering ' ' '
' ' ' '
'
2012-07-21

' Excessive steering efforts required during low speed manoeuvring and/or during parking manoeuvres ' ' ' ' Incorrect toe adjustment. Low power steering fluid. ADJUST as necessary. For additional information, <<204-00>> CHECK steering system for signs of steering fluid loss. BLEED the power steering system. For additional information, <<211-00>> Damaged accessory drive belt tensioner. Hose or cooler line restriction. Fluid aeration. Steering transducer not closed - no feed voltage. INSTALL a new accessory drive belt tensioner. CHECK hose or cooler lines for correct routing. INSTALL a new hose as necessary. BLEED the system. For additional information, <<Power Steering System Bleeding>> CHECK the steering transducer circuit. For additional information, REFER to the wiring diagrams. Carry out the electrical checks and tests. For additional information, REFER to the Electrical Checks and Tests in this section. ' Steering transducer not closed - cable fault. CHECK the steering transducer circuit. For additional information, REFER to the wiring diagrams. Carry out the electrical checks and tests. For additional information, REFER to the Electrical Checks and Tests in this section. ' ' Steering control module (SCM) defective. Power steering fluid delivery pressure or flow too low. CHECK the SCM and INSTALL a new SCM as necessary. CHECK the power steering pressure. For additional information, REFER to the Power Steering Pressure Test in this section. INSTALL a new power steering pump as necessary. For additional information, <<211-02>> ' Internal steering gear leakage. CHECK the power steering pressure. For additional information, REFER to the Power Steering Pressure Test in this section. INSTALL a new steering gear as necessary. For additional information, <<211-02>> Steering operation is very heavy when driving, but when stationary manoeuvring is good ' Steering transducer open early. CHECK steering transducer and INSTALL a new steering transducer as necessary. Carry out the electrical checks and tests. For additional information, REFER to the Electrical Checks and Tests in this section. Steering transducer open early, steering control module (SCM) fault. Steering transducer open early, speedo signal error. Steering transducer not open, (no power steering fluid flow). CHECK SCM and INSTALL a new SCM as necessary. CHECK speedo circuit. For additional information, REFER to the wiring diagrams. CHECK the power steering fluid condition. For additional information, REFER to the Power Steering Fluid condition check in this section.
www.JagDocs.com
' Steering operation is very light when driving, but when stationary manoeuvring is good
2012-07-21

' Steering transducer not open, steering control module (SCM) fault. CHECK the SCM and INSTALL a new SCM as necessary. Carry out the electrical checks and tests. For additional information, REFER to the Electrical Checks and Tests in this section. CHECK the speedo circuit. For additional information, REFER to the wiring diagrams. INSTALL a new power steering fluid low pressure pipe. CHECK for an air leak into the power steering system and repair as necessary. BLEED the power steering system. For additional information, ' Fluid loss at the power steering pump shaft seal. CHECK the power steering pump for signs of steering fluid loss. INSTALL a new power steering pump as necessary. For additional information, <<211-02>> ' Power steering fluid delivery pressure or flow too low. CHECK the power steering pump for signs of steering fluid loss. CHECK the power steering pressure. For additional information, REFER to the Power Steering Pressure Test in this section. INSTALL a new power steering pump as necessary. For additional information, <<211-02>> Steering heavy operation in one direction ' ' Lower steering column interference. Incorrect steering geometry. Faulty rotary valve/seal. CHECK the steering column is free from interference from the engine harness, sound proofing or the floor covering. CHECK the front wheel alignment. For additional information, <<204-00>> CHECK the power steering pressure. For additional information, REFER to the Power Steering Pressure Test in this section. INSTALL a new steering gear as necessary. For additional information, <<211-02>> ' Tire fouling on the wheel arch liner. CHECK for clearance between the tire and the wheel arch liner. Remove and refit the wheel arch liner or INSTALL a new wheel arch liner as necessary. Steering heavy operation in both directions Low power steering fluid. CHECK steering system for signs of steering fluid loss. BLEED the power steering system. For additional information, <<211-00>> ' Air in power steering system. CHECK the power steering pump for signs of steering fluid loss. INSTALL a new power steering pump as necessary. For additional information, <<211-02>>
' '
Steering transducer not open, speedo signal error. CHECK the power steering fluid low pressure pipe for restricted flow. Air in power steering system.
Steering heavy operation during rapid manoeuvring
10
2012-07-21

' Fluid loss at the power steering pump shaft seal. CHECK the power steering pump for signs of steering fluid loss. INSTALL a new power steering pump as necessary. For additional information, <<211-02>> ' Power steering fluid delivery pressure or flow too low. CHECK the power steering pump for signs of steering fluid loss. CHECK the power steering pressure. For additional information, REFER to the Power Steering Pressure Test in this section. INSTALL a new power steering pump as necessary. For additional information, <<211-02>> Steering operation varies from heavy to light when driving at constant speed ' ' Lower steering column interference. Incorrect speedometer signal. Steering transducer cable/connection faulty or grounded. CHECK the steering column is free from interference from the engine harness, sound proofing or the floor covering. CHECK the speedo circuit. For additional information, refer to the wiring diagrams. CHECK the steering transducer circuit. For additional information, refer to the wiring diagrams. Carry out the electrical checks and tests. For additional information, REFER to the Electrical Checks and Tests in this section. CHECK the steering column is free from interference from the engine harness, sound proofing or the floor covering. INSTALL a new steering column. For additional information, <<211-04>> CHECK for wear or failure of suspension bushes and ball joints. For additional information, <<204-00>>
www.JagDocs.com
Steering wheel varies from light to heavy two times per revolution ' '
Lower steering column interference. Steering column universal joints binding. Seized or damaged steering components.
11
2012-07-21

Noise
Condition Accessory drive belt squeal Chirp noise in the steering pump Power steering pump noisy ' Possible Sources Incorrect accessory drive belt tension or accessory drive belt glazed. Loose or worn accessory drive belt. Low power steering fluid. Action CHECK accessory drive belt condition and INSTALL a new accessory drive belt as necessary. For additional information, <<303-05>> CHECK accessory drive belt condition and INSTALL a new accessory drive belt as necessary. For additional information, <<303-05>> CHECK steering system for signs of steering fluid loss. BLEED the power steering system. For additional information, <<211-00>> Power steering pump worn or otherwise defective. CHECK for leaks. REPAIR as necessary. CHECK the power steering pressure. For additional information, REFER to the Power Steering Pressure Test in this section. INSTALL a new power steering pump as necessary. For additional information, <<211-02>> Whine type noise ' Aerated fluid. Power steering pump. BLEED the power steering system. For additional information, CHECK for leaks. REPAIR as necessary. INSTALL a new power steering pump as necessary. For additional information, <<211-02>> Noise during steering gear movement ' Low power steering fluid. CHECK steering system for signs of steering fluid loss. BLEED the power steering system. For additional information, <<211-00>> Water contamination to the power steering fluid. DRAIN the power steering system. BLEED the power steering system. For additional information, <<211-00>> CHECK and reposition power steering feed hoses and INSTALL new hoses as necessary. CHECK steering system for signs of steering fluid loss. BLEED the power steering system. For additional information, <<211-00>> ' Power steering pump drive loose. CHECK power steering coupling and power steering pump. INSTALL a new power steering coupling or power steering pump as necessary. For additional information, <<211-02>> ' Incorrect accessory drive belt tension or accessory drive belt glazed. Power steering pump drive pulley loose. Power steering pump retaining bolts loose. Power steering hose/pipe in contact with the vehicles body. Power steering hose restricted/twisted. CHECK accessory drive belt condition and INSTALL a new accessory drive belt as necessary. For additional information, <<303-05>> CHECK and TIGHTEN the power steering pump drive pulley retaining bolts as necessary. For additional information, <<303-03A>><<303-03B>> CHECK the power steering pump retaining bolts and TIGHTEN as necessary. CHECK and reposition power steering hoses/pipes, INSTALL new hoses/pipes as necessary. CHECK and reposition power steering hose, replace hose as necessary.
' Continuous noise
Cavitation due to restricted power steering feed hose. Low power steering fluid.
'
' ' '
12
2012-07-21
Vibration
Condition Feedback (knocking noises in the steering gear) - condition where roughness is felt in the steering wheel by the driver when the vehicle is driven over rough surfaces ' Possible Sources Loose/worn tie-rods. Action INSTALL a new tie-rod end. For additional information, <<211-03>>
Steering gear retaining bolts loose or damaged.
CAUTION: DO NOT attempt to adjust the steering gear yoke. Failure to follow this instruction will result in the steering gear warranty to become invalid. CHECK and TIGHTEN the steering gear retaining bolts. INSTALL new retaining bolts as necessary. For additional information, <<211-02>>
www.JagDocs.com
'
Loose suspension bushing, bolts or ball joints. Steering column retaining bolts loose.
TIGHTEN or INSTALL new components as necessary. For additional information, <<204-01>>
'
CAUTION: DO NOT attempt to adjust the steering gear yoke. Failure to follow this instruction will result in the steering gear warranty to become invalid. CHECK and TIGHTEN the steering column retaining bolts/nuts and pinch bolts if required. For additional information, <<211-04>>
'
Excessive wear in steering column assembly. Road wheel imbalance.
CHECK for steering column for wear in the universal joints and bearings. If wear is present, INSTALL a new steering column as necessary. For additional information, <<211-04>> CHECK for road wheel imbalance. CHECK for relevant SERVICE BULLETINS/SERVICE ACTIONS for the vehicle on Jaguar Communications Online (JCOL) or in hard copy form. CHECK for relevant SERVICE BULLETINS/SERVICE ACTIONS for the vehicle on Jaguar Communications Online (JCOL) or in hard copy form. CHECK for relevant SERVICE BULLETINS/SERVICE ACTIONS for the vehicle on Jaguar Communications Online (JCOL) or in hard copy form.
Nibble (Shimmy) Oscillation of the steering wheel (not vertical which is SHAKE). This is driven by road wheel imbalance. '
Steering wheel replacement.
'
Rack replacement.
13
2012-07-21
Description of General Steering System Noises Boom

Rhythmic sound like a drum roll or distant thunder. May cause pressure on the ear drum.
Buzz
Low-pitched sound, like a bee. Usually associated with vibrations.
Chatter
Rapidly repeating metallic sound.
Chuckle
Rapid noise that sounds like a stick against the spokes of a spinning bicycle wheel.
Chirp
High pitched rapidly repeating sound, like chirping birds.
Click
Light sound, like a ball point pen being clicked.
Click/Thump
Heavy metal-to-metal sound, like a hammer striking steel.
Grind
Abrasive sound, like a grinding wheel or sandpaper rubbing against wood.
Groan/Moan
Continuous, low-pitched humming sound.
Groan/Howl
Low, guttural sound, like an angry dog.
Hiss
Continuous sound like air escaping from a tire valve.
Hum
Continuous sound of varying frequencies, like a wire humming in the wind.
14
2012-07-21
Knock
Heavy, loud repeating sound like a knock on a door.
Ping
Similar to knock, except at higher frequency.
Rattle
A sound suggesting looseness, such as marbles rolling around in a can.
Roar
Deep, long, prolonged sound like an animal, or winds and ocean waves.
Rumble
Low, heavy continuous sound like that made by wagons or thunder.
www.JagDocs.com
Scrape
Grating noise like one hard plastic rubbing part rubbing against another.
Squeak
High-pitched sound like rubbing a clean window.
Squeal
Continuous, high-pitched sound like running finger nails across a chalkboard.
Tap
Light, hammering sound like tapping pencil on edge of table. May be rhythmic or intermittent.
Weep
Continuous mid-range sound (lower frequency than squeal, higher frequency than groan).
Whir/Whine
High-pitched buzzing sound, like an electric motor or drill.
Whistle
Sharp, shrill sound, like wind passing a small opening.
Description of Specific Steering System Noise Types Belt Squeal

15 2012-07-21
Belt squeal is a high frequency air-borne noise generated by slippage of the ribbed Vee belt on the power steering pump pulley. Squeal increases with system loading and at the end of lock.
Clonk
Clonk is a structure-borne noise heard as a loose-sounding rattle or vibration coming from the steering column. Clonk can be identified by driving and turning over cobblestones, rough roads, or high frequency bumps such as 25-50 mm tall tar strips. Clonk requires a tie-rod load impact.
Column Knock
Column knock is a loose-sounding rattle or vibration generated by the steering column shaft contacting other portions of the column assembly. The noise is both audible and tactile. Column knock is generated by driving over cobblestones or rough pavement. It is not necessary to turn the steering wheel to create this noise.
Column Rattle
Column rattle is a metallic sounding noise created when applying a highly impulsive force to the steering wheel. Column rattle is often used to combine the more general group of column noises including clonk and column knock. Column rattle noises can be caused by clonk, knock, loose column components, bonus parts etc. A series of parked, straight-line driving, and cornering test should be carried out to isolate the source/sources.
Grinding/Scrape
Grinding is a low frequency noise in the column when the steering wheel is turned. Is generally caused by interference between moving components such as the steering wheel to steering column shroud.
Grunt (Squawk)
Grunt is a 'honking' sound elicited when coming off one of the steering stops. Grunt is generally excited during parking manoeuvres with a low to medium speed steering input.
Hiss (Swish)
Hiss or Valve Hiss is a high-frequency sound coming from the steering gear when the system is loaded. It is a rushing or 'swish' noise that doesn't change frequency with RPM. Hiss is the general noise generated by the flow of hydraulic fluid through restrictions in the steering system. Restrictions include the rotary steering valve, power steering tubes, connectors, tuning orifices, etc. Hiss can be air-borne and structure-borne, but the structure-borne path through the steering intermediate shaft is usually dominant.
Moan (Groan)
Moan is the general structure-borne noise of the steering system. Moan is primarily transmitted to the driver via the body structure through the pump mount, engine mounts, power steering lines and power steering brackets. On some vehicles, moan is a load humming noise, often present when the wheel is turned and the system is loaded. It may change frequency with engine RPM and if the system is loaded or unloaded.
Rack Knock (Rack Slap)

CAUTION: DO NOT attempt to adjust the steering gear yoke. Failure to follow this instruction will result in the steering gear warranty to become invalid. Rack Knock is a rattle sound and steering wheel vibration caused by separation of the steering gear and pinion while
16
2012-07-21

driving over bumps. It is a structure-borne noise transmitted through the intermediate shaft and column. Rack knock can also be heard as a 'thump' or impact noise that occurs with the vehicle stationary when the steering wheel is released from a loaded position and allowed to return to rest. Noise occurs with the engine on or off.
Rattles
Rattles are noises caused by knocking or hitting with components in the steering system. Steering rattles can occur in the engine compartment, the suspension, or the passenger compartment . Rattles can be caused by loose parts, movable and flexible parts, and improper clearances.
Squeaks/Scrapes
Squeaks/Scrapes are noises due to friction or component rubbing anywhere in the steering system. Squeaks/Scrapes have appeared in steering linkages and joints, in column components and in column and steering wheel trim parts.
Weep
Weep is an air-borne noise, occasionally generated when turning the steering across lock at a constant rate. When present on a vehicle the noise, once initiated can often be maintained across a large proportion of the available steering movement.
www.JagDocs.com
Whistle
Whistle is similar to hiss but is louder and of a higher frequency. It is also more of a pure tone noise than hiss. Whistle is air-borne and is generated by a high flow rate of hydraulic fluid through a small restriction.
Zip
Zip noise is the air-borne noise generated by power steering pump cavitation when power steering fluid does not flow freely through the suction hose from the reservoir to the pump. Zip primarily occurs during cold weather at start-up.
Steering System Vibrations and Harshness Buzz

Buzz is a tactile rotary vibration felt in the steering wheel for slow steering inputs. Buzz can also be called a grinding feel and it is closely related to grunt and is caused by high system gain with low damping. Buzz is generally excited during parking manoeuvres with low to medium speed steering input.
Buzz (Electrical)
A different steering buzz can be caused by pulse width modulated (PWM) electric actuators used in variable assist steering systems. This buzz is felt by turning the ignition key to run without starting the engine and holding onto the steering wheel. In extreme cases, the buzz can be felt with the engine running also.
Column/Steering Wheel Shake

Column shake is a low frequency vertical vibration excited by primary engine vibrations.
Nibble (Shimmy)
Steering nibble is a rotary oscillation or vibration of the steering wheel, which can be excited at a specific vehicle speed. Nibble is driven by wheel and tire imbalance exciting a suspension recession mode, which then translates into steering gear travel and finally steering wheel nibble.
17
2012-07-21
Shudder (Judder)
Shudder is a low frequency oscillation of the entire steering system (tire, wheels, steering gear and linkage, etc.) when the vehicle is steered during static-park or at low speeds. Shudder is very dependent on road surface.
Torque Ripple
Torque ripple is a concern with Electric Power Steering (EPS) systems. Torque ripple is most evident at static-park steering the wheel very slowly from lock to lock. Torque ripple is primarily caused by motor commutation.
Torque/Velocity Variation (Phasing/Effort Cycling)

Steering wheel torque variation occurring twice in one revolution is normally as a result of problems with the lower steering column (intermediate shaft), but foul conditions generally result in either constant stiffness or single point stiffness. Depending upon the orientation of the joints, the steering can feel asymmetric (torque falling off in one direction and rising in the other) or else it can simply have pronounced peaks and troughs as the steering moves from lock to lock.
Wheel Fight (Kick Back)

Wheel fight is excess feedback of sudden road forces through the steering system and back to the driver. It is evaluated at all vehicle speeds over cobblestones, rough roads, and potholes. The tires, wheels, and suspension generate forces into the steering systems. Steering friction, hydraulic damping, hydraulic compliance, mechanical compliance, steering ratio, and assist gain all affect how much is transmitted to the driver.
Steering Linkage
CAUTION: Steering gear boots must be handled carefully to avoid damage. Use new clamps when installing steering gear boots. Inspect the boots for cuts, deterioration, twisting or distortion. Check the steering gear boots to make sure they are tight. Install new boots or clamps as necessary. NOTE: The following steps must be carried out with assistance. 1. With the wheels in the straight ahead position, gently turn the steering wheel to the left and the right to check for free play. 2. Free play should be between 0 and 6 mm (0 and 0.24 in) at the steering wheel rim. If the free play exceeds this limit, either the ball joints are worn, the lower steering column joints are worn or the backlash of the steering gear is excessive. 3. CAUTION: DO NOT attempt to adjust the steering gear yoke. Failure to follow this instruction will result in the steering gear warranty to become invalid.
The backlash of the steering gear cannot be adjusted, install a new steering gear. For additional information, <<211-02>> 4. Grasp the steering wheel firmly and move it up and down and to the left and right without turning the wheel to check for column bearing wear, steering wheel or steering column. For additional information, <<211-04>>
18
2012-07-21
1999 XK RANGE - Power Steering - 211-02
Lubricants, Fluids, Sealants and Adhesives Unit PAS Fluid Specification Dexron 3
Capacities Unit PAS System PAS Reservoir Liters 1.0 0.4
Torques Component Steering Rack Mounting Bracket to Crossbeam PAS Pump to Mounting Bracket PAS Pump to Cylinder Block Pulley to PAS Pump Hose-High Pressure to PAS Pump Steering Rack Pipe Latch Plate Bolt Outer Tie Rod End Locknut Reservoir to Brake Modulator Bracket Reservoir Retention Bracket Fluid Cooler to Bumper Beam Transfer Pipe to Steering Rack Transfer Pipe to Hydraulic Control Valve Nm 40-50 22-26 38-48 18-24 22-28 9-11 71-85 4-5 4-5 2.5-3.5 7-8 7-8
www.JagDocs.com
2012-07-21
Power Steering
Component Relationship
Item 1 2 3 4 5
Description Rack and Pinion Assembly PAS Pump Fluid Reservoir with Integral Filter Wire Bound Tube Type Fluid Cooler Hoses and Pipework
The power assisted steering system consists of: Rack and pinion assembly. Power assisted steering pump. Fluid reservoir. Fluid cooler. Associated hoses and pipework. NOTE: Absolute cleanliness must be observed when replenishing the fluid or dismantling any part of the system.
2012-07-21
If any major component is renewed: A new fluid reservoir, with integral filter, must be fitted. New fluid from a sealed container must be used.
Rack and Pinion Assembly
Mounting Brackets
www.JagDocs.com
Item 1 2 3
Description Resilient Wrap Around Handed Bushes Mounting Brackets Bracket Securing Bolts
The rack and pinion assembly: Incorporates servotronic control. Uses a positive center feel torsion bar. Is mounted on the rear face of the aluminium cross beam. Is supported in handed resilient wrap around bushes. Has bushes secured by two forged handed brackets bolted to the cross beam. Its function is to convert the rotary motion of the steering wheel, via the steering gear pinion, to the lateral motion of the rack. The rack and pinion assembly is not serviceable, but the following components may be treated as service items: Transfer pipework.
2012-07-21

Transducer. Clips and fittings for the above components. Centralizing cap. Outer Ball Joint. Rack Gaiters.
Major Components
Item 1 2 3 4 5 6 7 8 9 10 11
Description Rack Pinion Fluid Reservoir PAS Pump Fluid Return Line Fluid Pressure Line Pressure and Flow Limiting Valve Rack Housing Rack Gaiter Inner Ball Joint Tie Rod
2012-07-21

Operation Steering in the straight-ahead position
With the steering in the straight-ahead position: The valve restrictions are balanced. Equal pressure is present on both sides of the piston.
Fluid Flow Circuit
www.JagDocs.com
2012-07-21

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Description Rack Drive Pinion Operating Cylinder Oil Reservoir PAS Pump Return Line Pressure and Flow Limiting Valve Pressure Line Lower Steering Spindle Torsion Bar Upper Radial Groove Lower Radial Groove Rotary Distributor Control Sleeve Inlet Port Inlet Port Axial Groove Axial Groove Return Slot Return Groove Return Slot Web Control Slot
Turning the steering wheel clockwise

When the steering is turned clockwise: The rack / piston assembly of the operating cylinder move to the right. Pressurized fluid is supplied to the left piston chamber to provide power assistance. The three control ports of the rotary distributor are moved in a clockwise direction so that the inlet ports (16) are opened further. As this occurs, the inlet ports (15) close to prevent the fluid reaching axial grooves (17) in the control sleeve. With the valve in the operating position pressurized fluid flows through the inlet ports (16) to the lower radial groove (12) in the control sleeve. From the control sleeve, pressurized fluid flows to the left piston chamber to provide hydraulic assistance for the piston movement. The closed control slot (23) prevents fluid flowing back to the reservoir. The oil is forced out of the right piston chamber through the upper radial groove (11) in the sleeve to the return slots (19) in the rotary distributor. Webs (22) on the rotary distributor prevent the fluid flowing directly to the return grooves (20), which are always open in the direction of the control sleeve.
Turning the steering wheel counter-clockwise

When the steering wheel is turned counter-clockwise:
2012-07-21
The rack and piston of the operating cylinder move to the left. Pressurized fluid is supplied to the right piston chamber to provide power assistance.
Positive Center Feel Torsion Bar
Torsion Bar Components
www.JagDocs.com
Item 1 2 3 4
Description Torsion Bar Metal Bellows Spring End Piece Caged Ball Bearings
When the steering wheel motion commences, the spring force of the torsion bar must be overcome. The torsion bar is positively connected to the two end pieces. The metal bellows spring is arranged co-axially with the torsion bar. One end of the metal bellows spring is fastened to one of the end pieces. The opposite end is connected to a centring piece. The prism centring device consists of: Two centring pieces each of which has a prism shaped recess at its front end.
2012-07-21

Caged guided balls are arranged between these two recesses. The zero torsion position of the axially pre-loaded metal bellows spring is determined by the prism centring device. At the start of the torsional motion, the metal bellows spring produces a substantial additional torsional resistance. As soon as the prisms of the two centring pieces start being displaced to one another from a torsion bar angle of approx 0.2 degrees, the torsional rigidity will decrease and become comparable to a conventional torsion bar.
Variable Ratio Rack
Rack and Pinion Details
Item 1 2 3
Description Steering Rack Tooth Contact Angles at Center of Rack Tooth Contact Angles at Ends of Rack
The variable ratio rack permits quick and precise reactions at speed and optimum vehicle control during manoeuvring. The rack incorporates teeth of varying size and angle of contact. This results in a steering operation which is relatively direct with the steering wheel in the straight ahead position. As the steering is turned to the left or right, the ratio becomes lower.
2012-07-21

Servotronic Unit System Components
www.JagDocs.com
Item 1 2 3 4 5 6
Description Speedometer Electronic Control Unit Electro-Hydraulic Converter Steering Valve Housing PAS Steering Pump Battery
The Servotronic unit is speed dependent and is triggered by the electronic speedometer. It is entirely independent of the engine speed: A microprocessor evaluates the speed signal and decides the amount of hydraulic power assistance required. This in turn determines the amount of driver effort required. The power value is transmitted as impulses to the rotary spool steering valve, via an electro-hydraulic converter. The degree of assistance is proportional to the road speed. This means that minimum driver effort is required at parking speed. As the road speed increases, the steering characteristic feels more direct (less hydraulic assistance), enabling precise and responsive reactions to steering wheel movement.
2012-07-21

Power Assisted Steering Pump Steering Pump Mounting
Item 1 2 3
Description PAS Pump Pump Mounting Bracket High Pressure Port
The power assisted steering pump: Is mounted on a bracket installed on the front of the engine. Is of the roller vane type. Will provide 110 Bar fluid pressure. Is belt driven from the engine crankshaft. Its function is to provide hydraulic pressure for the PAS system. The pump is not serviceable and should be renewed complete with front bracket and high pressure port.
2012-07-21

Fluid Reservoir
Reservoir and Hoses
www.JagDocs.com
Item 1 2 3 4
Description Fluid Reservoir Supply Line Return Line Filler Cap
NOTE: 1. The integral filter is not serviceable. NOTE: 2. A new reservoir must be fitted if the steering rack, PAS Pump or fluid cooler are renewed. The fluid reservoir: Is located forward of the brake modulator. Incorporates a 10 micron nominal integral filter. Has a capacity of 0,4 liter.
10
2012-07-21
Supply and Return Hoses and Pipework
Latch - Plate Location
Item 1 2
Description Supply/Return Pipes and Latch-plate Assembly Latch-plate Securing Screw
The supply and return hoses and pipework: Are secured to the rack housing by a latch-plate and screw. The supply hose uses a hose clamp to secure it to the reservoir. The return pipe is mounted and clipped to the rack housing in two resilient mountings. The hose 'O' rings are serviceable.
11
2012-07-21

Quick-fit Connector
Connector Details
www.JagDocs.com
Item 1 2
Description Quick-fit Connector Return Tube A quick-fit connector with double 'O' ring seals is incorporated in the return hose and is clipped to the right hand chassis side member. The hoses and pipework are used to connect the system components together to form a functional system. All hoses and pipework should be renewed as complete assemblies. The quick-fit connector 'O' rings are not serviceable. All hoses and pipework are designed to reduce system noise. A special tool is necessary to disconnect the quick-fit connector.
12
2012-07-21

Fluid Cooler
Fluid Cooler Location
Item 1 2 3 4
Description Fluid Cooler Integral Hoses Cooler Mountings Body Cross Beam
The fluid cooler is installed on the body front cross-member: It is of the wire bound tube type. Is rubber mounted on the body front cross beam. Is integral with the return hose. Its function is to cool the fluid as it returns to the reservoir.
13
2012-07-21
Power Steering
The layout of the power steering circuits, both hydraulic and electrical, are detailed and illustrated in the Description and Operation section. Refer to the overall system diagram in the sub-section Servotronic Unit. There are two major components of the Servotronic rack which provide the unique, variable effort control, based on vehicle speed. The first is the Servotronic Valve which provides the variable steering effort and the second is the Positive Centre Feel Torsion Bar. The Servotronic Valve is controlled electronically by a Power Steering Control Module. The Servotronic valve provides hydraulic reaction to oppose normal movement of the power piston. The benefit of this is to give increased stiffness and feel to the system at higher vehicle speeds. To achieve the hydraulic reaction, a co-axial piston assembly has been incorporated into the valve housing, which is linked to the inner valve rotor and to the outer valve sleeve, via a series of ball bearings. The Servotronic valve consists of a variable size orifice (effectively) which varies in size depending on the position of a needle valve. The position of the needle valve is controlled by a solenoid, the armature of which will remain at any fixed point within its overall limit of travel, dependent on the amount of current supplied to the solenoid windings. As the speed of the vehicle increases, the current supplied to the valve is reduced in stages and the needle moves off its seat which allows pressurised oil to pass into the reaction circuit. The driver subsequently, has to apply more torque to the steering wheel to overcome the added reaction pressure.
www.JagDocs.com
Power Steering Pressure Test
Test Equipment
Item 1 2 3 4 5 6 7 8 9
Description Pressure Gauge Hose Pump Return Hose Pump Return Hose Connector Test Equipment to HP Hose Adaptor Pump HP Outlet to Hose Adaptor Pump Adaptor to Control Valve Hose Control Valve Pressure Gauge 'O' Ring
2012-07-21
Installing Test Equipment

To install the pressure test equipment: Place a suitable drain tray below the PAS pump. Install a hose clamp on the reservoir to pump hose prior to disconnecting any hoses, to avoid unnecessary loss of fluid. Disconnect the hose from the PAS pump high pressure outlet. Install the pump outlet to hose adaptor (5). Do not omit the 'O' ring (9). Connect the pump adaptor to control valve hose (6) of the test equipment. Install the adaptor (4) in the high pressure hose previously removed from the pump outlet. Connect the connector (3) of the test equipment hose (2) to the adaptor (4). Remove the hose clamp from the reservoir hose. Start the engine. With the control valve (7) OPEN and the engine idling, the following system pressures may be checked: During turning. When the steering is held on full lock. With the steering at rest. WARNING: TO AVOID EXCESSIVE HEATING OF THE PAS PUMP, DO NOT CLOSE THE VALVE FOR LONGER THAN NECESSARY. WARNING: DO NOT DRIVE THE VEHICLE WITH THE TEST EQUIPMENT INSTALLED. With the control valve (7) CLOSED the pump maximum output pressure can be checked.
Removing Test Equipment

To remove the test equipment: Install a hose clamp on the reservoir to pump hose. Removing the test equipment is a reversal of the installation instructions. Install a new 'O' ring (9) to the PAS pump high pressure outlet to hose connection. Install the original hose to the PAS pump. Remove the clamp from the reservoir to pump hose. Top-up the reservoir fluid. Bleed the PAS system; refer to this section.
Power Steering Control Module

As described above, the control of the valve is by varying the current which is applied to it. The current signal is provided by the Control Module which inputs a vehicle speed signal from the Instrument Cluster. The microprocessor and associated algorithm within the module, provides maximum output current (854mA) when the vehicle is stationary - the valve will be held closed, providing very easy steering. The current progressively decreases towards zero (15mA) as the frequency of the speed signal from the Instrument Cluster increases - the valve will be opening in stages. Consequently, an increasing amount of hydraulic pressure is applied to the reaction piston, which increases the feel to the driver.
2012-07-21

The PDU will diagnose all electrical components of the system. Before changing a component, check fuse No. 12 (10A) in the driver's side fuse box on the fascia. However, if this fuse is faulty a number of other components will also fail to function.
Control Module Connections
www.JagDocs.com
2012-07-21

Item 1 2 3 4 5 6 7 Description Servotronic Valve Power Steering Control Module Diagnostic Line Speed Signal from Instrument Cluster Ground Ignition Supply +12V Base of Power Steering Control Module
2012-07-21
Power Steering Control Valve Actuator 57.10.32

Removal 1. Remove steering rack. Refer to operation <<57.10.01>>.
2.
CAUTION: To prevent the ingress of foreign particles into the steering rack, make sure the blanking plugs stay in position,
Place steering rack on a work bench. 3. Clean exterior of steering rack.
www.JagDocs.com
4. Fit jaw protectors to a vice and position steering rack in the vice with the pinion housing uppermost. Carefully tighten the vice - do not use excessive clamping force.
2012-07-21
5. Drain residual fluid from steering rack. Place a drain pan under steering rack. Remove blanking plugs from pinion housing. Rotate pinion shaft three times lock-to-lock, to dispel as much residual fluid as possible. Fit blanking plugs.
6. Centralize steering rack. Centralize travel of steering rack in steering rack housing. CAUTION: The pinion shaft must not be rotated from this setting, until a new dirt protection shield has been fitted. Move pinion shaft to align centralising index - located on dirt protection shield, with alignment hole - located on pinion valve housing.
2012-07-21
7. Remove and discard dirt protection shield.
www.JagDocs.com
8. Remove oil transfer pipes. 1. Release union nuts. 2. Carefully, remove oil transfer pipes - taking care not to distort them. Remove and discard O-ring seals from pipes. Place pipes in a clean plastic bag until required for assembly. Fit blanking plugs to transfer ports.
2012-07-21
9. NOTE: Note orientation of transducer for assembly reference. Remove transducer. 1. Remove upper and lower screws. 2. Remove transducer. Remove and discard O-ring seals. Retrieve and discard filter. Place transducer in a clean plastic bag until required for assembly.
10. NOTE: Note orientation of pinion valve housing for assembly reference. Remove pinion valve housing. 1. Remove and discard screws. 2. Carefully lift the pinion valve housing from the steering rack using a steady upward twisting motion. Excessive force and rocking of the housing should be avoided, to prevent damaging the rotary valve O-ring seals. Remove and discard the O-ring seal from between the pinion housing and steering rack main body.
4 2012-07-21
11. Cover rotary valve assembly with a clean plastic bag. 12. Clean and inspect all relevant components and mating faces.
Installation
www.JagDocs.com
1. Prepare the new pinion valve housing. Remove plastic bag from rotary valve assembly. 1. Fit new O-ring seal to steering rack body. 2. Fit oil seal protector tool (provided with seal kit) to pinion shaft splines. 3. Apply grease, Texando F020 or equivalent, to pinion seal lip.
2. Fit pinion valve housing to steering rack. 1. Carefully fit the pinion valve housing to the steering rack using a steady downward twisting motion. Excessive force and rocking of the housing should be avoided, to prevent damaging the rotary valve O-ring seals. 2. Remove seal protector tool.
2012-07-21
3. Fit and tighten screws.
4. Fit transfer pipes. 1. Fit new O-ring seals to transfer pipes. Lightly grease the seals using Texando F020 or equivalent grease. 2. Remove blanking plugs. 3. Fit transfer pipes carefully, to avoid distortion. Ensure that they are fitted fully into the ports. 4. Tighten union nuts.
2012-07-21
www.JagDocs.com
5. Fit transducer to pinion valve housing. 1. Fit a new filter to pinion housing transducer port. 2. Fit new O-ring seals to transducer. Lightly grease O-ring seals using Texando F020 or equivalent grease. 3. Fit transducer, make sure of correct orientation as referenced in removal. 4. Fit and tighten new screws.
6. Fit dirt protection shield. Smear a small amount of Texando F020 or equivalent grease into the cavity of the pinion valve housing. Fit the dirt protection shield to the pinion shaft splines - make sure that the centralising index peg locates in the alignment hole of the pinion valve housing. 7. Operate the steering rack lock-to-lock to check for freedom of movement, without tight spots. The centralising index peg will shear (this is intentional).
2012-07-21
8. Centralise the steering rack. Centralise the rack, by sight, aligning the plastic centralising pin on the dirt protection shield (sheared since fitting) with the alignment hole in the pinion housing. 9. Remove steering rack from vice. 10. Fit steering rack to vehicle. Refer to Operation <<57.10.01>>.
2012-07-21
Power Steering Fluid Cooler 57.15.11

Quick Fit Connector Release Tool 310-044 (JD 182) Removal 1. Position vehicle on a four-post ramp. 2. Open engine compartment and fit paintwork protection covers. 3. Set engine compartment cover to service access position. 4. Place a drain pan under the vehicle.
www.JagDocs.com
5. Disconnect cooler to reservoir hose, at the reservoir end. 1. Release clip. 2. Disconnect hose. Fit blanking plugs to reservoir stub pipe and hose. Re-route hose to front of coolant radiator.
2012-07-21
6. Raise vehicle.
7. Disconnect the cooler to steering rack return hose. 1. Release the Quick Fit hose clip using special tool 310 - 044. 2. Disconnect hoses and remove tool. Fit blanking plugs to both sections of hose. Re-route hose to front of coolant radiator
8. Release cooler from retaining clips.
2012-07-21
9. Remove mounting rubbers from cooler. 10. Discard drained fluid.
www.JagDocs.com
Installation 1. Installation is reverse of removal procedure. Fit a new reservoir / filter assembly, refill with new fluid and bleed air from the system. Refer to operation <<57.15.08>>.
2012-07-21
Power Steering Fluid Reservoir 57.15.08

Removal 1. Open engine compartment and fit paintwork protection covers. 2. Place suitable absorbent material below fluid reservoir to absorb spillage.
3. Disconnect pump feed hose from reservoir. 1. Release clip. 2. Disconnect hose. Fit blanking plugs to reservoir stub pipe and hose.
4. Remove nuts from reservoir mounting bracket. Reposition reservoir to gain access to return hose.
2012-07-21
www.JagDocs.com
5. Remove return hose from reservoir. 1. Release clip. 2. Disconnect hose. Fit blanking plugs to reservoir stub pipe and hose. 6. Remove reservoir.
7. Remove reservoir from mounting bracket. 1. Remove clamp bolt. 2. Remove reservoir from bracket.
2012-07-21

Installation
1. Fit reservoir to mounting bracket. 1. Position bracket to reservoir. 2. Fit and tighten clamp bolt.
2. Connect return hose to reservoir. Remove blanking plugs. 1. Connect hose. 2. Position and tighten clip.
2012-07-21
www.JagDocs.com
3. Connect pump feed hose to reservoir. Remove blanking plugs. 1. Connect hose. 2. Position and tighten clip. 4. Remove absorbent material from below the reservoir. Clean any fluid spillage from below the reservoir.
5. Fit reservoir. 1. Fit mounting bracket to body studs. 2. Fit and tighten nuts.
2012-07-21
6. Fill reservoir with fluid to bottom of filler neck. Fill reservoir Wait for air to escape; this will be evident when air bubbles are no longer present. Top-up fluid to bottom of filler neck if necessary. 7. Raise front of vehicle and support on stands. Refer to section <<100-02>>. 8. Do not start engine, turn steering from lock-to-lock three times. 9. Start the engine. Immediately top up with fluid as air is expelled. Turn the steering lock-to-lock three times. 10. Switch engine off. 11. Lower vehicle.
2012-07-21
www.JagDocs.com
12. Top-up fluid level to maximum mark on dip-stick. Do not overfill. Fit reservoir filler cap. 13. Remove paintwork protection covers.
2012-07-21
Power Steering Fluid Reservoir to Power Steering Pump Supply Hose 57.15.20
Removal 1. Open engine compartment and fit paintwork protection covers. 2. Place a drain pan under the pump.
3. Disconnect hose from pump. 1. Release clip. 2. Disconnect hose and allow it to drain. Fit blanking plugs to pump and hose.
4. Disconnect hose from reservoir. 1. Release clip. 2. Disconnect hose.
2012-07-21

Fit blanking plugs to reservoir stub pipe and hose. Remove clips from hose. 5. Remove drain pan and discard fluid.
Installation 1. Installation is reverse of removal procedure. Refill with new fluid and bleed air from the system. Refer to General Procedures..
www.JagDocs.com
2012-07-21
Power Steering Pump 57.20.14

Removal 1. Open engine compartment and fit paintwork protection covers. 2. Set engine compartment cover to service access position. 3. Disconnect battery ground cable. Refer to operation <<86.15.19>>.
4. Loosen, but do not remove bolts which secure drive pulley to power steering pump. 5. Remove front end accessory drive belt. Refer to operation <<12.10.40>>.
6. Remove pulley from power steering pump.
2012-07-21

Remove bolts. Remove pulley.
www.JagDocs.com
7. Release harness retaining clip from engine oil dipstick-tube bracket, reposition harness.
8. Disconnect power steering pump inlet hose and drain the fluid. Place a drain pan under vehicle. 1. Release clip. 2. Disconnect hose and drain fluid. 3. Fit blanking plugs to pump and hose.
2012-07-21
9. Remove bolt from dipstick-tube retaining bracket.
10. Disconnect outlet hose from pump. 1. Release union nut. 2. Disconnect hose. 3. Fit blanking plugs to hose and pump.
2012-07-21
www.JagDocs.com
11. Remove power steering pump. Remove bolts. Remove pump by moving it forward and upwards.
12. Remove fixing nuts from pump body casting.
2012-07-21

Installation
1. Fit fixing nuts to pump body casting.
2. Fit power steering pump. Position pump to engine. Fit and tighten bolts.
2012-07-21
www.JagDocs.com
3. Connect outlet hose to pump. 1. Remove blanking plug from hose. 2. Remove and discard O-ring seal from hose. Fit a new O-ring seal. 3. Remove blanking plug from pump. 4. Connect and tighten hose union nut to pump.
4. Fit and tighten bolt securing dipstick tube to engine. Fit harness clip to dipstick-tube bracket.
2012-07-21
5. Connect inlet hose to pump. 1. Remove blanking plugs from hose and pump. 2. Connect hose to pump. 3. Secure hose with clip.
6. Fit drive pulley to pump. Fit, but do not tighten bolts. 7. Fit front end accessory drive belt. Refer to operation <<12.10.40>>.
2012-07-21
8. Tighten pulley bolts. 9. Clean any spilt fluid from around pump area. 10. Remove drain pan. 11. Fit a new power steering oil reservoir (combined reservoir and oil filter assembly) and bleed air from system. Refer to operation <<57.15.08>>. 12. Connect battery ground cable. Refer to operation <<86.15.15>>. 13. Remove paintwork protection covers..
www.JagDocs.com
2012-07-21
Power Steering Pump to Steering Gear Pressure Line 57.15.29

Removal 1. Open engine compartment and fit paintwork protection covers. 2. Raise vehicle on a four-post ramp. 3. Place a drain pan under steering rack.
4. Remove retaining straps which secure hose to steering rack.
5. Disconnect hose from steering rack. 1. Remove bolt from retaining plate.. 2. Release hose, hold it clear of steering rack and allow fluid to drain.
2012-07-21

3. Fit blanking plugs to hose and steering rack port. Remove drain pan and discard fluid.
www.JagDocs.com
6. From above the vehicle, disconnect hose from pump. 1. Release union nut. 2. Disconnect hose. 3. Fit blanking plugs to hose and pump port.
7. From below the vehicle remove hose. 1. Remove hose. 2. Remove mounting rubbers from hose.
Installation 1. Installation is reverse of removal procedure.
2012-07-21
2. Secure hose to track. 1. Locate hose and retaining plate. 2. Fit and tighten bolt.
3. Fit hose to pump. 1. Remove blanking plug from hose. 2. Fit a new O-ring seal to hose. 3. Remove blanking plug from pump. 4. Fit and tighten union nut. 4. Refill with new fluid and bleed air from the system. Refer to General Procedures.
2012-07-21
Steering Gear 57.10.01

Taper Separator 211-098 (JD 100) Removal 1. Open engine compartment and fit paintwork protection covers. 2. Centralize steering wheel and remove ignition key. 3. Raise vehicle on a four-post ramp. 4. Place a drain pan under the steering rack
www.JagDocs.com
5. From below the vehicle, check that steering rack is centralised by aligning the centralising notch on the dirt protection cover with the location hole in the pinion housing casting.
2012-07-21
6. Remove nuts from LH and RH tie rod ends.
7. Release tie rod end taper-pin from steering arm. 1. Fit special tool to tie rod end. 2. Tighten tool bolt to release taper. Remove tool. Repeat procedure on opposite tie rod end.
2012-07-21
www.JagDocs.com
9. Disconnect electrical connector from steering rack transducer.
2012-07-21
10. Remove insulation rubbers from hose secured to steering rack. 1. Remove tie straps. 2. Remove insulation rubbers.
11. Release retaining plate from pinion shaft cover, to access hoses. 1. Remove bolt. Move retaining plate along hose.
2012-07-21
www.JagDocs.com
12. Position drain pan under pinion-shaft housing and disconnect hoses. Allow fluid to drain.
13. Remove and discard O-ring seal from feed hose.
2012-07-21
14. Remove and discard O-ring seal from return hose. 15. Fit blanking plugs to feed hose, return hose and pinion housing ports. 16. NOTE: The steering rack mounting bushes are handed; they are marked accordingly and should be replaced as a pair. Remove drain pan and discard fluid. 17. Remove steering rack mounting bracket bushes. Refer to operation <<57.10.30>>. 18. NOTE: When removing steering rack, manoeuvre return pipe past the pinion housing to steering rack pipes. Remove steering rack. 19. Using a tap (M10 x 1.5 mm), clean the steering rack to crossbeam bolt hole threads.
Installation 1. NOTE: When installing steering rack, manoeuvre return pipe past the pinion housing to steering rack pipes. Position steering rack to vehicle. 2. Fit steering rack mounting bracket bushes. See operation <<57.10.30>>. 3. Unscrew tie rod end, taper pin nuts. Remove and discard protective covers from tie rod ends. 4. A new steering rack and pinion housing assembly is supplied with a dirt protection cover/centralizing cap fitted.
2012-07-21
5. Remove blanking plugs from feed and return hoses and pinion housing ports of the new steering rack.
www.JagDocs.com
6. Connect return hose to pinion shaft housing. Apply clean PAS fluid to a new O-ring and fit to hose. Connect and fully seat hose.
7. Connect feed hose to pinion shaft housing. Apply clean PAS fluid to a new O-ring and fit to hose. Connect and fully seat hose.
2012-07-21
8. Fit retaining plate to pinion housing. 1. Align retaining plate and hoses. 2. Fit and tighten bolt. 9. Clean any fluid spillage from steering rack and surrounding area.
2012-07-21
www.JagDocs.com
11. Connect tie rod ends. 1. Locate tie rod end into steering arm. 2. Fit and tighten nut. Repeat procedure to fit opposite tie rod end.
12. NOTE: Make sure steering wheel and wheels are in the straight ahead position before fitting steering column. Fit steering column to pinion shaft. Move column downwards onto pinion shaft splines. 1. Fit and tighten clamp bolt.
2012-07-21
13. Connect electrical connector to steering rack transducer. 14. Fit a new fluid reservoir, refill with new power steering fluid and bleed air from the system; refer to Operation <<57.15.08>>. 15. Check and adjust front wheel alignment.
10
2012-07-21
Steering Gear Bushing 57.10.30

Removal 1. NOTE: The steering rack mounting bracket bushes are handed; they are marked accordingly and should be replaced as a pair. Raise vehicle on a four-post ramp.
www.JagDocs.com
2. Release, but do not remove, steering rack RH mounting bracket bolts.
3. NOTE: For assembly reference note orientation of mounting bracket before removing. Remove steering rack LH mounting bracket. Remove bolts.
2012-07-21

Remove mounting bracket.
4. NOTE: For assembly reference note orientation of mounting bush before removing. Remove and discard LH mounting bush.
5. With reference to orientation of previous bush, fit new LH mounting bush to steering rack.
2012-07-21
www.JagDocs.com
6. With reference to orientation of mounting bracket as noted in removal, fit LH mounting bracket to steering rack. Fit bracket. Fit, but do not tighten bolts.
7. NOTE: For assembly reference note orientation of mounting bracket before removing. Remove steering rack RH mounting bracket. Remove bolts. Remove mounting bracket.
2012-07-21
8. NOTE: For assembly reference note orientation of mounting bush before removing.. Remove and discard RH mounting bush.
9. With reference to orientation of old bush, fit new RH mounting bush to steering rack.
2012-07-21
www.JagDocs.com
10. With reference to orientation of mounting bracket as noted in removal; fit RH mounting bracket to steering rack. Fit bracket. Fit, but do not tighten bolts.
Installation
1. Tighten bolts on both mounting brackets. 2. Lower vehicle.
2012-07-21
Steering Gear to Fluid Cooler Return Hose 57.15.30

Quick Fit Connector Release Tool 310-044 (JD 182) Removal 1. Open engine compartment and fit paintwork protection covers. 2. Raise vehicle on a four-post ramp. 3. Place a drain pan under steering rack.
4. Disconnect hose from steering rack. 1. Remove bolt from retaining plate. 2. Release hose, hold it clear of steering rack and allow fluid to drain. 3. Fit blanking plugs to hose and port.
2012-07-21
www.JagDocs.com
5. Disconnect cooler to steering rack hose. 1. Release Quick Fit hose clip using special tool 310 - 044. 2. Disconnect hoses and remove tool. Fit blanking plugs to both sections of hose. Remove drain pan and discard fluid.
Installation 1. Installation is reverse of removal procedure.
2. Tighten retaining plate bolt. 3. Fill with new fluid and bleed air from the system. Refer to General Procedures.
2012-07-21
1999 XK RANGE - Steering Linkage - 211-03
Torques Component Outer Tie Rod End Securing Nut Outer Tie Rod End Jam Nut Nm 71-85 71-85
2012-07-21
1999 XK RANGE - Steering Linkage - 211-03
Steering Linkage
Tie Rods and Joints
Major Components
www.JagDocs.com
Parts List Item 1 2 3 4 5 Description Rack Assembly Gaiter Inner Ball Joint Outer Tie Rod End Jam Nut
The steering linkage consists of tie rods, inner ball joints and outer tie rod ends and are used to convey the steering movements of the steering rack to the vertical link. The inner ball joints are part of the power steering rack assembly. Concertina type gaiters are installed between the rack housing and tie rods to retain lubricant and prevent the ingress of foreign matter. They also permit lateral steering movement of the rack and arced movements of the ball joints during suspension operation. The tie rods are threaded at their ends to accept the ball joints and outer tie rod ends and to provide toe adjustment. Jam nuts are used to secure the tie rod ends to the tie rods.
2012-07-21
1999 XK RANGE - Steering Column - 211-04
Torques Component Steering column to upper bracket retaining nuts Upper bracket to body retaining screws Steering column lower bracket retaining nuts Steering column lower shaft retaining bolts Upper and lower cowl retaining screws Steering wheel retaining bolt Column switchgear to column Nm 22 - 28 22 - 28 22 - 28 22 - 28 1.5 40 4-5
2012-07-21
Steering Column
Steering Wheel
www.JagDocs.com
Item 1 2 3 4
Description ICE switchpack Cruise control switchpack Horn pad Air bag module location
The steering wheel assembly incorporates: The speed control switchpack. The in-car entertainment (ICE) switchpack. The horn pad. The driver air bag module. <<501-20A>><<501-20B>>
2012-07-21

ICE Switchpack
Item 1 2 3 4
Description Volume increase control ICE select button Volume decrease button Radio skip cycle button
The in-car entertainment switchpack is installed to the left of the steering wheel center and performs the following functions: Increases (+) the volume of the selected audio output. Selects the radio, tape or compact disc. Decreases (-) the set the volume of the selected audio output. Skip cycles through the radio pre-set channels.
Cruise Control Switchpack
2012-07-21

Item 1 2 3 4 Description Speed set or increase button Speed resume button Speed set or decrease button Speed cancel button
The cruise control switchpack is installed to the right of the steering wheel center and performs the following functions: Sets the desired speed or increases (+) the set speed. Resumes the previously set speed. Sets the desired speed or or decreases (-) the set speed. Cancels the set speed.
Horn and Airbag Location
www.JagDocs.com
Item 1 2
Description Horn operating pad Air bag module location
The horn operating pad is mounted in the central area of the steering wheel. The driver air bag is mounted below the horn operating pad area, adjacent to the steering wheel hub. For air bag safety and service information, refer to <<501-20A>><<501-20B>> .
2012-07-21

Upper Steering Column
Parts List Item 1 2 3 4 5 6 Description Upper cowl Lower cowl Column adjustment switch Dimmer switch Tilt motor Reach motor
The upper steering column is adjustable for both tilt and reach. It is available with either manual or electrical operation of these functions. A dimmer switch is installed on the left side of the lower cowl Steering column upper and lower cowls are installed for both manual and electric columns.
Manual Adjustment
When a manual adjustment column is installed: The cable operated reach adjustment has approximately sixteen latched positions. The desired position is fixed by a rack and wedge. Tilt variations are stepped at approximately 3 intervals. Four latched positions are available. The uppermost position is unlatched. From the uppermost position the column may be pulled down to engage the first detent without using the tilt lever.
Serviceable Parts.
The only serviceable part is the Bowden wire and lever assembly.
Electric Adjustment.
When an electrically adjusted column is installed:
2012-07-21
If the ignition key is removed and the adjustment switch is in the 'AUTO' position, the column will tilt away for entry and exit. A column adjustment switch is installed on the left side of the lower cowl.
Serviceable Parts
Ignition switch assembly. Gearshift interlock solenoid. Tilt motor assembly. Reach motor assembly.
Lower Steering Column
www.JagDocs.com
Item 1 2 3 4 5
Description Universal joint to steering rack Dust seal Boot Universal joint to upper column Column outer slider
The lower steering column: Is a handed assembly. Has a telescopic slider arrangement allowing 20 mm of dynamic movement, which retracts further for installation or in the event of an accident. Has a bellows type rubber dust seal between the inner and outer sliders. Incorporates a column to toeboard seal which comprises a rolling element having two, low friction, PTFE
5 2012-07-21

rings. The rolling element locates in a rubber boot which seals to the toeboard. Has a lower universal joint connecting the lower column to the steering rack. Has an upper universal joint connecting the lower column to the upper column. Has a NVH damper incorporated into the upper universal joint assembly. May be installed in any orientation on the universal joint splines. Requires no setting or adjustment. Has no serviceable components. It is essential to disconnect the lower column from the steering rack before removing the engine or front suspension crossbeam. Should the telescopic slider mechanism become separated, for any reason, it must not be reassembled.
2012-07-21
Steering Column 57.40.02

Removal
www.JagDocs.com
1. Power the driver's seat to the lowest and most rearward position. 2. Remove the underscuttle; refer to Section <<501-05>>. 3. Remove the steering column lower cowl; refer to Section <<501-05>>. 4. Remove the steering column upper cowl; refer to Section <<501-05>>. 5. Remove the battery cover.
2012-07-21
6.
Disconnect the battery ground cable.
7. Center the steering. 1. Engage the steering column lock.
8. Unscrew and remove the upper steering column to universal joint nuts. 9. Remove the air bag module; refer to Section 501-20. 10. Remove the steering wheel; refer to this section.
2012-07-21
www.JagDocs.com
11. Disconnect the harness multiplugs. 1. Disconnect the tilt motor to fascia harness multiplug. 2. Disconnect the ignition switch to fascia harness multiplug. 3. Disconnect the air bag harness to cabin harness multiplug. 4. Disconnect the indicator switchgear to fascia harness multiplug. 5. Disconnect the washer switchgear to fascia harness multiplug. 12. Cut and remove the harness securing tie straps.
13. Disconnect the key lock solenoid and key barrel transponder harness multiplugs. 1. Disconnect the key lock solenoid harness multiplug. 2. Disconnect the key barrel transponder harness multiplug.
2012-07-21
14. Unscrew and remove the column lower mounting bracket securing bolts.
15. Unscrew and remove the column to upper mounting bracket securing nuts. 16. Remove the steering column. 1. Release the column from the universal joint. 2. Remove the steering column.
2012-07-21
www.JagDocs.com
17. Remove the switchgear mounting bracket assembly. 1. Unscrew and remove the bolts securing the switchgear mounting bracket assembly. 2. Remove the switchgear mounting bracket assembly.
18. Remove the key transponder from the lock barrel. 19. Insert the ignition key in the steering lock barrel and turn it to the auxiliary position.
2012-07-21
20. Remove the lock barrel assembly from the steering column. 1. Depress the lock barrel retaining peg. 2. Withdraw the lock barrel assembly.
21. Remove the key lock solenoid from the steering column housing. 1. Use a suitable pin punch to drive out the pin securing the key lock solenoid to the housing. 2. Withdraw the solenoid.
2012-07-21

Installation
www.JagDocs.com
1. Install the key lock solenoid to the steering column housing. 1. Install and fully seat the solenoid in the steering column housing. 2. Use a suitable drift to drive in the solenoid securing pin.
2. Install the lock barrel to the steering column lock. 1. Install and the lock barrel to the to the steering column lock. 2. Rotate the key to align lock barrel. 3. Fully seat the lock barrel. 4. Ensure that the retaining peg engages. 3. Turn the ignition key to the OFF position and remove it from the lock barrel.
2012-07-21
4. Install the lock barrel transponder.
5. Install the switchgear mounting bracket on the steering column. 1. Align the switchgear mounting bracket. 2. Install and tighten the switchgear mounting bracket bolts. 6. Place the steering column in the vehicle and through the column mounting bracket.
2012-07-21
7. Engage the lower steering column universal joint with the upper column.
www.JagDocs.com
8. Install the upper column nuts, but do not tighten them.
2012-07-21
9. Install and tighten the column lower securing nuts and bolts. 1. Install and tighten the column lower securing nuts. 2. Tighten the previously installed column upper securing nuts. 10. Apply a suitable thread locking compound and install the universal joint securing bolt and tighten to specification.
11. Connect the harness multiplugs. 1. Connect the washer switchgear to facia harness multiplug. 2. Connect the audible warning speaker to harness multiplug. 3. Connect the indicator switchgear to facia harness multiplug. 4. Connect the air bag harness multiplugs. 5. Connect the ignition switch to to facia harness multiplug. 6. Connect the tilt motor to facia harness multiplug.
10
2012-07-21
www.JagDocs.com
12. Connect the key lock solenoid and transponder harness multiplugs. 1. Connect the key lock solenoid harness multiplug. 2. Connect the key lock barrel transponder harness multiplug. 13. Install and tighten the harness securing tie straps. 14. Install the steering wheel; refer to this section. 15. Install the air bag module; refer to Section 501-20.
16. Reconnect the battery ground cable. 17. Install the battery cover. 18. Install the steering column upper cowl; refer to Section <<501-05>>.
11
2012-07-21
19. Install the steering column lower cowl; refer to Section <<501-05>>. 20. Install the underscuttle; refer to Section <<501-05>>.
12
2012-07-21
Steering Column Control Relay 57.40.34

Removal 1. Remove the driver's side dash liner; refer to Section <<501-05>>.
www.JagDocs.com
2. Remove the servotronic relay base from the mounting bracket.
3. Remove the relay from the base.
Installation 1. Installation is a reversal of the removal procedure
2012-07-21
Steering Column Lower Shaft 57.40.05

Removal 1. Raise and support the vehicle. <<100-02>>
2. Remove and discard the steering column lower shaft retaining bolt.
3. Detach the steering column lower shaft. 4. Lower the vehicle.
2012-07-21
5. Remove the floor covering retaining clip and reposition the floor covering.
www.JagDocs.com
6. Remove and discard the steering column lower shaft retaining bolt.
2012-07-21
7. Detach the steering column lower shaft.
8. Remove the steering column lower shaft. Detach the boot.
Installation NOTATION GIF ENTITY SYSTEM "..\GRAPHIC\E42128.GIF" 1. CAUTION: Make sure the boot is fully seated at the top and bottom.
Attach the boot.
2012-07-21
www.JagDocs.com
2.
CAUTION: Make sure the steering column lower shaft rolling element is fully seated into the boot.
CAUTION: Make sure the boot is fully seated at the top and bottom. Install the steering column lower shaft.
3.
CAUTION: Make sure the steering column lower shaft is fully installed to the steering column shaft splines.
CAUTION: Make sure the steering column lower shaft rolling element is fully seated into the boot.
2012-07-21
Attach the steering column lower shaft.
4.
WARNING: INSTALL A NEW STEERING COLUMN LOWER SHAFT RETAINING BOLT. FAILURE TO FOLLOW THIS INSTRUCTION, MAY RESULT IN PERSONAL INJURY. CAUTION: Make sure the steering column lower shaft is fully installed on the steering column shaft splines.
Install the steering column lower shaft retaining bolt. Tighten to 22 - 28 Nm.
5. Reposition the floor covering and install the floor covering retaining clip. 6. Raise the vehicle.
2012-07-21
7. Attach the steering column lower shaft.
www.JagDocs.com
8.
WARNING: INSTALL A NEW STEERING COLUMN LOWER SHAFT RETAINING BOLT. FAILURE TO FOLLOW THIS INSTRUCTION, MAY RESULT IN PERSONAL INJURY.
Install the steering column lower shaft retaining bolt. Tighten to 22 - 28 Nm.
2012-07-21
Steering Wheel 57.60.01

Removal 1. Remove the driver air bag module. For additional information, refer to<<501-20A>><<501-20B>> .
2. Centralize the steering wheel.
3. Detach and disconnect the switchpacks electrical connector.
2012-07-21
www.JagDocs.com
4. Detach the steering wheel. Remove and discard the steering wheel retaining bolt.
5. Remove the steering wheel. 1. Guide the wiring harnesses through the steering wheel aperture. 2. Remove the steering wheel.
Installation
2012-07-21
1. NOTE: Install a new steering wheel retaining bolt. To install, reverse the removal procedure. Tighten to 40 Nm.
2012-07-21
Tilt /Telescopic Motors 57.40.40

Removal 1. Remove the battery cover.
www.JagDocs.com
2.
WARNING: WAIT AT LEAST ONE MINUTE BEFORE STARTING WORK, BECAUSE THE AIR BAG HAS A BACK-UP POWER SOURCE AND MAY BE INADVERTENTLY DEPLOYED.
Disconnect the battery ground cable. 3. Remove the air bag module; refer to Section 501-20. 4. Remove the steering wheel; refer to this section. 5. Remove the underscuttle; refer to Section <<501-05>>.
2012-07-21
6. Disconnect the tilt motor potentiometer multiplug. 1. Release the multiplug from the mounting bracket. 2. Disconnect the multiplug.
7. Remove the tilt motor from the steering column. 1. Unscrew the tilt motor securing bolts. 2. Withdraw the tilt motor from the drive coupling. 8. Cut and remove the motor harness tie straps.
2012-07-21
www.JagDocs.com
9. Remove the tilt motor potentiometer. 1. Identify and disconnect the motor harness multiplugs. 2. Release the potentiometer securing tang. WARNING: DO NOT ROTATE THE POTENTIOMETER SPINDLE AFTER REMOVAL FROM THE MOTOR UNIT. 3. Remove the potentiometer from the tilt motor.
Installation
1. Install and align the potentiometer to the motor. 2. Connect the motor harness multiplugs. 3. Install and tighten the harness tie straps.
2012-07-21
4. Install the tilt motor to the steering column. 1. Align the motor to column drive coupling. 2. Align the motor securing bolt holes. 3. Install and tighten the motor assembly securing bolts to specification.
5. Connect the motor harness multiplug and install in mounting bracket. 6. Install the underscuttle; refer to Section <<501-05>>. 7. Install the steering wheel; refer to this section. 8. Install the air bag; refer to Section 501-20
2012-07-21
9. Reconnect the battery ground cable. 10. Install the battery cover.
www.JagDocs.com
2012-07-21
1999 XK RANGE - Steering Column Switches - 211-05
Torques Component Switchgear Securing Screws Steering Column Upper Cowl Steering Column Lower Cowl Nm 4-5 1,5 Nominal 1,5 Nominal
2012-07-21
Steering Column Switches

Ignition Switch
The key-operated ignition switch is located on the right hand side of the steering column and has four positions.
Position 'O'.
www.JagDocs.com
OFF. The only position in which the key can be inserted or removed. With the key removed, the steering lock engages.
Position 'I'.
2012-07-21
AUXILIARY. Certain circuits, i.e. radio and windows, can be operated without switching on the ignition.
Position 'II'.
IGNITION. All circuits, except the starter motor, are activated. The key remains in this position when driving.
Position 'III'.
START. The starter operates for as long as the key is held in this position, against the spring pressure. If the engine fails to start, the key must be returned to position 'I' before another start is attempted.
2012-07-21

Lighting Switch
www.JagDocs.com
Item 1 2 3 4 5 6 7
Description Direction Indicators All lamps Off Sidelamps Headlamps Headlamp Main Beam Main Beam Flash Message Center Function Button
The left hand column switch controls the following functions:
Direction Indicators.
The direction indicators operate when the ignition switch is in position 'II'. To indicate for a right or left turn, move the column switch stalk up or down respectively, until the switch latches in position. An audible ticking and a flashing green warning lamp on the instrument cluster indicates that the direction indicators are operating. S Upon completion of the turn, the switch automatically returns to the center position and the indicators cancel. If an indicator bulb fails, the warning lamp and ticking operate at twice the normal rate.
Sidelamps and Dipped Headlamps.

These are controlled by a rotary collar on the switch stalk as follows:
Off Position.
With the rotary collar in the 'OFF' position:
2012-07-21
All exterior lamps are switched 'OFF'.
Sidelamps Position.
With the rotary collar in the sidelamps position: The front sidelamps, tail, license plate and any other lamps required by local legislation are switched 'ON'. The sidelamps tell-tale lamp will be 'ON'.
Headlamps Position.
With the rotary collar in the headlamps position: The headlamps are switched 'ON' (with the ignition switch in position 'II') in addition to the lamps switched on in the sidelamps position. NOTE: If the ignition is switched to position 'O' with the rotary collar in the Headlamps 'ON' position: The sidelamps, tail and license plate lamps will stay on, but the headlamps will switch 'OFF'. When the ignition is switched to position 'II', they will come 'ON' automatically.
Headlamp Main Beam Position.

To select the main beam position: NOTE: The main beam only operates with the dipped headlamps switched 'ON'. Push the column switch stalk away from the steering wheel.
Main Beam Flash.

To flash the main beam: Pull the switch stalk towards the steering wheel. It may be flashed with the ignition switch in any position and will remain 'ON' for as long as the switch is held. Whenever the main beam is in operation, a blue warning lamp on the instrument cluster comes 'ON'.
Message Center Function Button.

The message center function button is located in the end of the switch stalk. Select the functions by repeatedly pressing the function button. The first press will switch from the odometer reading to the trip computer. Further presses will cycle through the trip computer data in sequence, until the odometer reading is displayed again.
2012-07-21

Wiper and Washer Switch
www.JagDocs.com
Item 1 2 3 4 5 6
Description Wipers Off Intermittent Wipe Normal Speed Wiper Operation High Speed Wiper Operation Flick Wipe Facility Programmed Wash/Wipe Button
The right hand column switch controls the following functions with the ignition in position 'II':
Position 'O'. Wipers Off.

With the wipers 'Off' position selected: The windscreen wipers are stationary and in the parked position.
Position 'I'. Intermittent Wipe.

With intermittent wipe selected: The collar can be rotated to vary the delay between wipes. Turn the collar counter-clockwise to increase the time delay. Six collar positions are available and will vary the delay from two seconds to twenty seconds.
Position 'II'. Normal Wiper Operation.

With normal wiper operation position selected: The wipers operate continuously at normal speed.
2012-07-21

Position 'III'. High Speed Wiper Operation.
With the high speed wiper position selected: The wipers will operate continuously at maximum speed.
Flick Wipe.
To obtain a flick wipe: Pull the switch stalk towards the steering wheel for a single slow speed wipe. With the switch held in this position, the wiper will operate continuously at slow speed until released.
Programmed Wash/Wipe.
To obtain the wash/wipe program: Press the button on the end of the switch stalk. A short press will briefly operate the washers and the wipers will complete three wipes. If the button is held depressed, the washers and wipers will operate continuously for up to twenty seconds. S When released, the washers will stop and the wipers complete a further three wipes. The drip wipe function will perform a single wiper sweep four seconds after the wipe/wash sequence has finished. If the 'Washer fluid low' message is displayed and the wash/wipe is selected, the wipers will operate but not the washers.
2012-07-21
Ignition Switch 86.65.03

Removal 1. Remove the battery cover.
www.JagDocs.com
2.
Disconnect the battery ground cable. 3. Remove the underscuttle; refer to Section <<501-05>>. 4. Remove the steering column lower cowl; refer to Section <<501-05>>.
2012-07-21
5. Release the ignition switch multiplug from the mounting bracket and disconnect it.
6. Remove the ignition switch from the lock assembly. 1. Unscrew the ignition switch securing screws. 2. Remove the ignition switch from the lock assembly.
2012-07-21

Installation
www.JagDocs.com
1. Install the ignition switch on the lock assembly. 1. Fully seat the ignition switch on the lock assembly. 2. Install and tighten the ignition switch securing screws. 2. Reconnect the ignition switch multiplug and locate it in the mounting bracket. 3. Install the steering column lower cowl; refer to Section <<501-05>>. 4. Install the underscuttle; refer to Section <<501-05>>.
2012-07-21
Steering Column Control Switch 57.40.33

Removal
1. Power the driver's seat to the lowest and most rearward position. 2. Remove the steering column lower cowl; refer to Section <<501-05>>.
3. Remove the column adjustment switch. 1. Disconnect the rheostat multiplug. 2. Disconnect the column switch harness multiplug. 3. Remove the cowl and switch assembly. 4. Release the column switch retaining tangs and withdraw the switch.
Installation 1. Installation is the reverse of the removal procedure.

1 2012-07-21
Steering Column Lock Module 86.80.36

Removal 1. Remove the underscuttle; refer to Section <<501-05>>. 2. Remove the steering column lower cowl; refer to Section <<501-05>>. 3. Remove the steering column upper cowl; refer to Section <<501-05>>.
www.JagDocs.com
4. Remove the ignition key. 5. Remove the battery cover.
2012-07-21
6.
Disconnect the battery ground cable. 7. Remove the driver's air bag module; refer to Section 501-20. 8. Remove the steering wheel; refer to Section <<211-04>>. 9. Remove the cassette and cancellation module; refer to Section <<211-04>>. 10. Remove the steering column switchgear mounting bracket; refer to this section.
11. Disconnect the wiring harness multiplug. 1. Cut the solenoid harness securing strap. 2. Disconnect the solenoid wiring harness multiplug.
2012-07-21
www.JagDocs.com
12. Remove the solenoid from the lock housing.. 1. Use a pin punch to drive out the pin securing the solenoid to the lock housing. 2. Withdraw the solenoid from the lock housing.
Installation
1. Install the solenoid to the steering lock housing. 1. Install and fully seat the solenoid to the steering lock housing. 2. Use a suitable pin punch to drive in a new pin to secure the solenoid to the lock housing.
2012-07-21
2. Install the steering column switchgear mounting bracket; refer to this section. 3. Install the cassette and cancellation module; refer to Section <<211-04>>. 4. Install the steering wheel; refer to Section <<211-04>>. 5. Install the air bag module; refer to Section 501-20.
6. Reconnect the battery ground cable. 7. Install the battery cover. 8. Install the underscuttle; refer to Section <<501-05>>. 9. Install the steering column upper cowl; refer to Section <<501-05>>. 10. Install the steering column lower cowl; refer to Section <<501-05>>.
2012-07-21
Steering Column Multifunction Switch 86.65.92

Removal 1. Remove underscuttle; refer to Section <<501-05>>. 2. Remove the steering column lower cowl; refer to Section <<501-05>>. 3. Remove the steering column upper cowl; refer to Section <<501-05>>. 4. Remove the battery cover.
www.JagDocs.com
5.
Disconnect the battery ground cable. 6. Remove the driver's air bag module; refer to Section 501-20. 7. Ensure that the steering wheel is in the straight ahead position. 8. Remove the steering wheel; refer to this section.
2012-07-21
9. Disconnect the harness multiplugs. 1. Disconnect the cancellation module multiplugs. 2. Release the wiper/washer multiplug from the mounting bracket and disconnect it. 3. Release the flasher/headlamp switch multiplug from the mounting bracket and disconnect it.
10. Remove the switch/assemblies cancellation module. 1. Unscrew and remove the bolts securing the switch assemblies/cancellation module to the mounting bracket. 2. Remove the steering column switchgear assembly. 3. Release the switch assemblies from the module and mounting bracket. 4. Remove the switch assemblies/cancellation module.
2012-07-21

Installation
www.JagDocs.com
1. Install and align the cancellation module and switch assemblies to the steering column mounting bracket. 1. Install and align the flasher switch assembly to the module mounting bracket. 2. Install and align the washer switch assembly to the module mounting bracket. 3. Install and align the switchgear assembly to the steering column. 4. Install and tighten the switch assemblies/cancellation module securing screws.
2. Connect the module harness multiplugs and install in the mounting bracket. 1. Connect the module harness multiplugs. 2. Install the multiplugs in the mounting bracket. 3. Connect the switch assembly multiplugs. 4. Install the multiplugs in the mounting bracket. 3. Install the steering wheel; refer to this section. 4. Install the air bag; refer to Section 501-20. 5. Install the steering column upper cowl; refer to Section <<501-05>>.
2012-07-21
6. Install the steering column lower cowl; refer to Section <<501-05>>. 7. Install the underscuttle; refer to Section <<501-05>>.
2012-07-21
Steering Column Multifunction Switch Mounting Bracket 76.46.33

Removal 1. Remove the underscuttle; refer to Section <<501-05>>. 2. Remove the steering column lower cowl; refer to Section <<501-05>>. 3. Remove the steering column upper cowl; refer to Section <<501-05>>. 4. Remove the battery cover.
www.JagDocs.com
5.
Disconnect the battery ground cable. 6. Remove the driver's air bag module; refer to Section 501-20.
2012-07-21
7. Ensure that the steering is centered. 8. Remove the steering wheel; refer to Section <<211-04>>.
9. Disconnect the cancellation module multiplugs.
2012-07-21
www.JagDocs.com
10. Remove the wiper/washer switch multiplug. 1. Release the multiplug from the mounting bracket. 2. Disconnect the multiplug.
11. Remove the flasher/headlamp switch multiplug. 1. Release the multiplug from the mounting bracket. 2. Disconnect the multiplug.
2012-07-21
12. Remove the switch assemblies/cancellation module. 1. Unscrew the switchgear securing screws. 2. Remove the switchgear assembly from the mounting bracket.
13. Remove the switch assemblies from the cancellation module and mounting bracket.
2012-07-21
14. Remove the cancellation module from the mounting bracket.
www.JagDocs.com
Installation
1. Install and align the cancellation module to the column mounting bracket.
2012-07-21
2. Install the flasher switch and washer switch assemblies to the module mounting bracket. 1. Install and align the flasher switch assembly. 2. Install and align the washer switch assembly.
3. Install switchgear assembly to the steering column. 1. Install and align the switchgear assembly to the steering column. 2. Install and tighten the switchgear and cancellation module securing bolts.
2012-07-21
www.JagDocs.com
4. Reconnect and locate the cancellation module harness multiplugs. 1. Reconnect the cancellation module harness multiplugs. 2. Locate the multiplugs to the mounting bracket.
5. Reconnect and locate the switch assembly multiplugs. 1. Reconnect the switch assembly harness multiplug. 2. Locate the multiplug to the mounting bracket.
2012-07-21
6. Install the steering wheel to the column in the correct orientation; refer to Section <<211-04>> 7. Install the driver's air bag; refer to Section 501-20
2012-07-21
www.JagDocs.com
10. Install the steering column upper and lower cowls. 1. Install the steering column upper cowl; refer to Section <<501-05>>. 2. Install the steering column lower cowl; refer to Section <<501-05>>. 11. Install the underscuttle; refer to Section <<501-05>>.
2012-07-21
1999 XK RANGE - Engine System - General Information - 303-00
Engine Description 90'Vee' 8 Cylinder 32 Valves 90'Vee' 8 Cylinder 32 Valves - Supercharged Model AJ27 AJ261/2 Capacity 4 Liters 4 Liters
Engine Torque Engine Maximum Delivered - 4.0L Maximum Delivered - 4.0L SC Nm (DIN)/Rpm 393 at 4250 525 at 3600
Engine Power Engine Maximum Delivered - 4.0L Maximum Delivered - 4.0L SC BHP (DIN)/Rpm 290 at 6100 370 at 6150
Lubricants, Fluids, Sealants and Adhesives Unit Engine Oil - USA/Canada Engine Oil - UK and ROW Anti-Freeze Sealant - Engine Block-to-Bedplate and Sump-to-Bedplate (RTV Silicone) Sealant - Engine Core Plugs and Block Stub Pipe (Anaerobic Sealant) Specification API SJ/EC and ILSAC GF2 API SJ/EC and ACEA A1-98 or A3-98 ESD-M97B49-A Loctite 5699 Ultra Grey Loctite 648
Capacities Unit Engine Oil - With Oil Cooler Engine Oil - Without Oil Cooler Coolant - Complete System Coolant - Complete System - Supercharged Coolant - Engine Only Liters 7,3 6,5 10 12 3,7
Valve Clearances (Cold) Inlet Exhaust 0.18 to 0.22 mm 0.23-0.27 mm
Firing Order Viewed from the driver's seat, Bank 1 (previously described as A-bank) is on the right hand side: 1-1, 2-1, 1-4, 1-2, 2-2, 1-3, 2-3, 2-4.
2012-07-19
Engine
Normally Aspirated
www.JagDocs.com
2012-07-19

Supercharged
The AJ27 power unit is available in 4.0 L versions, and comprises: An eight cylinder 90 degree 'V' configuration liquid cooled aluminium cylinder block incorporating 'Nikasil' plated cylinder bores. Pistons of open-ended skirt design, with two compression and one oil control ring. Two aluminium cylinder heads, each incorporating two camshafts. Four valves per cylinder. Aluminium valve lifters and top mounted shims. Variable valve timing (VVT) of the intake camshafts (normally aspirated only). Camshaft covers manufactured from Vinylester. Aluminium timing cover which accommodates the crankshaft front oil seal.
2012-07-19
Single row primary and secondary chains drive the camshafts of each cylinder bank. An aluminium bed plate, incorporating iron main bearing supports, which accommodate the oil pump pick-up, diverter valve (if fitted) and oil filter. Main bearings which are grooved in the upper positions and plain in the lower positions. They are manufactured from aluminium / tin material. A crankshaft with undercuts and rolled fillets for extra strength. Fracture-split connecting rods in sintered-forged steel. Brackets bolted to the front of the cylinder block are used to mount all accessories. A single, seven ribbed vee belt drives the front end accessories on all versions of the engine. A second, seven ribbed vee belt drives the supercharger. Automatic belt tensioners - one for the front end accessory drive and one for the supercharger where fitted. Each tensioner incorporates a belt wear indicator. An advanced engine management system incorporating electronic throttle control. The unit meets the requirements of the CARB OBDII USA legislation.
Ancillary Systems
The ancillary systems, driven by the engine, each have a detailed Description and Operation along with Diagnostic Procedures, and Removal and Installation instructions; refer to the following sections of this manual: Power Steering Pump - Section <<211-02>>. Air Conditioning Compressor - Section <<412-03>>. Engine Cooling Pump - Section 303-03. Generator - Section <<414-02>>. The drive belt, idler pulley and automatic tensioner are described in Section <<303-05>>. The engine starting system is described in Section <<303-06>>.
www.JagDocs.com
Engine Management and Emission Control System Engine Control Module (ECM)
Engine management and exhaust emissions are controlled by the ECM, which has the following main functions: Fuel injection. Idle speed. Ignition. Evaporative loss system. Engine cooling fans. Climate control compressor clutch demand. The microprocessor within the ECM receives signals from various sensors and other modules and uses a pre-determined program to compute engine management functions. Adaptive functions are incorporated in the ECM to cater for continuous adjustments to its computations to suit prevailing conditions. Because the system also controls emissions to suit all modes, neither CO levels nor idle speed require service attention or adjustment, except if an error or component failure should occur. On Board Diagnostics are controlled by the ECM with the continuous monitoring of incoming signals and the subsequent verification against what the module expects to 'see'. Should a signal be incorrect or missing, the ECM will substitute a fixed value to provide the 'limp home mode' and alert the driver of the problem. Fixed values may
3 2012-07-19
be adopted for: Transmission oil temperature. Mechanical guard position. Throttle blade angle. Camshaft position. Intake air temperature. Diagnostic trouble codes (DTC), including OBD II codes, are stored in the ECM memory and can be read by an appropriate retrieval tool. Should either the ECM or TCM fail, ensure that the control housing cooling fan is operating correctly. Failure of the cooling fan MUST be rectified before renewing a control module and details of a fan failure should accompany a returned control module. The ignition supply is the main power source for the ECM; this supply will be disconnected by an inertia switch if the vehicle is subject to a violent deceleration, as in a collision. The ECM has separate ignition and battery supply inputs. The battery input maintains the ECM memory as long as the vehicle battery is connected.
Engine Management System Components Electronic Throttle

The electronic throttle assembly, in response to signals from both the driver and the ECM, adjusts idle speed, sets the throttle valve to the position requested by the throttle pedal, cruise and traction control, power limitation and catalyst warm-up.
Mass Air Flow Meter

The air flow meter assembly outputs an analogue voltage to the ECM. This sensor measures air flow into the engine intake system and is calibrated to measure kg / hour.
Intake Air Temperature

The intake air temperature sensor is located in the air flow meter assembly and outputs an analogue voltage to the ECM. The ECM will substitute a default value equal to 50C should this sensor fail.
Fuel Injectors
The eight fuel injectors are located in individual apertures in the intake manifold. The fuel rail is separate and supplies fuel to the top of each injector. Air injection is provided to the base of each injector to further improve fuel delivery and atomisation. Air is provided by an air gallery which is integral with the intake manifold. The fuel injectors are electromagnetic solenoid valves controlled by the ECM. The electrical pulse time for the injector combined with the fuel pressure determines the volume of fuel injected to the manifold.
Fuel Delivery
The fuel pump provides fuel to the fuel rail where the circulating pressure is controlled by a pressure regulator valve; excess fuel is returned to the fuel tank. The pressure regulator valve is controlled by manifold depression so that fuel delivery pressure is maintained at approximately 3 bar above manifold pressure.
2012-07-19

Fuel Pump Relay
The ECM controls this component for normal engine running. The security system may disable this relay via communication with the ECM.
Fuel Level Sensing

The quantity of fuel in the tank is measured by the fuel level sensor . This signal is used by the ECM as an input to certain diagnostics.
Evaporative Valve
Excess vapour formed in the fuel tank is absorbed into the evaporative emission purge control canister. While the engine is running, the fuel absorbed in the canister is gradually purged back into the engine. The rate of purging is governed by the operating conditions of the engine and vapour concentration level. Operating conditions which affect the purge rate are: Speed and load. Coolant temperature. Time elapsed from start up. Closed loop fuelling. Determination of the vapour concentration is made by stepped opening of the EVAP valve and subsequent monitoring of the fuelling correction. This function is performed prior to purging, so that at the onset of purging, the EVAP valve can be set to the optimum position. Should the ECM be unable to determine the concentration before purging, a default value is employed, which is then modified whilst purging is in progress. When the purging process is operational the ECM modifies the basic fuelling calculation to maintain the correct air / fuel ratio. Purging is inhibited during fuel cut-off and stability / traction control intervention.
www.JagDocs.com
Coolant Temperature Sensor

The sensor outputs a voltage to the ECM which decreases as temperature increases.
Cooling Fans
In response to engine coolant temperature and climate control system demand, the ECM will energize the cooling fans.
Climate Control Compressor

The ECM will allow the compressor clutch to be engaged if the engine temperature and load demand are normal. Should the driver require maximum engine power or the coolant temperature be high, the request will be denied.
Cranking Signal
The ECM reacts to a signal from the Body Processor Module (BPM) when the starter motor relay is energized. This signal is used to trigger starting, fuel and ignition strategies.
Engine Speed and Crankshaft Position

Engine speed and crank position are monitored by a sensor which is mounted on the cylinder block (flywheel housing) in front of the crankshaft drive plate. It indicates rotational speed to the ECM in the form of 35 pulses per crank revolution. Engine speed is used for synchronization of fuel and ignition systems, as well as other functions.
2012-07-19
Camshaft Position
A camshaft position sensor is mounted at the rear of each cylinder head on the intake side and each provides four signals every 720 degrees of crankshaft rotation. The combination of signals from both sensors (normally only Bank 1 sensor is used in conjunction with the crankshaft sensor for normal fuelling and ignition functions) can indicate to the ECM when a particular piston is approaching TDC on the compression stroke. On supercharged engines, one sensor is mounted at the rear of Bank 1 cylinder head on the intake side and provides one signal every 720 degrees of crankshaft rotation. The signal, in conjunction with the signals from the crankshaft position sensor, indicates to the ECM that the piston of cylinder 1A is approaching TDC on the compression stroke.
Variable Valve Timing (Normally Aspirated Engine)

The valve timing (camshaft phasing) is infinitely variable within the maximum design limits of advance and retard. An actuating shuttle valve directs engine oil pressure to either side of the control piston within the VVT unit to advance or retard the intake camshaft, as calculated and controlled by the ECM. Movement of the actuating shuttle valve is by a linear solenoid. Closed loop sensing and control of each intake camshaft is provided by the ECM in response to signals from each camshaft position sensor.
Ignition
Ignition spark is produced by individual on-plug coil units. Each on-plug coil unit also comprises an amplifier module. The ECM controls each amplifier module which in turn switches the coil primary to generate the HT voltage within the secondary winding.
Knock Sensor
This sensor uses a piezo-electric sensing element to detect knock which may occur under acceleration at critical conditions. Should detonation be present the ECM will retard the ignition timing of individual cylinders.
Exhaust Gas Recirculation

The EGR valve (where fitted) reduces NOx emissions by recirculating a portion of the exhaust gases back into the intake manifold.
Heated Oxygen Sensors

The heated oxygen sensors, one per bank, are situated upstream of the catalysts. Integral to the sensors are heaters (under ECM control) which allow the sensors to reach their operating temperature as soon as possible after engine start. A comparison between the level of oxygen in the exhaust gas to that in the atmosphere produces an output signal. This signal is used by the engine closed loop fuel strategy to make fuelling corrections and so control overall emission levels.
Oxygen Sensors
These sensors, one per bank, are situated downstream of the heated oxygen sensors. The comparison of upstream and downstream signals allows determination of catalyst conversion efficiency.
2012-07-19

Cylinder and Crankshaft Grading
www.JagDocs.com
Example - *PJEAL* - Crankshaft Main Journal Diameter

Read the grade letters from LEFT to RIGHT = FRONT to REAR of engine eg. for this example engine, the crank journal at the front of the engine is grade P, and at the rear is grade L. The selection of main bearing shells is described in the following chart.
Example - *ABAA* - Crankshaft (Big End Bearing) Crankpin Diameter

Read the grade letters from LEFT to RIGHT = FRONT to REAR of engine eg. for this example engine, the crankpin at the front of the engine is grade A and at the rear is also grade A. Grade A = 56,000 to 55,994 mm (Bearing Shell Colour Code - Blue). Grade B = 55,994 to 55,988 mm (Bearing Shell Colour Code - Green). Grade C = 55,988 to 55,982 mm (Bearing Shell Colour Code - Yellow).
Example - *21222122* - Cylinder Bore and Piston

The cylinder bore grades read from LEFT to RIGHT as follows: Bank 2 - Cylinder 1, Bank 2 - Cylinder 2, Bank 2 - Cylinder 3, Bank 2 - Cylinder 4, Bank 1 - Cylinder 4, Bank 1 - Cylinder 3, Bank 1 - Cylinder 2, Bank 1 - Cylinder 1. (Note, in earlier publications Bank 1 was described as A-Bank and Bank 2 as B-Bank) Grade 1 Bore = 85,990 to 86,000 mm.
2012-07-19
Grade 2 Bore = 86,000 to 86,010 mm. Grade 3 Bore = 86,010 to 86,020 mm.
Example - *WPPNN* - Crankshaft Main Bearing Bore in Cylinder Block

Read the grade letters from LEFT to RIGHT = FRONT to REAR of engine eg. for this example engine, the crank journal bore at the front of the engine is grade W, and at the rear is grade N. The selection of main bearing shells is described in the following chart.
2012-07-19

Crankshaft Main Bearing Shell Selection Chart
www.JagDocs.com
The axes on the chart refer to: X1 Crankshaft Bore in Cylinder Block. Y1 Crankshaft Journal Diameter. The number in each diagonal band represents a PAIR of colour coded main bearing shells which must be used with a specific journal, depending on the combination of journal diameter and crankshaft bore diameter. The colour codes for each band are as follows: 1 - Blue / Green and Blue / Green, 2 - Blue / Green and Blue, 3 - Blue and Blue, 4 - Blue and Green, 5 - Green and Green, 6 - Green and Yellow, 7 - Yellow and Yellow. Consider crankshaft journal 5 (from the example grade markings on the cylinder block) - the cylinder block bore is
2012-07-19
Grade N and the crankshaft journal diameter is Grade L. From the chart, it will be seen that the point of intersection is in Band 4 which equates to one Blue shell and one Green shell. When the appropriate pair of colour codes have been selected for a journal, either colour may be installed to the cylinder block or to the bedplate, but, the shell which is to be installed to the cylinder block must have an oil groove and the shell which is to be installed to the bedplate must be plain.
Piston Identification
Item 1 2
Description 4.0L Normally Aspirated 4.0L Supercharged
10
2012-07-19

Piston / Connecting Rod Orientation
www.JagDocs.com
Item 1 2 3 4
Description FRONT of engine Thick Flange of Connecting Rod. Must face FRONT of engine on BANK 1 Grade on Piston Crown. To front of engine on both banks Thick Flange of Connecting Rod. Must face REAR of engine on BANK 2
11
2012-07-19
1999 XK RANGE - Engine - 303-01
Engine Description 90'Vee' 8 Cylinder 32 Valves 90'Vee' 8 Cylinder 32 Valves Model AJ27 AJ26.5 Capacity 4 Liters 4 Liters
Engine Torque Engine Maximum Delivered - 4.0L Maximum Delivered - 4.0L SC Nm (DIN)/Rpm 393 at 4250 526 at 3500
Engine Power Engine Maximum Delivered - 4.0L Maximum Delivered - 4.0L SC BHP (DIN)/Rpm 290 at 6100 365 at 6000
Lubricants, Fluids, Sealants and Adhesives Unit Engine Oil - USA/Canada Engine Oil - Mexico Engine Oil - UK and ROW Engine Oil - Supercharged Anti-Freeze Sealant-Engine Block-to-Bedplate and Sump-to-Bedplate (RTV Silicone) Sealant-Engine Core Plugs and Block Stub Pipe (Anaerobic Sealant) Specification API SH or SJ / ILSAC GF-2 API SJ API SH or SJ / ACEA A2 API SH or SJ / ACEA A3 ESD-M97B49-A Loctite 5699 Ultra Grey Loctite 648
Capacities Unit Engine Oil-With Oil Cooler Engine Oil-Without Oil Cooler Coolant-Complete System Coolant-Engine Only Liters 7,3 6,5 10 3,7
Valve Clearances Cold Engine Valve Clearance Inlet 0.20 mm Exhaust 0.25-0.30 mm
2012-07-19

Torque Specifications Description Accessory drive belt tensioner Accessory drive belt idler pulley Air intake tube to throttle body A/C pipes to receiver / drier A/C pipe manifold joints Camshaft bearing caps Camshaft cover Charge Air Cooler Adaptor to cylinder head (SC) Crankshaft damper bolt - no locking ring Crankshaft damper bolt - with locking ring Crankshaft position sensor Cylinder head bolts M10 Cylinder head bolts M8 (two at front of head) Driveshaft (propshaft) drive flange bolts ERG pipe to exhaust manifold Engine compartment cover (bonnet) hinges Engine coolant radiator top securing panel Engine front mounting Engine oil cooler pipes (clamp) Engine / Transmission assembly rear mounting centre bolt Engine / Transmission assembly rear mounting outer bolts Exhaust downpipe support bracket to flywheel housing Exhaust downpipe to lower mounting bracket Exhaust camshaft sprocket Exhaust manifold to cylinder head Exhaust manifold flange to downpipe Exhaust Torca clamps Fuel cross-over elbow Fuel feed pipe to intake manifold Fuel injector harness clips to camshaft cover (SC) Fuel pressure regulator to intake manifold Fuel rail to Charge Air Cooler Adaptor (SC) Intake manifold to cylinder heads Intake elbow support brackets Oil filter Oil Cooler PAS pump hose unions Primary timing chain fixed guide Primary timing chain tensioner Primary timing chain tensioner blade Secondary timing chain tensioner to cylinder Steering rack Nm 38-48 53-69 4-5 8-10 8-10 9-11 9-11 20-22 80 + 80 364-386 8-12 35 23-27 75-88 18-24 22-28 22-28 60-80 18-24 30-40 22-28 43-57 42-54 115-125 16-20 15-20 50-60 8-12 8-12 4-5 8-12 18-24 20-22 16-20 15-18 7 22-28 10-14 10-14 12-16 10-14 40-50 Lb-Ft Lb-In -
www.JagDocs.com
2012-07-19
Throttle body to intake elbow Throttle cable abutment to throttle body Throttle intake elbow to intake manifold Timing cover Variable camshaft timing oil control unit to intake camshaft Variable camshaft timing oil control unit housing (bolt and nut) Variable camshaft timing oil control solenoid Water pump pulley
18-24 4-6 18-24 11-13 40 + 90 19-23 10-14 10-14
2012-07-19
Valve Clearance Adjustment

Tappet adjustment 303-540
www.JagDocs.com
Air gun, fan nozzle 303-590
1. Open the engine compartment and fit paintwork protection sheets. Open to the service position. 2. Carefully remove both engine covers, taking care not to damage the plastic fixings or the rubber inserts.
2012-07-19
3. Disconnect the battery ground cable. Remove the battery cover. 4. Remove the cam cover from the 'A' bank and the 'B' bank. Refer to Operations <<12.29.43>> and <<12.29.44>>. 5. Check, and note the valve clearances, as described earlier in this section. 6. Use a rag to wipe up as much oil as possible from the tappet wells. 7. Valve adjustment involves considerable repetition. A SUMMARY OF THE PROCEDURE follows: 1. Fit the adjusting tool base plate to one cylinder head. 2. Rotate the crankshaft to position four valves ready for adjustment. 3. Use the attachment part of the special tool to adjust two valve clearances. Transfer the attachment and adjust the other two valve clearances. 4. Remove the attachment part from the adjusting tool base plate. 5. Repeat steps 2 to 4 three more times until all sixteen valves on the first cylinder head have been adjusted. 6. Repeat steps 1 to 5 for the other cylinder head. 7. Remove all equipment and reassemble the engine. 8. The following instructions describe the PROCEDURE FOR ADJUSTING THE VALVE CLEARANCES.
2012-07-19
www.JagDocs.com
9. Fit the base plate of the tappet adjusting tool 303 - 540 to one of the heads; use the bolts which are supplied with the tool. It should be fitted along the head, between the two camshafts, and bolted to the tapped holes which normally secure the cam cover. 10. Rotate the crankshaft so that there are four valves which are 'off the cam' (cam lobes uppermost), so that their clearance may be measured.
11.
CAUTION: Do not rotate the crankshaft while the attachment is fitted to the base plate.
Fit the attachment of 303 - 540 to the base plate. 1. Set the fingers of the attachment to the highest position (unscrew the knurled bolts). 2. Fit the attachment to the base plate, adjacent to the first two valves to be adjusted. 3. Tighten the screws to secure the attachment to the base plate.
2012-07-19
12. Position the fingers on to the outer edges of the tappet. It is essential that the recessed step on each finger, locates on the edge of the tappet as indicated. The use of a mirror will help, as viewing access is restricted.
13. Tighten the knurled bolts to compress the valve springs, until a firm resistance is felt.
2012-07-19
www.JagDocs.com
14.
WARNING: THE FOLLOWING OPERATIONS REQUIRE THE USE OF COMPRESSED AIR - ALWAYS WEAR SUITABLE EYE PROTECTION.
Remove, clean and measure the shims. 1. Surround the immediate working area with clean rag to contain any loose objects and shims displaced by the compressed air. 2. Use 303 - 590 Air Gun (with a fan nozzle) aimed at the edge of the shim to lift it from the tappet. Remove the shim from each tappet, noting the position of each. 15. Clean and measure the thickness of each shim. 16. Assess the increase or decrease required in shim thickness to produce the correct valve clearance. 17. Select two shims of the correct size, lubricate each and fit each to the respective tappet (as calculated in the previous step). Shims must be fitted with the size marking facing the tappet NOT the cam.
2012-07-19
18. Loosen the knurled screws on 303 - 540 attachment to allow the valve springs to return to their normal position. 19. Check the valve clearance of the two valves. If the clearance is correct, remove the attachment from the base plate. transfer the attachment to the other two valves which are in position to be adjusted. 20. Repeat the adjustment procedure, as described in the Summary.. 21. Refit the cam covers and associated components. Refer to Operations <<12.29.43>> and <<12.29.44>>. 22. Refit the engine covers. 23. Check the engine oil level; rectify as necessary. 24. Move the engine compartment cover from the service position and connect the gas struts. 25. Remove the paint protection sheets and close the cover. 26. Connect the battery and fit the battery cover. Refer to the Battery Reconnection Procedure <<86.15.15>>.
2012-07-19
Valve Clearance Check

1. Open the engine compartment and fit paintwork protection sheets. Open to the service position. 2. Carefully remove both engine covers, taking care not to damage the plastic fixings or the rubber inserts.
www.JagDocs.com
3. Disconnect the battery ground cable. Remove the battery cover. 4. Remove the cam cover from the 'A' bank and the 'B' bank. Refer to Operations <<12.29.43>> and <<12.29.44>>. 5. Rotate the crankshaft so that there are four valves which are 'off the cam' (cam lobes uppermost), so that their clearance may be measured. 6. Measure the gap on each of the four valves. Note which valve has been measured, along with its relevant clearance. 7. Rotate the crankshaft a small amount so that the next four valves are 'off the cam'. Measure and note the clearances. Repeat this step a further six times, until all valve clearances have been measured and noted. 8. Refit the cam covers and associated components. Refer to Operations <<12.29.43>> and <<12.29.44>>. 9. Refit the engine covers. 10. Move the engine compartment cover from the service position and connect the gas struts. 11. Remove the paint protection sheets and close the cover. 12. Connect the battery and fit the battery cover.
1 2012-07-19
Engine
Cylinder Block
The cylinder block is of an enclosed 'Vee' design with 'Nikasil' plated cylinder bores to reduce piston friction, improve warm up and oil retention. A low volume coolant jacket improves warm up time and reduces piston noise levels. Viewed from the driving position, the right-hand cylinder bank is designated A-bank and the left-hand cylinder bank as B-bank. The cylinder bores of each bank are numbered 1 to 4, from the front of the vehicle.
2012-07-23

Cylinder Block Drain Plug/Heater Unit
www.JagDocs.com
The coolant drain plug is located on the rear left side of the cylinder block. On vehicles supplied with a cold climate package (i.e. vehicles operating in conditions regularly below -30C) a cylinder block heater unit is fitted instead of the drain plug.
Knock Sensors
Two knock sensors are fitted to the cylinder block on the inboard side of each cylinder bank. The flying lead of each sensor is secured to a bracket on (or near to, depending on the model) the thermostat housing. These piezo-electric sensors provide inputs to the ECM to indicate the detection and location of detonation during combustion.
2012-07-23

Crankshaft
The cast iron crankshaft has undercut and rolled fillets for improved strength and six counter-balance weights ensure low levels of vibration from the four throw, five bearing configuration. The main bearing shells are aluminium / tin split plain type. An oil groove in the top half of each bearing transfers oil into the crankshaft oilway drillings for lubrication of the connecting rod bearings. A lead/bronze thrust washer is fitted on each side of the top half of the center main bearing. The crankshaft rear oil seal is lipped and is a press fit in the interface of the bedplate to cylinder block. A torsional vibration damper and pulley assembly is bolted to the crankshaft nose.
Connecting Rods and Pistons
The connecting rods are manufactured from sinter-forged steel and have fracture-split bearing caps. The opposing sides of each connecting rod being fractured at the bearing horizontal center line.
2012-07-23
The cylinder position is etched on adjoining sides of the joint to identify matching connecting rods and bearing caps. The connecting rod bearing shells are lead / bronze, split plain bearings.
www.JagDocs.com
The pistons are open ended skirt design with flat upper surfaces (dished on supercharged engines) to reduce heat absorption. The piston crown has four cut-outs to clear the valve heads for any available combination of cam profile and valve phasing. Three piston rings, two compression and one oil control, are fitted to each piston. Each piston is fitted on a wrist pin which operates in a lead / bronze bush fitted in the connecting rod.
Timing Gear
2012-07-23

Item 1 2 Description Primary Chain Tensioner Primary Chain
Single row primary and secondary chains drive the camshafts of each cylinder bank. The primary chains transmit the drive from two sprockets on the crankshaft to a sprocket on each intake camshaft. The secondary chains transmit the drive from a second, smaller sprocket on the intake camshaft to a sprocket on the exhaust camshaft. Each chain has a hydraulic tensioner operated by the engine lubricating system. A jet of oil from the end of each tensioner lubricates the chains. The primary chain tensioners act on pivoting flexible tensioner blades, the secondary chain tensioners act directly on the chains. Guide rails are used on the drive side of the primary chains. A key locates the two drive sprockets on the crankshaft and these are retained in position by the crankshaft torsional vibration damper.
Parts List Item 1 2 3 Description Variable Valve Timing Unit, where fitted Secondary Chain Secondary Chain Tensioner
The variable valve timing units and the exhaust camshaft sprockets are a non-interference, non-keyed fit on their respective camshafts. They are clamped in place on the camshafts by the securing bolt and clamping plate/washer.
2012-07-23

Timing Cover
www.JagDocs.com
Parts List Item 1 2 Description Crankshaft Front Oil Seal Silicon Rubber Gaskets The aluminium-alloy timing cover accommodates the crankshaft front oil seal. Silicon rubber in-groove gaskets seal the joint between the timing cover and the front face of the engine.
2012-07-23

Cylinder Heads and Valve Gear
Item 1 2 3 4 5
Description Cylinder Head Bolt Lifting Eye Valve Lifter Adjustment Shim Camshaft
Cylinder heads are unique to each cylinder bank and are secured, using deep seated bolts, to the cylinder block. Two hollow dowels align each cylinder head with the cylinder block. Each cylinder head gasket consists of a silicon beaded composite gasket with metal eyelets for the cylinder bores. Each cylinder head incorporates dual overhead camshafts operating four valves per cylinder via solid aluminium-alloy valve lifters. A steel shim in the top of each lifter allows adjustment of valve clearances.
2012-07-23
Valve head diameter is 31 mm for exhaust and 35 mm for intake, and all valve stems are 5 mm diameter. Valve seats and guides are sintered metal inserts. Collets, valve collars and spring seats locate the valve springs on the intake and exhaust valves. Valve stem seals are integrated into the spring seats. Four 14mm spark plugs are located in a recess on the center-line of each cylinder head. For spark plug details refer to Section <<303-07>>.
Camshafts
The chilled cast iron camshafts are each retained by five aluminium alloy caps - location numbers '0 to 4' for the intake camshaft and '5 to 9' for the exhaust, marked on the outer face of each cap. A machined flat near the front of each camshaft enables the camshafts to be locked, using a special tool, during the valve timing procedure.
Camshaft Sensor
The camshaft sensor is a variable reluctance sensor that provides an input to the ECM of intake camshaft position. On normally aspirated engines, a camshaft position sensor is mounted at the rear of each cylinder head on the inlet side and is triggered by a four toothed sensing ring, to provides four signals every 720 degrees of crankshaft rotation. The combination of signals from both sensors can indicate to the ECM when a particular piston is approaching TDC on the compression stroke, should it need to e.g. if a fault occured with the crankshaft position sensor. However, during normal operation, only the A-bank sensor is used in conjunction with the crankshaft sensor for normal fuelling and ignition functions. On supercharged engines, one camshaft sensor is fitted to the rear of the B-bank cylinder head and is triggered by a single toothed sensing ring fitted to the rear of the intake camshaft.
www.JagDocs.com
2012-07-23

Camshaft Covers
The camshaft covers are made from vinyl-ester plastic; the A-bank cover incorporates an outlet for the full load engine breather. The B-bank cover incorporates the engine oil filler cap and an outlet for the part load engine breather. Identical oil separators are incorporated inside the top of each cover. Each oil separator comprises a wire gauze packing in an open ended enclosure below the breather outlet.
Lifting Eyes
There are four lifting eyes for the engine. One lifting eye is cast into the front of each cylinder head assembly and the rear lifting eyes, also one per cylinder head, are bolt-on special tools.
2012-07-23

Bedplate
www.JagDocs.com
Item 1 2
Description Bedplate Sealant Track
This is a structural casting bolted to the bottom of the cylinder block to retain the crankshaft and to further improve overall rigidity. Slight changes to main bearing clearance due to expansion are minimised by means of iron inserts cast into the bedplate main bearing supports. Two hollow dowels align the bedplate with the cylinder block and the joint is sealed by a continuous bead of sealant. The engine speed sensor is located at the rear of the bedplate and is a variable reluctance sensor that provides an input to the ECM representing engine crankshaft speed and position.
10
2012-07-23
Intake Manifold (Normally Aspirated)
The intake manifold is manufactured in plastic with plastic integrated fuel rails and metal thread inserts; the very smooth internal surfaces give excellent air flow. Individual ducts lead off a central chamber to the inlet valves of each cylinder. Silicon rubber gaskets, located in channels in the intake manifold, seal the joints between the ducts and the cylinder heads. Supercharged engines do not have a conventional manifold, but use an Intercooler Adaptor Assembly on each cylinder head to pass cooled air from the intake air charge coolers (one for each bank) to the engine intake. The fuel injectors and fuel rail are also located on each Intercooler Adaptor Assembly.
Induction Elbow
The induction elbow provides the interface between the electronic throttle and the intake manifold. Connections on the induction elbow provide vacuum take-offs for various services. A boss on the rear of the elbow accommodates the EGR valve - where fitted. On engines without EGR, the boss is closed by a blanking plate.
11
2012-07-23

Exhaust Manifold
www.JagDocs.com
The thin walled cast iron manifolds are unique to each cylinder bank. On engines with Exhaust Gas Recirculation (EGR) (see Section <<303-08>>) the A-bank manifold has a transfer pipe connection. Spacers on the securing bolts allow expansion and retraction upon temperature changes whilst maintaining clamping loads. Heat shields are integrated in the exhaust manifold gaskets.
Engine Mountings
The engine is mounted at three points. At the front, on each side of the engine, there is a mounting bracket with a Hydramount mounted to the crossbeam. At the rear, a single rubber / metal composite mount is fixed to the cast crossmember. The rear engine mounting rubber provides support for the rear of the engine and the transmission unit. This is a rubber mount and metal bracket assembly secured with a single fixing onto the crossmember. This, in turn, is located on an extension bracket at the rear of the transmission unit. The three mountings are non-serviceable items.
12
2012-07-23

Engine Lubrication
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Description Valve Lifter Supply Main Bearing Supply Connecting Rod Bearing Supply Bedplate/Cylinder Block Interface Oil Pick-Up Pressure Relief Valve Oil Pressure Switch Oil Temperature Switch Oil Filter Structural Sump/Bedplate Interface Bedplate/Cylinder Block Interface Oil Pump Primary Chain Tensioner Supply Cylinder Block/Cylinder Head Interface Variable Valve Timing Supply Camshaft Bearing Supply Secondary Chain Tensioner Supply Oil Diverter (Where fitted) Oil Supply and Return
Oil is drawn from the reservoir in the oil pan and pressurized by the oil pump. The output from the oil pump is then filtered and distributed through the internal oil passages. Where an oil cooler is fitted, the oil is cooled before entering the filter. All moving parts are lubricated either by pressure or splash oil. Pressurized oil is also provided for operation of the variable valve timing units and the timing gear chain tensioners. With the exception of the pump and the oil level gauge (dip stick), all of the oil system components are installed on the structural sump. Oil is returned to the oil pan under gravity through large drain holes in the cylinder heads and the engine block to
13
2012-07-23

ensure quick return of the oil.
Oil Pick-Up
The plastic moulded oil pick-up is attached to the underside of the structural sump. It is immersed in the oil reservoir to provides a supply to the oil pump during all normal vehicle attitudes. A castellated inlet allows the supply to be maintained after any deformation of the sump pan (e.g. after grounding). A mesh screen in the inlet prevents debris from entering the oil system.
Oil Pressure Switch

Installed at the right front of the structural sump, the oil pressure switch connects a ground input to the instrument cluster when oil pressure is present. This switch operates at a pressure of 0,15 to 0,41 bar (2.2 to 5.9 lbf. in2).
Oil Temperature Switch

Installed at the right front of the structural sump adjacent to the pressure switch. Indicates to the Engine Control Module the temperature of the engine oil, for use in the variable valve timing computations.
www.JagDocs.com
Oil Pump
14
2012-07-23
An uprated (higher capacity) oil pump is fitted to cope with the increased demands of the linear VVT system. The pump is located at the front of the engine and is driven directly by the crankshaft. The inlet and outlet ports align with oil passages in the bedplate, with a rubber coated metal gasket to seal the pump to bedplate interface. An integral pressure relief valve regulates pump outlet pressure at 4,5 bar (65.25lbf/in2).
Oil Pan
The oil pan / sump comprises an aluminium-alloy structural sump bolted to the bedplate and a pressed steel pan with integral drain plug, bolted to the structural sump. Oil is drawn from the oil reservoir in the oil pan, pressurized by the oil pump, cooled (on vehicles with an oil cooler), filtered and distributed through internal oil passages. Oil returns to the pan under gravity.
Oil Filter
A renewable canister type oil filter is fitted on the adapter which is located on the right-hand side of the structural sump towards the front of the engine. An internal bypass facility permits full flow bypass if the filter is blocked.
Oil Level Gauge (Dipstick)

The oil level gauge is located towards the front of the engine on the left side of the oil pan, supported in a tube fitted in the bedplate. The holes in the end of the oil gauge indicate minimum and maximum oil levels; approximately 1 liter difference.
Oil Filler Cap

The oil filler cap is located on the top of the B-bank camshaft cover.
Windage Tray
A windage tray attached to the top of the structural sump isolates the oil pan from the disturbed air flow, caused by the rotation of the crankshaft; preventing oil aeration and improving oil drainage.
15
2012-07-23

Engine Oil Cooler (Where Fitted)
www.JagDocs.com
The engine oil cooler is located in front of the radiator, mounted off-center with two steady brackets bolted onto the front upper crossmember in front of the cooling module. When an oil cooler is fitted, an oil diverter valve is also fitted onto the oil filter with supply and return piping to and from the oil cooler.
Oil Diverter Valve (Oil-Cooler Vehicles Only)
This valve is fitted between the oil pump outlet and the oil filter inlet. The oil diverter valve operates thermostatically and at higher temperatures diverts the oil through the oil cooler. The valve begins to open between 103C and 107C and is fully open, diverting 100% of the oil, at 119C.
16
2012-07-23

Crankcase Ventilation
Item 1 2 3
Description Oil Entry Point Wire Gauze Breather Outlet
The engine is ventilated through a part-load and a full-load breather; one on each camshaft cover. These flexible plastic hoses incorporate O-ring seals and quick release connectors. The part-load breather ventilates the left-hand camshaft cover (B-bank) and feeds onto the throttle body adaptor and the purge valve. This breather is connected between the oil separator in the cover and the induction elbow. The full-load breather ventilates the right-hand cover (A-bank) and is connected between the oil separator in the cover and the air intake duct between the mass air flow sensor (MAFS) and the throttle body. The MAFS unit combines the two sensors: one for air flow and one for air inlet temperature. It is a hot wire sensor that provides an input which is (approximately) proportional to the mass air flow into the engine. Each camshaft cover oil separator consists of wire gauze packed into an open ended enclosure in the top of the cover, below the breather outlet.
Engine Covers
Engine covers are fitted over the fuel injectors on each cylinder bank and are isolated from the engine by rubber grommets to prevent noise.
Block Dowels, Block Plugs and Stub Pipe

A shaped plug / cover, known as the 'Valley' plug, is fitted to the top of the engine block at the centre of the 'Vee' formed by the angle between the 'A' and 'B' banks of the cylinder block.
Ring dowels
Ring dowels are used as follows: To assist in the location / installation of each cylinder head to its respective location on the block. Two are used to locate the main sump body to the cylinder block.
17
2012-07-23
Two are used at the rear of the engine block to locate the mating face of the transmission housing. Two are fitted into the casting at the front, one on each side, to locate and align the timing cover and two more each side of the front face to locate the VVT bush carriers (where fitted). Two are fitted each side near the front to locate the accessory mounting bracket and the generator mounting bracket.
Block Plugs
Two core plugs are fitted in the rear face of the engine block. Three flanged, threaded plugs with micro-encapsulated sealant and a sealing washer are fitted, one into the front face of the block behind the water pump, one to the rear face adjacent to the two core plugs and one to the rear of the left hand side.
Stub Pipe
A stub pipe in the centre of the raised part of the block casting for the thermostat housing, accommodates one end of the heater return hose.
www.JagDocs.com
18
2012-07-23

Engine Sealing
Three types of sealing methods are used on the engine: a) In-groove seals. b) Edgebond metal carrier gaskets. c) Formed-in-place (FIP) liquid sealant. For a) and b) the seals are to be renewed if the mating components are disturbed during service i.e. they are not re-usable. For c) no general servicing is required - sealant/joint designed for service life of engine (must be renewed if the mating components are disturbed). Two types of FIP sealant are used: Anaerobic (Loctite 648): used on core plugs and block stub pipe.
19
2012-07-23
RTV silicone sealant (Loctite 5699 Ultra Grey): used on block-to-bedplate and sump-to-bedplate joints. Designed service life is 150,000 miles.
Ignition System
The ignition system consists of eight ignition coils, one per spark plug, each incorporating an amplifier module which is controlled by one of two outputs from the ECM. Each output of the ECM controls four of the spark plug mounted ignition coils, two on each bank. The 14mm spark plugs, one per cylinder, locate in recesses along the center-line of each cylinder head. The on-plug ignition coils are secured to the camshaft covers and each on-plug coil has its own plastic cover.
Variable Valve Timing (VVT)
www.JagDocs.com
Item 1 2 3
Description Variable Valve Timing (VVT) Unit Solenoid / Shuttle Valve Bush Carrier
20
2012-07-23
For each intake camshaft there is a variable valve timing unit, a bush carrier assembly and a solenoid / shuttle valve. It is an infinitely variable system (within the prescribed operating range) operating on the intake camshafts only. There is the equivalent of 48 of crankshaft movement between the retarded and advanced positions. Engine oil pressure operates the system under the control of the ECM. The variable valve timing system improves both low speed and high speed engine performance, engine idle quality and exhaust emissions. Engine idle is improved due to the ECM being able to retard the valve timing by an additional 10 compared to the previous VVT system; this also reduces the internal EGR at idle, where it is not required. However, the internal EGR system is improved at normal engine running speeds to reduce NOx emission and eliminate the need for any external EGR system components.
Valve Timing Unit
21
2012-07-23

Parts List Item 1 2 3 4 5 Description Ring Piston Inner Sleeve Body and Sprocket Assembly Helical Gears - Piston to Body Helical Gears - Piston to Inner Sleeve
The valve timing unit turns the intake camshaft relative to the primary chain to advance or retard the timing. The unit consists of a body and sprocket assembly separated from an inner sleeve by a ring piston and two helical ring gears; the inner sleeve is bolted to the camshaft. The two helical ring gears are part of the cylindrical extention of the piston, one gear on the outer bore (meshing with the helical gear which is on the inner bore of the body and sprocket assembly) and one on the inner bore (meshing with the inner sleeve). As engine oil pressure moves the piston in the advance direction (to the right on the illustration) the helical ring gear on the outer bore of the piston causes the whole piston assembly to turn to the right as well as moving to the right. In the same way, the movement of the piston to the right, combined with the rotation caused by the outer helical gear assembly, causes the inner sleeve and hence the camshaft to rotate to the right in the advanced direction. The procedure is identical, but in the opposite direction for retarding the timing. A light bias spring in the retard direction is provided along with anti-backlash springs.
www.JagDocs.com
Bush Carrier
This contains the oil passages that link the engine oil supply from the cylinder block gallery to the variable valve timing (VVT) unit. A lug on the bush carrier locates in the central bore of the VVT unit. Two hollow dowels at the bush carrier and cylinder block ensure that the lug is accurately located within the valve timing unit. O-rings seal the joint between the lug and the valve timing unit.
22
2012-07-23

Variable Valve Timing (VVT) Solenoid / Shuttle Valve
The VVT solenoid / shuttle valve assembly is bolted to the bush carrier and protrudes through the camshaft cover. Electrical connection to the solenoid is from the engine harness.
23
2012-07-23
www.JagDocs.com
Parts List Item 1 2 3 4 Description Solenoid / Shutle Valve Assembly Bush Carrier Variable Valve Timing Unit Intake Camshaft The valve timing solenoid controls the position of the shuttle valve relative to the two ports in the bush carrier. The shuttle valve, depending on its position set by the solenoid at any instant, directs engine oil pressure to either the retard side or the advance side of the piston assembly. The position of the solenoid / shuttle valve is controlled by a return spring and a 300 Hz pulse-width-modulated signal provided by the ECM.
24
2012-07-23
Connecting Rod Bearings 12.17.16

Removal 1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors remain open until after the battery has been disconnected.
2. Disconnect the battery ground cable. Remove the battery cover. 3. Open the engine compartment and fit paintwork protection sheets. 4. Remove the engine compartment cover. Refer to operation <<76.16.01>>. 5. Remove the twin fan and motor assembly. Refer to Operation 26.25.12. 6. Remove the timing cover and all associated components, as detailed in Operation <<12.65.01>>. 7. Remove both front wheel and tyre assemblies. Refer to Operation <<74.20.05>>. 8. Remove the undertray. Refer to Operation <<76.22.90>>. 9. Remove the front crossmember for access. Refer to Operation 76.10.05.
2012-07-23
www.JagDocs.com
10. Drain the engine oil. 1. Position the waste oil bowser. 2. Remove the drain plug from the oil pan and drain the engine oil. Install a new sealing washer to the drain plug. Wipe the drain plug and install it to the oil pan to prevent oil dripping. Move the oil bowser away from the vehicle.
11. Remove the oil pan. 1. Remove the eighteen bolts which secure the oil pan to the oil pan body. 2. Remove the oil pan. 3. Remove the gasket from the oil pan body assembly. 12. Remove the oil pan body assembly. Refer to Operation <<12.60.48>>. 13. Install the old bolt which secured the crankshaft damper, to allow the crankshaft to be rotated. Use a new bolt on final installaion.
2012-07-23
14. The following group of instructions (until stated otherwise) describe the procedure to renew the bearing shells in one connecting rod. Repeat the instructions as necessary.
15. Rotate the crankshaft until the required connecting rod bolts are accessible. 1. Remove the bolts which secure the bearing cap. 2. Note the position of the identification marks and remove the cap. Remove the bearing shell from the cap and note the grade (colour coded).
16. Carefully move the connecting rod and piston assembly towards the cylinder head to disconnect it from the crankshaft. Rotate the crankshaft slightly if necessary.
2012-07-23
www.JagDocs.com
17. Remove the bearing shell from the connecting rod and note the grade (colour coded). The crankpin grades are also stamped on the cylinder block. 18. Refer to the Specification Section for details of the crankpin and bearing shell grades. 19. Clean all components and mating faces.
20. Install and align the new bearing shell to the connecting rod. 21. Apply new engine oil to the connecting rod bearing and to the crankpin.
2012-07-23
22. Carefully move the connecting rod and piston assembly towards the the crankshaft and connect it to the crankpin. Rotate the crankshaft slightly if necessary. 23. If necessary, refer to the Specification Section for details of piston and connecting rod orientation.
24. Install and align the new bearing shell to the connecting rod cap. 25. Apply new engine oil to the bearing shell.
2012-07-23
www.JagDocs.com
26. Install the cap and NEW bolts to the connecting rod. 1. Note the position of the identification marks and install the cap so that the identification marks are adjacent to those on the connecting rod. 2. Install the new bolts which secure the bearing cap.
27. Tighten the bolts as follows: Tighten each bolt to 8 to 12 Nm initial torque value. Tighten to a final torque of 57 to 63 Nm. 28. Check that the crankshaft turns freely. 29. Repeat the previous operations for each connecting rod bearing as necessary.
Installation 1. Install the oil pan body assembly. Refer to Operation <<12.60.48>>.
2012-07-23
2. Position and align the oil pan gasket to the oil pan body assembly. Insert the seal into the locating positions in the groove, working around from a corner. Press in the remainder of the seal, following the same procedure.
3. Install the oil pan to the oil pan body. 1. Position and align the oil pan. 2. Install, but do not tighten, all eighteen bolts which secure the oil pan.
2012-07-23
www.JagDocs.com
4. Tighten the bolts to the correct torque figure 11-13 Nm, in the sequence indicated. Tighten the drain plug to 30-40 Nm. Install a new oil filter. 5. Install the front crossmember. Refer to Operation 76.10.05. 6. Install the undertray. Refer to Operation <<76.22.90>>. 7. Install both front wheel and tyre assemblies. Refer to Operation <<74.20.05>>. 8. Install the timing cover and all associated components, as detailed in Operation <<12.65.01>>. 9. Install the twin fan and motor assembly. Refer to Operation 26.25.12. 10. NOTE: When the engine is started from cold and run for a short period only, before being switched off, a quantity of oil will be 'hung up' within the engine because it is not up to operating temperature. Should the oil level subsequently be topped-up, the level could become too high, causing oil burning. Typically, 0.875 L is hung up. Refill the engine with the correct specification engine oil. 11. Connect the battery and install the battery cover. Reset the side glass memory. Refer to the Battery Reconnection Procedure <<86.15.15>>. 12. Check the oil level and start the engine. Check for leaks and that the engine runs correctly. 13. Install the engine compartment cover. Refer to operation <<76.16.01>>. 14. Remove the paintwork protection sheets and close the engine compartment cover.
2012-07-23
Crankshaft Front Seal Vehicles Without: Supercharger 12.21.14

Crankshaft locking, main tool 303-191
Adaptor 303-191-02
Crankshaft front seal remover 303-541
2012-07-23
Crankshaft front seal replacer 303-542
www.JagDocs.com
Crankshaft pulley/damper remover 303-588 Removal 1. Open the engine compartment and fit paintwork protection sheets. 2. Set the engine compartment cover to the service access position. 3. Remove the drive belt from the front accessory drive. Refer to Operation <<12.10.40>>. 4. Remove the twin fan and motor assembly for access. Refer to Operation 26.25.12
2012-07-23
5.
CAUTION: Under no circumstances should the crankshaft setting peg 303-531 be used in the following operations, to lock the crankshaft. NOTE: Should extra locking of the crankshaft be required, use a lever against one torque converter boss. Remove the plastic mesh cover from the torque converter housing for access.
Install the crankshaft locking tool to the damper. 1. Install adaptor 303-191-02 to the main locking tool 303-191. 2. Reposition the crankshaft/damper to align the mounting holes and install the locking tool to the damper using the bolts provided with the tool. 3. Loosen, but do not remove the damper securing bolt from the crankshaft. 6. Remove the locking tool from the damper. Remove the damper securing bolt.
2012-07-23

7. NOTE: The damper only needs to be withdrawn along the crankshaft nose by approximately 2mm before removing the puller. The damper will then either be loose or only require a sharp tap with a mallet to release it from the split locking ring. Remove the damper from the crankshaft. 1. Transfer the adaptor 303-191-02 from the crankshaft locking tool to the damper extractor tool 303-588 (Use the socket head screws provided with the puller). 2. Locate the thrust button into the end of the crankshaft; the O-ring holds it in place. Assemble the puller to the damper. Extract the damper from the crankshaft. 8. Remove the puller components from the damper. Remove the thrust button from the end of the crankshaft.
www.JagDocs.com
9. Remove the split locking ring from the damper.
10. Remove the internal O-ring seal.
2012-07-23
11. Remove the crankshaft front seal. 1. Install and tighten the removal tool 303-541 to the crankshaft front seal. 2. Tighten the centre bolt of the tool to extract the seal. Remove the tool and seal assembly. Separate the seal from the tool. 12. Very carefully clean the threads of the crankshaft, using a plug tap M16x2, to remove all old cured sealant. Keep the tap horizontal. Do not enlarge the crankshaft thread - remove sealant only. 13. Clean all relevant parts and faces.
Installation
1. Locate the new oil seal into the timing cover. 1. Remove the transit ring from the oil seal. 2. Position the seal to the timing cover.
2012-07-23
www.JagDocs.com
2. Install the new oil seal to the timing cover. 1. Install oil seal replacer tool 303-542 to the oil seal. 2. Use the nut and bolt provided with the tool, to fully seat the seal to the timing cover. Only tighten the nut sufficiently to locate the seal and no more, or the timing cover could become distorted. Allow the tool to stay in position against the seal for at least five seconds. Remove the special tool from the seal. 3. If the damper is not to be installed immediately, the transit ring should be installed temporarily to the seal.
4. Install a new O-ring seal to the damper.
2012-07-23
5. Install the crankshaft damper. Apply petroleum jelly to the damper bore and O-ring seal. 1. Install the damper onto the crankshaft. 2. Install the split locking ring onto the crankshaft, inside the centre bore of the damper. 3. Install, but do not tighten, a new damper securing bolt.
6.
CAUTION: Under no circumstances should the crankshaft setting peg 303-531 be used in the following operations, to lock the crankshaft.
Tighten the damper securing bolt. 1. Reposition the damper to allow access to the bolt holes for installing the locking tool. 2. Install the locking tool (<<303-01>> and 303-01-02) to the damper using the bolts provided. 3. Fully tighten the damper securing bolt to 364-386 Nm. 7. Remove the locking tool from the damper.
2012-07-23
8. Install the drive belt to the front accessory drive. Refer to Section <<303-05>>. 9. Install the twin fan and motor assembly. Refer to Section 303-03. 10. Install the plastic mesh cover to the torque converter housing; if removed for access to lock the crankshaft. 11. Reset the engine compartment cover to the normal position and connect the gas struts. 12. Remove the paintwork protection sheets and close the engine compartment.
www.JagDocs.com
2012-07-23
Crankshaft Front Seal Vehicles With: Supercharger 12.21.14

Adaptor 303-191-02
Adaptor 303-191-03
2012-07-23
www.JagDocs.com
Crankshaft pulley/damper remover 303-588 Removal 1. Open the engine compartment and fit paintwork protection sheets. 2. Set the engine compartment cover to the service access position. 3. Remove the supercharger drive belt. Refer to Operation <<18.50.08>>. 4. Remove the drive belt from the front accessory drive. Refer to Operation <<12.10.40>>.
2012-07-23
5. Remove the twin fan and motor assembly for access. Refer to Operation 26.25.12
6.
2012-07-23
www.JagDocs.com
8. NOTE: The damper only needs to be withdrawn along the crankshaft nose by approximately 2mm before removing the puller. The damper will then either be loose or only require a sharp tap with a mallet to release it from the split locking ring. Remove the damper from the crankshaft. 1. Install adaptor 303-191-02 to the damper extractor tool 303-588 (Use the socket head screws provided with the puller). 2. Locate the thrust button into the end of the crankshaft; the O-ring holds it in place. Assemble the puller to the damper. Extract the damper from the crankshaft. 9. Remove the puller components from the damper. Remove the thrust button from the end of the crankshaft.
2012-07-23
2012-07-23

Installation
www.JagDocs.com
2012-07-23
2012-07-23
6.
www.JagDocs.com
Tighten the damper securing bolt. 1. Reposition the damper to allow access to the bolt holes for installing the locking tool. 2. Install the locking tool (303-191 and 303-191-03) to the damper using the bolts provided. 3. Fully tighten the damper securing bolt to 364-386 Nm. 7. Remove the locking tool from the damper. 8. Install the drive belt to the front accessory drive. Refer to Operation <<12.10.40>>.. 9. Install the supercharger drive belt. Refer to Operation <<18.50.08>>. 10. Install the twin fan and motor assembly. Refer to Section 303-03. 11. Install the plastic mesh cover to the torque converter housing; if removed for access to lock the crankshaft. 12. Reset the engine compartment cover to the normal position and connect the gas struts. 13. Remove the paintwork protection sheets and close the engine compartment.
2012-07-23
Crankshaft Inner Sprocket 12.65.76

Removal 1. Remove the left-hand primary timing chain. <<Primary Timing Chain LH>>
2. Note the orientation of the sprockets relative to each other (half a tooth out of line).
3. Remove the sprocket from the crankshaft. To remove the Bank 2 sprocket, the Bank 1 sprocket must be removed first. 4. Clean and inspect all relevant components.
2012-07-23

Installation
www.JagDocs.com
1. Fit the sprockets to the crankshaft. The teeth of Bank 1 and Bank 2 sprockets on the crankshaft must be out of phase with each other. If they are in-phase after fitting, remove the Bank 1 sprocket, turn it on its vertical axis and refit it. 2. Install the left-hand primary chain. <<Primary Timing Chain LH>>
2012-07-23
Crankshaft Pulley Vehicles Without: Supercharger 12.21.09

Adaptor 303-191-02
2012-07-23
www.JagDocs.com
Crankshaft pulley/damper remover 303-588 Removal 1. Open the engine compartment and fit paintwork protection sheets. 2. Set the engine compartment cover to the service access position. 3. Remove the drive belt from the front accessory drive. Refer to Operation <<12.10.40>>. 4. Remove the twin fan and motor assembly for access. Refer to Operation 26.25.12
2012-07-23
5.
2012-07-23

7. NOTE: The damper only needs to be withdrawn along the crankshaft nose by approximately 2mm before removing the puller. The damper will then either be loose or only require a sharp tap with a mallet to release it from the split locking ring. Remove the damper from the crankshaft. 1. Transfer the adaptor 303-191-02 from the crankshaft locking tool to the damper extractor tool 303-588 (Use the socket head screws provided with the puller). 2. Locate the thrust button into the end of the crankshaft; the O-ring holds it in place. Assemble the puller to the damper. Extract the damper from the crankshaft. 8. Remove the puller components from the damper. Remove the thrust button from the end of the crankshaft.
www.JagDocs.com
2012-07-23
Installation
2012-07-23
www.JagDocs.com
2012-07-23
6.
Tighten the damper securing bolt. 1. Reposition the damper to allow access to the bolt holes for installing the locking tool. 2. Install the locking tool (<<303-01>> and 303-01-02) to the damper using the bolts provided. 3. Fully tighten the damper securing bolt to 364-386 Nm. 7. Remove the locking tool from the damper.
2012-07-23
8. Install the drive belt to the front accessory drive. Refer to Section <<303-05>>. 9. Install the twin fan and motor assembly. Refer to Section 303-03. 10. Install the plastic mesh cover to the torque converter housing; if removed for access to lock the crankshaft. 11. Reset the engine compartment cover to the normal position and connect the gas struts. 12. Remove the paintwork protection sheets and close the engine compartment.
www.JagDocs.com
2012-07-23
Crankshaft Pulley Vehicles With: Supercharger 12.21.09

Adaptor 303-191-02
Adaptor 303-191-03
2012-07-23
www.JagDocs.com
Crankshaft pulley/damper remover 303-588 Removal 1. Open the engine compartment and fit paintwork protection sheets. 2. Set the engine compartment cover to the service access position. 3. Remove the supercharger drive belt. Refer to Operation <<18.50.08>>. 4. Remove the drive belt from the front accessory drive. Refer to Operation <<12.10.40>>.
2012-07-23
5. Remove the twin fan and motor assembly for access. Refer to Operation 26.25.12
6.
2012-07-23
www.JagDocs.com
8. NOTE: The damper only needs to be withdrawn along the crankshaft nose by approximately 2mm before removing the puller. The damper will then either be loose or only require a sharp tap with a mallet to release it from the split locking ring. Remove the damper from the crankshaft. 1. Install adaptor 303-191-02 to the damper extractor tool 303-588 (Use the socket head screws provided with the puller). 2. Locate the thrust button into the end of the crankshaft; the O-ring holds it in place. Assemble the puller to the damper. Extract the damper from the crankshaft. 9. Remove the puller components from the damper. Remove the thrust button from the end of the crankshaft.
2012-07-23
2012-07-23

Installation
www.JagDocs.com
2012-07-23
2012-07-23
6.
www.JagDocs.com
Tighten the damper securing bolt. 1. Reposition the damper to allow access to the bolt holes for installing the locking tool. 2. Install the locking tool (303-191 and 303-191-03) to the damper using the bolts provided. 3. Fully tighten the damper securing bolt to 364-386 Nm. 7. Remove the locking tool from the damper. 8. Install the drive belt to the front accessory drive. Refer to Operation <<12.10.40>>.. 9. Install the supercharger drive belt. Refer to Operation <<18.50.08>>. 10. Install the twin fan and motor assembly. Refer to Section 303-03. 11. Install the plastic mesh cover to the torque converter housing; if removed for access to lock the crankshaft. 12. Reset the engine compartment cover to the normal position and connect the gas struts. 13. Remove the paintwork protection sheets and close the engine compartment.
2012-07-23
Crankshaft Rear Seal Vehicles Without: Supercharger 12.21.20

Crankshaft Rear Oil Seal Remover / Replacer. 303-538 Removal 1. Open the engine compartment and fit paint protection sheets. 2. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors remain open until after the battery has been disconnected.
3. Disconnect the battery ground cable. Remove the battery cover. 4. Remove the transmission. Refer to Operation 44.20. 01 in Section <<307-01A>>. 5. Remove the drive plate. Refer to Operation <<12.53.13>>.
2012-07-23
www.JagDocs.com
6. Fit and align the seal removal tool 303 - 538 to the crankshaft. 1. Unscrew the two nuts towards the head of each bolt to allow the bolts to fit fully into the crankshaft. 2. Unscrew the cente bolt until it is below the face of the main tool and position the tool to the rear of the crankshaft. 3. Lightly tighten the two bolts so that they fully locate in the crankshaft.
7. Hold the tool against the crankshaft and lightly and evenly tighten the two nuts to the face of the tool; to secure the tool and to hold it parallel to the face of the crankshaft.
2012-07-23
8. Secure the oil seal to the tool using the three self-tapping screws spaced evenly around the face of the tool. Use the punch (provided) and a hammer to pierce the seal face and provide a pilot hole for one of the self-tapping screws provided. Fit a self-tapping screw and tighten by 11/2 turns only. DO NOT TIGHTEN BY MORE THAN TWO TURNS OR THE SCREW MAY BREAK. Repeat the above steps for the other two screws.
9. Hold the two bolts stationary and loosen fully the two nuts.
2012-07-23
www.JagDocs.com
10. Tighten the centre bolt. This will draw out the seal and tool assembly which will be supported by the two bolts.
11. Remove the two bolts to release the tool and seal assembly from the crankshaft. Remove the three self-tapping screws. Remove and discard the seal. Unscrew the centre bolt until it is below the face of the tool. 12. Clean all relevant components.
Installation 1. Ensure that the transit sleeve is correctly in place and fit the new seal over the crankshaft. Do not use any lubricant on the seal, the transit sleeve or the crankshaft. 2. Carefully remove the transit sleeve, leaving the seal in place.
4 2012-07-23
3. Fit the tool to the crankshaft. Ensure that the centre bolt is unscrewed to below the face which is to fit to the crankshaft and position the tool to the crankshaft. Check that the nuts are fully unscrewed and enter the two bolts to the crankshaft threads and lightly tighten.
4. Tighten the nuts, finger tight, to hold the tool assembly against the seal. Check that the seal and the tool are approximately parallel to the rear of the engine.
2012-07-23
www.JagDocs.com
5. Press the seal into the housing. Hold each bolt stationary, in turn, and tighten its nut a small amount (approximately two to three flats) in turn, to press the seal fully into the housing. until the tool is in contact with the cylinder block. 6. Remove the tool from the crankshaft. Check that the seal is located correctly. 7. Fit the drive plate. Refer to Operation <<12.53.13>>. 8. Install the transmission. Refer to Operation 44.20. 01 in Section <<307-01A>>. 9. Remove the paint protection sheets and close the engine compartment cover. 10. Connect the battery and fit the battery cover. Reset the side glass memory. Refer to the Battery Reconnection Procedure <<86.15.15>>.
2012-07-23
Crankshaft Rear Seal Vehicles With: Supercharger 12.21.20

Crankshaft Rear Oil Seal Remover / Replacer. 303-538 Removal 1. Open the engine compartment and fit paint protection sheets. 2. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors remain open until after the battery has been disconnected.
3. Disconnect the battery ground cable. Remove the battery cover. 4. Remove the transmission. Refer to Operation 44.20. 01 in Section <<307-01B>>. 5. Remove the drive plate. Refer to Operation (SC) <<12.53.13>>.
2012-07-23
www.JagDocs.com
6. Fit and align the seal removal tool 303 - 538 to the crankshaft. 1. Unscrew the two nuts towards the head of each bolt to allow the bolts to fit fully into the crankshaft. 2. Unscrew the cente bolt until it is below the face of the main tool and position the tool to the rear of the crankshaft. 3. Lightly tighten the two screws so that they fully locate in the crankshaft.
7. Hold the tool against the crankshaft and lightly and evenly tighten the two nuts to the face of the tool; to secure the tool and to hold it parallel to the face of the crankshaft.
2012-07-23
8. Secure the oil seal to the tool using the three self-tapping screws spaced evenly around the face of the tool. Use the punch (provided) and a hammer to pierce the seal face and provide a pilot hole for one of the self-tapping screws provided. Fit a self-tapping screw and tighten by 11/2 turns only. DO NOT TIGHTEN BY MORE THAN TWO TURNS OR THE SCREW MAY BREAK. Repeat the above steps for the other two screws.
9. Hold the two bolts stationary and loosen fully the two nuts.
2012-07-23
www.JagDocs.com
10. Tighten the centre bolt. This will draw out the seal and tool assembly which will be supported by the two bolts.
11. Remove the two bolts to release the tool and seal assembly from the crankshaft. Remove the three self-tapping screws. Remove and discard the seal. Unscrew the centre bolt until it is below the face of the tool. 12. Clean all relevant components.
Installation 1. Ensure that the transit sleeve is correctly in place and fit the new seal over the crankshaft. Do not use any lubricant on the seal, the transit sleeve or the crankshaft. 2. Carefully remove the transit sleeve, leaving the seal in place.
4 2012-07-23
3. Fit the tool to the crankshaft. Ensure that the centre bolt is unscrewed to below the face which is to fit to the crankshaft and position the tool to the crankshaft. Check that the nuts are fully unscrewed and enter the two bolts to the crankshaft threads and lightly tighten.
4. Tighten the nuts, finger tight, to hold the tool assembly against the seal. Check that the seal and the tool are approximately parallel to the rear of the engine.
2012-07-23
www.JagDocs.com
5. Press the seal into the housing. Hold each bolt stationary, in turn, and tighten its nut a small amount (approximately two to three flats) in turn, to press the seal fully into the housing. until the tool is in contact with the cylinder block. 6. Remove the tool from the crankshaft. Check that the seal is located correctly. 7. Fit the drive plate. Refer to Operation (SC) <<12.53.13>>. 8. Install the transmission. Refer to Operation 44.20. 01 in Section <<307-01B>>. 9. Remove the paint protection sheets and close the engine compartment cover. 10. Connect the battery and fit the battery cover. Reset the side glass memory. Refer to the Battery Reconnection Procedure <<86.15.15>>.
2012-07-23
Engine Front Cover 12.65.01

Removal
All vehicles
1. Set the hood to the service access position.
2. Disconnect the battery ground cable. Remove the battery cover. 3. Remove the left-hand valve cover. <<Valve Cover LH>> 4. Remove the right-hand valve cover. <<Valve Cover RH>> 5. Remove the crankshaft pulley. <<Crankshaft Pulley>>
2012-07-23
6. Remove the water pump pulley.
www.JagDocs.com
7. Detach the engine harness from the engine front cover.
2012-07-23
8. Remove the accessory drive belt tensioner. 1. Remove the accessory drive belt tensioner retaining bolt. 2. Remove the accessory drive belt tensioner.
Vehicles without supercharger

9. Carry out the cooling system drain procedure. <<303-03A>><<303-03B>>
10. Disconnect the radiator upper coolant hose.
2012-07-23
11. Remove the radiator upper coolant hose.
www.JagDocs.com
12. Disconnect the coolant hose.
2012-07-23

Vehicles with supercharger
13. Remove the supercharger belt tensioner.
All vehicles
14. Remove the accessory drive belt idler pulley.
2012-07-23

15. Disconnect the expansion tank to thermostat housing coolant hose.
www.JagDocs.com
16. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
2012-07-23
17. Reposition the coolant hose retaining clip.
18. Detach the thermostat housing. Remove and discard the thermostat housing seals.
2012-07-23
www.JagDocs.com
19. Remove the thermostat housing. Detach the heater core to thermostat housing coolant hose. Remove the thermostat housing.
20. Remove the supercharger idler pulley and mount. 1. Remove the retaining bolts. NOTE: The retaining bolt will remain captive. 2. Remove the supercharger idler pulley and mount.
2012-07-23

All vehicles
21. Remove the engine front cover. Remove and discard the engine front cover seals.
Installation
All vehicles
1. Fit new seals to the engine front cover. 1. Install the new seal to the inner groove on the face of the timing cover. 2. Install the new seal to the outer groove on the face of the timing cover.
2012-07-23
www.JagDocs.com
2. Apply sealant to the eight joints on the engine face. Sealant beads to be 3mm diameter and 12mm long. Cut the nozzle of the sealant tube to produce a 3mm bead. (Fit and tighten the securing bolts within twenty minutes of sealant application)
10
2012-07-23
3. Install the engine front cover. Complete the tightening sequence. Tighten to 11 - 13 Nm.
11
2012-07-23

www.JagDocs.com
4. Install the supercharger idler pulley and mount. 1. Tighten the retaining bolt. 2. Tighten the retaining bolts.
5. Attach the coolant hose. Reposition the retaining clip.
12
2012-07-23
6. Attach the thermostat housing. Tighten to 10 Nm.
13
2012-07-23
8. Connect the electrical connector.
www.JagDocs.com
All vehicles
9. Install the accessory drive belt idler pulley. Tighten to 61 Nm.
14
2012-07-23

10. Install the supercharger belt tensioner. Tighten to 40 Nm.
11. Connect the coolant hose.
15
2012-07-23
12. Install the radiator upper coolant hose.
www.JagDocs.com
13. Connect the radiator upper coolant hose.
All vehicles
14. Install the accessory drive belt tensioner. Tighten to 43 Nm.
16
2012-07-23
15. Attach the engine harness to the engine front cover.
16. Install the water pump pulley. Tighten to 12 Nm. 17. Install the crankshaft pulley. <<Crankshaft Pulley>> 18. Install the left-hand valve cover. <<Valve Cover LH>> 19. Install the right-hand valve cover. <<Valve Cover RH>> 20. Reset the hood to the normal position. 21. Connect the battery. <<414-01>>
17
2012-07-23

22. Carry out the cooling system filling procedure. <<303-03A>><<303-03B>>
www.JagDocs.com
18
2012-07-23
Engine Front Cover Gasket 12.65.04

Removal
All vehicles
1. Set the hood to the service access position.
2. Disconnect the battery ground cable. Remove the battery cover. 3. Remove the left-hand valve cover. <<Valve Cover LH>> 4. Remove the right-hand valve cover. <<Valve Cover RH>> 5. Remove the crankshaft pulley. <<Crankshaft Pulley>>
2012-07-23
6. Remove the water pump pulley.
www.JagDocs.com
7. Detach the engine harness from the engine front cover.
2012-07-23
8. Remove the accessory drive belt tensioner. 1. Remove the accessory drive belt tensioner retaining bolt. 2. Remove the accessory drive belt tensioner.

9. Carry out the cooling system drain procedure. <<303-03A>><<303-03B>>
10. Disconnect the radiator upper coolant hose.
2012-07-23
11. Remove the radiator upper coolant hose.
www.JagDocs.com
12. Disconnect the coolant hose.
2012-07-23

13. Remove the supercharger belt tensioner.
All vehicles
14. Remove the accessory drive belt idler pulley.
2012-07-23

15. Disconnect the expansion tank to thermostat housing coolant hose.
www.JagDocs.com
16. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
2012-07-23
17. Reposition the coolant hose retaining clip.
18. Detach the thermostat housing. Remove and discard the thermostat housing seals.
2012-07-23
www.JagDocs.com
19. Remove the thermostat housing. Detach the heater core to thermostat housing coolant hose. Remove the thermostat housing.
20. Remove the supercharger idler pulley and mount. 1. Remove the retaining bolts. NOTE: The retaining bolt will remain captive. 2. Remove the supercharger idler pulley and mount.
2012-07-23

All vehicles
21. Remove the engine front cover. Remove and discard the engine front cover seals.
Installation
All vehicles
1. Fit new seals to the engine front cover. 1. Install the new seal to the inner groove on the face of the timing cover. 2. Install the new seal to the outer groove on the face of the timing cover.
2012-07-23
www.JagDocs.com
2. Apply sealant to the eight joints on the engine face. Sealant beads to be 3mm diameter and 12mm long. Cut the nozzle of the sealant tube to produce a 3mm bead. (Fit and tighten the securing bolts within twenty minutes of sealant application)
10
2012-07-23
3. Install the engine front cover. Complete the tightening sequence. Tighten to 11 - 13 Nm.
11
2012-07-23

www.JagDocs.com
4. Install the supercharger idler pulley and mount. 1. Tighten the retaining bolt. 2. Tighten the retaining bolts.
12
2012-07-23
6. Attach the thermostat housing. Tighten to 10 Nm.
13
2012-07-23
8. Connect the electrical connector.
www.JagDocs.com
All vehicles
9. Install the accessory drive belt idler pulley. Tighten to 61 Nm.
14
2012-07-23

10. Install the supercharger belt tensioner. Tighten to 40 Nm.
11. Connect the coolant hose.
15
2012-07-23
12. Install the radiator upper coolant hose.
www.JagDocs.com
13. Connect the radiator upper coolant hose.
All vehicles
14. Install the accessory drive belt tensioner. Tighten to 43 Nm.
16
2012-07-23
15. Attach the engine harness to the engine front cover.
16. Install the water pump pulley. Tighten to 12 Nm. 17. Install the crankshaft pulley. <<Crankshaft Pulley>> 18. Install the left-hand valve cover. <<Valve Cover LH>> 19. Install the right-hand valve cover. <<Valve Cover RH>> 20. Reset the hood to the normal position. 21. Connect the battery. <<414-01>>
17
2012-07-23

22. Carry out the cooling system filling procedure. <<303-03A>><<303-03B>>
www.JagDocs.com
18
2012-07-23
Exhaust Camshaft LH 12.13.17

Removal 1. Open the engine compartment and fit paintwork protection sheets. 2. Set the engine compartment cover to the service access position. 3. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors remain open until after the battery has been disconnected.
4. Disconnect the battery ground cable. Remove the battery cover. 5. Remove Exhaust Camshaft Sprocket. Refer to Operation <<12.65.74>>. 6. Remove the camshaft locking tool 303 - 530 (fitted for previous operation).
2012-07-23
www.JagDocs.com
7. Remove the camshaft. 1. Remove the bolts which secure the camshaft caps; loosen them evenly, in stages. 2. Remove the camshaft caps. Note their orientation and markings - each is marked with its position (a number) and orientation (an arrow). 3. Remove the camshaft from the engine. 8. Clean and inspect all relevant components.
Installation
1. Apply oil (EP-90) to the camshaft and bearing surfaces, as follows: To the upper face of each bearing surface (two places) in the cylinder head. To the upper face of each bearing surface (two places) in each bearing cap. On the cam lobes ONLY, not on the base circle area.
2012-07-23
2. Refit the camshaft. 1. Fit the camshaft to position in the cylinder head, with the timing flats uppermost. 2. Fit the camshaft caps to their respective locations (5 to 9 from the front) and in the correct orientation (arrow to front of engine). 3. Fit and tighten the cap securing bolts. Tighten evenly, in stages, to 9-11 Nm. 3. Fit the camshaft locking tool 303 - 530 (fitted for following operation) align the camshaft as necessary.. 4. Refit Exhaust Camshaft Sprocket. Refer to Operation <<12.65.74>>. 5. With the camshaft (303 - 530) and crankshaft (303 - 531) setting tools removed, after the previous operation, adjust the valve clearances on the exhaust camshaft. refer to Operation <<12.29.48>>. 6. Move the engine compartment cover from the service position and connect the gas struts. 7. Remove the paint protection sheets and close the cover. 8. Connect the battery and fit the battery cover. Reset the side glass memory. Refer to the Battery Reconnection Procedure <<86.15.15>>.
2012-07-23
Exhaust Camshaft RH 12.13.15

Removal 1. Open the engine compartment and fit paintwork protection sheets. 2. Set the engine compartment cover to the service access position. 3. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors remain open until after the battery has been disconnected.
www.JagDocs.com
4. Disconnect the battery ground cable. Remove the battery cover. 5. Remove Exhaust Camshaft Sprocket. Refer to Operation <<12.65.73>>. 6. Remove the camshaft locking tool 303 - 530 (fitted for previous operation).
2012-07-23
7. Remove the camshaft. 1. Remove the bolts which secure the camshaft caps; loosen them evenly, in stages. 2. Remove the camshaft caps. Note their orientation and markings - each is marked with its position (a number) and orientation (an arrow). 3. Remove the camshaft from the engine. 8. Clean and inspect all relevant components.
Installation
1. Apply oil (EP-90) to the camshaft and bearing surfaces, as follows: To the upper face of each bearing surface (two places) in the cylinder head. To the upper face of each bearing surface (two places) in each bearing cap. On the cam lobes ONLY, not on the base circle area.
2012-07-23
www.JagDocs.com
2. Refit the camshaft. 1. Fit the camshaft to position in the cylinder head, with the timing flats uppermost. 2. Fit the camshaft caps to their respective locations (5 to 9 from the front) and in the correct orientation (arrow to front of engine). 3. Fit and tighten the cap securing bolts. Tighten evenly, in stages, to 9-11 Nm. 3. Fit the camshaft locking tool 303 - 530 (fitted for following operation) align the camshaft as necessary. 4. Refit Exhaust Camshaft Sprocket. Refer to Operation <<12.65.73>>. 5. With the camshaft (303 - 530) and crankshaft (303 - 531) setting tools removed, after the previous operation, adjust the valve clearances on the exhaust camshaft. refer to Operation <<12.29.48>>. 6. Move the engine compartment cover from the service position and connect the gas struts. 7. Remove the paint protection sheets and close the cover. 8. Connect the battery and fit the battery cover. Reset the side glass memory. Refer to the Battery Reconnection Procedure <<86.15.15>>.
2012-07-23
Exhaust Camshaft Sprocket LH Vehicles Without: Supercharger 12.65.74

Camshaft setting 303-530
Crankshaft setting 303-531
Timing chain tensioning 303-532 Removal 1. Open the engine compartment and fit paintwork protection sheets. 2. Set the engine compartment cover to the service access position.
2012-07-23
3. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors remain open until after the battery has been disconnected.
www.JagDocs.com
4. Disconnect the battery ground cable. Remove the battery cover. 5. Remove the cam cover from Bank 2. Refer to Operation <<12.29.43>>. 6. Raise the vehicle on a ramp.
7. Remove the crankshaft position sensor. 1. Remove the bolt which secures the crankshaft position sensor to the flywheel housing. Remove the sensor and allow it to hang free under the engine. 2. Remove the access grommet (for torque converter bolts) from the housing.
2012-07-23
8. Rotate the crankshaft until the triangular arrow indent on the drive plate is visible through the access hole; confirm that the timing flat on each camshaft is uppermost.
9. Install the crankshaft setting peg 303-531 to the crankshaft position sensor location. 1. Install the crankshaft setting peg 303-531. Position the crankshaft so that the setting peg engages fully into the timing slot. 2. Install and tighten the bolt to secure the setting peg. 10. Lower the vehicle on the ramp.
2012-07-23
11. Install the camshaft locking tool 303-530 to Bank 2 camshafts, aligning the shafts slightly as necessary.
www.JagDocs.com
12.
CAUTION: Use a length of steel strip that will not fall into the timing cover.
Protect the upper face of the timing cover from scratches, when removing the bolt which secures the sprocket. 1. Place a flat piece of steel strip along the timing cover horizontal jointing face, adjacent to the exhaust camshaft sprocket. 2. Secure the steel strip in place with adhesive tape.
2012-07-23
13. A ball-ended hexagon drive bit is required to remove the sprocket securing bolt. A suitable tool is available from Snap On as (FABLM10E) Long Series 10mm AF.
14. Remove the bolt which secures the sprocket to the exhaust camshaft. Move the sprocket forward from the camshaft boss. Remove the sprocket and leave the chain resting on the cylinder head. 15. Clean and inspect all relevant components.
2012-07-23

Installation
www.JagDocs.com
1. Push the tensioner piston into the body to provide clearance for installing. Tensioner fitted to cylinder head. 1. Insert a thin rigid wire through the hole in the end of the tensioner piston to displace the ball from the non-return valve seat. 2. With the wire in position, press the piston fully into the tensioner body. Remove the wire.
2. Install the sprocket to the secondary chain. 1. With the sprocket installed to the chain, temporarily position the sprocket onto the camshaft. 2. Adjust the position of the sprocket within the chain to allow the chain tensioning tool 303-532 to be approximately vertical, as shown.
2012-07-23
3. Install the camshaft sprocket. Install the bolt to secure the sprocket. Apply force to the tool (303-532) in an anti-clockwise direction to tension the chain on its drive side. Whilst applying the opposing force to the sprocket and chain, tighten the sprocket securing bolt to 115-125 Nm. Remove the chain tensioning tool. 4. Remove the tape and steel strip from the timing cover upper face. Wipe any residue of tape from the joint face. 5. Remove the camshaft locking tool. 6. Install the Cam Cover to Bank 2. Refer to Operation <<12.29.43>>. 7. Raise the vehicle on the ramp. 8. Remove the crankshaft setting tool 303-531.
2012-07-23
www.JagDocs.com
9. Install the crankshaft position sensor. 1. Install the sensor to the flywheel housing and fit the securing bolt. Tighten to 8-12 Nm. 2. Install the access grommet to the housing. 10. Lower the ramp. 11. Move the engine compartment cover from the service position and connect the gas struts. 12. Remove the paint protection sheets and close the engine compartment cover. 13. Connect the battery and install the battery cover. Reset the side glass memory. Refer to the Battery Reconnection Procedure <<86.15.15>>.
2012-07-23
Exhaust Camshaft Sprocket LH Vehicles With: Supercharger 12.65.74

Timing chain tensioning 303-532 Removal 1. Open the engine compartment and fit paintwork protection sheets. 2. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
2012-07-23

remain open until after the battery has been disconnected.
www.JagDocs.com
3. Disconnect the battery ground cable. Remove the battery cover. 4. Remove the Cam Cover from Bank 2. Refer to Operation <<12.29.43>>. 5. Raise the vehicle on a ramp.
2012-07-23
2012-07-23
www.JagDocs.com
11.
2012-07-23
13. Remove the bolt which secures the sprocket to the exhaust camshaft. Move the sprocket forward from the camshaft boss. Remove the sprocket and leave the chain resting on the cylinder head. 14. Clean and inspect all relevant components.
2012-07-23

Installation
www.JagDocs.com
1. Push the tensioner piston into the body to provide clearance for installing. Tensioner fitted to cylinder head. 1. Insert a thin rigid wire through the hole in the end of the tensioner piston to displace the ball from the non-return valve seat. 2. With the wire in position, press the piston fully into the tensioner body. Remove the wire.
2. Install the sprocket to the secondary chain. 1. With the sprocket installed to the chain, temporarily position the sprocket onto the camshaft. 2. Adjust the position of the sprocket within the chain to allow the chain tensioning tool 303-532 to be approximately vertical, as shown.
2012-07-23
3. Install the camshaft sprocket. Install the bolt to secure the sprocket. Apply force to the tool (303-532) in an anti-clockwise direction to tension the chain on its drive side. Whilst applying the opposing force to the sprocket and chain, tighten the sprocket securing bolt to 115-125 Nm. Remove the chain tensioning tool. 4. Remove the tape and steel strip from the timing cover upper face. Wipe any residue of tape from the joint face. 5. Remove the camshaft locking tool. 6. Install the Cam Cover to Bank 2. Refer to Operation <<12.29.43>>. 7. Raise the vehicle on the ramp. 8. Remove the crankshaft setting tool 303-531.
2012-07-23
www.JagDocs.com
9. Install the crankshaft position sensor. 1. Install the sensor to the flywheel housing and fit the securing bolt. Tighten to 8-12 Nm. 2. Install the access grommet to the housing. 10. Lower the ramp. 11. Remove the paint protection sheets and close the engine compartment cover. 12. Connect the battery and install the battery cover. Reset the side glass memory. Refer to the Battery Reconnection Procedure <<86.15.15>>.
2012-07-23
Exhaust Camshaft Sprocket RH Vehicles Without: Supercharger 12.65.73

Timing chain tensioning 303-532 Removal 1. Open the engine compartment and fit paintwork protection sheets. 2. Set the engine compartment cover to the service access position.
2012-07-23
www.JagDocs.com
2012-07-23
2012-07-23
www.JagDocs.com
12.
2012-07-23
14. Remove the bolt which secures the sprocket to the exhaust camshaft. Move the sprocket forward from the camshaft boss.
2012-07-23

15. Remove the secondary chain tensioner. The tensioner piston cannot be pushed into the body with the assembly in position. 1. Remove the two bolts which secure the tensioner. Lift the tensioner, sprocket (release it fully from the camshaft) and chain assembly. 2. Remove the tensioner rearward from between the chain. 16. Remove the sprocket and leave the chain resting on the cylinder head. 17. Clean and inspect all relevant components.
Installation
www.JagDocs.com
1. Install the sprocket to the secondary chain. 1. With the sprocket installed in the chain, temporarily position (do not install the securing bolt) the sprocket onto the camshaft. 2. Adjust the position of the sprocket within the chain to allow the chain tensioning tool 303-532 to be approximately vertical, as shown. Remove the chain tensioning tool; during future operations, do not move the sprocket within the chain.
2012-07-23
2. Push the tensioner piston into the body to provide clearance for installing. 1. Insert a thin rigid wire through the hole in the end of the tensioner piston to displace the ball from the non-return valve seat. 2. With the wire in position, press the piston fully into the tensioner body. Remove the wire.
3. Install the chain tensioner between the chain path. 1. Reposition the sprocket, still captive in the chain, upwards for access. 2. Install the chain tensioner between the sprockets. Position the cam sprocket, chain and tensioner assembly into position and locate the sprocket onto the camshaft spigot.
2012-07-23
www.JagDocs.com
4. Install the chain tensioner to the engine. 1. Fully seat the sprocket onto the camshaft and install the securing bolt, hand tight. 2. Install the two bolts which secure the tensioner and tighten to 10-14 Nm.
5. Install the camshaft sprocket. Install the chain tensioner tool 303-532 to the sprocket holes. Apply force to the tool in an anti-clockwise direction to tension the chain on its drive side. Whilst applying the opposing force to the sprocket and chain, tighten the sprocket securing bolt to 115-125 Nm. Remove the chain tensioning tool. 6. Remove the tape and steel strip from the timing cover upper face. Wipe any residue of tape from the joint face. 7. Remove the camshaft locking tool.
2012-07-23
8. Install the Cam Cover to Bank 1. Refer to Operation <<12.29.44>>. 9. Raise the vehicle on the ramp. 10. Remove the crankshaft setting tool 303-531.
11. Install the crankshaft position sensor. 1. Install the sensor to the flywheel housing and fit the securing bolt. Tighten to 8-12 Nm. 2. Install the access grommet to the housing. 12. Lower the ramp. 13. Move the engine compartment cover from the service position and connect the gas struts. 14. Remove the paint protection sheets and close the engine compartment cover. 15. Connect the battery and install the battery cover. Reset the side glass memory. Refer to the Battery Reconnection Procedure <<86.15.15>>.
2012-07-23
Exhaust Camshaft Sprocket RH Vehicles With: Supercharger 12.65.73

www.JagDocs.com
Timing chain tensioning 303-532 Removal 1. Open the engine compartment and fit paintwork protection sheets. 2. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
2012-07-23

remain open until after the battery has been disconnected.
2012-07-23
www.JagDocs.com
2012-07-23
11.
2012-07-23
www.JagDocs.com
2012-07-23

14. Remove the secondary chain tensioner. The tensioner piston cannot be pushed into the body with the assembly in position. 1. Remove the two bolts which secure the tensioner. Lift the tensioner, sprocket (release it fully from the camshaft) and chain assembly. 2. Remove the tensioner rearward from between the chain. 15. Remove the sprocket and leave the chain resting on the cylinder head. 16. Clean and inspect all relevant components.
Installation
1. Install the sprocket to the secondary chain. 1. With the sprocket installed to the chain, temporarily position (do not install the securing bolt) the sprocket onto the camshaft. 2. Adjust the position of the sprocket within the chain to allow the chain tensioning tool 303-532 to be approximately vertical, as shown. Remove the chain tensioning tool; during future operations, do not move the sprocket within the chain.
2012-07-23
www.JagDocs.com
2012-07-23
5. Install the camshaft sprocket. Install the chain tensioner tool 303-532 to the sprocket holes. Apply force to the tool in an anti-clockwise direction to tension the chain on its drive side. Whilst applying the opposing force to the sprocket and chain, tighten the sprocket securing bolt to 115-125 Nm. Remove the chain tensioning tool. 6. Remove the tape and steel strip from the timing cover upper face. Wipe any residue of tape from the joint face. 7. Remove the camshaft locking tool.
2012-07-23
8. Install the Cam Cover to Bank 1. Refer to Operation <<12.29.44>>. 9. Raise the vehicle on the ramp. 10. Remove the crankshaft setting tool 303-531.
www.JagDocs.com
11. Install the crankshaft position sensor. 1. Install the sensor to the flywheel housing and fit the securing bolt. Tighten to 8-12 Nm. 2. Install the access grommet to the housing. 12. Lower the ramp. 13. Remove the paint protection sheets and close the engine compartment cover. 14. Connect the battery and install the battery cover. Reset the side glass memory. Refer to the Battery Reconnection Procedure <<86.15.15>>.
2012-07-23
Exhaust Manifold LH 30.15.55

Removal 1. Open the engine compartment and fit paintwork protection sheets. 2. Remove the front silencer. Refer to Section <<309-00>>. 3. Remove the downpipe catalytic converter, left hand side. Refer to Section <<309-00>>.
4. Working from above the vehicle, remove the bolts which secure the front section of the exhaust manifold to the cylinder head.
5. If working on a left hand drive vehicle; working from below the vehicle, reposition the steering rack for access. 1. Remove the two bolts which secure the steering rack at the driver's side. 2. Loosen, but do not remove, the two bolts which secure the steering rack at the passenger side.
1 2012-07-23

Reposition the steering rack for access.
www.JagDocs.com
6. Working from below the vehicle, remove the manifold. 1. Remove the bolts which secure the rear section of the exhaust manifold to the cylinder head. 2. Remove the manifold and the manifold gasket. 7. Clean the manifold faces (if refitting) and the mating faces on the cylinder head. 8. Use a thread tap (plug) to clean out the threads of the manifold securing bolt holes, in the cylinder head.
Installation 1. Installation is the reverse of removal. Use new gaskets and new securing bolts for the manifold.
2012-07-23
Exhaust Manifold RH 30.15.56

Removal 1. Open the engine compartment and fit paintwork protection sheets. 2. Remove the air cleaner assembly. Refer to Section <<303-12>>. 3. Remove the front silencer. Refer to Section <<309-00>>. 4. Remove the downpipe catalytic converter, right hand side. Refer to Section <<309-00>>.
5. From above the vehicle, disconnect the EGR pipe from the exhaust manifold. 1. Remove the two nuts which secure the EGR flange to the right hand exhaust manifold. 2. Reposition the EGR pipe from the manifold.
2012-07-23
6. Remove the bolts which secure the front section of the exhaust manifold to the cylinder head.
www.JagDocs.com
7. If working on a right hand drive vehicle; reposition the steering rack for access. 1. Remove the two bolts which secure the steering rack at the passenger side. 2. Loosen, but do not remove, the two bolts which secure the steering rack at the driver's side. Reposition the steering rack for access.
2012-07-23
8. Working from below the vehicle, remove the manifold bolts. 1. Remove the bolts which secure the rear section of the exhaust manifold to the cylinder head.
9. Remove the manifold. 1. Remove the manifold and the manifold gasket from the cylinder head. 2. Remove the gasket from the EGR flange. 10. If fitting a new manifold, remove the two studs from the EGR flange of the manifold. and transfer them to the new manifold. 11. Clean the manifold faces (if refitting) and the mating faces on the cylinder head. 12. Use a thread tap (plug) to clean out the threads of the manifold securing bolt holes, in the cylinder head.
2012-07-23
Installation 1. Fit a spacer to each new manifold securing bolt (8 bolts).
www.JagDocs.com
2. Fit the manifold and manifold gasket. 1. Fit and align the new gasket to the cylinder head. 2. Fit and align the manifold to the cylinder head. 3. Fit the rear four bolts which secure the manifold, but do not tighten. 3. Working from above the vehicle, fit and tighten the remaining manifold securing bolts. 4. Working from below the vehicle, fully tighten the rear bolts on each manifold.
5. Refit the steering rack (if removed for access). 1. Reposition the steering rack. 2. Fit and tighten the rack mounting bolts on the passenger side.
4 2012-07-23

3. Tighten the rack mounting bolts on the driver's side.
6. From above the vehicle, connect the EGR pipe to the exhaust manifold. 1. Fit a new EGR gasket to the manifold. 2. Reposition the EGR pipe to the manifold. 3. Fit the two nuts which secure the EGR flange to the exhaust manifold. 7. Fit the downpipe catalytic converter, right hand side. Refer to Section <<309-00>>. 8. Fit the front silencer. Refer to Section <<309-00>>. 9. Fit the air cleaner assembly. Refer to Section <<303-12>>. 10. Remove paintwork protection sheets and close the engine compartment.
2012-07-23
Flexplate Vehicles Without: Supercharger 12.53.13

Removal 1. Open the engine compartment and fit paint protection sheets. 2. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors remain open until after the battery has been disconnected.
www.JagDocs.com
3. Disconnect the battery ground cable. Remove the battery cover. 4. Remove the Engine Covers, Air Intake Tube, Catalytic Converters and the Front Muffler. Drain the transmission fluid and remove the transmission for access. Refer to Operation <<44.20.01>> Transmission Remove, which includes each of the above operations.
2012-07-23
5. Remove the drive plate. Prevent the drive plate from rotating by use of a small wedge in the ring gear. Remove the bolts which secure the drive plate to the crankshaft. Remove the drive plate. 6. Clean the crankshaft mating face and any other components which are to be refitted.
Installation
1.
WARNING: MAKE SURE NEW DRIVE PLATE RETAINING BOLTS ARE INSTALLED. FAILURE TO FOLLOW THIS PROCEDURE MAY RESULT IN DAMAGE TO THE VEHICLE.
Fit the drive plate. Fit and align the drive plate to the crankshaft. Fit, but not tighten, the bolts which secure the drive plate to the crankshaft. Prevent the drive plate from rotating by use of a small wedge in the ring gear.
2 2012-07-23
www.JagDocs.com
2. Tighten the securing bolts in two stages and in the order shown. STAGE ONE tighten to 14-16 Nm.
3. Tighten the securing bolts in two stages and in the order shown. STAGE TWO tighten to 95-125 Nm. 4. Refit the Transmission, Catalytic Converters and the Front Muffler, Air Intake Tube and Engine Covers. Refill the transmission with new fluid. Refer to Operation <<44.20.01>> Transmission Install, which includes each of the above operations. 5. Remove the paint protection sheets and close the engine compartment cover. 6. Connect the battery and fit the battery cover. Reset the side glass memory. Refer to the Battery Reconnection Procedure <<86.15.15>>.
2012-07-23
Flexplate Vehicles With: Supercharger 12.53.13

Removal 1. Open the engine compartment and fit paint protection sheets. 2. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors remain open until after the battery has been disconnected.
3. Disconnect the battery ground cable. Remove the battery cover. 4. Remove the Engine Covers, Air Intake Tube, Catalytic Converters and the Front Muffler. Drain the transmission fluid and remove the transmission for access. Refer to Operation 44.20. 01 Transmission Remove, in Section <<307-01B>>, which includes each of the above operations.
2012-07-23
www.JagDocs.com
5. Remove the drive plate. Prevent the drive plate from rotating by use of a small wedge in the ring gear. Remove the bolts which secure the drive plate to the crankshaft. Remove the drive plate. 6. Clean the crankshaft mating face and any other components which are to be refitted.
Installation 1. The drive plate and securing bolts are different for 99MY compared to previous engines. The differences are as follows: Longer bolts. Spaceing plate welded to the drive plate on the crankshaft mating face. Smaller locating hole for stepped dowel. Plastic plug identifier (disposable) on new service part.
2012-07-23

2. Fit the drive plate. Fit and align the drive plate to the crankshaft. Fit, but not tighten, the bolts which secure the drive plate to the crankshaft. Prevent the drive plate from rotating by use of a small wedge in the ring gear.
3. Tighten the securing bolts in two stages and in the order shown. STAGE ONE tighten to 14-16 Nm.
4. Tighten the securing bolts in two stages and in the order shown. STAGE TWO tighten to 95-125 Nm. 5. Refit the Transmission, Catalytic Converters and the Front Muffler, Air Intake Tube and Engine Covers. Refill the transmission with new fluid. Refer to Operation 44.20. 01, Transmission Install, in Section <<307-01B>>, which includes each of the above operations. 6. Remove the paint protection sheets and close the engine compartment cover. 7. Connect the battery and fit the battery cover. Reset the side glass memory. Refer to the Battery Reconnection Procedure <<86.15.15>>.
3 2012-07-23
Oil Pan 12.60.44

Removal 1. Open the engine compartment and fit paintwork protection sheets. 2. Raise the vehicle on a ramp.
www.JagDocs.com
3. Drain the engine oil. 1. Position the waste oil bowser. 2. Remove the oil pan drain plug and drain the engine oil. Wipe the drain plug and refit it, to prevent oil dripping. Move the oil bowser away from the vehicle.
4. Remove the oil pan. 1. Remove the eighteen bolts which secure the oil pan to the oil pan body.
2012-07-23

2. Remove the oil pan from the oil pan body. 3. Remove the gasket from the oil pan body assembly. 5. Clean and inspect the sealing faces on the oil pan body assembly. Clean and inspect the new oil pan mating face.
Installation
1. Fit the oil pan gasket to the oil pan body assembly. Insert the seal into the locating positions in the groove, working around from a corner. Press in the remainder of the seal, following the same procedure.
2. Fit the oil pan to the oil pan body.. 1. Position and align the oil pan. 2. Fit, but do not tighten, all eighteen bolts which secure the oil pan.
2012-07-23
www.JagDocs.com
3. Tighten the oil pan bolts to the correct torque figure 11 - 13 Nm, in the sequence indicated. A new oil pan is supplied with the drain plug fitted. Check that the plug is tightened to the correct torque figure of 30 - 40 Nm. 4. NOTE: When the engine is started from cold and run for a short period only, before being switched off, a quantity of oil will be 'hung up' within the engine because it is not up to operating temperature. Should the oil level subsequently be topped-up, the level could become too high, causing oil burning. Typically, 0.875 L is hung up. Lower the ramp. Refill the engine with the correct specification engine oil. 5. Remove the paint protection sheets and close the engine compartment.
2012-07-23
Oil Pan Gasket 12.60.38

Removal 1. Open the engine compartment and fit paintwork protection sheets. 2. Raise the vehicle on a ramp.
3. Drain the engine oil. 1. Position the waste oil bowser. 2. Remove the drain plug and drain the engine oil. Fit a new sealing washer to the drain plug. Wipe the drain plug and refit it to the oil pan to prevent oil dripping. Move the oil bowser away from the vehicle.
4. Remove the oil pan.
2012-07-23

1. Remove the eighteen bolts which secure the oil pan. 2. Remove the oil pan. 3. Remove the gasket. 5. Clean and inspect the sealing faces on the oil pan. and mating faces.
Installation
www.JagDocs.com
1. Fit the oil pan gasket to the cylinder block adaptor body. Insert the seal into the locating positions in the groove, working around from a corner. Press in the remainder of the seal, following the same procedure.
2. Fit the oil pan. 1. Position and align the oil pan. 2. Fit, but do not tighten, all eighteen bolts which secure the oil pan.
2012-07-23
3. Tighten the bolts to the correct torque figure 11 - 13 Nm, in the sequence indicated. Tighten the drain plug to 30 - 40 Nm. Fit a new oil filter. 4. NOTE: When the engine is started from cold and run for a short period only, before being switched off, a quantity of oil will be 'hung up' within the engine because it is not up to operating temperature. Should the oil level subsequently be topped-up, the level could become too high, causing oil burning. Typically, 0.875 L is hung up. Lower the ramp. Refill the engine with the correct specification engine oil. 5. Remove the paint protection sheets and close the engine compartment.
2012-07-23
Oil Pressure Switch 88.25.07

Removal 1. Raise vehicle on four post ramp.
www.JagDocs.com
2. Remove oil pressure switch. Disconnect connector. Remove oil pressure switch from oil filter head.
Installation
1. NOTE: Fit new sealing washer to oil pressure switch. Installation is reverse of removal.
2012-07-23
Oil Pump Vehicles Without: Supercharger 12.60.26

2. Disconnect battery ground cable. Remove the battery cover. 3. Remove the engine compartment cover (bonnet) for improved access to the front of the engine. Refer to Operation <<76.16.01>>. 4. Remove the Crankshaft Sprocket B-bank. Refer to Operation <<12.65.76>>.
2012-07-23
www.JagDocs.com
5. Remove the oil pump. 1. Remove the four bolts which secure the oil pump to the cylinder block. 2. Remove the oil pump. 3. Remove the gasket. 6. Clean and inspect all components and mating faces.
2012-07-23
Installation
1. Fit the oil pump to the cylinder block. 1. Fit a new gasket to the block face. 2. Fit the oil pump onto the front of the crankshaft, to the block face; ensure that the drive flats on the inside of the pump gear engage correctly with the mating flats on the crankshaft. 3. Fit the securing bolts and tighten to 11 - 13 Nm. 2. Refit both sprockets to the crankshaft, both primary timing chains, the timing cover and all associated components. Refer to Operation <<12.65.76>>. 3. Refit the engine compartment cover (bonnet). Refer to Operation <<76.16.01>>. 4. Reset the side glass memory. Refer to the Battery Reconnection Procedure <<86.15.15>>.
2012-07-23
Oil Pump Vehicles With: Supercharger 12.60.26

www.JagDocs.com
2. Disconnect battery ground cable. Remove the battery cover. 3. Remove the engine compartment cover (bonnet) for improved access to the front of the engine. Refer to Operation <<76.16.01>> (SC). 4. Remove the Crankshaft Sprocket B-bank. Refer to Operation <<12.65.76>> (SC).
2012-07-23
5. Remove the oil pump. 1. Remove the four bolts which secure the oil pump to the cylinder block. 2. Remove the oil pump. 3. Remove the gasket. 6. Clean and inspect all components and mating faces.
2012-07-23

Installation
www.JagDocs.com
1. Fit the oil pump to the cylinder block. 1. Fit a new gasket to the block face. 2. Fit the oil pump onto the front of the crankshaft, to the block face; ensure that the drive flats on the inside of the pump gear engage correctly with the mating flats on the crankshaft. 3. Fit the securing bolts and tighten to 11 - 13 Nm. 2. Refit both sprockets to the crankshaft, both primary timing chains, the timing cover and all associated components. Refer to Operation <<12.65.76>> (SC). 3. Refit the engine compartment cover (bonnet). Refer to Operation <<76.16.01>> (SC). 4. Reset the side glass memory. Refer to the Battery Reconnection Procedure <<86.15.15>>.
2012-07-23
Primary Timing Chain LH 12.65.67

Timing chain tensioning 303-532
Wedges, primary chain 303-533
2012-07-23
Variable camshaft timing oil control unit setting tool 303-654 Removal
All vehicles
1. Remove the right-hand primary timing chain. <<Primary Timing Chain RH>>
www.JagDocs.com
2. Remove the variable camshaft timing oil control solenoid.
2012-07-23
3. Remove variable camshaft timing oil control unit housing. 1. Remove variable camshaft timing oil control unit housing retaining bolts. 2. Remove variable camshaft timing oil control unit housing.
4. Remove and discard the variable camshaft timing oil control unit housing O-ring seals.
All vehicles
NOTE: Vehicles without supercharger shown, vehicles with supercharger similar.
2012-07-23
5. Install the camshaft locking tool 303-530 to the left-hand camshafts, aligning the camshafts as necessary.
www.JagDocs.com
6. Loosen the exhaust camshaft sprocket retaining bolt.
2012-07-23

7. Loosen the variable camshaft timing oil control unit retaining bolt.
8. Loosen the intake camshaft sprocket retaining bolt.
All vehicles
2012-07-23
9. Remove the primary chain tensioner retaining bolts.
www.JagDocs.com
10. Remove the tensioner assembly. 1. Remove the tensioner. 2. Remove the tensioner back-plate.
2012-07-23
11. Remove the primary chain tensioner blade. 1. Remove the pivot bolt which secures the tensioner blade. 2. Remove the tensioner blade.
12. Push the tensioner piston (secondary chain) into the body to to release the tension on the left-hand secondary timing chain. Insert a thin rigid wire through the hole in the end of the tensioner piston to displace the ball from the non-return valve seat. With the wire in position, press the piston fully into the tensioner body. Remove the wire.
2012-07-23
www.JagDocs.com
13. Reposition the timing chain assembly forward along the camshaft bosses to enable the primary timing chain to clear the cylinder head casting.
14. Remove the left-hand primary timing chain.
2012-07-23
Installation
All vehicles
1. Install the chain tensioning tool 303-532 to the exhaust camshaft sprocket. Reposition the sprockets for the most advantageous position for use of the tool. Remove the tool.
2012-07-23
www.JagDocs.com
2. Install the primary timing chain. Install the primary chain over the crankshaft sprocket and the variable camshaft timing oil control unit (or intake camshaft sprocket - vehicles fitted with supercharger). There must be no slack on the drive side of the primary chain and the sprockets must not be rotated on the camshafts (or the tensioning tool may not fit).
3. Reposition the timing chain assembly along the intake camshaft.
10
2012-07-23
4. Install the primary chain tensioner blade. 1. Position the tensioner blade to the cylinder block. 2. Install the retaining / pivot bolt and tighten it to 12-16 Nm.
5. Push the tensioner piston into the body to provide clearance for fitting. 1. Install a thin rigid wire through the hole in the end of the tensioner piston to displace the ball from the non-return valve seat. 2. With the wire in position, press the piston fully into the tensioner body. Remove the wire.
11
2012-07-23
www.JagDocs.com
6. Assemble the tensioner. 1. Fit the two mounting bolts to the tensioner. 2. Locate the tensioner back-plate to the two bolts.
7. Install the primary chain tensioner retaining bolts. Tighten to 12 Nm.
12
2012-07-23
8. Tighten the exhaust camshaft sprocket retaining bolt. 1. Install the chain tensioner tool 303-532 to the sprocket holes. Apply force to the tool in an anti-clockwise direction to tension the chain on its drive side. 2. Whilst applying the opposing force to the sprocket and chain, tighten the sprocket retaining bolt to 115-125 Nm.
9. Rotate the variable camshaft timing oil control unit fully counter-clockwise to the fully retarded position. 1. Install the variable camshaft timing oil control unit setting tool 303-654. 2. Rotate the variable camshaft timing oil control unit fully anti-clockwise to the fully retarded position.
13
2012-07-23
www.JagDocs.com
10. Tighten the variable camshaft timing oil control unit retaining bolt. 1. Whilst still applying the opposing force to the sprocket and chain (using 303 - 532), check that the wedges are still in place, carry out the variable camshaft timing oil control unit retaining bolt tightening sequence. Tighten to 40 Nm + 90. Remove the chain tensioning tool and the wedge(s).
11. Tighten the intake camshaft retaining bolt. 1. Whilst still applying the opposing force to the sprocket and chain (using 303 - 532), check that the wedges are still in place, carry out the intake camshaft retaining bolt tightening sequence. Tighten to 40 Nm + 90. Remove the chain tensioning tool and the wedge(s).
14
2012-07-23

All vehicles
12. Remove the camshaft locking tool 303-530.
13. Install new seals to the variable camshaft timing oil control unit housing.
15
2012-07-23
www.JagDocs.com
14.
WARNING: CHECK THAT THE RING DOWELS ARE ENGAGED SQUARELY. FULLY LOCATE THE ASSEMBLY AS MUCH AS POSSIBLE BY HAND PRESSURE. FAILURE TO FOLLOW THIS PROCEDURE MAY RESULT IN DAMAGE TO THE VEHICLE. NOTE: Lubricate the seals and the bush.
Install the variable camshaft timing oil control unit housing to the cylinder block. 1. Install the variable camshaft timing oil control unit housing. 2. Install the two retaining bolts and one nut. Tighten to 19-23 Nm.
15. Install the variable camshaft timing oil control solenoid. Check the seal areas and locate the solenoid to the bush carrier. Install the retaining bolt. Tighten to 8-10 Nm.
All vehicles
16. Install the right-hand primary timing chain. <<Primary Timing Chain RH>>
16 2012-07-23
Primary Timing Chain RH 12.65.66

2012-07-23
www.JagDocs.com
Variable camshaft timing oil control unit setting tool 303-654
Locking tool, crankshaft pulley 303-191
2012-07-23
Remover, crankshaft pulley 303-588 Removal
All vehicles
1. Remove the engine front Cover. <<Engine Front Cover>>
2012-07-23
www.JagDocs.com
4. Remove and discard the variable camshaft timing oil control unit housing O-ring seals.
All vehicles
NOTE: Vehicles without supercharger shown, vehicles with supercharger similar. 5. Temporarily install the crankshaft pulley and retaining bolt, hand-tight only. 6. Raise the vehicle on the ramp.
2012-07-23
8.
CAUTION: Do not rotate the crankshaft counterclockwise. The timing chains may bind causing engine damage.
Position the crankshaft so the timing slot on the drive plate is visible through the CKP sensor location.
2012-07-23
www.JagDocs.com
9. Install the crankshaft setting tool 303-531. Position the crankshaft so the special tool fully engages into the timing slot on the drive plate. 10. Lower the vehicle on the ramp.
11.
CAUTION: Under no circumstances should the crankshaft setting peg 303-531 be used in the following operation to lock the crankshaft.
Using the special tools, remove the crankshaft pulley retaining bolt.
2012-07-23
12. Using the special tools remove the crankshaft pulley.
13. Install the camshaft locking tool 303 - 530 to the right-hand camshafts, aligning the camshafts as necessary.
2012-07-23
www.JagDocs.com
2012-07-23

16. Loosen the intake camshaft retaining bolt.
All vehicles
2012-07-23
www.JagDocs.com
19. Remove the chain tensioner blade. 1. Remove the pivot bolt which secures the tensioner blade. 2. Remove the tensioner blade.
10
2012-07-23
20. Remove the right-hand primary chain.
Installation
All vehicles
11
2012-07-23
www.JagDocs.com
1. Install the chain tensioning tool 303 - 532 to the exhaust camshaft sprocket. Reposition the sprockets for the most advantageous position for use of the tool. Remove the tool.
2. Install the right-hand primary timing chain. Install the primary chain to position over the crankshaft sprocket and the variable camshaft timing oil control unit (or intake camshaft sprocket - vehicles fitted with supercharger). There must be no slack on the drive side of the primary chain and the sprockets must not be rotated on the camshafts (or the tensioning tool may not fit).
12
2012-07-23
3. Fit the primary chain tensioner blade. 1. Position the tensioner blade to the cylinder block. 2. Fit the retaining / pivot bolt and tighten it to 12 - 16 Nm.
13
2012-07-23
www.JagDocs.com
5. Install the primary chain tensioner back plate. 1. Install the primary chain tensioner retaining bolts. 2. Install the primary chain tensioner back plate.
6. Install the primary chain tensioner. Tighten to 12 Nm.
14
2012-07-23
7. Install primary chain tensioner wedge 303-533 (or two if required) between the primary chain tensioner and tensioner blade, to take up the slack in the chain.
8. Tighten the exhaust camshaft sprocket retaining bolt. 1. Fit the chain tensioner tool 303 - 532 to the sprocket holes. Apply force to the tool in an anti-clockwise direction to tension the chain on its drive side. 2. Whilst applying the opposing force to the sprocket and chain, tighten the sprocket retaining bolt to 115 125 Nm.
15
2012-07-23

www.JagDocs.com
16
2012-07-23

All vehicles
12. Remove the camshaft locking tool 303 - 530. 13. Raise the vehicle on the ramp.
17
2012-07-23
www.JagDocs.com
14. Remove the crankshaft setting tool 303-531.
15. Install the crankshaft position sensor. 1. Install the sensor to the flywheel housing and fit the securing bolt. Tighten to 8 - 12 Nm. 2. Install the access grommet to the housing. 16. Lower the ramp.
18
2012-07-23

17. Fit new seals to the variable camshaft timing oil control unit housing.
18.
19
2012-07-23
www.JagDocs.com
19. Install the variable camshaft timing oil control solenoid. Tighten to 10 Nm.
All vehicles
20. Refit the engine front Cover. <<Engine Front Cover>>
20
2012-07-23
Secondary Timing Chain LH 12.65.69

2012-07-23
www.JagDocs.com
Variable camshaft timing oil control unit setting tool 303-654
Locking tool, crankshaft pulley 303-191
2012-07-23
Remover, crankshaft pulley 303-588 Removal
All vehicles
1. Remove the engine front Cover. <<Engine Front Cover>>
2012-07-23
www.JagDocs.com
4. Remove and discard the variable camshaft timing oil control unit housing O-ring seals. 1. Remove the sealing rings from the variable camshaft timing oil control unit housing.
All vehicles
NOTE: Vehicles without supercharger shown, vehicles with supercharger similar. 5. Temporarily install the crankshaft pulley and retaining bolt, hand-tight only. 6. Raise the vehicle on a ramp.
2012-07-23
8.
2012-07-23
www.JagDocs.com
11.
CAUTION: Under no circumstances should the crankshaft setting peg 303-531 be used in the following operation to lock the crankshaft.
Using the special tools, remove the crankshaft pulley retaining bolt.
2012-07-23
12. Using the special tools remove the crankshaft pulley.
13. Install the camshaft locking tool 303-530 to the left-hand camshafts, aligning the camshafts as necessary.
2012-07-23
www.JagDocs.com
2012-07-23

16. Loosen the intake camshaft sprocket retaining bolt.
All vehicles
2012-07-23
www.JagDocs.com
19. Remove the primary chain tensioner blade. 1. Remove the pivot bolt which secures the tensioner blade. 2. Remove the tensioner blade.
10
2012-07-23
21. Reposition the timing chain assembly forward along the camshaft bosses to enable the primary timing chain to clear the cylinder head casting.
11
2012-07-23
22. Detach the left-hand primary timing chain, and allow it rest against the crankshaft sprocket.
www.JagDocs.com
23. Remove the secondary timing chain. 1. Remove the variable camshaft timing oil control unit (or intake camshaft sprocket - vehicles fitted with supercharger) and exhaust camshaft sprocket retaining bolts. 2. Remove the variable camshaft timing oil control unit (or intake camshaft sprocket - vehicles fitted with supercharger), exhaust sprocket and secondary chain as an assembly (release the chain from the tensioner which is still secured to the cylinder head). Remove the secondary chain from the variable camshaft timing oil control unit (or intake camshaft sprocket - vehicles fitted with supercharger) and the sprocket.
Installation
All vehicles
12 2012-07-23
1. Install the secondary timing chain. NOTE: Assemble the variable camshaft timing oil control unit (or intake camshaft sprocket - vehicles fitted with supercharger), the exhaust camshaft sprocket and the secondary chain, in preparation for fitting to the engine. 1. Fit the assembly to the camshafts with the chain correctly positioned over the tensioner; variable camshaft timing oil control unit (or intake camshaft sprocket - vehicles fitted with supercharger) to the inlet and the sprocket to the exhaust. 2. Fit, but do not tighten, each bolt which secures the variable camshaft timing oil control unit (or intake camshaft sprocket - vehicles fitted with supercharger) and the exhaust sprocket to the camshafts. Allow the variable camshaft timing oil control unit sufficient space to fit the primary chain, in a later operation.
2. Install the chain tensioning tool 303-532 to the exhaust camshaft sprocket, Bank 2. Reposition the sprocket and the variable camshaft timing oil control unit (or intake camshaft sprocket vehicles fitted with supercharger) for the most advantageous position for use of the tool. Remove the tool.
13
2012-07-23
www.JagDocs.com
3. Attach the primary timing chain. Attach the primary chain over the variable camshaft timing oil control unit (or intake camshaft sprocket vehicles fitted with supercharger). There must be no slack on the drive side of the primary chain and the variable camshaft timing oil control unit must not be rotated on the camshaft (or the tensioning tool may not fit).
4. Reposition the timing chain assembly along the intake camshaft.
14
2012-07-23
5. Install the primary chain tensioner blade. 1. Position the tensioner blade to the cylinder block. 2. Install the retaining / pivot bolt and tighten it to 12-16 Nm.
15
2012-07-23
www.JagDocs.com
7. Assemble the tensioner. 1. Fit the two mounting bolts to the tensioner. 2. Locate the tensioner back-plate to the two bolts.
8. Install the primary chain tensioner retaining bolts. Tighten to 12 Nm.
16
2012-07-23
9. Tighten the exhaust camshaft sprocket retaining bolt. 1. Install the chain tensioner tool 303-532 to the sprocket holes. Apply force to the tool in an anti-clockwise direction to tension the chain on its drive side. 2. Whilst applying the opposing force to the sprocket and chain, tighten the sprocket retaining bolt to 115-125 Nm.
17
2012-07-23
www.JagDocs.com
18
2012-07-23

All vehicles
13. Remove the camshaft locking tool 303-530.
14. Install new seals to the variable camshaft timing oil control unit housing.
19
2012-07-23
www.JagDocs.com
15.
16. Install the variable camshaft timing oil control solenoid. Check the seal areas and locate the solenoid to the bush carrier. Install the securing bolt. Tighten to 8-10 Nm.
20
2012-07-23

All vehicles
17. Raise the vehicle on the ramp.
19. Install the crankshaft position sensor. 1. Install the sensor to the flywheel housing and fit the securing bolt. Tighten to 8 - 12 Nm. 2. Install the access grommet to the housing. 20. Lower the ramp. 21. Refit the engine front Cover. <<Engine Front Cover>>
21
2012-07-23
Secondary Timing Chain RH 12.65.68

RemovalNOTE: Vehicles without supercharger shown, vehicles with supercharger similar. 1. Remove the right-hand primary chain. <<Primary Timing Chain RH>>
www.JagDocs.com
2. Push the tensioner piston (secondary chain) into the body to to release the tension on the right-hand secondary timing chain. 1. Insert a thin rigid wire through the hole in the end of the tensioner piston to displace the ball from the non-return valve seat. 2. With the wire in position, press the piston fully into the tensioner body. Remove the wire.
3. Remove the secondary timing chain. 1. Remove the variable camshaft timing oil control unit (or intake camshaft sprocket - vehicles fitted with supercharger) and exhaust camshaft sprocket retaining bolts.
2012-07-23

2. Remove the variable camshaft timing oil control unit (or intake camshaft sprocket - vehicles fitted with supercharger), exhaust sprocket and secondary chain as an assembly (release the chain from the tensioner which is still secured to the cylinder head). Remove the secondary chain from the variable camshaft timing oil control unit (or intake camshaft sprocket - vehicles fitted with supercharger) and the sprocket. 4. Clean and inspect all relevant components.
Installation
1. Install the secondary timing chain. NOTE: Assemble the variable camshaft timing oil control unit (or intake camshaft sprocket - vehicles fitted with supercharger), the exhaust camshaft sprocket and the secondary chain, in preparation for fitting to the engine. 1. Fit the assembly to the camshafts with the chain correctly positioned over the tensioner; variable camshaft timing oil control unit (or intake camshaft sprocket - vehicles fitted with supercharger) to the inlet and the sprocket to the exhaust. 2. Fit, but do not tighten, each bolt which secures the variable camshaft timing oil control unit (or intake camshaft sprocket - vehicles fitted with supercharger) and the exhaust sprocket to the camshafts. Allow the variable camshaft timing oil control unit sufficient space to fit the primary chain, in a later operation. 2. Install the right-hand primary chain. <<Primary Timing Chain RH>>
2012-07-23
Secondary Timing Chain Tensioner LH 12.65.64

www.JagDocs.com
Timing chain tensioning 303-532 RemovalNOTE: Vehicles without supercharger shown, vehicles with supercharger similar
2012-07-23
1. Disconnect the battery ground cable. Remove the battery cover. 2. Remove the left-hand valve cover. <<Valve Cover LH>> 3. Raise the vehicle on a ramp.
2012-07-23
www.JagDocs.com
5.
2012-07-23
9.
2012-07-23
www.JagDocs.com
2012-07-23
13. Remove the secondary chain tensioner. 1. Remove the two bolts which secure the tensioner. Lift the tensioner, sprocket (release it fully from the camshaft) and chain assembly. 2. Remove the tensioner rearward from between the chain. 14. Remove the sprocket if required, or leave it in the chain resting on the cylinder head. 15. Clean and inspect all relevant components.
2012-07-23

Installation
www.JagDocs.com
1. Install the sprocket to the secondary chain. 1. With the sprocket installed to the chain, temporarily position (do not install the securing bolt) the sprocket onto the camshaft. 2. Adjust the position of the sprocket within the chain to allow the chain tensioning tool 303-532 to be approximately vertical, as shown. Remove the chain tensioning tool; during future operations, do not move the sprocket within the chain.
2012-07-23
2012-07-23
www.JagDocs.com
5. Install the camshaft sprocket. Install the chain tensioner tool 303-532 to the sprocket holes. Apply force to the tool in an anti-clockwise direction to tension the chain on its drive side. Whilst applying the opposing force to the sprocket and chain, tighten the sprocket securing bolt to 115-125 Nm. Remove the chain tensioning tool. 6. Remove the tape and steel strip from the timing cover upper face. Wipe any residue of tape from the joint face.
7. Remove the camshaft locking tool. 8. Install the left-hand valve Cover. <<Valve Cover LH>> 9. Raise the vehicle on the ramp.
2012-07-23
11. Install the crankshaft position sensor. 1. Install the sensor to the flywheel housing and fit the securing bolt. Tighten to 8 - 12 Nm. 2. Install the access grommet to the housing. 12. Lower the ramp. 13. Move the engine compartment cover from the service position and connect the gas struts. 14. Remove the paint protection sheets and close the engine compartment cover. 15. Connect the battery. <<414-01>>
10
2012-07-23
Secondary Timing Chain Tensioner RH 12.65.63

www.JagDocs.com
Timing chain tensioning 303-532 RemovalNOTE: Vehicles without supercharger shown, vehicles with supercharger similar
2012-07-23
1. Disconnect the battery ground cable. Remove the battery cover. 2. Remove the right-hand valve cover.<<Valve Cover RH>> 3. Raise the vehicle on a ramp.
2012-07-23
www.JagDocs.com
5.
2012-07-23
9.
2012-07-23
www.JagDocs.com
2012-07-23

12. Remove the secondary chain tensioner. 1. Remove the two bolts which secure the tensioner. Lift the tensioner, sprocket (release it fully from the camshaft) and chain assembly. 2. Remove the tensioner rearward from between the chain. 13. Remove the sprocket if required, or leave it in the chain resting on the cylinder head. 14. Clean and inspect all relevant components.
Installation
1. Install the sprocket to the secondary chain. 1. With the sprocket installed in the chain, temporarily position (do not install the securing bolt) the sprocket onto the camshaft. 2. Adjust the position of the sprocket within the chain to allow the chain tensioning tool 303-532 to be approximately vertical, as shown. Remove the chain tensioning tool; during future operations, do not move the sprocket within the chain.
2012-07-23

www.JagDocs.com
2012-07-23
5. Install the camshaft sprocket. Install the chain tensioner tool 303-532 to the sprocket holes. Apply force to the tool in an anti-clockwise direction to tension the chain on its drive side. Whilst applying the opposing force to the sprocket and chain, tighten the sprocket securing bolt to 115-125 Nm. Remove the chain tensioning tool. 6. Remove the tape and steel strip from the timing cover upper face. Wipe any residue of tape from the joint face.
7. Remove the camshaft locking tool. 8. Install the right-hand valve cover. <<Valve Cover RH>> 9. Raise the vehicle on the ramp.
2012-07-23
www.JagDocs.com
11. Install the crankshaft position sensor. 1. Install the sensor to the flywheel housing and fit the securing bolt. Tighten to 8 - 12 Nm. 2. Install the access grommet to the housing. 12. Lower the ramp. 13. Move the engine compartment cover from the service position and connect the gas struts. 14. Remove the paint protection sheets and close the engine compartment cover. 15. Connect the battery. <<414-01>>
2012-07-23
Upper Oil Pan Vehicles Without: Supercharger 12.60.48

Installer/remover, Oil Filter 303-752 Removal 1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors remain open until after the battery has been disconnected.
2. Disconnect the battery ground cable. Remove the battery cover. 3. Open the engine compartment and fit paintwork protection sheets. 4. Set the engine compartment cover to the service access position. 5. Remove the timing cover and all associated components, as detailed in Operation <<12.65.01>>. 6. Remove both front wheel and tyre assemblies. Refer to Operation <<74.20.05>>.
2012-07-23
7. Remove the undertray. Refer to Operation <<76.22.90>>.
www.JagDocs.com
8. Remove the two bolts which secure the generator cooling duct to the oil pan body and remove the duct. 9. Remove the front cross member for access. Refer to Operation 76.10.05. Includes cruciform strut assembly on convertible.
10. Drain the engine oil. 1. Position the waste oil bowser. 2. Remove the drain plug from the oil pan and drain the engine oil. Fit a new sealing washer to the drain plug. Wipe the drain plug and install it to the oil pan to prevent oil dripping. Move the oil bowser away from the vehicle.
2012-07-23
11. Remove the oil pan. 1. Remove the eighteen bolts which secure the oil pan to the oil pan body. 2. Remove the oil pan. 3. Remove the gasket from the oil pan body assembly.
12. NOTE: Place a suitable container underneath filter to prevent oil spillage. Using the special tool, remove the oil filter. 13. Remove the oil pressure switch. <<Oil Pressure Switch - >>
2012-07-23
www.JagDocs.com
14. Remove the crankshaft position sensor. 1. Remove the bolt which secures the crankshaft position sensor to the flywheel housing. 2. Remove the access grommet from the housing. Remove the sensor and allow it to hang free under the engine. Release the harness clips from the oil pan body.
15. Remove the bolt which secures the transmission cooler pipes and remove the clamping bracket.
2012-07-23
16. Release the air conditioning compressor. Remove the lower securing bolts. Loosen, but do not remove, the upper securing bolts. Release the compressor from the lower dowel.
17. Remove the four bolts (two each side) which secure the exhaust downpipes to the oil pan body.
2012-07-23
www.JagDocs.com
18. Remove the oil pick-up pipe. 1. Remove the bolts which secure the pipe. 2. Remove the pipe. 3. Remove and discard the seal.
2012-07-23
19. Remove the bolts, ten outer and six inner, which secure the oil pan body. Remove the oil pan body.
2012-07-23
20. Remove the eight screws and release the windage tray.
www.JagDocs.com
21. Remove the oil filter adaptor. 22. Clean all components and relevant mating faces; cylinder block, oil pan, oil pan body, windage tray, oil pick-up pipe, diverter valve and timing cover.
2012-07-23

Installation
1. Reposition the windage tray and install the eight screws, tighten to 5-7 Nm.
2. Install the oil filter adaptor and tighten to 26-34 Nm.
2012-07-23
www.JagDocs.com
3. Apply a continuous bead of RTV sealant (Loctite 5699) 3 mm diameter, around the bed plate flange OR around the oil pan body flange; as indicated. It is important that the oil pan body is bolted to the bedplate within twenty minutes of applying the RTV sealant.
10
2012-07-23
4. Apply a continuous bead of RTV sealant (Loctite 5699) 2 mm diameter, around the oil pick-up pipe and the diverter valve flanges; as indicated. It is important that the oil pan body is bolted to the bedplate within twenty minutes of applying the RTV sealant.
11
2012-07-23
www.JagDocs.com
5. Position and align the oil pan body to the bedplate. Install the sixteen bolts and tighten to 20-22 Nm in the sequence indicated. Confirm that the transmission face of the sump body is level with the transmission face of the cylinder block; within the limits 0.1 mm proud to 0.2 mm below the level of the block face.
12
2012-07-23
6. Install the oil pick-up pipe. 1. Install a new O-ring seal to the pick-up pipe. 2. Lubricate the O-ring seal with clean engine oil and install the pipe to the oil pan body. 3. Install and tighten the bolts to 11-13 Nm.
7. Install the oil pan gasket to the oil pan body assembly. Insert the seal into the locating positions in the groove, working around from a corner. Press in the remainder of the seal, following the same procedure.
13
2012-07-23
www.JagDocs.com
8. Install the oil pan to the oil pan body.. 1. Position and align the oil pan. 2. Install, but do not tighten, all eighteen bolts which secure the oil pan.
9. Tighten the bolts to the correct torque figure 11-13 Nm, in the sequence indicated. Tighten the drain plug to 30-40 Nm. 10. Install the oil pressure switch. <<Oil Pressure Switch - >>
14
2012-07-23
11. NOTE: Apply a suitable amount of clean engine oil to lubricate the oil filter O-ring seal. Using the special tool, install the oil filter. Tighten the oil filter to 15-18 Nm.
12. Install the crankshaft position sensor. 1. Install the sensor to the flywheel housing and fit the securing bolt. Tighten to 8-12 Nm. 2. Install the access grommet to the housing. Connect the harness clips to the oil pan body.
15
2012-07-23
13. Install the four bolts (two each side) which secure the exhaust downpipes to the oil pan body and transmisssion casing.
www.JagDocs.com
14. Install the air conditioning compressor. Locate the compressor onto the lower dowel. Tighten the upper securing bolts. Install and tighten the lower securing bolts to 18-24 Nm. Tighten the upper securing bolts to 18-24 Nm.
16
2012-07-23
15. Position the transmission cooler pipes and the clamping bracket. Install the bolt to secure the clamp and tighten to 7-9 Nm. 16. Install the front crossmember. Refer to Operation 76.10.05. Includes cruciform strut assembly on convertible.
17. Position the generator cooling duct to the oil pan body and install the two bolts. 18. Install the undertray. Refer to Operation <<76.22.90>>. 19. Install both front wheel and tyre assemblies. Refer to Operation <<74.20.05>>. 20. Install the timing cover and all associated components, as detailed in Operation <<12.65.01>>. 21. NOTE:
17
2012-07-23

When the engine is started from cold and run for a short period only, before being switched off, a quantity of oil will be 'hung up' within the engine because it is not up to operating temperature. Should the oil level subsequently be topped-up, the level could become too high, causing oil burning. Typically, 0.875 L is hung up. Refill the engine with the correct specification engine oil. 22. Connect the battery and install the battery cover. Reset the side glass memory. Refer to the Battery Reconnection Procedure <<86.15.15>>. 23. Check the oil level and start the engine. Check for leaks and that the engine runs correctly. 24. Reposition the engine compartment cover and connect the gas struts. 25. Remove the paintwork protection sheets and close the engine compartment cover.
www.JagDocs.com
18
2012-07-23
Upper Oil Pan Vehicles With: Supercharger 12.60.48

Installer/remover, Oil Filter 303-752 Removal 1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors remain open until after the battery has been disconnected.
2. Disconnect the battery ground cable. Remove the battery cover. 3. Open the engine compartment and fit paintwork protection sheets. 4. Remove the engine compartment cover. Refer to Operation <<76.16.01>>. 5. Remove the twin fan and motor assembly. Refer to Operation 26.25.12. 6. Remove the coolant outlet pipe. Refer to Operation <<26.31.08>>.
2012-07-23
7. Remove the supercharger drive belt. Refer to Operation <<18.50.08>>. 8. Remove the supercharger drive belt idler pulley. Refer to Operation <<18.50.09>>.
www.JagDocs.com
9. Remove the supercharger idler pulley mounting bracket. 1. Remove the three bolts which secure the mounting bracket. 2. Remove the mounting bracket. 10. Remove the supercharger drive belt tensioner. Refer to Operation <<18.50.24>>. 11. Remove the timing cover and all associated components, as detailed in Operation <<12.65.01>>. 12. Remove both front wheel and tyre assemblies. Refer to Operation <<74.20.05>>. 13. Remove the undertray. Refer to Operation <<76.22.90>>.
2012-07-23
14. Remove the two bolts which secure the generator cooling duct to the oil pan body and remove the duct. 15. Remove the front cross member for access. Refer to Operation 76.10.05. Includes cruciform strut assembly on convertible.
16. Drain the engine oil. 1. Position the waste oil bowser. 2. Remove the drain plug from the oil pan and drain the engine oil. Fit a new sealing washer to the drain plug. Wipe the drain plug and install it to the oil pan to prevent oil dripping. Move the oil bowser away from the vehicle.
2012-07-23
www.JagDocs.com
17. Remove the oil pan. 1. Remove the eighteen bolts which secure the oil pan to the oil pan body. 2. Remove the oil pan. 3. Remove the gasket from the oil pan body assembly.
18. Disconnect the oil cooler pipes. 1. Remove the bolt which secures the oil cooler pipes. 2. Disconnect the oil cooler pipes from the oil pan body assembly. 3. Remove and discard the O-ring seals from the pipes and install blanking plugs to the pipes and unions.
2012-07-23
19. NOTE: Place a suitable container underneath filter to prevent oil spillage. Using the special tool, remove the oil filter. 20. Remove the oil pressure switch. <<Oil Pressure Switch - >>
21. Remove the crankshaft position sensor. 1. Remove the bolt which secures the crankshaft position sensor to the flywheel housing. 2. Remove the access grommet from the housing. Remove the sensor and allow it to hang free under the engine. Release the harness clips from the oil pan body.
2012-07-23
22. Remove the bolt which secures the transmission cooler pipes and remove the clamping bracket.
www.JagDocs.com
23. Release the air conditioning compressor. Remove the lower securing bolts. Loosen, but do not remove, the upper securing bolts. Release the compressor from the lower dowel.
2012-07-23
24. Remove the four bolts (two each side) which secure the exhaust downpipes to the oil pan body.
25. Remove the oil pick-up pipe. 1. Remove the bolts which secure the pipe. 2. Remove the pipe. 3. Remove and discard the seal.
2012-07-23
www.JagDocs.com
26. Remove the diverter valve. 1. Remove the bolts which secure the valve. 2. Remove the valve. 3. Remove and discard the O-ring seal.
2012-07-23
27. Remove the bolts, ten outer and six inner, which secure the oil pan body. Remove the oil pan body.
2012-07-23
28. Remove the eight screws and release the windage tray.
www.JagDocs.com
29. Remove the oil filter adaptor. 30. Clean all components and relevant mating faces; cylinder block, oil pan, oil pan body, windage tray, oil pick-up pipe, diverter valve and timing cover.
10
2012-07-23

Installation
1. Reposition the windage tray and install the eight screws, tighten to 5-7 Nm.
2. Install the oil filter adaptor and tighten to 26-34 Nm.
11
2012-07-23
www.JagDocs.com
3. Apply a continuous bead of RTV sealant (Loctite 5699) 3 mm diameter, around the bed plate flange OR around the oil pan body flange; as indicated. It is important that the oil pan body is bolted to the bedplate within twenty minutes of applying the RTV sealant.
12
2012-07-23
4. Apply a continuous bead of RTV sealant (Loctite 5699) 2 mm diameter, around the oil pick-up pipe and the diverter valve flanges; as indicated. It is important that the oil pan body is bolted to the bedplate within twenty minutes of applying the RTV sealant.
13
2012-07-23
www.JagDocs.com
5. Position and align the oil pan body to the bedplate. Install the sixteen bolts and tighten to 20-22 Nm in the sequence indicated.
14
2012-07-23
6. Install the oil diverter valve. 1. Install a new O-ring seal to the diverter valve. 2. Lubricate the O-ring seal with clean engine oil and install the valve into the oil pan body. 3. Install and tighten the bolts to 11-13 Nm.
7. Install the oil pick-up pipe. 1. Install a new O-ring seal to the pick-up pipe. 2. Lubricate the O-ring seal with clean engine oil and install the pipe to the oil pan body. 3. Install and tighten the bolts to 11-13 Nm.
15
2012-07-23
www.JagDocs.com
8. Install the oil pan gasket to the oil pan body assembly. Insert the seal into the locating positions in the groove, working around from a corner. Press in the remainder of the seal, following the same procedure.
9. Install the oil pan to the oil pan body.. 1. Position and align the oil pan. 2. Install, but do not tighten, all eighteen bolts which secure the oil pan.
16
2012-07-23
10. Tighten the bolts to the correct torque figure 11-13 Nm, in the sequence indicated. Tighten the drain plug to 30-40 Nm. 11. Install the oil pressure switch. <<Oil Pressure Switch - >>
12. NOTE: Apply a suitable amount of clean engine oil to lubricate the oil filter O-ring seal. Using the special tool, install the oil filter. Tighten the oil filter to 15-18 Nm.
17
2012-07-23
www.JagDocs.com
13. Install the crankshaft position sensor. 1. Install the sensor to the flywheel housing and fit the securing bolt. Tighten to 8-12 Nm. 2. Install the access grommet to the housing.
14. Install the four bolts (two each side) which secure the exhaust downpipes to the oil pan body.
18
2012-07-23
15. Install the air conditioning compressor. Locate the compressor onto the lower dowel. Tighten the upper securing bolts. Install and tighten the lower securing bolts to 18-24 Nm. Tighten the upper securing bolts to 18-24 Nm.
16. Position the transmission cooler pipes and the clamping bracket. Install the bolt to secure the clamp and tighten to 7-9 Nm.
19
2012-07-23
www.JagDocs.com
17. Connect the oil cooler pipes to the oil pan body assembly (vehicles with engine oil cooler). 1. Remove the blanking plugs and install new O-ring seals. 2. Connect the oil cooler pipes. 3. Install the clamp and bolt which secures the oil cooler pipes. Tighten to 18-24 Nm. 18. Install the front crossmember. Refer to Operation 76.10.05. Includes cruciform strut assembly on convertible.
19. Position the generator cooling duct to the oil pan body and install the two bolts. 20. Install the undertray. Refer to Operation <<76.22.90>>. 21. Install both front wheel and tyre assemblies. Refer to Operation <<74.20.05>>. 22. Install the timing cover and all associated components, as detailed in Operation <<12.65.01>>. Do not efill the cooling system at this stage.
20
2012-07-23
23. Install the supercharger drive belt tensioner. Refer to Operation <<18.50.24>>.
24. Install the supercharger idler pulley mounting bracket. 1. Position the mounting bracket to the timing cover. 2. Install the three bolts which secure the mounting bracket. Tighten to 8-10 Nm. 25. Install the supercharger drive belt idler pulley. Refer to Operation <<18.50.09>>. (34-46 Nm). 26. Install the supercharger drive belt. Refer to Operation <<18.50.08>>. 27. Install the coolant outlet pipe. Refer to Operation <<26.31.08>>. 28. Install the twin fan and motor assembly. Refer to Operation 26.25.12. 29. Refill the cooling system. Refer to Operation 26.10.01 in General Procedures section of the cooling system. 30. NOTE: When the engine is started from cold and run for a short period only, before being switched off, a quantity of oil will be 'hung up' within the engine because it is not up to operating temperature. Should the oil level subsequently be topped-up, the level could become too high, causing oil burning. Typically, 0.875 L is hung up. Refill the engine with the correct specification engine oil. 31. Connect the battery and install the battery cover. Reset the side glass memory. Refer to the Battery Reconnection Procedure <<86.15.15>>. 32. Check the oil level and start the engine. Check for leaks and that the engine runs correctly. 33. Install the engine compartment cover. Refer to Operation <<76.16.01>>. 34. Remove the paintwork protection sheets and close the engine compartment cover.
21 2012-07-23
Valve Cover LH 12.29.43

Removal
www.JagDocs.com
1. Detach the coolant hose.
2. Remove the engine left-hand cover.
2012-07-23
3. Disconnect the variable camshaft timing oil control solenoid electrical connector.
All vehicles
4. Remove the oil level indicator tube. Remove and discard the O-ring seal. 5. Remove the left-hand ignition coil-on-plugs.<<303-07>>
2012-07-23
6. Disconnect the breather hose from the left-hand valve cover.
www.JagDocs.com
7. Remove the coolant expansion tank retaining bolt.
2012-07-23
8. Detach the coolant expansion tank.
9. Release the clips which secure the engine harness to the cam cover.
2012-07-23

10. Detach the fuel injection supply manifold wiring harness retaining bracket.
www.JagDocs.com
All vehicles
11. Remove the cam cover assembly. 1. Remove the oil filler cap. 2. Remove the valve cover retaining bolts. 3. Remove the cam cover.
2012-07-23
12. NOTE: On removal of the valve cover retaining bolts note their positions in the valve cover. Remove the valve cover retaining bolts. Remove and discard the valve cover retaining bolt O-ring seals.
13. Remove the main seals from the cam cover. 1. Remove and discard the outer seal. 2. Remove and discard the spark plug apertures seals. 3. Remove the variable camshaft timing oil control solenoid seal. 14. Clean all relevant parts and mating faces.
2012-07-23

Installation
All vehicles
www.JagDocs.com
1. Install new valve cover seals. 1. Install a new outer seal. 2. Install two new spark plug aperture seals. 3. Install a new variable camshaft timing oil control solenoid seal.
2. Install the valve cover retaining bolts to their positions previously noted. 1. Install the valve cover retaining bolts. Install new valve cover retaining bolt O-ring seals.
2012-07-23
3. Apply bead of silicone gasket sealant or equivalent meeting Jaguar specification on the two places where the cylinder head and front cover join. The application of sealant must be 3mm diameter by 12mm long. Install the cam cover immediately after applying the sealant. The cover should be installed directly to the head without smearing the sealant.
4. Install the valve cover. Complete the tightening sequence. Tighten to 11 Nm. 5. Install the oil filler cap.
2012-07-23

www.JagDocs.com
6. Attach the fuel injection supply manifold wiring harness retaining bracket. Tighten to 5 Nm.
All vehicles
7. Reposition the clips which secure the engine harness to the cam cover.
2012-07-23
8. Attach the coolant expansion tank.
9. Install the coolant expansion tank retaining bolt. Tighten to 10 Nm.
10
2012-07-23
10. Connect the breather hose to the left-hand valve cover. 11. Install the left-hand ignition coil-on-plugs.<<303-07>>
www.JagDocs.com
12. Install the oil level indicator tube. Install a new O-ring seal. Tighten to 7 Nm.
11
2012-07-23

13. Connect the variable camshaft timing oil control solenoid electrical connector.
14. Install the engine left-hand cover.
12
2012-07-23
15. Attach the coolant hose.
www.JagDocs.com
13
2012-07-23
Valve Cover RH 12.29.44

Removal
All vehicles
1. Open the engine compartment and fit paintwork protection sheets.
2. Disconnect the intake tube from the throttle body. 1. Remove the two bolts which secure the intake tube to the throttle body. 2. Disconnect the intake tube from the throttle body.
3. Disconnect the air cleaner cover. Release the five clips which secure the air cleaner cover.
2012-07-23
www.JagDocs.com
4. Disconnect the mass air flow meter electrical connector. 1. Disconnect the breather pipe from the camshaft cover. 2. Disconnect the mass air flow meter electrical connector.
5. Remove the intake tube / air flow meter / air cleaner cover assembly. 1. Remove the intake tube / air flow meter / air cleaner cover assembly. 2. Remove and discard the rubber seal; air intake tube to throttle body.
2012-07-23

6. Remove the engine right-hand cover.
7. Disconnect the variable camshaft timing oil control solenoid electrical connector.
All vehicles
8. Remove the right-hand ignition coil-on-plugs. <<303-07>>
2012-07-23
9. Release the clips which secure the engine harness to the cam cover.
www.JagDocs.com
10. Detach the engine wiring harness.
2012-07-23
11. Detach the fuel injection supply manifold wiring harness retaining bracket.
All vehicles
12. Remove the cam cover assembly. 1. Release the fourteen screws which secure the cam cover. The screws stay in place within the cover, held by the seals. 2. Remove the cam cover, screws and seals, as an assembly.
2012-07-23
www.JagDocs.com
13. Separate the screws and seals from the cam cover. 1. One at a time, remove each securing screw from the cam cover. 2. Remove the rubber sealing ring from each securing screw.
14. Remove the main seals from the cam cover. 1. Remove and discard the outer seal. 2. Remove and discard the two seals from around the spark plug apertures. 3. Remove the seal for the variable camshaft timing oil control solenoid. 15. Clean all relevant parts and mating faces.
2012-07-23

Installation
All vehicles
1. Install the new main seals to the cam cover. 1. Install the new outer seal. 2. Install the two new spark plug aperture seals. 3. Install the seal to the variable camshaft timing oil control solenoid aperture.
2. Install the securing screws to the cam covers. 1. Install a new sealing ring to each screw assembly. 2. Install the screws to the cam covers. Each screw is retained by the cam cover gasket. Refer to the tightening sequence diagram for details of where to install the studs.
2012-07-23
www.JagDocs.com
3. Apply RTV sealant WSS-M4G320-A3 to two places on the joint between the timing cover and the cylinder head. The application of sealant must be 3mm diameter by 12mm long. Install the cam cover immediately after applying the sealant. The cover should be installed directly to the head without smearing the sealant.
4. Install the cam cover. Position the cam cover onto the cylinder head without smearing the sealant and start the threads of each securing screw.
2012-07-23
5. Tighten the securing screws to 9-11 Nm. Tighten in the sequence indicated. Screws annotated in a square have studs to install other components onto, and must be installed in the positions shown.
6. Attach the fuel injection supply manifold wiring harness retaining bracket.
2012-07-23
7. Attach the engine wiring harness.
www.JagDocs.com
All vehicles
8. Reposition the clips which secure the engine harness to the cam cover. 9. Install the right-hand ignition coil-on-plugs. <<303-07>>
10
2012-07-23

10. Connect the variable camshaft timing oil control solenoid electrical connector.
11. Install the engine right-hand cover.
11
2012-07-23

All vehicles
www.JagDocs.com
12. Install the intake tube / air flow meter / air cleaner cover assembly. 1. Install a new rubber seal; air intake tube to throttle body. 2. Install the intake tube / air flow meter / air cleaner cover assembly.
13. Connect the mass air flow meter electrical connector. 1. Connect the breather pipe to the camshaft cover. 2. Connect the mass air flow meter electrical connector.
12
2012-07-23
14. Reconnect the air cleaner cover. Install the five clips which secure the air cleaner cover.
15. Connect the intake tube to the throttle body. 1. Connect the intake tube to the throttle body. 2. Install the two bolts which secure the intake tube to the throttle body. 16. Remove the paintwork protection sheets and close the engine compartment.
13
2012-07-23
1999 XK RANGE - Engine Cooling - 303-03A
Cooling System Draining, Filling and Bleeding Vehicles Without: Supercharger
Drain
1. Open the engine compartment and fit paintwork protection sheets. 2. Ensure that the cooling system is cool and very carefully, remove the pressure cap from the header tank. 3. Raise the vehicle.
www.JagDocs.com
4. Drain the coolant. Place a coolant drain tray on the floor, below the radiator drain plug. 1. Remove the radiator drain plug. and allow the coolant to drain.
2012-07-19
5. Fit a new seal to the drain plug. 1. Remove the seal from the drain plug. and clean the plug face. Fit a new seal.
6. Refit the radiator drain plug. Clean any coolant from the underside of the vehicle. Remove the drain tray. 7. Lower the vehicle.
2012-07-19

Refill
www.JagDocs.com
1. Refill the cooling system with a 50% solution of water and Jaguar Antifreeze / Corrosion Inhibitor ESD M97B49 - A. Fill the cooling system at the header tank until the level stabilises at the top of the breather neck. Allow at least 2 minutes for air to purge from the system. Top up the header tank as required and fit the pressure cap. 2. Switch on the ignition, switch off the climate control system and start the engine. 3. Run the engine at between 1500 and 2000 rpm until the cooling fans operate. 4. Switch on the A/C system, set to maximum heat, and check that heat is coming from the heater at the fascia vents or the footwell outlets. 5. Switch off the engine and allow it to cool down. 6. When cool, remove the pressure cap and top up the system as necessary at the header tank.
2012-07-19
7. If necessary, fit new seals to the pressure cap. 1. Remove both O-rings from the pressure cap. Fit and fully seat new O-rings to the pressure cap. 8. Fit the pressure cap. 9. Remove the paintwork protection sheets and close the engine cover.
2012-07-19
Cooling System Draining, Filling and Bleeding Vehicles With: Supercharger
Drain
1. Open the engine compartment and fit paintwork protection sheets. 2. Ensure that the cooling system is cool and very carefully, remove the pressure cap from the header tank. 3. Raise the vehicle.
www.JagDocs.com
4. Drain the coolant. Place a coolant drain tray on the floor, below the radiator drain plug. 1. Remove the radiator drain plug. and allow the coolant to drain.
2012-07-19
5. Fit a new seal to the drain plug. 1. Remove the seal from the drain plug. and clean the plug face. Fit a new seal.
6. Refit the radiator drain plug. Clean any coolant from the underside of the vehicle. Remove the drain tray. 7. Lower the vehicle.
2012-07-19

Refill
www.JagDocs.com
1. Refill the cooling system with a 50% solution of water and Jaguar Antifreeze / Corrosion Inhibitor ESD M97B49 - A. 1. Remove the threaded plug and Dowty washer from the charge air cooler fill point. 2. Fill the cooling system at the header tank until the level stabilises near the top of the charge air cooler fill point. This will take some time, as air is being purged from the system. Ensure that the header tank is full. 2. NOTE: To ensure that air is not drawn into the system during the following operations: Do not remove the cap from the header tank whilst the charge air cooling system is open to atmosphere. Do not switch on the ignition when the charge air cooling system is open to atmosphere because the electrical cooling pump may draw air into the system. Fit the pressure cap to the header tank.
2012-07-19
3. Pour coolant carefully into the charge air cooler fill point until the system is full. Fit the plug and washer to the fill point. 4. Remove the pressure cap from the header tank. 5. Switch on the ignition and switch off the climate control system. Leave the ignition switched on (do not start the engine) for at least 2 minutes to allow the charge air cooler electric water pump to operate and to purge any air from the charge air cooler radiator to the header tank. (This operation will be repeated later) 6. Switch off the ignition for at least 1 minute. 7. Leave the ignition switched on (do not start the engine) for at least 2 minutes to allow the charge air cooler electric water pump to operate and to purge any air from the charge air cooler radiator to the header tank.
8. Top up the cooling system. 1. Top up the header tank and fit the pressure cap. 2. Remove the plug from the charge air cooler fill point. Pour coolant carefully into the charge air cooler fill point until the system is full. 3. Fit the plug and washer to the fill point. 9. Run the engine at between 1500 and 2000 rpm until the cooling fans operate. 10. Switch on the climate control system, set to maximum heat, and check that heat is coming from the heater at the fascia vents or the footwell outlets. 11. Switch off the engine and allow it to cool down. 12. When cool, remove the pressure cap and top up the system as necessary at the header tank.
2012-07-19
www.JagDocs.com
13. If necessary, fit new seals to the pressure cap. 1. Remove both O-rings from the pressure cap. Fit and fully seat new O-rings to the pressure cap. Fit the pressure cap. 14. Check that the pressure cap is fitted. Remove the plug from the charge air cooler fill point. Pour coolant carefully into the charge air cooler fill point until the system is full. Fit the plug to the fill point, using a new Dowty sealing washer. 15. Remove the paintwork protection sheets and close the engine cover.
2012-07-19
Coolant Expansion Tank Vehicles Without: Supercharger 26.15.01

Removal WARNING: NEVER REMOVE THE COOLANT EXPANSION TANK PRESSURE CAP UNDER ANY CIRCUMSTANCES WHILE THE ENGINE IS OPERATING. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN PERSONAL INJURY. WARNING: TO AVOID HOT COOLANT OR STEAM BLOWING OUT OF THE COOLING SYSTEM, USE EXTREME CARE WHEN REMOVING THE COOLANT EXPANSION TANK PRESSURE CAP. WAIT UNTIL THE ENGINE HAS COOLED DOWN, THEN INSULATE THE COOLANT PRESSURE CAP WITH A SUITABLE CLOTH AND SLOWLY LOOSEN THE COOLANT EXPANSION TANK PRESSURE CAP UNTIL THE COOLING SYSTEM PRESSURE IS RELEASED. DO NOT REMOVE THE COOLANT EXPANSION TANK PRESSURE CAP. STEP BACK WHILE THE PRESSURE IS RELEASED FROM THE SYSTEM. WHEN ALL OF THE PRESSURE HAS BEEN RELEASED SLOWLY REMOVE THE COOLANT EXPANSION TANK PRESSURE CAP (STILL WITH THE SUITABLE CLOTH IN POSITION) FROM THE COOLANT EXPANSION TANK. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN PERSONAL INJURY 1. Open the engine compartment and fit paintwork protection sheets. 2. Release the cooling system pressure. Remove the coolant expansion tank pressure cap. 3. Place a cloth under the expansion tank to absorb any spillage caused by disconnecting the hoses.
4. Disconnect the hose from the expansion tank.
2012-07-19
www.JagDocs.com
5. Disconnect the hose from the expansion tank. 6. Fit blanking plugs to the pipe and the tank.
7. Remove the expansion tank from the mounting. Remove the bolt which secures the tank. Remove the tank from the rear mounting grommets. Disconnect the coolant level sensor connector.
2012-07-19
8. Remove the expansion tank from the vehicle. 1. Use a pipe clamp to clamp the bottom hose branch. 2. Release the pipe clip and move it along the pipe. 3. Disconnect the tank from the bottom hose and remove it from the vehicle.
Installation
1. Installation is the reverse of the removal procedure. Tighten to 10 Nm. Fill the cooling system to the correct level.
2012-07-19
Coolant Expansion Tank Vehicles With: Supercharger 26.15.01

Removal 1. Open the engine compartment and fit paintwork protection sheets. 2. Ensure that the cooling system is cool and very carefully, remove the pressure cap. 3. Place a cloth under the expansion tank to absorb any spillage caused by disconnecting the hoses.
www.JagDocs.com
4. Release the hoses from the expansion tank. 1. Release the hose clip (expansion tank to radiators). Disconnect the hose. 2. Release the hose clip (expansion tank to coolant output pipe). Disconnect the hose. 3. Release the hose clip (expansion tank to coolant recovery bottle). Disconnect the hose. 5. Fit blanking plugs to the hoses and the tank.
2012-07-19
6. Remove the expansion tank from the mounting. 1. Remove the bolt which secures the tank. 2. Remove the tank from the rear mounting grommets. 3. Disconnect the coolant level sensor connector.
7. Remove the expansion tank from the vehicle. 1. Use a pipe clamp to clamp the lower hose branch. 2. Release the hose clip and move it along the hose. 3. Disconnect the tank from the lower hose and remove it from the vehicle. 8. Empty any surplus coolant from the expansion tank into a drain tray. 9. Remove the cloth from the engine and clean any spillage from the engine bay.
2012-07-19
10. Remove the coolant level probe. 1. Use a lever to release the probe from the expansion tank and remove it.
www.JagDocs.com
2012-07-19
Coolant Outlet Pipe 26.31.08

Removal 1. Open the engine compartment and fit paintwork protection sheets. 2. Drain the radiator. Refer to this Section. Retain the coolant drain tray in position to catch any spillage when removing the outlet pipe.
3. Disconnect the top hose and breather pipe from the coolant outlet pipe. 1. Release and reposition the hose clip, and disconnect the top hose. 2. Release and disconnect the breather pipe quick fit connector. 3. Disconnect the multi-plug from the temperature sensor and unscrew the sensor from the outlet pipe. 4. Release and reposition the hose clip along the bypass hose.
2012-07-19
4. Disconnect the bottom hose from the thermostat housing. 1. Release and reposition the hose clip along the hose. 2. Disconnect the bottom hose.
www.JagDocs.com
5. Disconnect the coolant outlet pipe from the cylinder heads. 1. Remove the four bolts which secure the outlet pipe. 2. Remove the outlet pipe from the bypass hose and from the cylinder heads (still connected to the heater hose). 6. Release and reposition the clip which secures the heater hose to the outlet pipe and disconnect the hose. Remove the outlet pipe.
7. Remove the thermostat from the outlet pipe. 1. Remove the three bolts which secure the thermostat cover to the outlet pipe. 2. Remove the thermostat cover, the thermostat and the seal from the outlet pipe. Discard the seal. 8. Remove and discard the sealing rings from the outlet pipe grooves.
2012-07-19
Installation 1. Installation is the reverse of the removal procedure. Use new sealing rings on the coolant outlet pipe and thermostat housing. The thermostat ball valve must locate in the recess in the cover. 2. Tighten the coolant outlet pipe bolts to 8 - 12 Nm. If replacing the coolant temperature sensor, tighten to 15 - 19 Nm. 3. Refill the cooling system as described in this section.
2012-07-19
Cooling Fan Motor 26.25.24

Removal 1. Remove the Twin Fan and Motor Assembly (26.25.12) described in this section. Do not remove the harness and pipe securing clips from the assembly.
www.JagDocs.com
2. Remove the fan and motor unit from the twin fan and motor assembly. 1. Remove the three nuts which secure the fan and motor unit. 2. Remove the fan and motor unit.
3. Remove the fan rubber mountings. 1. Remove the spacer from each rubber mounting. 2. Remove the three rubber mountings. Installation 1. Installation is the reverse of the removal procedure.
1 2012-07-19
Cooling Fan Motor and Shroud 26.25.25

All vehicles
1. Open the driver's door, or both doors if necessary, to allow the side windows to drop. Ensure that the doors remain open until after the battery has been disconnected.
2. Disconnect the battery ground cable. Remove the battery cover. 3. Open the engine compartment and fit paintwork protection sheets.

4. Drain the cooling system. <<Cooling System Draining, Filling and Bleeding - Vehicles With: Supercharger>>
2012-07-19
www.JagDocs.com
5. Remove the radiator upper hose.
All vehicles
6. Remove the two nuts which secure the fan and motor assembly to the radiator. 7. Raise the vehicle.
2012-07-19
8. Disconnect the harness multiplug from the cooling fan. 1. Disconnect the multiplug from the high speed fan and reposition the harness from the retaining clip.
9. Disconnect the harness multiplug from the cooling fan. 1. Disconnect the multiplug from the low speed fan and reposition the harness from the retaining clip.
2012-07-19
www.JagDocs.com
10. Carefully release and reposition the climate control pipe from the securing clip on the fan and motor assembly. 11. Lower the vehicle. 12. Carefully remove the fan and motor assembly from the vehicle. 13. Remove the harness and pipe securing clips from the assembly. Installation 1. Installation is the reverse of the removal procedure. Ensure that the fan and motor assembly locate into the lower mountings. 2. Connect the battery and fit the battery cover. Refer to the Battery Reconnection Procedure in Section <<414-01>>.
2012-07-19
Degas Bottle 26.15.03

Removal 1. WARNING: NEVER REMOVE THE COOLANT EXPANSION TANK PRESSURE CAP UNDER ANY CIRCUMSTANCES WHILE THE ENGINE IS OPERATING. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN PERSONAL INJURY. WARNING: TO AVOID HOT COOLANT OR STEAM BLOWING OUT OF THE COOLING SYSTEM, USE EXTREME CARE WHEN REMOVING THE COOLANT EXPANSION TANK PRESSURE CAP. WAIT UNTIL THE ENGINE HAS COOLED DOWN, THEN INSULATE THE COOLANT PRESSURE CAP WITH A SUITABLE CLOTH AND SLOWLY LOOSEN THE COOLANT EXPANSION TANK PRESSURE CAP UNTIL THE COOLING SYSTEM PRESSURE IS RELEASED. DO NOT REMOVE THE COOLANT EXPANSION TANK PRESSURE CAP. STEP BACK WHILE THE PRESSURE IS RELEASED FROM THE SYSTEM. WHEN ALL OF THE PRESSURE HAS BEEN RELEASED SLOWLY REMOVE THE COOLANT EXPANSION TANK PRESSURE CAP (STILL WITH THE SUITABLE CLOTH IN POSITION) FROM THE COOLANT EXPANSION TANK. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN PERSONAL INJURY Release the cooling system pressure. Remove the coolant expansion tank pressure cap. 2. Remove the right-hand front fender splash shield. <<501-02>>
3. Detach the degas bottle breather pipe.
2012-07-19
www.JagDocs.com
4. Detach the coolant hose from the degas bottle. Detach the coolant hose from the retaining clip.
5. Remove the degas bottle retaining nut.
2012-07-19
6. Remove the degas bottle.
Installation 1. To install, reverse the removal procedure.
2012-07-19
Engine Coolant Level Switch 26.40.11

Removal 1. Open the engine compartment and fit paintwork protection sheets. 2. Remove the expansion tank; refer to Operation (<<26.15.01>>.).
www.JagDocs.com
3. Remove the coolant level probe. 1. Use a lever to release the probe from the expansion tank and remove it. 4. Clean the expansion tank probe aperture.
2012-07-19
Radiator Vehicles Without: Supercharger 26.40.01

Removal 1. Open the driver's door, or both doors if necessary, to allow the side windows to drop. Ensure that the doors remain open until after the battery has been disconnected. 2. Open the engine compartment and fit paintwork protection sheets.
3. Disconnect the battery ground cable. Remove the battery cover. 4. Drain the coolant from the radiator. 5. Depressurise the climate control system. Refer to Operation <<82.30.30>>. Observe all safety warnings and precautions stated in that section. 6. Remove the air cleaner assembly; refer to Operation 19.10.05.
2012-07-19
www.JagDocs.com
7. Disconnect harness multiplug from the cooling fan (working from under the vehicle). 1. Disconnect the multiplug from the high speed fan and reposition the harness from the retaining clip.
8. Disconnect harness multiplug from the cooling fan (working from under the vehicle). 1. Disconnect the multiplug from the low speed fan and reposition the harness from the retaining clip.
2012-07-19
9. Disconnect the transmission oil cooler lower pipe. 1. Disconnect and reposition the union nut, lower cooler pipe to radiator. Disconnect the pipe. 2. Remove and discard the O-ring seal from the pipe and install blanking plugs to the pipe and to the union on the radiator. 3. Reposition the climate control pipe from the clip on the fan cowl.
10. From above the vehicle, disconnect the transmission oil cooler upper pipe. 1. Disconnect and reposition the union nut, upper cooler pipe to radiator. Disconnect the pipe. 2. Remove and discard the O-ring seal from the pipe and install blanking plugs to the pipe and to the union on the radiator.
2012-07-19
www.JagDocs.com
11. Disconnect the radiator bottom hose. 1. Slacken the hose retaining clip and reposition the clip along the hose. 2. Disconnect the hose from the radiator.
12. Remove the radiator top retaining panel. 1. Remove the five bolts which secure the panel. 2. Remove the panel. 3. Remove the radiator top mounting rubbers.
2012-07-19
13. Disconnect the radiator top hose. 1. Slacken the hose retaining clip and reposition the clip along the hose. 2. Disconnect the hose from the radiator.
14. Disconnect the radiator breather hose. 1. Slacken the hose (radiator to expansion tank) retaining clip and reposition the clip along the hose. 2. Disconnect the hose from the radiator.
2012-07-19
www.JagDocs.com
15. Disconnect the pipe from the climate control receiver / drier. 1. Remove the bolt which secures the pipe to the receiver / drier and disconnect the pipe. 2. Remove and discard the O-ring. 3. Install blanking plugs to the pipe and the receiver drier.
16. Disconnect the pipe from the climate control condenser joint (condenser to compressor). 1. Remove the nut which secures the pipe to the condenser and disconnect the pipe. 2. Remove and discard the O-ring. 3. Install blanking plugs to the pipe and the condenser.
2012-07-19
17. Remove the radiator. 1. With assistance, remove the radiator assembly. Clean coolant spillage from the radiator lower carrier panel.
18. Remove the fan cowl from the radiator assembly. 1. Remove the two nuts which secure the cowl to the radiator. 2. Remove the cowl from the radiator.
2012-07-19
www.JagDocs.com
19. Remove the condenser from the radiator. 1. Remove the two bolts which secure the condenser pipe protective bracket and remove the bracket. 2. Remove the two bolts which secure the condenser to the radiator. 3. Remove the condenser. 4. Remove the radiator lower mounting rubbers.
Installation
1. Install new foam sealing strips to the radiator top, bottom and left side.
2012-07-19
2. Install the condenser to the radiator. 1. Position the condenser. 2. Install the two bolts which secure the condenser to the radiator. 3. Position the condenser pipe protective bracket and install the two securing bolts.
3. Install the fan cowl to the radiator assembly. 1. Position the cowl to the radiator. 2. Install the two nuts which secure the cowl to the radiator. Tighten to 5-7 Nm. 3. Install the radiator lower mounting rubbers. 4. With assistance, reposition the radiator to the vehicle. Check that the lower mounting rubbers are located correctly.
2012-07-19
www.JagDocs.com
5. Connect the radiator coolant top hose. 1. Reposition and connect the top hose to the radiator. 2. Install and tighten the hose clip.
6. Connect the pipe to the receiver / drier. 1. Remove the blanking plugs from the pipe and from the receiver / drier. 2. Install a new O-ring seal to the pipe. 3. Reconnect the pipe to the receiver / drier and install the securing bolt. Tighten to 8-10 Nm.
10
2012-07-19
7. Connect the pipe to the compressor. 1. Remove the blanking plugs from the pipe. 2. Install a new O-ring seal to the pipe. 3. Reconnect the pipe to the compressor / condenser joint and install the securing nut. Tighten to 8-10 Nm.
8. Connect the radiator coolant bottom hose. 1. Reposition and connect the bottom hose to the radiator. 2. Install and tighten the hose clip.
11
2012-07-19
www.JagDocs.com
9. Connect the transmission oil cooler upper pipe. 1. Remove the blanking plugs and install a new O-ring seal to the pipe. Reposition the pipe and the union nut to the radiator. 2. Connect and tighten the union nut.
10. Install the radiator top securing panel. 1. Position and align the top securing panel. 2. Install the five securing bolts to the panel. Tighten to 8-10 Nm.
12
2012-07-19
11. From below the vehicle, connect the transmission lower cooler pipe to the radiator. 1. Remove the blanking plugs and install a new O-ring seal to the cooler pipe. 2. Reposition the pipe and the union nut to the radiator. 3. Connect and tighten the union nut. 4. Reposition and install the climate control pipe to the clips on the fan cowl.
12. Connect the harness multiplug to the cooling fans. 1. Connect the multiplug to the high speed fan and reposition the harness into the retaining clip.
13
2012-07-19
www.JagDocs.com
13. Connect the harness multiplug to the cooling fans. 1. Connect the multiplug to the low speed fan and reposition the harness into the retaining clip. 14. Check the level and replenish the transmission fluid as necessary. 15. From above the vehicle, install the air cleaner assembly; refer to Opeeration 19.10.05. 16. Refill the cooling system. Refer to the Refill Procedure 26.10.01. 17. Repressurise the climate control system. Refer to Operation <<82.30.30>>. Observe all safety warnings and precautions stated in that section. 18. Connect the battery and install the battery cover. Reset the side glass memory. Refer to the Battery Reconnection Procedure <<86.15.15>>.
14
2012-07-19
Radiator Vehicles With: Supercharger 26.40.01

3. Disconnect the battery ground cable. Remove the battery cover. 4. Drain the coolant from the radiator. 5. Depressurise the climate control system. Refer to Operation <<82.30.30>>. Observe all safety warnings and precautions stated in that section. 6. Remove the air cleaner assembly; refer to Operation 19.10.05.
2012-07-19
www.JagDocs.com
7. Disconnect harness multiplug from the cooling fan (working from under the vehicle). 1. Disconnect the multiplug from the high speed fan and reposition the harness from the retaining clip.
8. Disconnect harness multiplug from the cooling fan (working from under the vehicle). 1. Disconnect the multiplug from the low speed fan and reposition the harness from the retaining clip.
2012-07-19
9. Disconnect the transmission oil cooler lower pipe. 1. Disconnect and reposition the union nut, lower cooler pipe to radiator. Disconnect the pipe. 2. Remove and discard the O-ring seal from the pipe and install blanking plugs to the pipe and to the union on the radiator. 3. Reposition the climate control pipe from the clip on the fan cowl.
10. From above the vehicle, disconnect the transmission oil cooler upper pipe. 1. Disconnect and reposition the union nut, upper cooler pipe to radiator. Disconnect the pipe. 2. Remove and discard the O-ring seal from the pipe and install blanking plugs to the pipe and to the union on the radiator.
2012-07-19
www.JagDocs.com
11. Disconnect the radiator bottom hose. 1. Slacken the hose retaining clip and reposition the clip along the hose. 2. Disconnect the hose from the radiator.
12. Remove the radiator top retaining panel. 1. Remove the five bolts which secure the panel. 2. Remove the panel. 3. Remove the radiator top mounting rubbers.
2012-07-19
13. Disconnect the radiator top hose. 1. Slacken the hose retaining clip and reposition the clip along the hose. 2. Disconnect the hose from the radiator.
14. Disconnect the radiator breather hose. 1. Slacken the hose (radiator to expansion tank) retaining clip and reposition the clip along the hose. 2. Disconnect the hose from the radiator.
2012-07-19
www.JagDocs.com
15. Disconnect the pipe from the climate control receiver / drier. 1. Remove the bolt which secures the pipe to the receiver / drier and disconnect the pipe. 2. Remove and discard the O-ring. 3. Install blanking plugs to the pipe and the receiver drier.
16. Disconnect the pipe from the climate control condenser joint (condenser to compressor). 1. Remove the nut which secures the pipe to the condenser and disconnect the pipe. 2. Remove and discard the O-ring. 3. Install blanking plugs to the pipe and the condenser.
2012-07-19
17. Remove the radiator. With assistance, remove the radiator assembly. Clean coolant spillage from the radiator lower carrier panel.
18. Remove the fan cowl from the radiator assembly. 1. Remove the two nuts which secure the cowl to the radiator. 2. Remove the cowl from the radiator.
2012-07-19
www.JagDocs.com
19. Remove the condenser from the radiator. 1. Remove the two bolts which secure the condenser pipe protective bracket and remove the bracket. 2. Remove the two bolts which secure the condenser to the radiator. 3. Remove the condenser. 4. Remove the radiator lower mounting rubbers.
Installation
1. Install new foam sealing strips to the radiator top, bottom and left side.
2012-07-19
2. Install the condenser to the radiator. 1. Position the condenser. 2. Install the two bolts which secure the condenser to the radiator. 3. Position the condenser pipe protective bracket and install the two securing bolts.
3. Install the fan cowl to the radiator assembly. 1. Position the cowl to the radiator. 2. Install the two nuts which secure the cowl to the radiator. 3. Install the radiator lower mounting rubbers. 4. With assistance, reposition the radiator to the vehicle. Check that the lower mounting rubbers are located correctly.
2012-07-19
www.JagDocs.com
5. Connect the radiator coolant top hose. 1. Reposition and connect the top hose to the radiator. 2. Install and tighten the hose clip.
6. Connect the pipe to the receiver / drier. 1. Remove the blanking plugs from the pipe and from the receiver / drier. 2. Install a new O-ring seal to the pipe. 3. Reconnect the pipe to the receiver / drier and install the securing bolt. Tighten to 8-10 Nm.
10
2012-07-19
7. Connect the pipe to the compressor. 1. Remove the blanking plugs from the pipe. 2. Install a new O-ring seal to the pipe. 3. Reconnect the pipe to the compressor / condenser joint and install the securing nut. Tighten to 8-10 Nm.
8. Connect the radiator coolant bottom hose. 1. Reposition and connect the bottom hose to the radiator. 2. Install and tighten the hose clip.
11
2012-07-19
www.JagDocs.com
9. Connect the transmission oil cooler upper pipe. 1. Remove the blanking plugs and install a new O-ring seal to the pipe. Reposition the pipe and the union nut to the radiator. 2. Connect and tighten the union nut.
10. Install the radiator top securing panel. 1. Position and align the top securing panel. 2. Install the five securing bolts to the panel. Tighten to 8-10 Nm.
12
2012-07-19
11. From below the vehicle, connect the transmission lower cooler pipe to the radiator. 1. Remove the blanking plugs and install a new O-ring seal to the cooler pipe. 2. Reposition the pipe and the union nut to the radiator. 3. Connect and tighten the union nut. 4. Reposition and install the climate control pipe to the clips on the fan cowl.
12. Connect the harness multiplug to the cooling fans. 1. Connect the multiplug to the high speed fan and reposition the harness into the retaining clip.
13
2012-07-19
www.JagDocs.com
13. Connect the harness multiplug to the cooling fans. 1. Connect the multiplug to the low speed fan and reposition the harness into the retaining clip. 14. Check the level and replenish the transmission fluid as necessary. 15. From above the vehicle, install the air cleaner assembly; refer to Operation 19.10.05. 16. Refill the cooling system. Refer to the Refill procedure (SC) 26.10.01. 17. Repressurise the climate control system. Refer to Operation <<82.30.30>>. Observe all safety warnings and precautions stated in that section. 18. Connect the battery and install the battery cover. Reset the side glass memory. Refer to the Battery Reconnection Procedure <<86.15.15>>.
14
2012-07-19
Radiator Lower Hose 26.30.07

Removal 1. Open the engine compartment and fit paintwork protection sheets. 2. Drain the radiator. Refer to General Procedures. Retain the coolant drain tray in position to catch any spillage when removing the thermostat cover.
3. Disconnect the hose from the charge air cooler radiator. 1. Slacken the hose retaining clip and reposition the clip along the hose. 2. Disconnect the hose from the radiator.
4. Disconnect the bottom hose from the radiator. 1. Slacken the hose retaining clip and reposition the clip along the hose. 2. Disconnect the hose from the radiator.
1 2012-07-19
www.JagDocs.com
5. Disconnect the radiator bottom hose from the thermostat cover and air charge cooler. 1. Release and reposition the hose clip, and disconnect the bottom hose from the thermostat cover. 2. Release and reposition the hose clips, and disconnect the two sections of moulded hose from the air charge cooler. Remove the hose assembly. 6. Remove the spring band clips from the hose.
Installation 1. Installation is the reverse of the removal procedure. 2. Refill the cooling system as described in General Procedures.
2012-07-19
Radiator Upper Hose 26.30.01

Removal 1. Open the engine compartment and fit paintwork protection sheets. 2. Drain the radiator. Refer to General Procedures. Retain the coolant drain tray in position to catch any spillage when removing the hose.
3. Disconnect the top hose from the coolant outlet pipe. 1. Release and reposition the hose clip, and disconnect the top hose.
4. Release the top hose from the radiator. 1. Release the hose retaining clip and reposition the clip along the hose. 2. Disconnect the hose from the radiator. Remove the hose clips from the top hose.
1 2012-07-19
Installation 1. Installation is the reverse of the removal procedure. 2. Refill the cooling system as described in General Procedures.
www.JagDocs.com
2012-07-19
Thermostat Vehicles Without: Supercharger 26.45.07

Removal 1. Open the engine compartment and fit paintwork protection sheets. 2. Drain the radiator. Refer to this Section. Retain the coolant drain tray in position to catch any spillage when removing the thermostat cover. 3. Remove the engine cover panels for access.
4. Disconnect the radiator bottom hose from the thermostat cover. 1. Release and reposition the hose clip, and disconnect the bottom hose from the thermostat cover.
5. Remove the thermostat cover.
2012-07-19
1. Remove the three bolts which secure the thermostat cover to the housing. 2. Remove the thermostat cover from the housing.
www.JagDocs.com
6. Remove the thermostat from the housing. 1. Remove the thermostat from the housing. 2. Remove (and discard) the seal from the thermostat. Fit a new seal to the thermostat. The seal may be fitted either way round.
Installation 1. Installation is the reverse of the removal procedure. 2. Fit the thermostat so that the vent ball valve locates in the recess in the cover.
3. Tighten the thermostat cover bolts to 8 - 10 Nm. 4. Refill the cooling system as described in this section.
2012-07-19
Thermostat Vehicles With: Supercharger 26.45.07

3. Disconnect the bottom hose from the coolant outlet pipe. 1. Release and reposition the hose clip. 2. Disconnect the bottom hose.
4. Remove the thermostat from the outlet pipe. 1. Remove the three bolts which secure the thermostat cover to the outlet pipe. 2. Remove the thermostat cover, the thermostat and the seal from the outlet pipe. Discard the seal.
2012-07-19
Installation 1. Installation is the reverse of the removal procedure. Use new sealing rings on the coolant outlet pipe and thermostat housing. The thermostat ball valve must locate in the recess in the cover. 2. Tighten the thermostat cover bolts to 8 - 10 Nm. 3. Refill the cooling system as described in this section.
www.JagDocs.com
2012-07-19
Thermostat Housing Cover 26.45.22

2012-07-19
www.JagDocs.com
2012-07-19
Thermostat Housing Cover Seal 26.45.20

2012-07-19
www.JagDocs.com
2012-07-19
Water Pump Vehicles Without: Supercharger 26.50.01

Removal 1. Open the engine compartment and fit paintwork protection sheets. 2. Drain the cooling system.
3. Slacken the three screws which secure the water pump pulley.
4.
CAUTION: When releasing the belt tension, never apply any torque in a clockwise direction to the pulley centre bolt (left hand thread) as it could subsequently loosen.
2012-07-19
Remove the drive belt from the generator and accessory drive. 1. Use a spanner e.g. Churchill JD-230 or Snap On XDHM 1415, on the centre bolt of the belt tensioner idler pulley, to turn the adjuster assembly to the left against spring tension. 2. Whilst holding the tensioner against spring tension, remove the drive belt from the generator pulley. Release the tensioner slowly and remove the spanner. Disconnect the belt from the other pulleys, as necessary, to move it clear of the pump pulley.
www.JagDocs.com
5. Remove the pulley from the water pump. 1. Remove the pulley securing screws. 2. Remove the pulley from the water pump.
6. Remove the water pump. 1. Remove the five bolts which secure the water pump. 2. Remove the water pump from the engine.
2012-07-19
7. Remove the gasket. 1. Remove and discard the water pump gasket. 2. Remove and discard the water pump O-ring seal. 8. Clean any coolant spillage from the engine compartment. 9. Clean all relevant parts and sealing faces.
Installation
1. To install, reverse the removal procedure. Install a new water pump gasket and O-ring seal.
2012-07-19
2. Tighten the water pump bolts to 8 Nm + 90.
www.JagDocs.com
3. Tighten the water pump pulley bolts to 10-14 Nm. 4. Fill the cooling system.
2012-07-19
Water Pump Vehicles With: Supercharger 26.50.01

Removal 1. Open the engine compartment and fit paintwork protection sheets. 2. Drain the cooling system. 3. Remove the supercharger drive belt. Refer to Operation <<18.50.08>>.
5.
CAUTION:
2012-07-19
When releasing the belt tension, never apply any torque in a clockwise direction to the pulley centre bolt (left hand thread) as it could subsequently loosen. Remove the drive belt from the generator and accessory drive. 1. Use a spanner e.g. Churchill JD-230 or Snap On XDHM 1415, on the centre bolt of the belt tensioner idler pulley, to turn the adjuster assembly to the left against spring tension. 2. Whilst holding the tensioner against spring tension, remove the drive belt from the generator pulley. Release the tensioner slowly and remove the spanner. Disconnect the belt from the other pulleys, as necessary, to move it clear of the pump pulley.
www.JagDocs.com
6. Remove the pulley from the water pump. 1. Remove the pulley securing screws. 2. Remove the pulley from the water pump.
7. Remove the water pump. 1. Remove the five bolts which secure the water pump. 2. Remove the water pump from the engine.
2012-07-19
8. Remove the gasket. 1. Remove and discard the water pump gasket. 2. Remove and discard the water pump O-ring seal. 9. Clean any coolant spillage from the engine compartment. 10. Clean all relevant parts and sealing faces.
Installation
1. To install, reverse the removal procedure. Install a new water pump gasket and O-ring seal.
2012-07-19
2. Tighten the water pump securing bolts to 8 Nm + 90.
www.JagDocs.com
3. Tighten the water pump pulley bolts to 10-14 Nm. 4. Fill the cooling system.
2012-07-19
Water Pump Pulley Vehicles Without: Supercharger 26.50.05

Removal 1. Open the engine compartment and fit paintwork protection sheets.
3. Remove the drive belt from the generator and accessory drive. 1. Use a spanner e.g. Churchill JD - 230 or Snap On XDHM 1415, on the centre bolt of the belt tensioner idler pulley, to turn the adjuster assembly to the left against spring tension. 2. Whilst holding the tensioner against spring tension, remove the drive belt from the generator pulley. Release the tensioner slowly and remove the spanner. Disconnect the belt from the other pulleys, as necessary, to move it clear of the pump pulley.
2012-07-19
www.JagDocs.com
4. Remove the pulley from the water pump. 1. remove the pulley securing screws. 2. Remove the pulley from the water pump. Clean relevant parts and faces.
Installation 1. Installation is the reverse of the removal procedure. Tighten the pulley securing bolts to 10 - 14 Nm.
2012-07-19
Water Pump Pulley Vehicles With: Supercharger 26.50.05

Removal 1. Open the engine compartment and fit paintwork protection sheets. 2. Remove the supercharger drive belt. Refer to Operation <<18.50.08>>.
4.
2012-07-19
Remove the drive belt from the generator and accessory drive. 1. Use a spanner e.g. Churchill JD - 230 or Snap On XDHM 1415, on the centre bolt of the belt tensioner idler pulley, to turn the adjuster assembly to the left against spring tension. 2. Whilst holding the tensioner against spring tension, remove the drive belt from the generator pulley. Release the tensioner slowly and remove the spanner. Disconnect the belt from the other pulleys, as necessary, to move it clear of the pump pulley.
www.JagDocs.com
5. Remove the pulley from the water pump. 1. remove the pulley securing screws. 2. Remove the pulley from the water pump. Clean relevant parts and faces.
Installation 1. Installation is the reverse of the removal procedure. Tighten the pulley securing bolts to 10 - 14 Nm.
2012-07-19
1999 XK RANGE - Supercharger Cooling - 303-03B
Water Pump
Removal 1. Open the driver's door, or both doors if necessary, to allow the side windows to drop. Ensure that the doors remain open until after the battery has been disconnected.
2. Disconnect the battery ground cable. Remove the battery cover. 3. Open the engine compartment and fit paintwork protection sheets. 4. Set the engine compartment cover to the service access position. 5. Remove the air cleaner assembly. Refer to Operation 19.10.05.
2012-07-19
www.JagDocs.com
6. Disconnect the harness electrical connector. 1. Release the harness connector from the mounting bracket. 2. Disconnect the harness connector.
7. Remove the two bolts which secure the mounting bracket to the vehicle body.
2012-07-19
8. Reposition the pump to allow hose clamps to be fitted. Fit a hose clamp to the inlet pipe and one to the outlet pipe.
9. Disconnect the pipes from the pump and remove the pump. 1. Release and reposition the hose clip along the inlet hose and disconnect the hose. 2. Release and reposition the hose clip along the outlet hose and disconnect the pump from the hose. 3. Fit blanking plugs to the pipes and to the pump. Remove the pump and mounting bracket assembly from the vehicle.
2012-07-19
www.JagDocs.com
10. Remove the mounting bracket from the pump. 1. Remove the nuts which secure the clamp. 2. Remove the bracket and insulation rubber from the pump. 11. Clean the adjacent area of any water spillage.
Installation 1. Fitting is the reverse of the removal procedure. 2. Connect the battery and fit the battery cover. Reset the side glass memory. Refer to the Battery Reconnection Procedure <<86.15.15>>. 3. Switch on the ignition and allow the pump to operate for one minute to circulate coolant. Switch off the ignition. Top up the coolant. If necessary, refer to Operation 26.10.01 (SC) Coolant Refill Procedure.
2012-07-19
1999 XK RANGE - Fuel Charging and Controls - 303-04
Torque Specifications Component Fuel injector clamp plate retaining bolts - vehicles with supercharger Intake manifold fuel feed pipe to fuel rail bolts Harness to camshaft cover nuts Fuel pressure regulator / return pipe to fuel rail bolts - vehicles with supercharger Fuel injection supply manifold to charge air cooler adaptor bolts - vehicles with supercharger Fuel injection supply manifold retaining bolts - vehicles without supercharger Fuel rail to fuel cross-over pipe bolt - vehicles with supercharger Fuel feed pipe to fuel rail bolts - vehicles with supercharger Throttle body retaining bolts Nm 4-6 8-12 4-5 8-12 18-24 12 8-12 8-12 18-24
2012-07-19
Fuel Charging and Controls

This section provides service information for the fuel distribution components located on the engine and includes the supercharger, where fitted. Refer to Section <<310-01>> for information on the fuel tank, fuel lines and related fuel supply items.
www.JagDocs.com
2012-07-19

Vehicles Without Supercharger Location of fuel charge components - vehicles without supercharger
2012-07-19

Parts List Item Description 1 2 3 4 Fuel pressure regulator Throttle body Intake manifold/fuel injection supply manifold Fuel injector
Fuel Distribution
Fuel is supplied to the engine via eight fuel injectors. The injectors are located in fuel injection supply manifold. Fuel pumped from the tank enters a feed pipe at the rear of bank 2. Fuel flow is along bank 2, across the top front of the engine (cross-over pipe) and through bank 1, the unused fuel returning to the tank via a pressure regulator. The fuel injectors are each controlled electrically from the engine control module (ECM). A test valve is fitted to the fuel injection supply manifold. This valve allows the fuel system to be depressurized during servicing and troubleshooting.
Fuel Injector
www.JagDocs.com
The eight fuel injectors are located in individual apertures in the intake manifold. The fuel rail is separate and supplies fuel to the top of each injector. Air injection is provided to the base of each injector to further improve fuel delivery and atomisation. Air is provided by an air gallery which is integral with the intake manifold. The fuel injectors are electromagnetic solenoid valves controlled by the ECM. The electrical pulse time for the injector combined with the fuel pressure determines the volume of fuel injected to the manifold.
2012-07-19

Fuel Pressure Regulator
The pressure regulator is a diaphragm-operated valve that regulates fuel-rail pressure at 3,0 bar above the intake manifold pressure. A pipe connects the throttle induction elbow to the pressure regulator to provide the vacuum control signal. On supercharged engines, the pressure regulator vacuum feed is taken from the top of the supercharger outlet duct. The regulator is fitted between the rear end of the fuel injection supply manifold and the fuel return line to the tank.
Throttle Body
2012-07-19

Item 1 2 3 4 5 6 Description Throttle Motor Throttle Position (TP) Sensor Coolant Inlet Coolant Outlet Air Assist Control Valve Accelerator pedal position (APP) sensor
Throttle Body
The main features of the motorised throttle body are: Fully motorised control of the throttle valve from the ECM. The throttle valve is coupled to a dc motor via reduction gears and quadrant and is positively driven by the engine management system between the fully closed and fully open positions, in both directions, without any intervening mechanisms, ie it is a 'full authority' system. A twin potentiometer sensor on the motor end of the throttle shaft provides direct feedback of the actual valve angle to the EMS and is similar to the throttle position sensor in operation. Mechanical, cable operated 'limp home' mode with restricted throttle opening. The limp home mechanism consists of the accelerator input shaft link lever and the two throttle shaft levers, all three levers being interlocked for limp home operation. If a failure in the throttle mechanism or control system results in the engine management system selecting the limp home mode, motor power is cut by de-energising the motor supply relay and/or by de-activating the PWM motor control signal. In limp home mode, the throttle valve is operated mechanically from the drivers pedal and throttle opening is restricted to a range from idle to a maximum of approximately 30 degrees. Air assisted fuel injection control valve with integral air feed. The air assist injection improves the atomisation of the fuel spray pattern during cold temperatures. This reduces the hydrocarbon (HC) produced by combustion. By improving combustion stability when cold, allows the use of increased ignition retardation for faster catalyst warm up, providing a further reduction of HC emissions. The throttle body also has an accelerator pedal position (APP) sensor consisting of twin potentiometers which provide separate analogue input signals, proportional to driver demand to the ECM. As a further safety feature the two potentiometers have different input/output characteristics for unique signal identifications and any corrupt signal between the expected outputs will cause the ECM to switch the throttle to limp home mode.
www.JagDocs.com
2012-07-19

Vehicles With Supercharger
Fuel Injector
The eight injectors installed in the fuel rails of supercharged engines are of a higher flow rating than those installed in normally aspirated engines and are secured in position by spring clips. The fuel is supplied to the side each injector. Seals are installed between the injector mounts of the fuel rails and the related recesses in the charge air cooler adaptors.
Charge Air Cooler Adaptors

The charge air cooler adaptors: provide the interface between the charge air coolers and the cylinder heads locate the fuel rails and injectors For removal and installation refer to section <<303-01>>.
Fuel Rails
The plastic fuel rails locate in the charge air cooler adaptors: Bank 2 fuel rail has the fuel feed pipe attached at the rear of the engine and the fuel cross-over pipe at the front Bank 1 fuel rail connects to the other side of the cross-over pipe at the front of the engine and the fuel return pipe / pressure regulator at the rear
Fuel Cross-over Pipe

The fuel cross-over pipe connects the fuel rails together but is not interchangeable between the normally aspirated engine and the supercharged version.
2012-07-19
Fuel Charging and Controls

1. Verify the customer concern. 2. Confirm which, if any, warning lights and/or messages were displayed on the instrument cluster. NOTE: If any warning lights and/or messages were displayed when the fault occurred, refer to the Driver Information table for DTCs associated with the display, then to the DTC index table for possible sources and actions. Some warnings will appear to clear when the ignition is cycled. This is often because the warning has flagged as a result of one of the vehicle's on-board diagnostic routines having run to detect the fault. If the same routine is not run when the ignition is switched ON, the warning will not reflag until the routine does run. See the DTC summaries for drive cycle routines. 3. Visually inspect for obvious signs of mechanical or electrical damage. Visual Inspection Chart Mechanical Engine oil level Cooling system coolant level Fuel Contamination Throttle body Poly-vee belt Electrical Fuses. Wiring harness Electrical connector(s) Sensor(s) Engine control module (ECM) Transmission control module Check spark plug type. Only resisted plugs should be fitted. Refer to specifications section for gap Relay date codes. If the date on the relay is between R6 k1 and R6 k8, replace the relay 4. Verify the following systems are working correctly: Air intake system Cooling system Charging system 5. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 6. Where the Jaguar approved diagnostic system is available, complete the S93 report before clearing any or all fault codes from the vehicle. NOTE: If a DTC cannot be cleared, then there is a permanent fault present that flags again as soon as it is cleared. (The exception to this is P1260, which will only clear following an ignition OFF/ON cycle after rectification.) 7. If the cause is not visually evident and the Jaguar approved diagnostic system is not available, use a fault code reader to retrieve the fault codes before proceeding to the Diagnostic Trouble Code (DTC) Index Chart, or the Symptom Chart if no DTCs are set. NOTE: If the DTC flagged was not present for two or more consecutive cycles, it is classed as temporary, and will be deleted following three cycles during which no fault was present. This could result in a reported warning light/message with no stored DTCs. If a fault is present for three consecutive cycles, the DTC becomes permanent, and will remain in the module's memory for 40 drive cycles. (A cycle is an ignition OFF/ON, which will occur during the owner's normal use of the vehicle. No action on the part of the technician is necessary to perform this cycle. A drive cycle is a series of conditions needed to make the on-board diagnostic routine run, and may need a specific action on the part of the technician. See the DTC summaries for drive cycle routines)
www.JagDocs.com
2012-07-19
8. Using the Jaguar approved diagnostic system where available, and a scan tool where not, check the freeze frame data for information on the conditions applicable when the fault was flagged. The format of this will vary, depending on the tool used, but can provide information useful to the technician in diagnosing the fault.
CAUTION: When probing connectors to take measurements in the course of the pinpoint tests, use the adaptor kit, part number 3548-1358-00. NOTE: When performing electrical voltage or resistance tests, always use a digital multimeter (DMM) accurate to 3 decimal places, and with an up-to-date calibration certificate. When testing resistance, always take the resistance of the DMM leads into account. NOTE: Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests. Symptom Chart Symptom Engine cranks, but does not fire Possible source Security system /Immobiliser engaged Throttle contaminated Harness damage Fuel pump relay Fuel system Refer to service action S491 Engine cranks and fires, but will not start Fuel pump relay Throttle contaminated Purge valve Fuel pump Engine coolant temperature (ECT) sensor Spark plugs fouled Ignition coil failure(s) Check for water ingress into spark plug wells (SC only) HT short to ground (tracking) check rubber boots for cracks/damage Cylinder compression loss (short-term. Refer to bulletin; 303-52) Refer to service action S491 For fuel pump relay tests, <<303-14>> Check bulletins for throttle cleaning procedure. For evaporative emissions tests, <<303-13>> Check fuel pressure, <<310-00>> For ECT sensor circuit tests, <<303-14>> For ignition system, <<303-07>> Check bulletins and service actions. Action Contact dealer technical support for information on security system. Check bulletins for throttle cleaning procedure. For fuel pump relay circuit tests, <<303-14>> Check fuel pressure, <<310-00>> Check for associated DTCs. Check service actions.
2012-07-19

Difficult to start cold Rochester valve Battery Throttle contaminated Fuel pump Engine coolant temperature (ECT) sensor Purge valve Cylinder compression loss (short-term. Refer to bulletin; 303-52) Blocked part-load breather (service action S474) Refer to service action S491 Difficult to start hot Rochester valve Purge valve Throttle contaminated Fuel pump Engine coolant temperature (ECT) sensor Blocked part-load breather (service action S474) Injector leak For Rochester valve test, <<303-14>> Check fuel pressure, <<310-00>> For evaporative emissions tests, <<303-13>> Check bulletins for throttle cleaning procedure. Check fuel pressure. For ECT sensor tests, <<303-14>> Check bulletins and service actions. For rochester valve tests, <<303-14>> For battery information, <<414-01>> Check bulletins for throttle cleaning procedure. Check fuel pressure, <<310-00>> For ECT sensor circuit tests, <<303-14>> For evaporative emissions tests, <<303-13>> Check bulletins and service actions.
www.JagDocs.com
2012-07-19

' Difficult to start after hot soak (vehicle standing after engine has reached operating temperature) Rochester valve Throttle contaminated Purge valve Fuel pump Engine coolant temperature (ECT) sensor Blocked part-load breather (service action S474) Injector leak Engine stalls soon after start Fuel pump relay ECM relay Throttle contaminated CMP/CKP sensor synchronization malfunction Harness Fuel pump MAF sensor malfunction Engine coolant temperature (ECT) sensor Fuel lines Air leakage Fuel pressure regulator For fuel pump and ECM relay tests, <<303-14>> Check bulletins for throttle cleaning procedure. For CMP/CKP sensor tests, <<303-14>> Check fuel pressure, <<310-00>> For MAF sensor and ECT sensor tests, <<303-14>> For fuel line information, <<310-01>> For intake system information, <<303-12>> For fuel pressure regulator check, .
2012-07-19

Engine hesitates/poor acceleration Fuel pump Exhaust gas recirculation (EGR) Air leakage Stop lamp switch Throttle sensors Throttle motor Spark plugs fouled Check for water ingress into spark plug wells (SC only) Ignition coil failure(s) HT short to ground (tracking) check rubber boots for cracks/damage ECM failure Engine backfires Fuel pump Air leakage MAF sensor HO2 sensors Spark plugs Check for water ingress into spark plug wells (SC only) HT short to ground (tracking) check rubber boots for cracks/damage Ignition coil failure(s) Check fuel pressure, <<310-00>> For intake system information, <<303-12>> For MAF and HO2 sensor circuit tests, <<303-14>> For ignition system, <<303-07>> Check fuel pressure, <<310-00>> For EGR information, <<303-08>> For intake system information, <<303-12>> For stop lamp switch information, refer to the wiring diagrams. For throttle position sensor and throttle motor relay tests, <<303-14>> For ignition system, <<303-07>> Contact dealer technical support for advice on possible ECM failure.
www.JagDocs.com
2012-07-19

Engine surges Air leakage Fuel pump Stop lamp switch MAF sensor Harness Throttle sensors Throttle motor Spark plugs Check for water ingress into spark plug wells (SC only) HT short to ground (tracking) check rubber boots for cracks/damage ECM failure Engine detonates/knocks Fuel pump HO2 sensors Air leakage Blocked part-load breather (service action S474) Mass air flow (MAF) sensor No throttle response Poor throttle response Throttle sensors Throttle motor Throttle sensors Throttle motor Air leakage Mass air flow (MAF) sensor For throttle position sensor and throttle motor relay circuit tests, <<303-14>> For intake system, <<303-12>> For MAF sensor tests, <<303-14>> For throttle position sensor and throttle motor relay circuit tests, <<303-14>> Check fuel pressure. <<310-00>> For HO2 sensor circuit tests, check for DTC indicating which sensor and follow indicated pinpoint test. For intake system information, <<303-12>> Check service action S474. For MAF sensor circuit tests, <<303-14>> For intake system information, <<303-12>> Check fuel pressure, <<310-00>> For stop lamp switch information, refer to the wiring diagrams. For MAF sensor, throttle position sensor and throttle motor relay tests, <<303-14>> For ignition system, <<303-07>> Contact dealer technical support for advice on possible ECM failure.
Driver Information Chart

NOTE: Use this table to identify DTCs associated with the message centre display, then refer to the DTC index for possible sources and actions. NOTE: For definitions of Default Modes, see the foot of this table.
2012-07-19

Warning light Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Amber Amber Amber Amber Amber Amber Amber Amber Amber Amber Red Amber Red Amber Amber Amber Amber Amber Message Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Default Mode Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Engine shut-down when combined with other throttle failures Engine shut-down when combined with other throttle failures Cruise inhibited Cruise inhibited Cruise inhibited Cruise inhibited Cruise inhibited Cruise inhibited Cruise inhibited Cruise inhibited Cruise inhibited Cruise inhibited Limp-Home unavailable. Reverse throttle progression enabled Limp-Home unavailable. Reverse throttle progression enabled. High idle speed Limp-Home unavailable. Reverse throttle progression enabled Engine Speed Limit (runs normally, limited to 3000 RPM) Engine Speed Limit (runs normally, limited to 3000 RPM) Engine Speed Limit (runs normally, limited to 3000 RPM) Engine Speed Limit (runs normally, limited to 3000 RPM) Reverse throttle progression enabled DTC P1224 P1229 P0122, P0123, P0222, P0223 P0121 P1122, P1123 P1222, P1223 P1121, P1632 P1251, P0560, P1658 P1631 P1611 P1633 P1609 P0506, P0507 P1656 P1254 P1250 P1516 P1517 P1571 P1696 P0568 P0570 P0569 P0567 P0566 P1697 P0560, P1254 P1250, P1254 P1250 P0116, P0117, P0118, P0125 P0101, P0102, P0103, P0104 P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P1313, P1314 P0327, P0328, P0332, P0333, P1648 P1474
www.JagDocs.com
2012-07-19

Amber Amber Amber Amber Amber Amber Amber Amber Amber Amber Amber Amber Amber Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance None None None Engine Speed Limit (runs normally, limited to 3000 RPM) Engine Speed Limit (runs normally, limited to 3000 RPM) Engine Speed Limit (runs normally, limited to 3000 RPM) Gearbox default to 4th gear Gearbox default to 4th gear Gearbox default to 4th gear Gearbox default to 4th gear Gearbox default to 4th gear Gearbox default to 4th gear Gearbox default to 4th gear Gearbox default to 4th gear Gearbox default to 4th gear Gearbox default to 4th gear P1230 P1671 P1112, P1113 P1601 (SC only) P1605 (NA only) P0702 P1795 P1796 P1797 P1605 P0705 (SC only) P0706 P1720
Default mode Definitions

MECHANICAL LIMP-HOME MODE No electronic throttle operation. (Mechanical operation for last quarter of pedal travel) Maximum 25 throttle opening, depending on adjustment of throttle mechanical linkage. Engine speed restricted to 3000 RPM maximum, by fuel cut-off. High idle speed. (1200 RPM approx.) Misfire at idle, due to cylinder cut as a means of controlling idle speed. (The misfire will switch cylinders, as the strategy varies the cylinder cut) Cruise Control Inhibited REVERSE THROTTLE PROGRESSION ENABLED Electronic throttle operation, limited to maximum 25 Cruise Control Inhibited NOTE: The throttle operation uses the same map as for reverse gear. ENGINE SPEED LIMIT Engine runs normally, up to 3000 RPM. Engine speed restricted to 3000 RPM maximum, by fuel cut-off. Cruise Control Inhibited LIMP-HOME UNAVAILABLE Cruise Control Inhibited Reverse throttle progression engaged at second occurrence of DTC flagging.
2012-07-19
Diagnostic Trouble Code (DTC) index

DTC P0171 Condition Right-hand cylinders combustion too lean Possible Causes Air intake leak between MAF sensor and throttle Fuel filter system blockage Fuel injector blockage Fuel pressure regulator failure (low fuel pressure) Low fuel pump output H02S harness wiring fault Exhaust leak (before catalyst) ECM receiving incorrect signal from one or more of the following sensors - ECT, MAF, IAT, TP. P0172 Right-hand cylinders combustion too rich Engine misfire Blocked air filter Fuel system return blockage Leaking fuel injector(s) Fuel pressure regulator failure (high fuel pressure) ECM receiving incorrect signal from one or more of the following sensors - ECT, MAF, IAT, TP. Left-hand cylinders combustion too lean P0174 Air intake leak between MAF sensor and throttle Fuel filter system blockage Fuel injector blockage Fuel pressure regulator failure (low fuel pressure) Low fuel pump output H02S harness wiring fault Exhaust leak (before catalyst) ECM receiving incorrect signal from one or more of the following sensors - ECT, MAF, IAT, TP. For air intake system information, <<303-12>> Check the fuel filter, <<310-01>> Check the fuel injectors, For fuel pressure regulator check, Goto <<D>> . Check the fuel pressure, <<310-00>> Check for DTCs indicating which HO2 sensor is faulty, <<303-14>> Check for DTCs indicating a sensor fault, <<303-14>> Check for 'engine misfire detected' DTCs. Check the air filter element, <<303-12>> Check the fuel lines, <<310-01>> Check the fuel injectors, For fuel pressure regulator check, Goto <<D>> . Check the fuel pressure, <<310-00>> Check for DTCs indicating a sensor fault, <<303-14>> Action For air intake information, <<303-12>> Check fuel filter, <<310-01>> Check fuel injectors, <<Fuel Injector - Vehicles With: Supercharger>> For fuel pressure regulator check, Goto <<D>> . Check fuel pressure, <<310-00>> For HO2 sensor circuit tests, <<303-14>> Check the exhaust system, <<309-00>> Check for DTCs indicating a sensor fault, <<303-14>>
www.JagDocs.com
2012-07-19

P0175 Left-hand cylinders combustion too rich Engine misfire Blocked air filter Fuel system return blockage Leaking fuel injector(s) Fuel pressure regulator failure (high fuel pressure) ECM receiving incorrect signal from one or more of the following sensors - ECT, MAF, IAT, TP P0201 Fuel injector circuit malfunction, Cyl 1 Injector disconnected Injector wiring open or short circuit Injector failure ' ' ' ' ' ' ' ' ' ' ' ' ' ' P0202 P0203 P0204 P0205 P0206 P0207 P0208 Fuel injector circuit malfunction, Cyl 3 Fuel injector circuit malfunction, Cyl 5 Fuel injector circuit malfunction, Cyl 7 Fuel injector circuit malfunction, Cyl 2 Fuel injector circuit malfunction, Cyl 4 Fuel injector circuit malfunction, Cyl 6 Fuel injector circuit malfunction, Cyl 8 For fuel injector circuit tests, Goto <<A>> . Check for 'engine misfire detected' DTCs. Check the air filter element, <<303-12>> Check the fuel lines, <<310-01>> Check the fuel injectors, <<Fuel Injector - Vehicles With: Supercharger>> For fuel pressure regulator check, Goto <<D>> . Check for DTCs indicating a sensor fault, <<303-14>>
10
2012-07-19

P0300 Random misfire detected ECM to ignition module primary circuit faults (cylinder misfire detected DTCs also logged) Ignition module to ignition coil primary circuit fault(s) (cylinder misfire DTC also logged) Ignition module ground circuit; open circuit, high resistance Ignition coil failure(s) Ignition module failure(s) Check for water ingress into spark plug wells (SC only) HT short to ground (tracking) check rubber boots for cracks/damage Spark plug failure/fouled/incorrect gap Cylinder compression low Fuel injector circuit fault(s) [injector DTCs also logged] Fuel delivery pressure (low/high) Fuel injectors restricted/leaking Fuel contamination PAS pulley bolts loose (see Service Action S462) Worn camshaft/broken valve springs P0301 ' ' ' ' ' ' ' P0460 Misfire detected, Cyl 1 ' ' ' ' ' ' ' Fuel level sense signal performance Refer to possible sources for P0300 P0302 P0303 P0304 P0305 P0306 P0307 P0308 Fuel level sensor to instrument cluster circuits intermittent short or open circuit Fuel level sensor failure Instrument cluster fault (incorrect fuel level data) Refer to actions for P0300 Misfire detected, Cyl 3 Misfire detected, Cyl 5 Misfire detected, Cyl 7 Misfire detected, Cyl 2 Misfire detected, Cyl 4 Misfire detected, Cyl 6 Misfire detected, Cyl 8 For fuel level sensor circuit tests, Goto <<B>> . For ignition circuit tests, <<303-07>> For engine information, <<303-00>> For fuel injector circuit tests, Goto <<A>> . Check fuel pressure, <<310-00>> Check fuel injectors, Check service actions.
www.JagDocs.com
11
2012-07-19

Concern with throttle motor control circuit P1229 Throttle motor disconnected Throttle motor to ECM drive circuits; short circuit or open circuit Throttle motor failure P1224 Concern with throttle control position Throttle adaptations not performed after battery disconnect TP sensor disconnected TP sensor to ECM sense circuits; open circuit, high resistance Throttle motor relay failure Throttle motor relay to ECM circuit fault Throttle motor relay power supply open circuit ECM ground circuit fault (relay coil drive) Throttle motor to ECM drive circuits; open circuit, short circuit, high resistance Throttle motor failure Throttle body failure P1250 Engine load malfunction Air intake leak Engine breather leak TP sensor circuit fault (DTC P0121) Throttle valve spring failure P1646 Fuel pump 2 (S/C) relay malfunction. NOTE. This DTC applies only to the S/C system fuel pump 2 Fuel pump 2 relay failure Fuel pump 2 relay to ECM circuit fault Fuel pump 2 relay coil power supply open circuit ECM ground circuit fault (relay coil drive) For fuel pump 2 relay circuit tests, Goto <<C>> . Check air intake for leaks, <<303-12>> Check engine breather system for leaks, check throttle valve spring. See <<pinpoint test f>>or P0121. Carry out throttle adaptation procedure, <<303-14>> ECM adaptation. For TP sensor, throttle motor, and ECM circuit tests, <<303-14>> For throttle body information, <<Throttle Body - >> For throttle motor circuit tests, <<303-14>>
Pinpoint Tests A : DTC P0201, P0202, P0203, P0204, P0205, P0206, P0207, P0208; FUEL INJECTOR CIRCUIT MALFUNCTION
NOTE: The DTC set will indicate which cylinder injector or circuit is faulty. Only in the event of multiple cylinder misfires will it be necessary to check more than one injector or circuit, in which case, multiple DTCs will be set.
A1 : CHECK THE INJECTOR COIL RESISTANCE

1. Turn the ignition switch to the OFF position. 2. Disconnect the relevant injector electrical connector, (PI07 to PI14, vehicles without supercharger, IJ03 to IJ10, vehicles with supercharger).
12
2012-07-19
3. Measure the resistance between the injector pins. Is the resistance between 12 and 16 ohms? -> Yes Goto <<A2>> -> No INSTALL a new injector. <<Fuel Injector - Vehicles With: Supercharger>> CLEAR the DTC. TEST the system for normal operation.
A2 : CHECK THE INJECTOR COIL INSULATION

1. Measure the resistance between the injector pin 1 and the injector body. 2. Measure the resistance between the injector pin 2 and the injector body. Are both resistances greater than 10 Mohms? -> Yes Goto <<A3>> -> No INSTALL a new injector. <<Fuel Injector - Vehicles With: Supercharger>> CLEAR the DTC. TEST the system for normal operation.
www.JagDocs.com
A3 : CHECK THE INJECTOR SUPPLY VOLTAGE

1. Turn the ignition switch to the ON position. 2. Disconnect the relevant injector harness electrical connector, (PI07 to PI14, vehicles without supercharger, IJ03 to IJ10, vehicles with supercharger). 3. Measure the voltage between the relevant injector harness electrical connector, (PI10 to PI19) pin 2 and GROUND. Is the voltage greater than 12 Volts? -> Yes Goto <<A4>> -> No REPAIR the circuit between the relevant injector harness electrical connector, (PI07 to PI14, vehicles without supercharger, IJ03 to IJ10, vehicles with supercharger) pin 2 and battery. This circuit includes the EMS fuse box, fuse 05, and the fuel injection relay. For additional information, refer to wiring diagrams. CLEAR DTC. TEST the system for normal operation.
A4 : CHECK THE INJECTOR GROUND CIRCUIT

1. Turn the ignition switch to the OFF position. 2. Disconnect the battery negative terminal. 3. Disconnect the ECM electrical connector, EM15. 4. Measure the resistance between the relevant injector harness electrical connector, (PI07 to PI14, vehicles without supercharger, IJ03 to IJ10, vehicles with supercharger) pin 1 and EM15, pins as follows Injector Cyl 1 pin 1 (BU) and EM15, pin 07 (BU). Injector Cyl 2 pin 1 (BS) and EM15, pin 17 (BS). Injector Cyl 3 pin 1 (BN) and EM15, pin 16 (BN).
13 2012-07-19
Injector Cyl 4 pin 1 (BY) and EM15, pin 06 (BY). Injector Cyl 5 pin 1 (BG) and EM15, pin 18 (BG). Injector Cyl 6 pin 1 (BO) and EM15, pin 05 (BO). Injector Cyl 7 pin 1 (BW) and EM15, pin 04 (BW). Injector Cyl 8 pin 1 (BP) and EM15, pin 15 (BP). Is the resistance less than 5 ohms? -> Yes Goto <<A5>> -> No REPAIR the circuit between the relevant injector harness electrical connector pin 1 and the ECM electrical connector. For additional information, refer to wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
A5 : CHECK THE INJECTOR GROUND CIRCUIT FOR SHORT CIRCUIT TO BATTERY

1. Reconnect the battery negative terminal. 2. Measure the voltage between the relevant injector harness electrical connector, (PI07 to PI14, vehicles without supercharger, IJ03 to IJ10, vehicles with supercharger) pin 1 and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<A6>>
A6 : CHECK THE INJECTOR GROUND CIRCUIT FOR SHORT CIRCUIT TO GROUND

1. Measure the resistance between the relevant injector harness electrical connector, (PI07 to PI14, vehicles without supercharger, IJ03 to IJ10, vehicles with supercharger) pin 1 and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Contact dealer technical support for advice on possible ECM failure.
B : DTC P0460; FUEL LEVEL SENSE SIGNAL PERFORMANCE B1 : CHECK THE FUEL LEVEL SENSOR REFERENCE GROUND
1. Disconnect the fuel level sensor electrical connector, BT15. 2. Measure the resistance between BT15 and GROUND. Is the resistance greater than 5 ohms?
14
2012-07-19
-> Yes Goto <<B2>> -> No Goto <<B3>>
B2 : CHECK THE FUEL LEVEL SENSOR REFERENCE GROUND CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the instrument cluster electrical connector, FC25. 2. Measure the resistance between FC25, pin 14 (RW) and BT15 (RW). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<B3>>
www.JagDocs.com
B3 : CHECK THE FUEL LEVEL SENSOR (EMPTY)

1. Disconnect the fuel level sensor electrical connectors, BT14 and BT15. 2. Empty the fuel tank. 3. Measure the resistance between the fuel level sensor connections. Is the resistance 900 ohms? -> Yes Goto <<B4>> -> No INSTALL a new fuel level sensor. <<310-01>> CLEAR the DTC. TEST the system for normal operation.
B4 : CHECK THE FUEL LEVEL SENSOR (FULL)

1. Fill the fuel tank. 2. Measure the resistance between the fuel level sensor connections. Is the resistance 80 ohms? -> Yes Goto <<B5>> -> No INSTALL a new fuel level sensor. <<310-01>> CLEAR the DTC. TEST the system for normal operation.
B5 : CHECK THE FUEL LEVEL SENSOR SIGNAL WIRE FOR HIGH RESISTANCE
1. Disconnect the instrument cluster electrical connector, FC25.
15 2012-07-19
2. Measure the resistance between FC25, pin 13 (BW) and BT14 (BW). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new instrument cluster. <<413-01>> CLEAR the DTC. TEST the system for normal operation.
C : DTC P1646; FUEL PUMP 2 (SC) RELAY MALFUNCTION

NOTE: This DTC applies only to the supercharged system fuel pump 2.
C1 : CHECK THE FUEL PUMP 2 RELAY POWER SUPPLY

1. Remove the fuel pump 2 relay. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between the relay base, pin 01 and GROUND. Is the voltage greater than 10 volts? -> Yes Goto <<C2>> -> No REPAIR the circuit between the relay base, pin 01 and battery. This circuit includes the trunk fuse box, the ignition positive relay, and the high power protection module. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
C2 : CHECK THE FUEL PUMP 2 RELAY TO ECM CIRCUIT

1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM13. 3. Measure the resistance between the relay base, pin 02 and EM13, pin 09 (KB). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new fuel pump 2 relay. CLEAR the DTC. TEST the system for normal operation.
D : CHECK THE FUEL PRESSURE REGULATOR FUNCTION

CAUTION: Do not run the engine for more than 30 seconds with the vacuum hose disconnected.
16
2012-07-19
D1 : CHECK FOR FUEL PRESSURE CHANGE WHEN THE REGULATOR IS DISCONNECTED

1. Connect a fuel pressure gauge set, <<310-00>> 2. Start the engine. 3. Note the fuel pressure reading with the fuel pressure regulator vacuum hose connected. 4. Disconnect the fuel pressure regulator vacuum hose. 5. Note the new reading. Does the fuel pressure increase when the hose is disconnected? -> Yes Check for DTCs. Carry out pinpoint tests indicated. -> No INSTALL a new fuel presssure regulator. TEST the system for normal operation.
www.JagDocs.com
17
2012-07-19
Fuel Injection Supply Manifold Vehicles Without: Supercharger 19.60.13

Removal WARNING: PLACE THE VEHICLE IN A QUARANTINED AREA AND ARRANGE 'NO SMOKING/PETROL FUMES' SIGNS ABOUT THE VEHICLE. WARNING: BEFORE ANY WORK IS CARRIED OUT ON THE FUEL SYSTEM, GROUND THE VEHICLE TO EARTH AND MAINTAIN THE GROUND CONNECTION UNTIL THE WORK IS COMPLETE. WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE VAPORS ARE ALWAYS PRESENT AND MAY IGNITE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WARNING: THE FUEL SYSTEM REMAINS PRESSURIZED FOR A LONG TIME AFTER THE IGNITION IS SWITCHED OFF. THE FUEL PRESSURE MUST BE RELIEVED BEFORE ATTEMPTING ANY REPAIRS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WARNING: AFTER CARRYING OUT REPAIRS, THE FUEL SYSTEM MUST BE CHECKED VISUALLY FOR LEAKS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WARNING: THIS PROCEDURE INVOLVES FUEL HANDLING. BE PREPARED FOR FUEL SPILLAGE AT ALL TIMES AND ALWAYS OBSERVE FUEL HANDLING PRECAUTIONS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WARNING: IF TAKEN INTERNALLY DO NOT INDUCE VOMITING, SEEK IMMEDIATE MEDICAL ATTENTION. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WARNING: IF FUEL CONTACTS THE EYES, FLUSH THE EYES WITH COLD WATER OR EYEWASH SOLUTION AND SEEK MEDICAL ATTENTION. WARNING: WASH HANDS THOROUGHLY AFTER HANDLING, AS PROLONGED CONTACT MAY CAUSE IRRITATION. SHOULD IRRITATION DEVELOP, SEEK MEDICAL ATTENTION. WARNING: DO NOT CARRY OR OPERATE CELLULAR PHONES WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE VAPORS ARE ALWAYS PRESENT AND MAY IGNITE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
2012-07-19
www.JagDocs.com
1. Disconnect the battery ground cable. Remove the battery cover. 2. Release the fuel system pressure. <<310-00>>
3. Detach the coolant pipe.
2012-07-19
5. NOTE: Place an absorbent cloth underneath fuel connection to absorb any spillages. NOTE: Cap the fuel line and fuel injection supply manifold to prevent contamination. Disconnect the fuel feed hose. 1. Disconnect the fuel feed hose at the Quick Fit connector, using special tool 310 - 044.
2012-07-19
www.JagDocs.com
6. NOTE: Place an absorbent cloth underneath fuel connection to absorb any spillages. NOTE: Cap the fuel line and fuel injection supply manifold to prevent contamination. Disconnect the fuel return hose. 1. Disconnect the fuel return hose at the Quick Fit connector, using special tool 310 - 054.
7. NOTE: Left-hand shown, right-hand similar. Disconnect the fuel injectors electrical connectors.
2012-07-19
8. Detach the right-hand camshaft (CMP) sensor wiring harness from the intake elbow.
9. Detach the left-hand CMP sensor wiring harness from the intake elbow.
2012-07-19
www.JagDocs.com
10. Disconnect the fuel pressure regulator vacuum hose.
2012-07-19
11. Remove the fuel injection supply manifold. Remove and discard the fuel injector to intake manifold O-ring seals.
2012-07-19

Installation
www.JagDocs.com
1.
CAUTION: Make sure the fuel injectors are correctly located in the intake manifold. Failure to follow these instructions may result in damage to the vehicle. NOTE: Install new fuel injector O-ring seals.
Install the fuel injection supply manifold. Tighten to 12 Nm.
2012-07-19
2. Connect the fuel pressure regulator vacuum hose.
3. Attach the left-hand CMP sensor wiring harness to the intake elbow.
2012-07-19
www.JagDocs.com
4. Attach the right-hand CMP sensor wiring harness to the intake elbow.
5. NOTE: Left-hand shown, right-hand similar. Connect the fuel injectors electrical connectors.
10
2012-07-19
6. NOTE: Uncap the fuel line and fuel injection supply manifold. NOTE: Remove and dispose of absorbent cloth whilst complying to local health and safety standards. Connect the fuel feed hose. 1. Connect the fuel feed hose at the Quick Fit connector. Ensure that the hose is fully seated to the feed pipe.
7. NOTE: Uncap the fuel line and fuel injection supply manifold. NOTE: Remove and dispose of absorbent cloth whilst complying to local health and safety standards. Connect the fuel return hose. 1. Connect the fuel return hose at the Quick Fit connector. Ensure that the hose is fully seated to the feed pipe.
11
2012-07-19
www.JagDocs.com
9. Attach the coolant pipe. 10. Connect the battery ground cable.<<414-01>>
12
2012-07-19
Fuel Injection Supply Manifold LH Vehicles With: Supercharger 19.60.05

Removal 1. Remove fuel injectors; refer to (SC) <<18.10.01>>.
2. Disconnect fuel feed pipe from fuel rail. 1. Remove two bolts. 2. Reposition fuel feed pipe. 3. Discard O-ring.
3. Remove fuel rail from charge air cooler adaptor. 1. Remove three bolts. 2. Reposition fuel rail and remove cross-over pipe securing bolt. Discard O-ring from fuel cross-over pipe. Remove fuel rail.
2012-07-19
www.JagDocs.com
4. Remove seals between fuel rail and charge air cooler adaptor. 1. Discard seals. 2. Clean and inspect mating faces.
Installation 1. Install new seals between fuel rail and charge air cooler adapter ensuring that they are fully seated.
2. Install fuel rail to fuel cross-over pipe. Install new O-ring and lubricate with petroleum jelly. 1. Install bolt.
2012-07-19
3. Install fuel rail to charge air cooler adaptor. Locate fuel rail into adaptor. 1. Install bolts.
4. Connect fuel feed pipe to fuel rail. 1. Install new O-ring and lubricate with petroleum jelly. 2. Install two bolts. 5. Install fuel injectors; refer to (SC) <<18.10.01>>.
2012-07-19
Fuel Injection Supply Manifold RH Vehicles With: Supercharger 19.60.04

Removal 1. Remove fuel injectors; refer to (SC) <<18.10.01>>.
www.JagDocs.com
2. Disconnect fuel pressure regulator. 1. Remove bolts. 2. Reposition pressure regulator. Discard O-ring.
3. Remove fuel rail from charge air cooler adaptor. 1. Remove three bolts. 2. Remove fuel rail; still connected to fuel crossover pipe and fuel return pipe.
2012-07-19
4. Remove fuel rail from fuel cross-over pipe. 1. Remove bolt. 2. Discard O-ring.
5. Remove fuel rail to charge air cooler adaptor seals. 1. Discard seals. 2. Clean and inspect mating faces.
Installation 1. Install new seals between fuel rail and charge air cooler adapter, ensuring they are fully seated.
2012-07-19
www.JagDocs.com
2. Install fuel rail to fuel cross-over pipe. 1. Install new O-ring and lubricate with petroleum jelly. 2. Install bolt.
3. Install fuel rail to charge air cooler adaptor. 1. Align fuel rail to adaptor; still connected to fuel crossover pipe and fuel return pipe. Locate fuel rail into adaptor. 2. Install three bolts which secure fuel rail to adaptor. Tighten to 18-24 Nm.
2012-07-19
4. Install fuel pressure regulator. Install a new O-ring to fuel pressure regulator and lubricate with petroleum jelly 1. Install bolts. 5. Install fuel injectors; refer to (SC) <<18.10.01>>.
2012-07-19
Fuel Injector Vehicles Without: Supercharger 18.10.01

Removal WARNING: PLACE THE VEHICLE IN A QUARANTINED AREA AND ARRANGE 'NO SMOKING/PETROL FUMES' SIGNS ABOUT THE VEHICLE. WARNING: BEFORE ANY WORK IS CARRIED OUT ON THE FUEL SYSTEM, GROUND THE VEHICLE TO EARTH AND MAINTAIN THE GROUND CONNECTION UNTIL THE WORK IS COMPLETE. WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE VAPORS ARE ALWAYS PRESENT AND MAY IGNITE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WARNING: THE FUEL SYSTEM REMAINS PRESSURIZED FOR A LONG TIME AFTER THE IGNITION IS SWITCHED OFF. THE FUEL PRESSURE MUST BE RELIEVED BEFORE ATTEMPTING ANY REPAIRS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WARNING: AFTER CARRYING OUT REPAIRS, THE FUEL SYSTEM MUST BE CHECKED VISUALLY FOR LEAKS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WARNING: THIS PROCEDURE INVOLVES FUEL HANDLING. BE PREPARED FOR FUEL SPILLAGE AT ALL TIMES AND ALWAYS OBSERVE FUEL HANDLING PRECAUTIONS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WARNING: IF TAKEN INTERNALLY DO NOT INDUCE VOMITING, SEEK IMMEDIATE MEDICAL ATTENTION. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WARNING: IF FUEL CONTACTS THE EYES, FLUSH THE EYES WITH COLD WATER OR EYEWASH SOLUTION AND SEEK MEDICAL ATTENTION. WARNING: WASH HANDS THOROUGHLY AFTER HANDLING, AS PROLONGED CONTACT MAY CAUSE IRRITATION. SHOULD IRRITATION DEVELOP, SEEK MEDICAL ATTENTION. WARNING: DO NOT CARRY OR OPERATE CELLULAR PHONES WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE VAPORS ARE ALWAYS PRESENT AND MAY IGNITE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
www.JagDocs.com
Left-hand fuel injector and right-hand fuel injector
2012-07-19
3. NOTE: Left-hand shown, right-hand similar. Disconnect the fuel injectors electrical connectors.
2012-07-19

Left-hand fuel injector
www.JagDocs.com
4. Detach the left-hand camshaft position (CMP) sensor wiring harness from the intake elbow.
5. Detach the left-hand fuel injectors and fuel supply manifold from the intake manifold.
2012-07-19

Right-hand fuel injector
6. Detach the right-hand camshaft position (CMP) sensor wiring harness from the intake elbow.
7. Disconnect the fuel pressure regulator vacuum hose.
2012-07-19
www.JagDocs.com
8. Detach the right-hand fuel injectors and fuel supply manifold from the intake manifold.
Left-hand fuel injector and right-hand fuel injector
9. Remove the fuel injector 1. Remove the fuel injector retaining clip. 2. Remove the fuel injector.
2012-07-19
10. Remove and discard the fuel injector O-ring seals.
Installation
1. To install, reverse the removal procedure. Install new fuel injector O-ring seals. Lubricate the O-ring seals with petroleum jelly to aid installation.
2012-07-19
www.JagDocs.com
2. Tighten to 12 Nm.
3. Tighten to 12 Nm. 4. Connect the battery ground cable. <<414-01>>
2012-07-19
Fuel Injector Vehicles With: Supercharger 18.10.01

Removal 1. Disconnect battery ground cable (IMPORTANT, see SRO <<86.15.19>> for further information).
2.
WARNING: BEFORE PROCEEDING, IT IS ESSENTIAL THAT THE WARNING NOTES GIVEN IN SECTION <<100-00>> (UNDER THE HEADING 'SAFETY PRECAUTIONS') ARE READ AND UNDERSTOOD.
Depressurize fuel system; refer to <<19.50.02>>.
3. Disconnect injector connector. 1. Disconnect and reposition bank 1 or 2 fuel injector harness connector to allow access to injector. 2. Loosen but do not remove nut securing injector harness support bracket to camshaft cover. Reposition injector harness to allow access to injector. 3. Detach injector connector.
2012-07-19
www.JagDocs.com
4. Remove fuel injector. 1. Prise out injector retaining clip, ensuring that it is not ejected and lost. Note orientation of clip. 2. Using a suitable implement, carefully lever injector from fuel rail. 3. Discard injector O-rings. 5. Clean all mating faces.
Installation 1. Install fuel injector. 1. Install new O-rings, lubricated with petroleum jelly, to fuel injector. 2. Install fuel injector into fuel rail. Press firmly until it is felt to click into place. 3. Hold injector firmly down and install injector securing clip in correct orientation. 2. Re-connect injector and harness connectors. 3. Tighten harness nut to 4-5Nm. 4. Reconnect battery ground cable (IMPORTANT, see SRO <<86.15.15>> for further information).
2012-07-19
Fuel Injectors Vehicles With: Supercharger 18.10.02

2.
Depressurize fuel system; refer to <<19.50.02>>. 3. Drain radiator coolant; refer to 26.10.01. 4. Remove air cleaner cover / intake assembly; refer 19.10.30. 5. Remove throttle body; refer to <<19.70.04>>. 6. Remove throttle induction elbow; refer to (SC) <<19.70.28>>. 7. Remove exhaust gas re-circulation valve (EGR) if fitted; refer to 17.45.01. 8. Remove supercharger outlet duct and gasket; refer to <<18.50.16>>. 9. Remove coolant outlet pipe; refer to (SC) <<26.31.08>> . 10. Remove supercharger drive belt; refer to <<18.50.08>>. 11. Remove supercharger assembly; refer to <<18.50.15>>. 12. Remove bank 1 or 2 charge air cooler as required; refer to <<18.50.18>> and / or <<18.50.19>>.
2012-07-19
www.JagDocs.com
13. Disconnect fuel injector harness. 1. Disconnect injector connectors. 2. Loosen two nuts which secure harness to camshaft cover. 3. Reposition harness to allow access to injectors.
14.
CAUTION: Take care to avoid dropping any objects or foreign matter into induction manifold with the fuel injectors removed.
Remove fuel injector(s). 1. Prise out injector retaining clip, ensuring that it is not ejected and lost. Note orientation of the clip. 2. Using a suitable implement, carefully lever injector from fuel rail. 3. Discard injector O-rings. 15. Clean all mating faces.
2012-07-19
Installation 1. Install fuel injector(s). 1. Install new O-rings, lubricated with petroleum jelly, to fuel injector. 2. Install fuel injector into fuel rail. Press firmly until it is felt to click into place. 3. Hold injector firmly down and fit injector securing clip in the correct orientation.
2. Connect fuel injector harness. 1. Reposition harness. 2. Tighten nuts which secure harness to camshaft cover. 3. Re-connect injectors. 3. Install charge air cooler; refer to <<18.50.18>> and / or <<18.50.19>>. 4. Install supercharger assembly; refer to <<18.50.15>>. 5. Install supercharger drive belt; refer to <<18.50.08>>. 6. Install coolant outlet pipe; refer to <<26.31.08>>. 7. Install throttle induction elbow; refer to <<19.70.28>>. 8. Install exhaust gas re-circulation valve (EGR) if applicable; refer to 17.45.01. 9. Install throttle body; refer to <<19.70.04>>. 10. Install supercharger outlet duct; refer to <<18.50.16>>. 11. Install air cleaner cover / intake assembly; refer to 19.10.30.
2012-07-19
12. Refill cooling system; refer to (SC) 26.10.01 . 13. Reconnect battery ground cable (IMPORTANT, see SRO <<86.15.15>> for further information).
www.JagDocs.com
2012-07-19
Throttle Body Vehicles Without: Supercharger 19.70.04

Removal
1. Disconnect the battery ground cable. Remove the battery cover.
2.
WARNING: NEVER REMOVE THE COOLANT EXPANSION TANK PRESSURE CAP UNDER ANY CIRCUMSTANCES WHILE THE ENGINE IS OPERATING. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN PERSONAL INJURY. WARNING: TO AVOID HOT COOLANT OR STEAM BLOWING OUT OF THE COOLING SYSTEM, USE EXTREME CARE WHEN REMOVING THE COOLANT EXPANSION TANK PRESSURE CAP. WAIT UNTIL THE ENGINE HAS COOLED DOWN, THEN INSULATE THE COOLANT PRESSURE CAP WITH A SUITABLE CLOTH AND SLOWLY LOOSEN THE COOLANT EXPANSION TANK PRESSURE CAP UNTIL THE COOLING SYSTEM PRESSURE IS RELEASED. DO NOT REMOVE THE COOLANT EXPANSION TANK PRESSURE CAP. STEP BACK WHILE THE PRESSURE IS RELEASED FROM THE SYSTEM. WHEN ALL OF THE PRESSURE HAS BEEN RELEASED SLOWLY REMOVE THE COOLANT EXPANSION TANK PRESSURE CAP (STILL WITH THE SUITABLE CLOTH IN POSITION) FROM THE COOLANT EXPANSION TANK. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN PERSONAL INJURY.
Release the cooling system pressure. Remove the coolant expansion tank pressure cap.
2012-07-19
www.JagDocs.com
3. Disconnect the intake tube from the throttle body. 1. Remove the two bolts which secure the intake tube to the throttle body. 2. Disconnect the intake tube from the throttle body.
4. Disconnect the air cleaner cover. Release the five clips which secure the air cleaner cover.
2012-07-19
5. Disconnect the mass air flow meter electrical connector. 1. Disconnect the breather pipe from the camshaft cover. 2. Disconnect the mass air flow meter electrical connector.
6. Remove the intake tube / air flow meter / air cleaner cover assembly. 1. Remove the intake tube / air flow meter / air cleaner cover assembly. 2. Remove and discard the rubber seal; air intake tube to throttle body.
2012-07-19
www.JagDocs.com
7. Detach the coolant pipe.
2012-07-19
10. Disconnect the throttle body electrical connectors.
2012-07-19
www.JagDocs.com
11. Detach the right-hand camshaft position (CMP) sensor wiring harness.
12. NOTE: Cap the coolant hose to minimize coolant loss. Disconnect the throttle body coolant hose.
2012-07-19
13. NOTE: Cap the coolant hose to minimize coolant loss. Disconnect the throttle body coolant hose.
14. Disconnect the accelerator inner cable. 1. Reposition the accelerator pulley to the full throttle position. 2. Disconnect the accelerator inner cable.
2012-07-19
www.JagDocs.com
15. Disconnect the accelerator outer cable. 1. Remove and discard the retaining strap. 2. Disconnect the accelerator outer cable.
16. Disconnect the throttle body electrical connectors.
2012-07-19
17. Detach the left-hand CMP sensor wiring harness from the throttle body elbow.
18. Disconnect the air assist control valve hose.
2012-07-19
www.JagDocs.com
19. Remove the throttle body. Remove and discard the throttle body gasket.
Installation
1. NOTE: Install a new throttle body gasket. Install the throttle body. Tighten to 21 Nm.
10
2012-07-19
2. Connect the air assist control valve hose.
3. Attach the left-hand CMP sensor wiring harness to the throttle body elbow.
11
2012-07-19
www.JagDocs.com
4. Connect the throttle body electrical connectors.
5. Connect the accelerator inner cable. 1. Reposition the accelerator pulley to the full throttle position. 2. Connect the accelerator inner cable.
12
2012-07-19
6. NOTE: Uncap the coolant hose. Connect the throttle body coolant hose.
7. NOTE: Uncap the coolant hose. Connect the throttle body coolant hose.
13
2012-07-19
www.JagDocs.com
8. Attach the left-hand CMP sensor wiring harness to the throttle body elbow.
9. Connect the throttle body electrical connectors.
14
2012-07-19
10. Install the engine right-hand cover.
15
2012-07-19
www.JagDocs.com
12. Attach the coolant pipe.
13. Install the intake tube / air flow meter / air cleaner cover assembly. 1. Install a new rubber seal; air intake tube to throttle body. 2. Install the intake tube / air flow meter / air cleaner cover assembly.
16
2012-07-19
14. Connect the mass air flow meter electrical connector. 1. Connect the breather pipe from the camshaft cover. 2. Connect the mass air flow meter electrical connector.
15. Reconnect the air cleaner cover. Install the five clips which secure the air cleaner cover.
17
2012-07-19
www.JagDocs.com
16. Connect the intake tube to the throttle body. 1. Install the two bolts which secure the intake tube to the throttle body. 2. Connect the intake tube from the throttle body. 17. Fill the cooling system to the correct level. 18. Install the coolant expansion tank pressure cap. 19. Carry out the battery reconnection procedure. For additional information refer to Section <<414-01>>. 20. NOTE: Make sure all electrical loads are switched OFF. NOTE: Make sure the accelerator outer cable is disconnected. Turn the ignition switch to the ON position for 5 seconds. 21. Turn the ignition switch to the OFF position for a minimum of 10 seconds. NOTE: If the cooling fans are running, wait untill they stop and leave the ignition switch in the OFF position for an additional 10 seconds. 22. Adjust the accelerator cable. <<310-02>> 23. Turn the ignition switch to the ON position for 5 seconds. 24. Turn the ignition switch to the OFF position for a minimum of 10 seconds.
18
2012-07-19
Throttle Body Vehicles With: Supercharger 19.70.04

Removal 1. CAUTION: This process assumes the use of the original throttle cable. The cable setting procedure in this instance is NOT appropriate for a new cable; see <<19.20.06>>.
Disconnect battery ground cable (IMPORTANT, see SRO <<86.15.19>> for further information). 2. Remove air cleaner cover / intake assembly; refer 19.10.30
3. Disconnect connectors and vacuum pipe.
2012-07-19
4. Rotate throttle quadrant to allow disconnection of inner cable.
www.JagDocs.com
5. NOTE: Do not disturb adjusting nut Release throttle cable locking nut and displace outer cable from the abutment bracket.
6. Remove coolant hoses. Install suitable blanking plugs.
2012-07-19
7. Release connector from bracket under LH side of assembly.
8. Remove throttle body to induction elbow securing bolts.
2012-07-19
www.JagDocs.com
9. Remove throttle body from induction elbow. 1. Remove throttle body. 2. Discard gasket. Clean mating faces. Blank off inlet tract to prevent ingress of foreign matter.
10. Remove throttle cable and intake duct brackets.
2012-07-19

Installation
1. Install throttle cable and intake duct brackets.
2. Install throttle. Install new gasket.
2012-07-19
3. Install connector.
www.JagDocs.com
4. Install coolant hoses.
2012-07-19
5. Reposition outer cable to abutment bracket. Install but do not tighten adjusting nut.
6.
CAUTION: Under no circumstances should quadrant be held clear of throttle stop by cable tension. NOTE: Make sure there is neither tension nor slack in the cable.
Install throttle cable. Tighten locknut without altering setting or introducing twist into the cable outer.
2012-07-19
7. Connect connectors and vacuum pipe. 8. Where appropriate check kickdown setting is within specification and reset if required as detailed from step 6 (Installation). PDU users see <<44.15.38>>
www.JagDocs.com
9. Connect scantool. Read 'Current Powertrain Data'. Display PID 120F (pedal demand).
2012-07-19
10. NOTE: Ensure that contact with switch does not result in switch movement. Push throttle pedal until light contact is made with kickdown switch.
11. Specified PID value = 3.66 to 3.76 volts (2F9 + or - A hex). If the value is outside these limits, proceed to step 9 (Installation). If the value is within these limits, proceed to step 13 (Installation). 12. Pull carpet from around kickdown switch. 13. Disconnect kickdown switch flying lead connector (to avoid cable twist as the switch is rotated).
2012-07-19
14. Adjust kickdown switch to the value as defined in step 8 (Installation). 15. Reconnect kickdown flying lead connector and verify setting. 16. Install air cleaner cover / intake assembly; refer 19.10.30. 17. Check coolant level and top up if required. 18. Reconnect battery ground cable (IMPORTANT, see SRO <<86.15.15>> for further information).
www.JagDocs.com
10
2012-07-19
1999 XK RANGE - Accessory Drive - 303-05
Accessory Drive
Item 1 2 3 4 5 6 7
Description Coolant Pump Drive Air-Conditioning Compressor Drive Power Steering Pump Drive Automatic Belt Tensioner Crankshaft Pulley Idler Pulley Generator Drive
Crankshaft Pulley
The combined crankshaft pulley and torsional vibration damper drives a single 7-ribbed vee belt. The belt drives all of the engine-mounted accessories; the generator, the power assisted steering pump, the air-conditioning compressor and the coolant water pump.
Idler Pulley
An idler pulley on the right-hand accessory mounting increases the wrap-angle around the generator pulley.
Coolant Pump Drive

The coolant pump pulley is the uppermost of the accessory drive pulleys. The coolant pump is installed between the two cylinder banks on the front face of the engine.
2012-07-19
Power Assisted Steering Pump Drive

The power assisted steering pump pulley is located on the left side of the group of drives for the engine accessories above the air-conditioning compressor.
Air Conditioning Compressor Drive

This is positioned at the lowest point of the front-end accessory-d rive on the left hand side.
Generator Drive
This is installed on the right hand accessory mounting.
www.JagDocs.com
2012-07-19

Drive Belt
Item 1 2
Description Acceptable Drive Belt Cracking Unacceptable Drive Belt Damage
The drive belt should be inspected at every routine service for excessive wear and damage. A drive belt which displays symptoms of cracking may be perfectly fit for further service. Should cracking be detected, serviceability may be assessed using the following guidelines: Fifteen cracks per rib over a 100 mm length of drive belt is acceptable. Section(s) of belt missing from any rib is not acceptable and the drive belt must be renewed.
2012-07-19
Automatic Belt Tensioner
www.JagDocs.com
Item 1 2 3 4
Description Belt Wear Indicator Renew Belt Indicator New Belt Maximum Length New Belt Minimum Length
The automatic belt tensioner consists of an idler pulley which is free to rotate on a bearing, located at the end of a
2012-07-19
spring-loaded pivot arm. The pivot arm can be turned counter-clockwise (viewed from the front of the engine) for belt removal and installation. A belt-wear indicator is incorporated on the rear horizontal face of the pivot arm.
Accessory Mounting Brackets
Parts List Item 1 2 Description Right Hand Mounting Bracket Left Hand Mounting Bracket
All engine accessories are rigidly-mounted onto the cylinder block by means of accessory mounting brackets on the left and right-hand sides of the engine. The left-hand bracket supports the air-conditioning compressor and steering pump. The right-hand bracket supports the generator. Dowels between the accessory mounting brackets and the engine ensure that the accessory pulleys are accurately aligned with the accessory drive belt.
2012-07-19
Accessory Drive Belt 12.10.40

Removal 1. Open the engine compartment and fit paintwork protection sheets. 2. Check the belt wear indicator marks to confirm that the drive belt is within limits.
www.JagDocs.com
3.
Remove the drive belt from the accessory drive. 1. Use a spanner e.g. Churchill JD-230 or Snap On XDHM 1415, on the centre bolt of the belt tensioner idler pulley, to turn the adjuster assembly to the left, viewed from the front, against spring tension. 2. Whilst holding the tensioner against spring tension, remove the drive belt from the generator pulley. Release the tensioner slowly and remove the spanner. Disconnect the belt from the other pulleys, as necessary.
Installation 1. Installation is the reverse of the removal procedure. Ensure that the belt is correctly and squarely located on each pulley.
2012-07-19
Accessory Drive Belt Idler Pulley 12.10.43

1. Remove the drive belt for access. Refer to Operation (<<12.10.40>>)
2. Remove the idler pulley. 1. Remove the securing bolt from the idler pulley. 2. Remove the idler pulley. Installation 1. Installation is the reverse of the removal procedure. Tighten the pulley securing bolt to 53 -69 Nm. Ensure that the belt is correctly and squarely located on each pulley.
2012-07-19
Accessory Drive Belt Tensioner 12.10.41

www.JagDocs.com
2. Remove the tensioner assembly, which includes the tensioner pulley.. 1. Remove the bolt which secures the tensioner assembly to the engine. 2. Remove the tensioner assembly. Installation 1. Installation is the reverse of the removal procedure. Tighten the tensioner assembly securing bolt to 38 -48 Nm. Ensure that the belt is correctly and squarely located on each pulley.
2012-07-19
Accessory Drive Belt Tensioner Pulley 12.10.42

2. Remove the tensioner pulley from the arm. 1. Remove the securing bolt, left hand thread, from the tensioner pulley. 2. Remove the tensioner pulley from the arm. Installation 1. Installation is the reverse of the removal procedure. Tighten the pulley securing bolt, left hand thread, to the correct torque figure. Ensure that the belt is correctly and squarely located on each pulley.
2012-07-19
Supercharger Belt 18.50.08

Removal
www.JagDocs.com
1. Disconnect RH fan motor connector.
2. Check supercharger drive belt length by observing belt wear indicator marks on side of tensioner. 1. Pointer at this mark, indicates minimum new belt length. 2. Pointer at this mark, indicates maximum new belt length. 3. Pointer at this mark, indicates belt must be renewed.
2012-07-19
3. Remove drive belt from supercharger. Fit 1/2 inch square drive ratchet or bar into square aperture on front face of tensioner. Using bar, turn tensioner assembly to the right (viewed from front) against spring tension. Whilst holding the tensioner against spring tension, remove drive belt from tensioner pulley. Release tensioner slowly and remove bar. Disconnect belt from other pulleys and remove it from rear of tensioner.
Installation 1. NOTE: Ensure that belt is correctly and squarely located on each pulley. Check belt wear indicator marks to confirm that drive belt is within limits. Installation is a reversal of the removal procedure.
2012-07-19
Supercharger Belt Idler Pulley 18.50.09

Removal 1. Remove supercharger drive belt; refer to <<18.50.08>>.
www.JagDocs.com
2. Remove supercharger drive belt idler pulley. Remove bolt . Remove idler pulley.
Installation
1. Installation is a reversal of the removal procedure.
2012-07-19
Supercharger Belt Tensioner 18.50.24

Removal 1. Remove twin fan and motor assembly; refer to (SC) 26.25.12. 2. Remove supercharger drive belt; refer to <<18.50.08>>.
3. Remove tensioner from alternator mounting bracket. Remove bolt. Remove tensioner.
Installation
1. Install drive belt tensioner to alternator mounting bracket.
2012-07-19
Locate tensioner using its locating pegs. 2. Install supercharger drive belt; refer to <<18.50.08>>. 3. Install twin fan and motor assembly; refer to (SC) 26.25.12.
www.JagDocs.com
2012-07-19
1999 XK RANGE - Starting System - 303-06
Starting System
Manufacturer - NipponDenso. Type - RA1.4. Weight - 3.75 kg (8.27 lb) Output - 1.4 kW Rated Time - 30 seconds Rotation - Clockwise, viewed from pinion end The starter is of the pre-engaged type; located at the rear left-side of the engine. When the starter is operated from the key-switch, the engagement lever moves the pinion into mesh with the engine ring gear teeth, the electrical contacts within the solenoid complete the high power circuit and the starter motor operates to turn the engine.
2012-07-19

Starter Relay
www.JagDocs.com
The starter motor control relay is the front one of the three, located on the right hand inner wing panel, beneath the bulkhead compartment right hand cover.
Starter Drive Plate
The starter drive plate is attached to the rear of the crankshaft by eight bolts.
2012-07-19

Timing Disc
A timing disc, for the engine speed sensor, is spot-welded to the front face of the starter drive plate.
Starting System Operation
2012-07-19
Item 1 2 3 4 5 6 7 8 9 10 11 12
Description Battery To Rear Fusebox High Power Protection Module To Front Fuseboxes Starter Relay Body Processor Module (BPM) Engine Control Module (ECM) Ignition Switch CRANK Signal Ignition ON Signal Inertia Switch Starter Motor and Solenoid
The illustration above is a simplified explanation of how the starting system operates in conjunction with the Body Processor Module (BPM) and the Engine Control Module (ECM). Refer to the Starting Circuit Diagram in the Electrical Guide.
www.JagDocs.com
Ignition Switch to ON Position

When the ignition key is set to the normal run position, the following sequence occurs: The isolation relay in each fusebox is energised to supply battery power to the fuses and associated circuits. The BPM 'IGN ON' terminal is taken to 0V by the ignition switch. The BPM checks that various parameters are correct e.g. - inertia switch is in the active condition transmission is in PARK - security system has been correctly disabled.
Ignition Switch at CRANK Position

When the ignition key is set to the crank position, the following sequence occurs: The BPM 'CRANK SELECTED' terminal is taken to 0V by the ignition switch. The BPM 'O/P ENGINE CRANK' terminal provides a path to ground for the starter relay coil, via Fuse 5 (10A) located in the under bonnet fusebox. This path to ground also indicates to the ECM 'I/P ENGINE CRANK' terminal, by taking it to 0V, that the engine has been requested to crank. With the starter relay contacts closed, power via Fuse 3 (25A) in the engine management fusebox, is supplied to the pull-in winding of the starter solenoid. The solenoid main contacts close and are held closed by the solenoid hold-in winding. Battery power is supplied to the starter motor through the solenoid main contacts, direct from the battery and the High Power Protection Module.
2012-07-19

Starter Motor Internal Connections
Item 1 2 3 4 5 6 7
Description Battery Ignition Switch Solenoid Contacts Solenoid Pull-In Winding Solenoid Hold-In Winding Solenoid Starter Motor Main Body
2012-07-19
Refer to the Starting Circuit Diagram in the Electrical Guide for the actual layout and connection details. The starter motor and solenoid in the previous figure are shown diagramatically to indicate simply, the electrical circuit and various connections.
www.JagDocs.com
2012-07-19
Starting System Vehicles With: Supercharger

WARNING: MAKE SURE THE VEHICLE IS IN NEUTRALOR PARK FOR VEHICLES WITH AUTOMATIC TRANSMISSION, NEUTRAL FOR VEHICLES WITH MANUAL TRANSMISSION, AND APPLY THE PARKING BRAKE. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN PERSONAL INJURY. 1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical or electrical damage, correct fitment, etc. Visual Inspection Chart Mechanical Starter Motor Flywheel Ring Gear Engine Seized Electrical Battery condition, state of charge Starter Motor Fuse 3 of the EMS fuse box High power protection module Starter relay Ignition switch Wiring harness(es) Damaged, loose or corroded connectors Body processor module (BPM) Engine Control Module (ECM) 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the concern is not visually evident, refer to the Diagnostic trouble code (DTC) index.
CAUTION: When probing connectors to take measurements in the course of the pinpoint tests, use the adaptor kit, part number 3548-1358-00. Failure to follow this instruction may result in damage to the vehicle. NOTE: When performing electrical voltage or resistance tests, always use a digital multimeter (DMM) accurate to 3 decimal places, and with an up-to-date calibration certificate. When testing resistance, always take the resistance of the DMM leads into account. NOTE: Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.
2012-07-19

Symptom Chart Symptom (general) Non-Start Symptom (specific) Engine does not crank Possible source Engine siezed Battery and/or cables Inhibitor circuit Starter motor Starter relay Ignition switch ECM relay Body processor module ' Engine cranks too fast/slow Battery and/or cables Starter motor Cylinder compression Check the battery condition and state of charge. For starter motor and cable tests, Goto <<A>> . Check compressions. Action Check that the engine turns. Check the battery condition and state of charge. For starter motor and cable tests, Goto <<A>> .
www.JagDocs.com

DTC P1245 Description Engine crank signal low voltage Possible Source Starter relay coil to ECM/BPM circuit open circuit Action For starter relay circuit tests, Goto <<B>> . For starter relay circuit tests, Goto <<B>> .
P1246
Engine crank signal high voltage
Starter relay coil to ECM/BPM circuit short circuit to B+ voltage BPM failure
Pinpoint Tests A : CHECK THE POWER SUPPLY, GROUND AND TRIGGER TO THE STARTER CIRCUIT
NOTE: During cranking with the engine disabled, observe the engine cranking speed. A cranking speed as low as 90 RPM is acceptable, but will be difficult to measure. A degree of discretion must be used as to when an engine is cranking too slowly.
A1 : CHECK THE VOLT DROP ACROSS THE STARTER CIRCUIT

1. Measure the volt drop across the circuit between the battery positive terminal and the starter motor terminal, ST10. Is the volt drop greater than 1 volt? -> Yes CHECK the battery connections, cable connections at false bulkhead stud connector, and starter motor. Make sure all connections are in good condition and secure. If all connections are sound, INSTALL a new battery lead. <<414-01>> TEST the system for normal operation.
2012-07-19
-> No Goto <<A2>>
A2 : CHECK THE VOLT DROP ACROSS THE STARTER CIRCUIT (CRANKING)

1. Disable the fuel or ignition system to prevent the engine starting. 2. Turn the ignition switch to the CRANK position. 3. Measure the volt drop across the circuit between the battery positive terminal and the starter motor terminal, ST10. Is the volt drop greater than 1 volt? -> Yes CHECK the battery connections, cable connections at false bulkhead stud connector, and starter motor. Make sure all connections are in good condition and secure. If all connections are sound, INSTALL a new battery lead. <<414-01>> TEST the system for normal operation. -> No Goto <<A3>>
A3 : CHECK THE GROUND TO THE STARTER MOTOR

1. Measure the resistance between the engine GROUND lead and the starter motor body. Is the resistance greater than 5 ohms? -> Yes Clean the connection between the starter motor body and it's fittings, recheck the resistance. TEST the system for normal operation. -> No Goto <<A4>>
A4 : CHECK THE STARTER SIGNAL FROM THE STARTER RELAY

1. Remove the fuel pump relay. 2. Disconnect the starter motor signal electrical connector, ST03 (WR). 3. Turn the ignition switch to the CRANK position. 4. Measure the voltage between ST03 (WR) and GROUND. Is the voltage less than 10 volts? -> Yes Goto <<A5>> -> No INSTALL a new starter motor. <<Starter Motor - >> TEST the system for normal operation.
A5 : CHECK THE STARTER SIGNAL CIRCUIT FOR HIGH RESISTANCE

1. Remove the starter relay. 2. Measure the resistance between the starter relay base, pin 05 and ST03 (WR). Is the resistance greater than 5 ohms? -> Yes
2012-07-19
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<B1>>
B : DTC P1245, P1246; ENGINE CRANK SIGNAL HIGH/LOW VOLTAGE B1 : CHECK THE STARTER RELAY 'ACTIVATE' SIGNAL AT THE RELAY BASE
1. Remove the starter relay. 2. Turn the ignition switch to the CRANK position. 3. Measure the resistance between the relay base, pin 02 and GROUND. Is the resistance greater than 5 ohms? -> Yes Goto <<B2>> -> No Check the starter relay supply circuits and relay operation. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
www.JagDocs.com
B2 : CHECK THE STARTER RELAY 'ACTIVATE' SIGNAL AT THE ECM

1. Disconnect the ECM electrical connector, EM11. 2. Turn the ignition switch to the CRANK position. 3. Measure the resistance between EM11, pin 06 (GO) and GROUND. Is the resistance greater than 5 ohms? -> Yes Goto <<B3>> -> No INSTALL a new starter relay. TEST the system for normal operation.
B3 : CHECK THE STARTER RELAY/ECM/BPM CIRCUIT FOR HIGH RESISTANCE

1. Disconnect the battery negative terminal. 2. Disconnect the BPM electrical connector, FC14. 3. Measure the resistance between the relay base, pin 02 and EM11, pin 06 (GO). 4. Measure the resistance between the relay base, pin 02 and FC14, pin 73 (GO). Is either resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<B4>>
B4 : CHECK THE STARTER RELAY/ECM/BPM CIRCUIT FOR SHORT TO HIGH VOLTAGE
2012-07-19
1. Reconnect the battery negative terminal. 2. Measure the voltage between the relay base, pin 02 and GROUND. Is the voltage greater than 6 volts? -> Yes REPAIR the short circuit to high voltage.For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<B5>>
B5 : CHECK THE IGNITION SWITCHED GROUND TO THE BPM

1. Turn the ignition switch to the CRANK position. 2. Measure the resistance between FC14, pin 41 (RW) and GROUND. Is the resistance greater than 5 ohms? -> Yes Goto <<B6>> -> No Contact dealer technical support for advice on possible BPM failure.
B6 : CHECK THE IGNITION SWITCHED GROUND CIRCUIT TO THE BPM FOR HIGH RESISTANCE
1. Disconnect the ignition switch electrical connector, fC04. 2. Measure the resistance between FC14, pin 41 (RW) and FC04, pin 01 (RW). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new ignition switch. CLEAR the DTC. TEST the system for normal operation.
2012-07-19
Starting System Vehicles Without: Supercharger

Verification and Inspection
WARNING: MAKE SURE THE VEHICLE IS IN NEUTRALOR PARK AND APPLY THE PARKING BRAKE. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN PERSONAL INJURY. 1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical or electrical damage. Visual Inspection Chart Mechanical Starter Motor Flywheel Ring Gear Engine Seized Electrical Battery condition, state of charge Starter Motor Fuse 5, EMS fuse box Fuse 3, Engine compartment fuse box High power protection module Starter relay Ignition switch Wiring harness(es) Damaged, loose or corroded connectors Body processor module (BPM) Engine Control Module (ECM) 3. If an obvious cause for an observed or reported concern is found, correct the cause, (if possible) before proceeding to the next step. 4. Where the Jaguar approved diagnostic system is available, complete the S93 report before clearing any or all fault codes from the vehicle. NOTE: If a DTC cannot be cleared, then there is a permanent fault present that flags again as soon as it is cleared. (The exception to this is P1260, which will only clear following an ignition OFF/ON cycle after rectification.) 5. If the cause is not visually evident and the Jaguar approved diagnostic system is not available, use a scan tool to retrieve the fault codes before proceeding to the Diagnostic Trouble Code (DTC) Index Chart, or the Symptom Chart if no DTCs are set. 6. Using the Jaguar approved diagnostic system where available, and a scan tool where not, check the freeze frame data for information on the conditions applicable when the fault was flagged. The format of this will vary, depending on the tool used, but can provide information useful to the technician in diagnosing the fault.
www.JagDocs.com
Symptom Chart
CAUTION: When probing connectors to take measurements in the course of the pinpoint tests, use the adaptor kit, part number 3548-1358-00. NOTE:
2012-07-19
When performing electrical voltage or resistance tests, always use a digital multimeter (DMM) accurate to 3 decimal places, and with an up-to-date calibration certificate. When testing resistance, always take the resistance of the DMM leads into account. NOTE: Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests. Symptom (general) Non-Start Symptom (specific) Engine does not crank Possible source Engine siezed Battery and/or cables Starter motor Starter relay Ignition switch ECM relay TCM Body processor module ' Engine cranks too fast/slow Battery and/or cables Starter motor Cylinder compression Check the battery condition and state of charge. For starter motor and cable tests, Goto <<C>> Check compressions. Action Check that the engine turns. Check the battery condition and state of charge. For starter motor and cable tests, Goto <<C>>

DTC P1245 Description Engine crank signal low voltage Engine crank signal high voltage Possible Source Starter relay coil to ECM/BPM circuit open circuit Starter relay coil to ECM/BPM circuit short circuit to B+ voltage BPM failure Action . Goto <<D>> . . Goto <<D>> .
P1246
Pinpoint Tests C : CHECK THE POWER SUPPLY, GROUND AND TRIGGER TO THE STARTER CIRCUIT
NOTE: Do not begin this test without a fully charged and sound battery. NOTE: During cranking with the engine disabled, observe the engine cranking speed. A cranking speed as low as 90 RPM is acceptable, but will be difficult to measure. A degree of discretion must be used as to when an engine is cranking too slowly.
C1 : CHECK THE VOLT DROP ACROSS THE STARTER CIRCUIT

2 2012-07-19
1. Measure the volt drop across the circuit between the battery positive terminal and the starter motor terminal, ST10. Is the volt drop greater than 1 volt? -> Yes CHECK the battery connections, cable connections at false bulkhead stud connector, and starter motor. Make sure all connections are in good condition and secure. If all connections are sound, INSTALL a new battery lead. <<414-01>>TEST the system for normal operation. -> No Goto <<C2>>
C2 : CHECK THE VOLT DROP ACROSS THE STARTER CIRCUIT (CRANKING)

1. Disable the fuel or ignition system to prevent the engine starting. 2. Turn the ignition switch to the CRANK position. 3. Measure the volt drop across the circuit between the battery positive terminal and the starter motor terminal, ST10. Is the volt drop greater than 1 volt? -> Yes CHECK the battery connections, cable connections at false bulkhead stud connector, and starter motor. Make sure all connections are in good condition and secure. If all connections are sound, INSTALL a new battery lead. <<414-01>>TEST the system for normal operation. -> No Goto <<C3>>
www.JagDocs.com
C3 : CHECK THE GROUND TO THE STARTER MOTOR

1. Measure the resistance between the engine GROUND lead and the starter motor body. Is the resistance greater than 5 ohms? -> Yes Clean the connection between the starter motor body and it's fittings, recheck the resistance. TEST the system for normal operation. -> No Goto <<C4>>
C4 : CHECK THE STARTER SIGNAL FROM THE STARTER RELAY

1. Disconnect the starter motor signal electrical connector, ST03 (WR). 2. Turn the ignition switch to the CRANK position. 3. Measure the voltage between ST03 (WR) and GROUND. Is the voltage less than 10 volts? -> Yes Goto <<C5>> -> No INSTALL a new starter motor. <<Starter Motor - >> TEST the system for normal operation.
2012-07-19
C5 : CHECK THE STARTER SIGNAL CIRCUIT FOR HIGH RESISTANCE

1. Remove the starter relay. 2. Measure the resistance between the starter relay base, pin 05 and ST03 (WR). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<D1>>
D : DTC P1245, P1246; ENGINE CRANK SIGNAL HIGH/LOW VOLTAGE D1 : CHECK THE STARTER RELAY 'ACTIVATE' SIGNAL AT THE RELAY BASE
1. Remove the starter relay. 2. Turn the ignition switch to the CRANK position. 3. Measure the resistance between the relay base, pin 02 and GROUND. Is the resistance greater than 5 ohms? -> Yes Goto <<D2>> -> No Check the starter relay supply circuits and relay operation. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
D2 : CHECK THE STARTER RELAY 'ACTIVATE' SIGNAL AT THE ECM

1. Disconnect the ECM electrical connector, EM82. 2. Turn the ignition switch to the CRANK position. 3. Measure the resistance between EM82, pin 02 (GO) and GROUND. Is the resistance greater than 5 ohms? -> Yes Goto <<D3>> -> No Contact dealer technical support for advice on possible ECM failure.
D3 : CHECK THE STARTER RELAY/ECM/BPM CIRCUIT FOR HIGH RESISTANCE

1. Disconnect the battery negative terminal. 2. Disconnect the BPM electrical connector, FC14. 3. Measure the resistance between the relay base, pin 02 and EM82, pin 02 (GO). 4. Measure the resistance between the relay base, pin 02 and FC14, pin 73 (GO). Is either resistance greater than 5 ohms?
2012-07-19
-> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<D4>>
D4 : CHECK THE STARTER RELAY/ECM/BPM CIRCUIT FOR SHORT TO HIGH VOLTAGE

1. Reconnect the battery negative terminal. 2. Measure the voltage between the relay base, pin 02 and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit to high voltage.For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<D5>>
www.JagDocs.com
D5 : CHECK THE IGNITION SWITCHED GROUND TO THE BPM

1. Turn the ignition switch to the CRANK position. 2. Measure the resistance between FC14, pin 41 (RW) and GROUND. Is the resistance greater than 5 ohms? -> Yes Goto <<D6>> -> No Contact dealer technical support for advice on possible BPM failure.
D6 : CHECK THE IGNITION SWITCHED GROUND CIRCUIT TO THE BPM FOR HIGH RESISTANCE
1. Disconnect the ignition switch electrical connector, fC04. 2. Measure the resistance between FC14, pin 41 (RW) and FC04, pin 01 (RW). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new ignition switch. CLEAR the DTC. TEST the system for normal operation.
2012-07-19
Starter Motor 86.60.01

3. Disconnect the battery ground cable. Remove the battery cover. 4. Place the vehicle on a ramp. 5. Working from below the vehicle, remove the power steering rack for access. Refer to Section <<211-02>>.
2012-07-19
www.JagDocs.com
6. Disconnect the starter motor main terminal. 1. Reposition the rubber boot from the main terminal. 2. Remove the nut from the starter motor main terminal. 3. Disconnect the main cable from the terminal.
7. Disconnect the starter motor solenoid terminal. 1. Reposition the rubber boot from the terminal. 2. Remove the nut from the solenoid terminal. 3. Disconnect the cable from the terminal.
2012-07-19
8. Remove the starter motor securing bolts. 1. Remove the upper securing bolt. Preferably, use a short 13 mm spanner or a Snap On Half Moon spanner CMX1113 to initially loosen the bolt. (Refer to the next step). 2. Remove the lower securing bolt. 3. Carefully remove the starter motor.
9. The upper bolt may be removed (after loosening) using a 3/8' square drive 13 mm socket, extensions and U.J as shown.
Installation 1. Installation is the reverse of the removal procedure. Tighten the starter motor securing bolts to 38 -48 Nm. 2. Refit the steering rack as detailed in Section <<211-02>>. Refill the reservoir with the recommended fluid and bleed the steering system. 3. Lower the ramp. Remove the protection sheets and close the engine compartment cover. 4. Connect the battery and fit the battery cover. Refer to the Battery Reconnection Procedure in Section <<414-01>>.
3 2012-07-19
1999 XK RANGE - Engine Ignition - 303-07
General Specifications Item / Model Firing Order (cylinder - bank) Spark Plug Type (Leaded markets - service fit only) Normally Aspirated Supercharged Spark Plug Gap (Leaded markets - service fit only) Normally Aspirated Supercharged High Temperature Nickel Anti-Seize Lubricant (Spark Plug Thread) NGK BKR5E-11 NGK PFR5G-11E NGK PFR6G-13E mm (in) 1.0 - 1.1 (0.039 - 0.043) 1.0 - 1.1 (0.039 - 0.043) 1.2 - 1.3 (0.047 - 0.051) 'Neverseez' (ESE-M12A4-A) Specification 1-1, 1-2, 4-1, 2-1, 2-2, 3-1, 3-2, 4-2
www.JagDocs.com
Torque Specifications Component Spark Plugs Coil on Plug Bolts Coil Cover Bolts Nm 25 - 29 4-6 4-6
2012-07-19
Engine Ignition
Ignition System
The ignition system provides timing control in accordance with the engine management strategy and powertrain sensor inputs; the system consists of: engine control module ignition coil-on-plug ignition coil-on-plug supply relay spark plugs
Engine Control Module (ECM)

provides triggering for the ignition coil-on-plug to control individual firing of the spark plugs
Ignition Coils
Ignition Coil-on-plug
Four separate ignition coil-on-plugs are mounted to each camshaft cover, directly above the spark plugs and are controlled by the ECM. Each ignition coil-on-plug comprises an encapsulated ignition control module and a direct push on connection to the spark plug.
Spark Plug
The spark plug changes the high voltage pulse into a spark which ignites the fuel and air mixture. Refer to specification in this section for spark plug details covering different markets and models.
2012-07-19
Engine Ignition Vehicles With: Supercharger

1. Verify the customer concern. 2. Confirm which, if any, warning lights and/or messages were displayed on the instrument cluster. NOTE: If any warning lights and/or messages were displayed when the fault occurred, refer to the Driver Information table for DTCs associated with the display, then to the DTC index table for possible sources and actions. Some warnings will appear to clear when the ignition is cycled. This is often because the warning has flagged as a result of one of the vehicle's on-board diagnostic routines having run to detect the fault. If the same routine is not run when the ignition is switched ON, the warning will not reflag until the routine does run. See the DTC summaries for drive cycle routines. 3. Visually inspect for obvious signs of mechanical or electrical damage. Visual Inspection Chart Mechanical Engine oil level Cooling system coolant level Fuel Contamination Throttle body Poly-vee belt Electrical Fuses. Wiring harness Electrical connector(s) Sensor(s) Engine control module (ECM) Relay date codes. If the date on the relay is between R6 k1 and R6 k8, replace the relay 4. Verify the following systems are working correctly: Air intake system Cooling system Charging system Fuel charging system 5. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 6. Where the Jaguar approved diagnostic system is available, complete the S93 report before clearing any or all fault codes from the vehicle. NOTE: If a DTC cannot be cleared, then there is a permanent fault present that flags again as soon as it is cleared. (The exception to this is P1260, which will only clear following an ignition OFF/ON cycle after rectification.) 7. If the cause is not visually evident and the Jaguar approved diagnostic system is not available, use a fault code reader to retrieve the fault codes before proceeding to the Diagnostic Trouble Code (DTC) Index Chart, or the Symptom Chart if no DTCs are set. NOTE: If the DTC flagged was not present for two or more consecutive cycles, it is classed as temporary, and will be deleted following three cycles during which no fault was present. This could result in a reported warning light/message with no stored DTCs. If a fault is present for three consecutive cycles, the DTC becomes permanent, and will remain in the module's memory for 40 drive cycles. (A cycle is an ignition OFF/ON, which will occur during the owner's normal use of the vehicle. No action on the part of the technician is necessary to perform this cycle. A drive cycle is a series of conditions needed to make the on-board diagnostic routine run, and may need a specific action on the part of the technician. See the DTC summaries for drive cycle routines)
www.JagDocs.com
2012-07-19
8. Using the Jaguar approved diagnostic system where available, and a scan tool where not, check the freeze frame data for information on the conditions applicable when the fault was flagged. The format of this will vary, depending on the tool used, but can provide information useful to the technician in diagnosing the fault.
CAUTION: When probing connectors to take measurements in the course of the pinpoint tests, use the adaptor kit, part number 3548-1358-00. NOTE: When performing electrical voltage or resistance tests, always use a digital multimeter (DMM) accurate to 3 decimal places, and with an up-to-date calibration certificate. When testing resistance, always take the resistance of the DMM leads into account. NOTE: Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests. Symptom Chart Symptom Engine cranks, but does not fire Possible source Security system /Immobiliser engaged Harness Fuel system ECM fault Engine cranks and fires, but will not start Fuel pump relay Fuel pump Cylinder compression loss (short-term. Refer to bulletin; 303-52) Engine coolant temperature (ECT) sensor Spark plugs fouled Ignition coil failure(s) Check for water ingress into spark plug wells (SC only) HT short to ground (tracking) check rubber boots for cracks/damage Difficult to start cold Battery Fuel pump Cylinder compression loss (short-term. Refer to bulletin; 303-52) Spark plugs fouled For battery information, <<414-01>> Check fuel pressure. <<310-00>> For compression loss, REFER to the technical service bulletins. For ignition system tests, REFER to pinpoint tests in this section. For fuel pump relay tests, <<303-14>> Check fuel pressure, <<310-00>> For compression loss, REFER to the technical service bulletins. For ECT sensor tests, <<303-14>> For ignition system tests, REFER to pinpoint tests in this section. Action Contact dealer technical support for information on security system. Check fuel system pressure, <<310-00>> For ECM tests, <<303-14>>
2012-07-19

Difficult to start hot Rochester valve (Mexico only) Injector leak Purge valve Fuel pump Engine coolant temperature (ECT) sensor Difficult to start after hot soak (vehicle standing after engine has reached operating temperature) Rochester valve (Mexico only) Injector leak Purge valve Fuel pump Engine coolant temperature (ECT) sensor Engine stalls soon after start Fuel pump relay ECM relay Harness damage Fuel pump Engine coolant temperature (ECT) sensor Fuel lines Fuel pressure regulator Air leakage Check for DTCS. For fuel pump and ECM relay tests, <<303-14>> Check fuel pressure. <<310-00>> For ECT sensor tests, <<303-14>> For fuel line information, <<310-01>> For fuel pressure regulator, <<303-04>> For intake system information, <<303-12>> For Rochester valve test, <<303-14>> For injector leak test, REFER to technical service bulletin; 303-39. Check fuel pressure, <<310-00>> For evaporative emissions components, <<303-13>> For ECT sensor tests, <<303-14>> For Rochester valve test, <<303-14>> For injector leak test, REFER to technical service bulletin; 303-39. Check fuel pressure. For evaporative emissions components, <<303-13>> For ECT sensor tests, <<303-14>>
www.JagDocs.com
2012-07-19

Engine hesitates/poor acceleration Fuel pump Air leakage Fuel pressure regulator Fuel lines Harness damage Throttle sensors Throttle motor Spark plugs fouled Ignition coil failure(s) Check for water ingress into spark plug wells (SC only) HT short to ground (tracking) check rubber boots for cracks/damage Exhaust gas recirculation (EGR) (SC only) Engine backfires Fuel pump Fuel lines Air leakage Mass air flow (MAF) sensor Spark plugs Check for water ingress into spark plug wells (SC only) HT short to ground (tracking) check rubber boots for cracks/damage Check fuel pressure, <<310-00>> For fuel pump and lines, <<310-01>> For intake system, <<303-12>> For MAF sensor tests, <<303-14>> For ignition system tests, REFER to pinpoint tests in this section. Check fuel pressure, <<310-00>> For intake system information, <<303-12>> For fuel pressure regulator, <<303-04>> For fuel lines information, <<310-01>> For throttle position sensor and throttle motor relay tests, <<303-14>> For ignition system tests, REFER to pinpoint tests in this section. For EGR information, <<303-08>>
2012-07-19

Engine surges Air leakage Fuel pump Fuel lines Mass air flow (MAF) sensor Harness damage Throttle sensors Throttle motor Spark plugs Check for water ingress into spark plug wells (SConly) HT short to ground (tracking) check rubber boots for cracks/damage Engine detonates/knocks Fuel lines Fuel pressure regulator Air leakage Mass air flow (MAF) sensor Oxygen sensors Fuel pump No throttle response Poor throttle response Throttle sensors Throttle motor Throttle sensors Throttle motor Air leakage Mass air flow (MAF) sensor For throttle position sensor and throttle motor relay tests, <<303-14>> For intake system, <<303-12>> For MAF sensor tests, <<303-14>> For throttle position sensor tests, throttle motor relay tests, <<303-14>> For fuel lines, <<310-01>> For fuel pressure regulator, <<303-04>> For intake system, <<303-12>> For MAF sensor and oxygen sensor tests, <<303-14>> Check fuel pressure, <<310-00>> For intake system, <<303-12>> Check fuel pressure, <<310-00>> For fuel pump and lines, <<310-01>> For MAF sensor, throttle position sensor and throttle motor relay tests, <<303-14>> For ignition system tests, REFER to pinpoint tests in this section.
www.JagDocs.com

2012-07-19

Warning light Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Amber Amber Amber Amber Amber Amber Amber Amber Amber Amber Red Amber Red Amber Amber Amber Amber Amber Message Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Default Mode Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Engine shut-down when combined with other throttle failures Engine shut-down when combined with other throttle failures Cruise inhibited Cruise inhibited Cruise inhibited Cruise inhibited Cruise inhibited Cruise inhibited Cruise inhibited Cruise inhibited Cruise inhibited Cruise inhibited Limp-Home unavailable. Reverse throttle progression enabled Limp-Home unavailable. Reverse throttle progression enabled. High idle speed Limp-Home unavailable. Reverse throttle progression enabled Engine Speed Limit (runs normally, limited to 3000 RPM) Engine Speed Limit (runs normally, limited to 3000 RPM) Engine Speed Limit (runs normally, limited to 3000 RPM) Engine Speed Limit (runs normally, limited to 3000 RPM) Reverse throttle progression enabled DTC P1224 P1229 P0122, P0123, P0222, P0223 P0121 P1122, P1123 P1222, P1223 P1121, P1632 P1251, P0560, P1658 P1631 P1611 P1633 P1609 P0506, P0507 P1656 P1254 P1250 P1516 P1517 P1571 P1696 P0568 P0570 P0569 P0567 P0566 P1697 P0560, P1254 P1250, P1254 P1250 P0116, P0117, P0118, P0125 P0101, P0102, P0103, P0104 P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P1313, P1314 P0327, P0328, P0332, P0333, P1648 P1474
2012-07-19

Amber Amber Amber Amber Amber Amber Amber Amber Amber Amber Amber Amber Amber Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance None None None Engine Speed Limit (runs normally, limited to 3000 RPM) Engine Speed Limit (runs normally, limited to 3000 RPM) Engine Speed Limit (runs normally, limited to 3000 RPM) Gearbox default to 4th gear Gearbox default to 4th gear Gearbox default to 4th gear Gearbox default to 4th gear Gearbox default to 4th gear Gearbox default to 4th gear Gearbox default to 4th gear Gearbox default to 4th gear Gearbox default to 4th gear Gearbox default to 4th gear P1230 P1671 P1112, P1113 P1601 (SC only) P1605 (NA only) P0702 P1795 P1796 P1797 P1605 P0705 (SC only) P0706 P1720
www.JagDocs.com

2012-07-19

Diagnostic Trouble Code (DTC) Index DTC P0300 Description Random misfire detected Possible Source ECM to ignition coil primary circuit faults (cylinder misfire detected DTCs also logged) Ignition coil ground circuit; open circuit, high resistance Fuel injector circuit fault(s) [injector DTCs also logged] Ignition coil failure(s) Check for water ingress into spark plug wells (SC only) HT short to ground (tracking) check rubber boots for cracks/damage Spark plug failure/fouled/incorrect gap Cylinder compression low Fuel delivery pressure (low/high) Fuel injectors restricted/leaking Fuel contamination PAS pulley bolts loose (see Service Action S462) Worn camshaft/broken valve springs P0301 ' ' ' ' ' ' ' Misfire detected, Cyl 1 ' ' ' ' ' ' ' REFER to possible sources for P0300 P0302 P0303 P0304 P0305 P0306 P0307 P0308 REFER to actions for P0300 Misfire detected, Cyl 3 Misfire detected, Cyl 5 Misfire detected, Cyl 7 Misfire detected, Cyl 2 Misfire detected, Cyl 4 Misfire detected, Cyl 6 Misfire detected, Cyl 8 Action For ignition system tests, Goto <<A>> . For injector circuit tests, <<303-04>> Check compressions. Check fuel pressure, <<310-00>> For fuel injectors, <<303-04>> For fuel tank and lines information, <<310-01>> Check PAS pulley bolt torque (see Service Action S462). For engine information, <<303-01>>
2012-07-19

P0351 Ignition coil primary/secondary circuit malfunction, cyl 1 ECM to ignition module primary circuit open circuit, short circuit to ground, high resistance Ignition module to ignition coil primary circuit open circuit, short circuit to ground, high resistance Ignition module ground circuit open circuit, high resistance Ignition coil failure Ignition module failure ' ' ' ' ' ' ' P0603 P1000 P1111 P1313 ' ' ' ' ' ' ' ECM data corrupted System checks not complete since last memory clear System checks complete since last memory clear Misfire rate catalyst damage, Right-hand cylinders. NOTE. This DTC will flag only when accompanied by a random or individual cylinder misfire DTC; P0300, P0301 to P0304 ' P0352 P0353 P0354 P0355 P0356 P0357 P0358 ECM OBD diagnostic monitors have not completed OBD diagnostic monitors have completed Refer to possible causes for P0300-P0308 P1314 Ignition coil primary/secondary circuit malfunction, cyl 3 Ignition coil primary/secondary circuit malfunction, cyl 5 Ignition coil primary/secondary circuit malfunction, cyl 7 Ignition coil primary/secondary circuit malfunction, cyl 2 Ignition coil primary/secondary circuit malfunction, cyl 4 Ignition coil primary/secondary circuit malfunction, cyl 6 Ignition coil primary/secondary circuit malfunction, cyl 8 Contact dealer technical support for advice on possible ECM failure Carry out comprehensive component monitor drive cycle. Refer to the DTC section of JTIS, accessed by the icon on the opening page. No action necessary Refer to actions for P0300-P0308 For ignition circuit tests, Goto <<A>> .
www.JagDocs.com
'
Misfire rate catalyst damage, Left-hand cylinders. NOTE. This DTC will flag only when accompanied by a random or individual cylinder misfire DTC; P0300 to P0308 Misfire excess emission. NOTE. This DTC will flag only when accompanied by an individual cylinder misfire DTC; P0300 to P0308 For ignition circuit tests, Goto <<A>> .
' P1367
' Ignition monitor (ignition module 1)
P1316 Ignition module 1 disconnected Ignition module 1 to ECM circuits open circuit, short circuit to ground or short circuit to B+ voltage Ignition module 1 ground circuit fault Ignition coil relay failure Ignition coil open/short circuit Ignition module 1 failure
2012-07-19

P1368 Ignition monitor (ignition module 2) Ignition module 2 disconnected Ignition module 2 to ECM circuits open circuit, short circuit to ground or short circuit to B+ voltage Ignition module 2 ground circuit fault Ignition coil relay failure Ignition coil open/short circuit Ignition module 2 failure For ignition circuit tests, Goto <<A>> .
Pinpoint Tests A : DTC P0300, P0351, P0352, P0353, P0354, P0355, P0356, P0357, P0358; RANDOM MISFIRE DETECTED, COIL PRIMARY/SECONDARY CIRCUIT MALFUNCTION
NOTE: Unless multiple cylinder misfires are apparent, only one circuit will normally need to be tested. The DTC set will indicate which cylinder is misfiring.
A1 : CHECK COIL FUNCTION BY SUBSTITUTION

1. Swap the suspect coil for a known good unit. 2. CLEAR the DTC. TEST the system for normal operation. Does the same DTC reoccur? The DTC will indicate if the same cylinder is misfiring. -> Yes Goto <<A2>> -> No INSTALL a new coil. <<Ignition Coil-On-Plug LH - >><<Ignition Coil-On-Plug RH - >> CLEAR the DTC. TEST the system for normal operation.
A2 : CHECK THE IGNITION COIL SUPPLY VOLTAGE CIRCUIT

1. Disconnect the relevant ignition coil electrical connector(s). 2. Turn the ignition switch to the ON position. 3. Measure the voltage between: Cyl 1 PI12, pin 1 (PW) and GROUND. Cyl 2 PI22, pin 1 (PW) and GROUND. Cyl 3 PI19, pin 1 (PW) and GROUND. Cyl 4 PI23, pin 1 (PW) and GROUND. Cyl 5 PI20, pin 1 (PW) and GROUND. Cyl 6 PI24, pin 1 (PW) and GROUND. Cyl 7 PI21, pin 1 (PW) and GROUND.
10
2012-07-19
Cyl 8 PI25, pin 1 (PW) and GROUND. Is the voltage less than 10.5 Volts? -> Yes REPAIR the relevant ignition coil supply voltage circuit. This circuit includes the ignition coil relay. For additional information, refer to the wiring diagrams. CLEAR the DTCs. TEST the system for normal operation. -> No Goto <<A3>>
A3 : CHECK THE IGNITION COIL GROUND CIRCUIT FOR HIGH RESISTANCE

1. Turn the ignition switch to the OFF position. 2. Disconnect the relevant ignition module electrical connector(s), EM27 and EM29. 3. Measure the resistance between: Cyl 1 PI12, pin 2 (GU) and EM27, pin 08 (GU). Cyl 2 PI22, pin 2 (GB) and EM29 pin 08 (GB). Cyl 3 PI19, pin 2 (GR) and EM29, pin 11 (GR). Cyl 4 PI23, pin 2 (GS) and EM27, pin 07 (GS). Cyl 5 PI20, pin 2 (GO) and EM29, pin 07 (GO). Cyl 6 PI24, pin 2 (GK) and EM27, pin 12 (GK). Cyl 7 PI21, pin 2 (GW) and EM27, pin 11 (GW). Cyl 8 PI25, pin 2 (GP) and EM29, pin 12 (GP). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTCs. TEST the system for normal operation. -> No Goto <<A4>>
www.JagDocs.com
A4 : CHECK THE POWER SUPPLIES TO THE IGNITION MODULES

1. Turn the ignition switch to the ON position. 2. Measure the voltage between EM27, pin 10 (PW) and GROUND. 3. Measure the voltage between EM29, pin 10 (PW) and GROUND. Are both voltages greater than 10 volts? -> Yes Goto <<A5>> -> No REPAIR the circuit between EM27, pin 10 (PW) and/or EM29, pin 10 (PW). This circuit includes the Ignition coil relay, and the harness splice, EMS22. For additional information, refer to the wiring diagrams.
11
2012-07-19
A5 : CHECK THE GROUNDS TO THE IGNITION MODULES

1. Turn the ignition switch to the OFF position. 2. Measure the resistance between EM27, pin 09 (B) and GROUND. 3. Measure the resistance between EM27, pin 09 (B) and GROUND. Is either resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. This circuit includes the harness splice, EMS04. For additional information, refer to the wiring diagrams. CLEAR the DTCs. TEST the system for normal operation. -> No Goto <<A6>>
A6 : CHECK THE CIRCUIT BETWEEN THE IGNITION MODULES AND THE ECM FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM13. 3. Measure the resistance between the following Cyl 1 EM27, pin 02 (LGU) and EM13, pin 26 (LGU). Cyl 2 EM29, pin 02 (LGP) and EM13, pin 34 (LGP). Cyl 3 EM29, pin 05 (LGW) and EM13, pin 25 (LGW). Cyl 4 EM27, pin 03 (LGS) and EM13, pin 33 (LGS). Cyl 5 EM29, pin 03 (LGO) and EM13, pin 24 (LGO). Cyl 6 EM27, pin 06 (LGR) and EM13, pin 32 (LGR). Cyl 7 EM27, pin 05 (LGK) and EM13, pin 23 (LGK). Cyl 8 EM29, pin 06 (LGY) and EM13, pin 31 (LGY). Is the resistance greater than 5 Ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTCs. TEST the system for normal operation. -> No INSTALL a new ignition module for the affected cylinder(s). CLEAR the DTCs. TEST the system for normal operation. If the DTC is repeated, contact dealer technical support for advice on possible ECM failure.
12
2012-07-19
Engine Ignition Vehicles Without: Supercharger

1. Verify the customer concern. 2. Confirm which, if any, warning lights and/or messages were displayed on the instrument cluster. NOTE: If any warning lights and/or messages were displayed when the fault occurred, refer to the Driver Information table for DTCs associated with the display, then to the DTC index table for possible sources and actions. Some warnings will appear to clear when the ignition is cycled. This is often because the warning has flagged as a result of one of the vehicle's on-board diagnostic routines having run to detect the fault. If the same routine is not run when the ignition is switched ON, the warning will not reflag until the routine does run. See the DTC summaries for drive cycle routines. 3. Visually inspect for obvious signs of mechanical or electrical damage. Visual Inspection Chart Mechanical Engine oil level Cooling system coolant level Fuel Contamination Throttle body Poly-vee belt Electrical Fuses. Wiring harness Electrical connector(s) Sensor(s) Engine control module (ECM) Relay date codes. If the date on the relay is between R6 k1 and R6 k8, replace the relay 4. Verify the following systems are working correctly: Air intake system Cooling system Charging system Fuel charging system 5. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 6. Where the Jaguar approved diagnostic system is available, complete the S93 report before clearing any or all fault codes from the vehicle. NOTE: If a DTC cannot be cleared, then there is a permanent fault present that flags again as soon as it is cleared. (The exception to this is P1260, which will only clear following an ignition OFF/ON cycle after rectification.) 7. If the cause is not visually evident and the Jaguar approved diagnostic system is not available, use a fault code reader to retrieve the fault codes before proceeding to the Diagnostic Trouble Code (DTC) Index Chart, or the Symptom Chart if no DTCs are set. NOTE: If the DTC flagged was not present for two or more consecutive cycles, it is classed as temporary, and will be deleted following three cycles during which no fault was present. This could result in a reported warning light/message with no stored DTCs. If a fault is present for three consecutive cycles, the DTC becomes permanent, and will remain in the module's memory for 40 drive cycles. (A cycle is an ignition ON/OFF, which will occur during the owner's normal use of the vehicle. No action on the part of the technician is necessary to perform this cycle. A drive cycle is a series of conditions needed to make the on-board diagnostic routine run, and may need a specific action on the part of the technician. See the DTC summaries for drive cycle routines) 8. Using the Jaguar approved diagnostic system where available, and a scan tool where not, check the freeze frame data for information on the conditions applicable when the fault was flagged. The format of this will vary, depending on the tool used, but can provide information useful to the technician in diagnosing the fault.
www.JagDocs.com
CAUTION: When probing connectors to take measurements in the course of the pinpoint tests, use the adaptor kit, part number 3548-1358-00. NOTE:
2012-07-19
When performing electrical voltage or resistance tests, always use a digital multimeter (DMM) accurate to 3 decimal places, and with an up-to-date calibration certificate. When testing resistance, always take the resistance of the DMM leads into account. NOTE: Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests. Symptom Chart Symptom Engine cranks, but does not fire Possible source Security system /Immobiliser engaged Harness Fuel system ECM fault Engine cranks and fires, but will not start Fuel pump relay Fuel pump Cylinder compression loss (short-term. Refer to bulletin; 303-52) Engine coolant temperature (ECT) sensor Spark plugs fouled Ignition coil failure(s) Check for water ingress into spark plug wells (SC only) HT short to ground (tracking) check rubber boots for cracks/damage Difficult to start cold Battery Fuel pump Cylinder compression loss (short-term. Refer to bulletin; 303-52) Spark plugs fouled Difficult to start hot Rochester valve (Mexico only) Injector leak Purge valve Fuel pump Engine coolant temperature (ECT) sensor Difficult to start after hot soak (vehicle standing after engine has reached operating temperature) Rochester valve (Mexico only) Injector leak Purge valve Fuel pump Engine coolant temperature (ECT) sensor For Rochester valve test, <<303-14>> For injector leak test, REFER to technical service bulletin; 303-39. Check fuel pressure. For evaporative emissions components, <<303-13>> For ECT sensor tests, <<303-14>> For Rochester valve test, <<303-14>> For injector leak test, REFER to technical service bulletin; 303-39. Check fuel pressure. For evaporative emissions components, <<303-13>> For ECT sensor tests, <<303-14>> For battery information, <<414-01>> Check fuel pressure. Refer to Technical service bulletins. For ignition system tests, refer to pinpoint tests in this section. For fuel pump relay tests, <<303-14>> Check fuel pressure. Refer to Technical service bulletins. For ECT sensor tests, <<303-14>> For ignition system tests, refer to pinpoint tests in this section. Action Contact Dealer technical support for information on security system. Check fuel system pressure, <<310-00>> For ECM tests, <<303-14>>
2012-07-19
Engine stalls soon after start
Fuel pump relay ECM relay Harness damage Fuel pump Engine coolant temperature (ECT) sensor Fuel lines Fuel pressure regulator Air leakage
Check for DTCS. For fuel pump and ECM relay tests, <<303-14>> Check fuel pressure. For ECT sensor tests, <<303-14>> For fuel line information, <<310-01>> For fuel pressure regulator, <<303-04>> For intake system information, <<303-12>>
Engine hesitates/poor acceleration
Fuel pump Air leakage Fuel pressure regulator Fuel lines Harness damage Throttle sensors Throttle motor Spark plugs fouled Ignition coil failure(s) Check for water ingress into spark plug wells (SC only) HT short to ground (tracking) check rubber boots for cracks/damage Exhaust gas recirculation (EGR) (SC only)
Check fuel pressure. For intake system information, <<303-12>> For fuel pressure regulator, For fuel lines information, <<310-01>> For throttle position sensor and throttle motor relay tests, <<303-14>> For ignition system tests, refer to pinpoint tests in this section. For EGR information, <<303-08>>
www.JagDocs.com
Engine backfires
Fuel pump Fuel lines Air leakage Mass air flow (MAF) sensor Spark plugs Check for water ingress into spark plug wells (SC only) HT short to ground (tracking) check rubber boots for cracks/damage
Check fuel pressure. For fuel pump and lines, <<310-01>> For intake system, <<303-12>> For MAF sensor tests, <<303-14>> For ignition system tests, refer to pinpoint tests in this section.
2012-07-19
Engine surges
Air leakage Fuel pump Fuel lines Mass air flow (MAF) sensor Harness damage Throttle sensors Throttle motor Spark plugs Check for water ingress into spark plug wells (SConly) HT short to ground (tracking) check rubber boots for cracks/damage
For intake system, <<303-12>> Check fuel pressure. For fuel pump and lines, <<310-01>> For MAF sensor, throttle position sensor and throttle motor relay tests, <<303-14>> For ignition system tests, refer to pinpoint tests in this section.
Engine detonates/knocks
Fuel lines Fuel pressure regulator Air leakage Mass air flow (MAF) sensor Oxygen sensors Fuel pump
For fuel lines, <<310-01>> For fuel pressure regulator, <<303-04>> For intake system, <<303-12>> For MAF sensor and oxygen sensor tests, <<303-14>> Check fuel pressure.
No throttle response Poor throttle response
Throttle sensors Throttle motor Throttle sensors Throttle motor Air leakage Mass air flow (MAF) sensor
For throttle position sensor tests, throttle motor relay tests, <<303-14>> For throttle position sensor and throttle motor relay tests, <<303-14>> For intake system, <<303-12>> For MAF sensor tests, <<303-14>>

2012-07-19
Warning light Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Amber Amber Amber Amber Amber Amber Amber Amber Amber Amber Red Amber Red Amber Amber Amber Amber Amber Amber Amber Amber Amber Amber Amber Amber
Message Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance
Default Mode Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Engine shut-down when combined with other throttle failures Engine shut-down when combined with other throttle failures Cruise inhibited Cruise inhibited Cruise inhibited Cruise inhibited Cruise inhibited Cruise inhibited Cruise inhibited Cruise inhibited Cruise inhibited Cruise inhibited Limp-Home unavailable. Reverse throttle progression enabled Limp-Home unavailable. Reverse throttle progression enabled. High idle speed Limp-Home unavailable. Reverse throttle progression enabled Engine Speed Limit (runs normally, limited to 3000 RPM) Engine Speed Limit (runs normally, limited to 3000 RPM) Engine Speed Limit (runs normally, limited to 3000 RPM) Engine Speed Limit (runs normally, limited to 3000 RPM) Reverse throttle progression enabled Engine Speed Limit (runs normally, limited to 3000 RPM) Engine Speed Limit (runs normally, limited to 3000 RPM) Engine Speed Limit (runs normally, limited to 3000 RPM) Gearbox default to 4th gear Gearbox default to 4th gear Gearbox default to 4th gear Gearbox default to 4th gear
DTC P1224 P1229 P0122, P0123, P0222, P0223 P0121 P1122, P1123 P1222, P1223 P1121, P1632 P1251, P0560, P1658 P1631 P1611 P1633 P1609 P0506, P0507 P1656 P1254 P1250 P1516 P1517 P1571 P1696 P0568 P0570 P0569 P0567 P0566 P1697 P0560, P1254 P1250, P1254 P1250 P0116, P0117, P0118, P0125 P0101, P0102, P0103, P0104 P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P1313, P1314 P0327, P0328, P0332, P0333, P1648 P1474 P1230 P1671 P1112, P1113 P1601 (SC only) P1605 (NA only) P0702 P1795
www.JagDocs.com
2012-07-19
Amber Amber Amber Amber Amber Amber
Restricted Performance Restricted Performance Restricted Performance None None None
Gearbox default to 4th gear Gearbox default to 4th gear Gearbox default to 4th gear Gearbox default to 4th gear Gearbox default to 4th gear Gearbox default to 4th gear
P1796 P1797 P1605 P0705 (SC only) P0706 P1720

2012-07-19
DTC P0300
Description Random misfire detected
Possible Source ECM to ignition coil primary circuit faults (cylinder misfire detected DTCs also logged) Ignition coil ground circuit; open circuit, high resistance Fuel injector circuit fault(s) [injector DTCs also logged] Ignition coil failure(s) Check for water ingress into spark plug wells (SC only) HT short to ground (tracking) check rubber boots for cracks/damage Spark plug failure/fouled/incorrect gap Cylinder compression low Fuel delivery pressure (low/high) Fuel injectors restricted/leaking Fuel contamination PAS pulley bolts loose (see Service Action S462) Worn camshaft/broken valve springs
Action For ignition system tests, refer to pinpoint tests in this section. For injector circuit tests, <<303-04>> Check compressions. Check fuel pressure. For fuel injectors, <<303-04>> For fuel tank and lines information, <<310-01>> Check PAS pulley bolt torque. (see Service Action S462) For engine information, <<303-01>>
www.JagDocs.com
P0301
Misfire detected, Cyl 1
ECM to ignition coil primary circuit faults (cylinder misfire detected DTCs also logged) Ignition coil ground circuit; open circuit, high resistance Fuel injector circuit fault(s) [injector DTCs also logged] Ignition coil failure(s) Check for water ingress into spark plug wells (SC only) HT short to ground (tracking) check rubber boots for cracks/damage Spark plug failure/fouled/incorrect gap Cylinder compression low Fuel delivery pressure (low/high) Fuel injectors restricted/leaking Fuel contamination PAS pulley bolts loose (see Service Action S462) Worn camshaft/broken valve springs
For ignition system tests, refer to pinpoint tests in this section. For injector circuit tests, <<303-04>> Check compressions. Check fuel pressure. For fuel injectors, <<303-04>> For fuel tank and lines information, <<310-01>> Check PAS pulley bolt torque. (see Service Action S462) For engine information, <<303-01>>
' ' ' ' ' ' '
' ' ' ' ' ' '
P0302 P0303 P0304 P0305 P0306 P0307 P0308
Misfire detected, Cyl 3 Misfire detected, Cyl 5 Misfire detected, Cyl 7 Misfire detected, Cyl 2 Misfire detected, Cyl 4 Misfire detected, Cyl 6 Misfire detected, Cyl 8
2012-07-19
P0351
Ignition coil primary/secondary circuit malfunction, cyl 1
ECM to ignition coil primary circuit open circuit, short circuit to ground, high resistance Ignition coil ground circuit open circuit, high resistance Ignition coil failure
For ignition coil circuit tests, Goto <<B>>
' ' ' ' ' ' ' P0603 P1000 P1111 P1313
' ' ' ' ' ' ' ECM data corrupted System checks not complete since last memory clear System checks complete since last memory clear Misfire rate catalyst damage, Right-Hand bank. NOTE. This DTC will flag only when accompanied by a random or individual cylinder misfire DTC; P0300, P0301 to P0304 ' ' Ignition monitor (Right-Hand bank)
P0352 P0353 P0354 P0355 P0356 P0357 P0358 ECM OBD diagnostic monitors have not completed OBD diagnostic monitors have completed Refer to possible causes for P0300-P0308
Ignition coil primary/secondary circuit malfunction, cyl 3 Ignition coil primary/secondary circuit malfunction, cyl 5 Ignition coil primary/secondary circuit malfunction, cyl 7 Ignition coil primary/secondary circuit malfunction, cyl 2 Ignition coil primary/secondary circuit malfunction, cyl 4 Ignition coil primary/secondary circuit malfunction, cyl 6 Ignition coil primary/secondary circuit malfunction, cyl 8 Contact Dealer technical support for advice on possible ECM failure Carry out comprehensive component monitor drive cycle. Refer to the DTC section of JTIS, accessed by the icon on the opening page. No action necessary Refer to actions for P0300-P0308
' ' P1367
P1314 P1316 Ignition monitoring circuit between splice and ECM open circuit, short circuit to ground, or short circuit to B+ voltage Ignition coil group ground circuit fault Ignition coil relay failure
Misfire rate catalyst damage, Left-Hand bank. NOTE. This DTC will flag only when accompanied by a random or individual cylinder misfire DTC; P0300 to P0308 Misfire excess emission. NOTE. This DTC will flag only when accompanied by an individual cylinder misfire DTC; P0300 to P0308 For ignition coil circuit tests, Goto <<B>>
P1368
Ignition monitor (Left-Hand bank)
Ignition monitoring circuit between splice and ECM open circuit, short circuit to ground, or short circuit to B+ voltage Ignition coil group ground circuit fault Ignition coil relay failure
For ignition coil circuit tests, Goto <<B>>
Pinpoint Tests B : DTC P0300, P0351, P0352, P0353, P0354, P0355, P0356, P0357, P0358, P1367, P1368; RANDOM MISFIRE DETECTED, COIL PRIMARY/SECONDARY CIRCUIT MALFUNCTION, IGNITION MONITOR MALFUNCTION
NOTE: Unless multiple cylinder misfires are apparent, only one circuit will normally need to be tested. The DTC set will indicate which cylinder is misfiring.
B1 : CHECK COIL FUNCTION BY SUBSTITUTION

1. Swap the suspect coil for a known good unit. 2. CLEAR the DTC. TEST the system for normal operation. Does the same DTC reoccur? The DTC will indicate if the same cylinder is misfiring.
2012-07-19
-> Yes INSTALL a new coil. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<B2>>
B2 : CHECK THE IGNITION COIL SUPPLY VOLTAGE CIRCUIT

1. Disconnect the relevant ignition coil electrical connector(s). 2. Turn the ignition switch to the ON position. 3. Make sure the ignition coil relay is energised. 4. Measure the voltage between: Cyl 1 PI51, pin 4 (RW) and GROUND. Cyl 2 PI55, pin 4 (RW) and GROUND. Cyl 3 PI52, pin 4 (RW) and GROUND. Cyl 4 PI56, pin 4 (RW) and GROUND. Cyl 5 PI53, pin 4 (RW) and GROUND. Cyl 6 PI57, pin 4 (RW) and GROUND. Cyl 7 PI54, pin 4 (RW) and GROUND. Cyl 8 PI58, pin 4 (RW) and GROUND. Is the voltage less than 10.5 Volts? -> Yes REPAIR the relevant ignition coil supply voltage circuit. This circuit includes the ignition coil relay. For additional information, refer to the wiring diagrams. CLEAR the DTCs. TEST the system for normal operation. -> No Goto <<B3>>
www.JagDocs.com
B3 : CHECK THE IGNITION COIL GROUND CIRCUIT

1. Turn the ignition switch to the OFF position. 2. Disconnect the relevant ignition coil electrical connector(s). 3. Measure the resistance between: Cyl 1 PI51, pin 1 (B) and GROUND. Cyl 2 PI55, pin 1 (B) and GROUND. Cyl 3 PI52, pin 1 (B) and GROUND. Cyl 4 PI56, pin 1 (B) and GROUND. Cyl 5 PI53, pin 1 (B) and GROUND. Cyl 6 PI57, pin 1 (B) and GROUND. Cyl 7 PI54, pin 1 (B) and GROUND. Cyl 8 PI58, pin 1 (B) and GROUND. Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTCs. TEST the system for normal operation. -> No Goto <<B4>>
2012-07-19
B4 : CHECK THE IGNITION COIL SWITCHING CIRCUITS FOR HIGH RESISTANCE

1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM84. 3. Disconnect the relevant ignition coil electrical connector(s). 4. Measure the resistance between; Cyl 1 PI51, pin 1 (GU) and EM84, pin 12 (GU). Cyl 2 PI55, pin 3 (GB) and EM84, pin 20 (GB). Cyl 3 PI52, pin 3 (GR) and EM84, pin 11 (GR). Cyl 4 PI56, pin 3 (GS) and EM84, pin 19 (GS). Cyl 5 PI53, pin 3 (GO) and EM84, pin 10 (GO). Cyl 6 PI57, pin 3 (GK) and EM84, pin 18 (GK). Cyl 7 PI54, pin 3 (GW) and EM84, pin 09 (GW). Cyl 8 PI58, pin 3 (GP) and EM84, pin 17 (GP). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTCs. TEST the system for normal operation. -> No Goto <<B5>>
B5 : CHECK THE IGNITION COIL (CYLS 1, 4, 6, AND 7) MONITOR CIRCUITS FOR HIGH RESISTANCE
1. Reconnect the ECM electrical connector, EM84. 2. Disconnect the ECM electrical connector, EM83. 3. Disconnect the relevant ignition coil electrical connector(s). 4. Measure the resistance between; Cyl 1 PI51, pin 2 (YG) and EM83, pin 10 (YG). Cyl 4 PI56, pin 2 (YG) and EM83, pin 10 (YG). Cyl 6 PI57, pin 2 (YG) and EM83, pin 10 (YG). Cyl 7 PI54, pin 2 (YG) and EM83, pin 10 (YG). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. This circuit includes the harness splice, PIS11. For additional information, refer to the wiring diagrams. CLEAR the DTCs. TEST the system for normal operation. -> No Goto <<B6>>
B6 : CHECK THE IGNITION COIL (CYLS 1, 4, 6, AND 7) MONITOR CIRCUITS FOR SHORT TO B+ VOLTAGE
1. Reconnect the battery negative terminal. 2. Disconnect the relevant ignition coil electrical connector(s). 3. Measure the voltage between; Cyl 1 PI51, pin 2 (YG) and GROUND.
10
2012-07-19
Cyl 4 PI56, pin 2 (YG) and GROUND. Cyl 6 PI57, pin 2 (YG) and GROUND. Cyl 7 PI54, pin 2 (YG) and GROUND. Is the voltage greater than 1 volt? -> Yes REPAIR the short to B+ voltage. For additional information, refer to the wiring diagrams. CLEAR the DTCs. TEST the system for normal operation. -> No Goto <<B7>>
B7 : CHECK THE IGNITION COIL (CYLS 1, 4, 6, AND 7) MONITOR CIRCUITS FOR SHORT TO GROUND
1. Disconnect the relevant ignition coil electrical connector(s). 2. Measure the resistance between; Cyl 1 PI51, pin 2 (YG) and GROUND. Cyl 4 PI56, pin 2 (YG) and GROUND. Cyl 6 PI57, pin 2 (YG) and GROUND. Cyl 7 PI54, pin 2 (YG) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short to GROUND. For additional information, refer to the wiring diagrams. CLEAR the DTCs. TEST the system for normal operation. -> No Goto <<B8>>
www.JagDocs.com
B8 : CHECK THE IGNITION COIL (CYLS 2, 3, 5, AND 8) MONITOR CIRCUITS FOR HIGH RESISTANCE
1. Disconnect the relevant ignition coil electrical connector(s). 2. Measure the resistance between; Cyl 2 PI55, pin 2 (YG) and EM83, pin 11 (YG). Cyl 3 PI52, pin 2 (YG) and EM83, pin 11 (YG). Cyl 5 PI53, pin 2 (YG) and EM83, pin 11 (YG). Cyl 8 PI58, pin 2 (YG) and EM83, pin 11 (YG). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. This circuit includes the harness splice, PIS11. For additional information, refer to the wiring diagrams. CLEAR the DTCs. TEST the system for normal operation. -> No Goto <<B9>>
B9 : CHECK THE IGNITION COIL (CYLS 2, 3, 5, AND 8) MONITOR CIRCUITS FOR SHORT TO B+ VOLTAGE
1. Reconnect the battery negative terminal. 2. Disconnect the relevant ignition coil electrical connector(s). 3. Measure the voltage between; Cyl 2 PI55, pin 2 (YG) and GROUND. Cyl 3 PI52, pin 2 (YG) and GROUND.
11 2012-07-19
Cyl 5 PI53, pin 2 (YG) and GROUND. Cyl 7 PI58, pin 2 (YG) and GROUND. Is the voltage greater than 1 volt? -> Yes REPAIR the short to B+ voltage. For additional information, refer to the wiring diagrams. CLEAR the DTCs. TEST the system for normal operation. -> No Goto <<B10>>
B10 : CHECK THE IGNITION COIL (CYLS 2, 3, 5, AND 8) MONITOR CIRCUITS FOR SHORT TO GROUND
1. Disconnect the relevant ignition coil electrical connector(s). 2. Measure the resistance between; Cyl 2 PI55, pin 2 (YG) and GROUND. Cyl 3 PI52, pin 2 (YG) and GROUND. Cyl 5 PI53, pin 2 (YG) and GROUND. Cyl 7 PI58, pin 2 (YG) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short to GROUND. For additional information, refer to the wiring diagrams. CLEAR the DTCs. TEST the system for normal operation. -> No INSTALL a new ECM. <<303-04>> Before replacing a ECM, contact Dealer technical support.
C : CHECK SPARK PLUG RESISTANCE C1 : CHECK SPARK PLUG RESISTANCE

1. Remove the suspect spark plug(s). <<Spark Plugs - >> 2. Measure the resistance between the spark plug center electrode tip and the spark plug HT contact. Is the resistance between 8,000 and 12,000 ohms? (nominal 10,000 ohms) -> Yes Check ignition coil and circuits. See possible sources list for misfire. -> No INSTALL a new spark plug. <<Spark Plugs - >> CLEAR the DTC. TEST the system for nomal operation.
12
2012-07-19
Ignition Coil-On-Plug LH 18.20.44

www.JagDocs.com
2. Remove the coolant expansion tank for access. Remove screw. Position tank aside and secure with suitable tie.
3. Remove coil on-plug cover. Remove six bolts. Remove cover. Clean mating faces.
2012-07-19
4. Detach harness from retaining clips as necessary and disconnect relevant coil connector.
5. Remove relevant ignition coil. Remove bolts. Remove coil.
2012-07-19

Installation
www.JagDocs.com
2.
2012-07-19
Ignition Coil-On-Plug RH 18.20.43

Removal 1. Disconnect battery ground cable (IMPORTANT, see SRO <<86.15.19>> for further information). 2. Remove the air intake tube / meter / air cleaner cover for access; refer to 19.10.30.
3. Remove coil on-plug cover. Remove six bolts. Remove cover. Clean mating faces.
4. Detach harness from retaining clips as necessary and disconnect relevant coil connector.
2012-07-19
www.JagDocs.com
5. Remove relevant ignition coil. Remove bolts. Remove coil.
Installation
2012-07-19
2.
2012-07-19
Spark Plugs 18.20.02

Removal 1. Disconnect battery ground cable (IMPORTANT, see SRO <<86.15.19>> for further information). 2. Remove air intake tube / meter / air cleaner cover for access; refer to 19.10.30. 3. Remove ignition coils; refer to 18.20.41 (bank 1) and 18.20.42 (bank 2).
www.JagDocs.com
4. Remove spark plugs. 5. Clean all components as necessary.
2012-07-19

Installation
1. Installation is a reversal of the removal procedure. Check electrode gap is to the correct specification. Refer to the Specification Section and current Service Bulletins. Apply suitable lubricant e.g. Neverseez Compound, to lower four threads of spark plug(s) adjacent to the electrodes. The lubricant must be applied to full thread depth for at least 180 of the thread circumference. The electrodes must not be contaminated during this process.
2.
2012-07-19
1999 XK RANGE - Engine Emission Control - 303-08
Engine Emission Control Vehicles Without: Supercharger

1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical or electrical damage, correct fitment, etc. Visual Inspection Chart Mechanical Engine oil level Cooling system coolant level Fuel level Fuel Contamination/grade/quality Throttle body Poly-vee belt Engine breather system pipework/connections EGR pipework condition. (cracking, etc) 3. Verify the following systems are working correctly: Air intake system Cooling system Charging system Fuel charging system Ignition system 4. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step 5. Where the Jaguar approved diagnostic system is available, complete the S93 report before clearing any or all fault codes from the vehicle. NOTE: If a DTC cannot be cleared, then there is a permanent fault present that flags again as soon as it is cleared. (The exception to this is P1260, which will only clear following an ignition OFF/ON cycle after rectification.) 6. If the cause is not visually evident and the Jaguar approved diagnostic system is not available, use a fault code reader to retrieve the fault codes before proceeding to the diagnostic trouble code (DTC) index chart, or the symptom chart if no DTCs are set. 7. Using the Jaguar approved diagnostic system where available, and a scan tool where not, check the freeze frame data for information on the conditions applicable when the fault was flagged. The format of this will vary, depending on the tool used, but can provide information useful to the technician in diagnosing the fault. Electrical Fuses Wiring harness Electrical connector(s) Sensor(s) Engine control module (ECM)
www.JagDocs.com
CAUTION: When probing connectors to take measurements in the course of the pinpoint tests, use the adaptor kit, part number 3548-1358-00. NOTE: When performing electrical voltage or resistance tests, always use a digital multimeter (DMM) accurate to 3
1 2012-07-19
decimal places, and with an up-to-date calibration certificate. When testing resistance, always take the resistance of the DMM leads into account. NOTE: Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests. Symptom Chart Symptom (general) Poor driveability Symptom (specific) Engine hesitates/poor acceleration/rough idle/noise Possible source Fuel pump Air leakage Fuel pressure regulator Fuel lines Harness damage Throttle sensors Throttle motor Spark plugs fouled Ignition coil failure(s) Check for water ingress into spark plug wells (SC only) HT short to ground (tracking) check rubber boots for cracks/damage Exhaust gas recirculation (EGR) Action Check fuel pressure, <<310-00>> For air intake system information, <<303-12>> For fuel pressure regulator tests, <<303-04>> For fuel line information, <<310-01>> For throttle sensor circuit tests, <<303-14>> For throttle motor circuit tests, <<303-04>> For ignition system tests, <<303-07>> Inspect EGR components, for circuit tests, Goto <<A>> .
2012-07-19

DTC P0400 Description Exhaust gas recirculation (EGR) flow malfunction Possible Source EGR valve connector pins high resistance EGR pipe/exhaust manifold leak EGR pipe blocked EGR valve stuck open/closed, blocked EGR valve failure P0405 Exhaust gas recirculation (EGR) drive circuits open circuit EGR valve power supply circuit open circuit EGR valve to ECM drive circuit pair - EGR pins 1/3, 4/6 open circuit, high resistance EGR valve failure (stepper motor open circuit) P0406 Exhaust gas recirculation (EGR) drive circuits short circuit EGR valve to ECM drive circuit pair - EGR pins 1/3, 4/6 short circuit to ground or high voltage EGR valve failure (stepper motor short circuit) For EGR valve circuit tests, Goto <<A>> . For EGR valve circuit tests, Goto <<A>> . Action Check the EGR pipe, valve and manifold for leaks/blockages. Check the EGR valve function. For EGR valve circuit tests, Goto <<A>> .
www.JagDocs.com
Pinpoint Tests A : DTC P0400, P0405; EGR VALVE FLOW MALFUNCTION/DRIVE CIRCUITS OPEN CIRCUIT A1 : CHECK THE EMS POWER SUPPLIES TO THE EGR VALVE
1. Disconect the EGR valve electrical connector, PI34. 2. Turn the ignition switch to the ON position. 3. Make sure the EMS relay is energised. 4. Measure the voltage between PI34, pins 02 and 05 (WP) and GROUND. Is the voltage at both pins greater than 10 volts? -> Yes Goto <<A2>> -> No REPAIR the circuit between the EGR valve and battery. This circuit includes the EMS relay and the EMS fuse box, fuse 10. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
A2 : CHECK THE EGR VALVE COIL WINDINGS FOR CONTINUITY

1. Measure the resistance between pins 04 and 06 of the EGR valve. 2. Measure the resistance between pins 01 and 03 of the EGR valve. Are both resistances greater than 80 ohms? -> Yes
2012-07-19
Goto <<A3>> -> No INSTALL a new EGR valve. CLEAR the DTC. TEST the system for normal operation.
A3 : CHECK THE EGR VALVE COIL WINDINGS TO POWER SUPPLY CIRCUIT FOR CONTINUITY
1. Measure the resistance between pins 02 and 03 of the EGR valve. 2. Measure the resistance between pins 05 and 06 of the EGR valve. Are both resistances less than 80 ohms? -> Yes Goto <<A4>> -> No INSTALL a new EGR valve. CLEAR the DTC. TEST the system for normal operation.
A4 : CHECK THE EGR VALVE TO ECM CIRCUITS FOR OPEN CIRCUIT

1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM12. 3. Measure the resistance between the following PI34, pin 04 (YU) and EM85, pin 03 (YU). PI34, pin 01 (YG) and EM85, pin 04 (YG). PI34, pin 06 (YR) and EM85, pin 09 (YR). PI34, pin 03 (YR) and EM85, pin 10 (YR). Are the resistances greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<A5>>
A5 : CHECK THE EGR VALVE TO ECM CIRCUITS FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Measure the voltage between the following PI34, pin 04 (YU) and GROUND. PI34, pin 01 (YG) and GROUND. PI34, pin 06 (YR) and GROUND. PI34, pin 03 (YR) and GROUND. Are the voltages greater than 10 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<A6>>
2012-07-19
A6 : CHECK THE EGR VALVE TO ECM CIRCUITS FOR SHORT TO GROUND

1. Measure the resistance between the following PI34, pin 04 (YU) and GROUND. PI34, pin 01 (YG) and GROUND. PI34, pin 06 (YR) and GROUND. PI34, pin 03 (YR) and GROUND. Are the resistances less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Contact dealer technical support for advice on possible ECM failure.
www.JagDocs.com
2012-07-19
Engine Emission Control Vehicles With: Supercharger

1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical or electrical damage, correct fitment, etc. Visual Inspection Chart Mechanical Engine oil level Cooling system coolant level Fuel level Fuel Contamination/grade/quality Throttle body Poly-vee belt Engine breather system pipework/connections EGR pipework condition. (cracking, etc) 3. Verify the following systems are working correctly: Air intake system Cooling system Charging system Fuel charging system Ignition system 4. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step 5. Where the Jaguar approved diagnostic system is available, complete the S93 report before clearing any or all fault codes from the vehicle. NOTE: If a DTC cannot be cleared, then there is a permanent fault present that flags again as soon as it is cleared. (The exception to this is P1260, which will only clear following an ignition OFF/ON cycle after rectification.) 6. If the cause is not visually evident and the Jaguar Approved Diagnostic System is not available, use a fault code reader to retrieve the fault codes before proceeding to the Diagnostic Trouble Code (DTC) Index Chart, or the Symptom Chart if no DTCs are set. 7. Using the Jaguar approved diagnostic system where available, and a scan tool where not, check the freeze frame data for information on the conditions applicable when the fault was flagged. The format of this will vary, depending on the tool used, but can provide information useful to the technician in diagnosing the fault. Electrical Fuses. Wiring harness Electrical connector(s) Sensor(s) Engine control module (ECM)
CAUTION: When probing connectors to take measurements in the course of the pinpoint tests, use the adaptor kit, part number 3548-1358-00. NOTE: When performing electrical voltage or resistance tests, always use a digital multimeter (DMM) accurate to 3
1 2012-07-19
decimal places, and with an up-to-date calibration certificate. When testing resistance, always take the resistance of the DMM leads into account. NOTE: Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests. Symptom Chart Symptom (general) Poor driveability Symptom (specific) Engine hesitates/poor acceleration Possible source Fuel pump Air leakage Fuel pressure regulator Fuel lines Harness damage Throttle sensors Throttle motor Spark plugs fouled Ignition coil failure(s) Check for water ingress into spark plug wells (SC only) HT short to ground (tracking) check rubber boots for cracks/damage Exhaust gas recirculation (EGR) Action Check fuel pressure, <<310-00>> For air intake system information, <<303-12>> For fuel pressure regulator tests, <<303-04>> For fuel line information, <<310-01>> For throttle sensor circuit tests, <<303-14>> For throttle motor circuit tests, <<303-04>> For ignition system tests, <<303-07>> Inspect EGR components, for circuit tests, Goto <<B>> .
www.JagDocs.com
2012-07-19

DTC P0400 Description Exhaust gas recirculation (EGR) flow malfunction Possible Source EGR valve connector pins high resistance EGR pipe/exhaust manifold leak EGR pipe blocked EGR valve stuck open/closed, blocked EGR valve failure P0405 Exhaust gas recirculation (EGR) drive circuits open circuit EGR valve power supply circuit open circuit EGR valve to ECM drive circuit pair - EGR pins 1/3, 4/6 open circuit, high resistance EGR valve failure (stepper motor open circuit) P0406 Exhaust gas recirculation (EGR) drive circuits short circuit EGR valve to ECM drive circuit pair - EGR pins 1/3, 4/6 short circuit to ground or high voltage EGR valve failure (stepper motor short circuit) For EGR valve circuit tests, Goto <<B>> . For EGR valve circuit tests, Goto <<B>> . Action Check the EGR pipe, valve and manifold for leaks/blockages. Check the EGR valve function. For EGR valve circuit tests, Goto <<B>> .
Pinpoint Tests B : DTC P0400, P0405; EGR VALVE FLOW MALFUNCTION/DRIVE CIRCUITS OPEN CIRCUIT B1 : CHECK THE EMS POWER SUPPLIES TO THE EGR VALVE
1. Disconect the EGR valve electrical connector, PI34. 2. Turn the ignition switch to the ON position. 3. Make sure the EMS relay is energised. 4. Measure the voltage between PI34, pins 02 and 05 (WP) and GROUND. Is the voltage at both pins greater than 10 volts? -> Yes Goto <<B2>> -> No REPAIR the circuit between the EGR valve and battery. This circuit includes the EMS relay and the EMS fuse box, fuse 10. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
B2 : CHECK THE EGR VALVE COIL WINDINGS FOR CONTINUITY

1. Measure the resistance between pins 04 and 06 of the EGR valve. 2. Measure the resistance between pins 01 and 03 of the EGR valve. Are both resistances greater than 80 ohms? -> Yes
2012-07-19
Goto <<B3>> -> No INSTALL a new EGR valve. CLEAR the DTC. TEST the system for normal operation.
B3 : CHECK THE EGR VALVE COIL WINDINGS TO POWER SUPPLY CIRCUIT FOR CONTINUITY
1. Measure the resistance between pins 02 and 03 of the EGR valve. 2. Measure the resistance between pins 05 and 06 of the EGR valve. Are both resistances less than 80 ohms? -> Yes Goto <<B4>> -> No INSTALL a new EGR valve. CLEAR the DTC. TEST the system for normal operation.
B4 : CHECK THE EGR VALVE TO ECM CIRCUITS FOR OPEN CIRCUIT

1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM12. 3. Measure the resistance between the following PI34, pin 04 (YU) and EM12, pin 01 (YU). PI34, pin 01 (YG) and EM12, pin 02 (YG). PI34, pin 06 (YN) and EM12, pin 03 (YN). PI34, pin 03 (YR) and EM12, pin 04 (YR). Are the resistances greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<B5>>
www.JagDocs.com
B5 : CHECK THE EGR VALVE TO ECM CIRCUITS FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Measure the voltage between the following PI34, pin 04 (YU) and GROUND. PI34, pin 01 (YG) and GROUND. PI34, pin 06 (YN) and GROUND. PI34, pin 03 (YR) and GROUND. Are the voltages greater than 10 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<B6>>
2012-07-19
B6 : CHECK THE EGR VALVE TO ECM CIRCUITS FOR SHORT TO GROUND

1. Measure the resistance between the following PI34, pin 04 (YU) and GROUND. PI34, pin 01 (YG) and GROUND. PI34, pin 06 (YN) and GROUND. PI34, pin 03 (YR) and GROUND. Are the resistances less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Contact dealer technical support for advice on possible ECM failure.
2012-07-19
1999 XK RANGE - Intake Air Distribution and Filtering - 303-12
Charge Air Cooler LH 18.50.19

Removal 1. Disconnect battery ground cable (IMPORTANT, see SRO <<86.15.19>> for further information). 2. Drain radiator coolant; refer to 26.10.01. 3. Remove air cleaner cover / intake assembly; refer to 19.10.30. 4. Remove throttle body; refer to <<19.70.04>>. 5. Remove exhaust gas re-circulation valve (EGR) if installed; refer to 17.45.01. 6. Remove throttle intake elbow; refer to (SC) <<19.70.28>>. 7. Remove supercharger outlet duct; refer to <<18.50.16>>. 8. Remove coolant outlet pipe; refer to operation (SC) <<26.31.08>>. 9. Remove supercharger drive belt; refer to <<18.50.08>>. 10. Remove supercharger; refer to operation <<18.50.15>>. 11. Detach engine harness retaining clip from rear of charge air cooler.
www.JagDocs.com
12. Disconnect hoses from charge air cooler. Place absorbent cloth in appropriate position. Disconnect hoses.
2012-07-19
13.
CAUTION: Take care to avoid dropping any objects or foreign matter into engine inlet duct with charge air cooler removed.
Remove charge air cooler from the engine. 1. Remove eight bolts. Remove charge air cooler. 2. Discard gasket. Clean all mating faces.
Installation
1. Install charge air cooler to adaptor. 1. Install new gasket. 2. Install charge air cooler.
2012-07-19
www.JagDocs.com
2. Connect hoses to charge air cooler. Connect hoses. 3. Install supercharger; refer to <<18.50.15>>. 4. Install supercharger drive belt; refer to <<18.50.08>>. 5. Install engine coolant outlet pipe; refer to <<26.31.08>>. 6. Install supercharger outlet duct and new gasket; refer to <<18.50.16>>. 7. Install throttle intake elbow; refer to <<19.70.28>>. 8. Install exhaust gas re-circulation valve (EGR) if applicable; refer to 17.45.01. 9. Install throttle body; refer to <<19.70.04>>. 10. Install air cleaner cover / intake assembly; refer to 19.10.30. 11. Refill cooling system; refer to (SC) (26.10.01). 12. Reconnect battery ground cable (IMPORTANT, see SRO <<86.15.15>> for further information).
2012-07-19
Charge Air Cooler RH 18.50.18

Removal 1. Disconnect battery ground cable (IMPORTANT, see SRO <<86.15.19>> for further information). 2. Drain radiator coolant; refer to 26.10.01. 3. Remove air cleaner cover / intake assembly; refer to 19.10.30. 4. Remove throttle body; refer to <<19.70.04>>. 5. Remove exhaust gas re-circulation valve (EGR) if installed; refer to 17.45.01. 6. Remove throttle intake elbow; refer to (SC) <<19.70.28>>. 7. Remove supercharger outlet duct; refer to <<18.50.16>>. 8. Remove coolant outlet pipe; refer to operation (SC) <<26.31.08>>. 9. Remove supercharger drive belt; refer to <<18.50.08>>. 10. Remove supercharger; refer to operation <<18.50.15>>. 11. Remove intake air temperature sensor 2 from charge air cooler; refer to <<18.30.52>>. 12. Detach engine harness retaining clip from rear of charge air cooler.
2012-07-19
13. Disconnect hoses from charge air cooler. Place absorbent cloth in appropriate position. Disconnect hoses.
www.JagDocs.com
14.
CAUTION: Take care to avoid dropping any objects or foreign matter into engine inlet duct with charge air cooler removed.
Remove charge air cooler from the engine. 1. Remove eight bolts. Remove charge air cooler. 2. Discard gasket. Clean all mating faces.
Installation
2012-07-19
1. Install charge air cooler to adaptor. 1. Install new gasket. 2. Install charge air cooler.
2. Connect hoses to charge air cooler. Connect hoses. 3. Install intake air temperature sensor 2 to charge air cooler; refer to <<18.30.52>>. 4. Install supercharger; refer to <<18.50.15>>. 5. Install supercharger drive belt; refer to <<18.50.08>>. 6. Install engine coolant outlet pipe; refer to <<26.31.08>>. 7. Install supercharger outlet duct and new gasket; refer to <<18.50.16>>. 8. Install throttle intake elbow; refer to <<19.70.28>>. 9. Install exhaust gas re-circulation valve (EGR) if applicable; refer to 17.45.01. 10. Install throttle body; refer to <<19.70.04>>. 11. Install air cleaner cover / intake assembly; refer to 19.10.30. 12. Refill cooling system; refer to (SC) (26.10.01). 13. Reconnect battery ground cable (IMPORTANT, see SRO <<86.15.15>> for further information).
2012-07-19
Charge Air Cooler Gasket LH 18.50.22

Removal 1. Remove charge air cooler, bank 2; refer to <<18.50.19>>.
Installation 1. Installation is a reversal of the removal procedure.
www.JagDocs.com
2012-07-19
Charge Air Cooler Gasket RH 18.50.21

Removal 1. Remove charge air cooler, bank 1; refer to <<18.50.18>>.
2012-07-19
Supercharger 18.50.15
Removal 1. Disconnect battery ground cable (IMPORTANT, see SRO <<86.15.19>> for further information). 2. Drain radiator coolant; refer to 26.10.01. 3. Remove air cleaner cover / intake assembly; refer to 19.10.30. 4. Remove throttle body; refer to <<19.70.04>>. 5. Remove exhaust gas re-circulation valve (EGR) if installed; refer to 17.45.01. 6. Remove throttle intake elbow; refer to (SC) <<19.70.28>>. 7. Remove supercharger outlet duct; refer to <<18.50.16>>. 8. Remove coolant outlet pipe; refer to operation (SC) <<26.31.08>>. 9. Remove supercharger drive belt; refer to <<18.50.08>>. 10. Disconnect remaining coolant hoses from charge air coolers. Position pipes to facilitate removal of supercharger. Install suitable blanking plugs.
www.JagDocs.com
11. Remove supercharger from engine. 1. Remove bolt. 2. Remove bolts . 3. Remove supercharger.
2012-07-19
Installation
1. Install supercharger. 2. Connect all hoses to charge air coolers. 3. Install supercharger drive belt; refer to <<18.50.08>>. 4. Install engine coolant outlet pipe; refer to <<26.31.08>>. 5. Install supercharger outlet duct and new gasket; refer to <<18.50.16>>. 6. Install throttle intake elbow; refer to <<19.70.28>>. 7. Install exhaust gas re-circulation valve (EGR) if applicable; refer to 17.45.01. 8. Install throttle body; refer to <<19.70.04>>. 9. Install air cleaner cover / intake assembly; refer to19.10.30. 10. Refill cooling system; refer to (SC) (26.10.01).
2012-07-19
Supercharger Outlet Pipe 18.50.16

Removal 1. Remove air cleaner cover / intake assembly; refer to 19.10.30. 2. Drain radiator coolant; refer to operation (SC) 26.10.01.
www.JagDocs.com
3. Disconnect coolant hoses and vacuum pipe from supercharger outlet duct. Place absorbent rags under the two coolant hoses which are connected to the outlet duct. 1. Remove vacuum pipe. 2. Disconnect hoses. Plug hoses and outlet duct stub pipes to prevent spillage.
2012-07-19
4.
CAUTION: Take care to avoid any coolant from dripping into supercharger.
Remove supercharger outlet duct. 1. Remove three bolts. 2. Remove four bolts. Discard rubber seals from bolts. 3. Remove outlet duct. Discard outlet duct gasket. 5. Blank supercharger outlet with body tape, or similar, to prevent ingress of foreign matter.
6. Remove charge air cooler inlet assembly. 1. Remove two bolts. 2. Remove two bolts. 3. Remove charge air cooler inlet assembly.
2012-07-19
7. Remove ducts from charge air cooler inlet assembly. 1. Remove two clamp plates. 2. Discard two ducts. 8. Clean all relevant parts and mating faces.
Installation 1. Re-assemble charge air cooler clamp inlet assembly. Use new ducts.
www.JagDocs.com
2. Install charge air cooler inlet assembly to charge air coolers.
2012-07-19
3.
CAUTION: Take care to avoid ingress of dirt or foreign matter into the supercharger.
Install supercharger outlet duct. 1. Remove blanking tape from outlet port of supercharger. Clean supercharger outlet mating face. 2. Install new gasket. 3. Install duct. 4. Install new rubber seals to the four bolts.
2012-07-19
www.JagDocs.com
4. Secure charge air cooler inlet assembly to supercharger outlet duct. 1. Install bolts.
5. Install coolant hoses and vacuum pipe to outlet duct. 1. Install vacuum pipe. 2. Install coolant hoses. 6. Refill cooling system; refer to (SC) (26.10.01). 7. Install intake tube / air flow meter / air cleaner cover assembly; refer to 19.10.30.
2012-07-19
Supercharger Outlet Pipe Gasket 18.50.17

Removal 1. Remove supercharger outlet duct; refer to <<18.50.16>>.
2012-07-19
Throttle Body Elbow 19.70.28

Removal 1. WARNING: BEFORE PROCEEDING, IT IS ESSENTIAL THAT WARNING NOTES GIVEN IN SECTION <<100-00>> (UNDER HEADING 'SAFETY PRECAUTIONS') ARE READ AND UNDERSTOOD.
Disconnect battery ground cable (IMPORTANT, see SRO <<86.15.19>> for further information). 2. Remove air cleaner cover / intake assembly; refer 19.10.30. 3. Remove throttle assembly; refer to <<19.70.04>>. 4. Remove exhaust gas recirculation (EGR) valve where installed; refer 17.45.01.
www.JagDocs.com
5. Release intake elbow from right-hand support bracket. Release brake servo vacuum pipe and disconnect pipe. 1. Disconnect vacuum pipe. 2. Remove upper bolt.
2012-07-19
6. Release intake elbow from left-hand support bracket. 1. Disconnect vacuum pipe. 2. Disconnect engine breather T-piece. 3. Remove upper bolt. 4. Loosen, but do not remove, lower two bolts.
7. Remove intake elbow from supercharger. 1. Release and pull back clips securing bypass hoses at charge air coolers. 2. Remove four bolts. 3. Remove hoses from charge air cooler stub pipes. Remove assembly from vehicle. 4. Discard gasket. Clean all mating faces.
2012-07-19
www.JagDocs.com
8. Remove by-pass valve assembly from intake elbow. 1. Remove two bolts. Remove by-pass assembly from elbow and discard O-ring. 9. Where necessary, remove blanking plate from intake elbow. Remove bolts. Discard gasket. Clean all mating faces.
Installation 1. Where necessary, install blanking plate to intake elbow. Install new gasket. Install bolts (18-24Nm).
2012-07-19
2. Install by-pass valve assembly to intake elbow. Install new O-ring and lubricate with petroleum jelly. 1. Install bolts.
3. Install intake elbow to supercharger. 1. Install two bolts to intake elbow and install new gasket. 2. Position intake elbow assembly with by-pass hoses located on charge air cooler stub pipes. 3. Install and tighten four bolts . 4. Position hose securing clips.
4. Install left-hand support bracket to intake elbow and re-connect pipework. 1. Install bolt. 2. Fully tighten two bolts. 3. Connect breather/purge pipe T-piece to intake elbow. 4. Connect vacuum pipe to intake elbow.
2012-07-19
www.JagDocs.com
5. Install right-hand support bracket to intake elbow. 1. Install bolt. 6. Install exhaust gas re-circulation valve (EGR) if applicable; refer to 17.45.01. 7. Install throttle assembly; refer to <<19.70.04>>. 8. Install air cleaner cover / intake assembly; refer to 19.10.30. 9. Reconnect battery ground cable (IMPORTANT, see SRO <<86.15.15>> for further information).
2012-07-19
Throttle Body Elbow Gasket 19.70.29

Removal 1. Remove throttle intake elbow; refer to (SC)<<19.70.28>>.
2012-07-19
1999 XK RANGE - Evaporative Emissions - 303-13
Evaporative Emissions
To reduce the emission of fuel vapor, the fuel tank is vented to atmosphere through activated evaporative emission canisters which collect the fuel vapor. The evaporative emission canister is periodically purged of fuel vapor when the evaporative emission canister purge valve opens the vapor line between the evaporative emission canister and the air intake induction elbow. This action allows manifold depression to draw air through the evaporative emission canister atmospheric vent, taking up the deposited fuel vapor from the charcoal adsorber inside the evaporative emission canister and burning the resulting fuel vapor in the engine. There are two variants of the evaporative emissions system. All systems use the charcoal adsorber storage evaporative emission canisters and purge valve and operate as described above. The specific features of each system are described below. The evaporative systems are designated as : Vehicles with on-board refuelling vapor recovery Vehicles without on-board refueling vapor recovery
Evaporative Emissions Canister Purge Valve
www.JagDocs.com
The evaporative emission canister purge valve controls the flow rate of fuel vapor drawn into the engine during the canister purge operation. The valve is opened by a vacuum feed from the induction elbow : the vacuum feed is controlled by the integral valve solenoid and is applied when the solenoid is energized. The solenoid is pulsed on (energized) and off by a fixed frequency (100Hz) variable pulse width control signal (pulse width modulation). By varying the pulse on to off time, the ECM controls the duty cycle of the valve (time that the valve is open to time closed) and thus the vapor flow rate to the engine. With no ECM signal applied to the valve solenoid, the valve remains closed.
Canister Purge Operation

The following pre-conditions are necessary for purging to commence : after battery disconnection/reconnection, engine management adaptations must be re-instated. engine has run for at least 8 seconds. engine coolant temperature is not less than 70 C.
2012-07-19
engine not running in the fuel cut off condition (eg overrun). the adaptive fuel correction function has not registered a rich or lean failure the evaporative emission leak test has not failed no faults have been diagnosed in the relevant sensor and valve circuits - air flow meter (AFM), engine coolant temperature sensor, evaporative canister purge valve and evaporative emission canister vent solenoid. If these conditions have been satisfied, purging is started. If any failures are registered, purging is inhibited. The canister(s) is purged during each drive cycle at various rates in accordance with the prevailing engine conditions. The engine management software stores a map of engine speed (RPM) against engine load (grams of air inducted / rev). For any given engine speed and load, a vapor purge rate is assigned (purge rate increases with engine speed and load). The preset purge rates are based on the assumption of a vapor concentration of 100%. The actual amount of vapor is measured by the closed loop fueling system : the input of evaporative fuel into the engine causes the outputs from the upstream oxygen sensors to change, the amount of change providing a measure of the vapor concentration. This feedback causes the original purge rate to be adjusted and also reduces the amount of fuel input via the injectors to maintain the correct air to fuel ratio. Engine speed/load mapping and the corresponding purge rates are different for vehicles fitted on-board refueling vapor recovery and vehicles without on-board refueling vapor recovery.
2012-07-19

Vehicles With On-board Refueling Vapor Recovery.
www.JagDocs.com
Item 1 2 3 4 5
Description Evaporative emission canister purge valve Evaporative emission canister Fuel vapor vent valve housing Evaporative emission canister vent solenoid Evaporative emission canister
The system has the following features : on-board refueling vapor recovery to reduce the fuel vapor vented directly to atmosphere from the filler nozzle when refueling . a fuel tank pressure sensor and an evaporative emission canister vent solenoid are fitted to allow the on-board diagnostic facility to test for leaks in the fuel and evaporative system. The evaporative emission canister vent solenoid is a solenoid operated device controlled by the ECM. The valve is normally open and is closed only during the leak test sequence.
2012-07-19
The fuel tank pressure sensor is fitted to the fuel vapor vent valve housing and provides a voltage to the ECM which is proportional to tank vapor pressure.
Operation Of On-board Refueling Vapor Recovery

The on-board refueling vapor recovery system enables fuel vapor generated during refueling to be collected by the charcoal canisters. During normal running of the vehicle, the vapor is collected and purged in the same way as for vehicles without on-board refueling vapor recovery. The on-board refueling vapor recovery system features are : Narrow fuel filler pipe and tank check valve. Fuel level vent valve fitted to the fuel vapor vent valve housing and consisting of a two stage shut-off valve with rollover protection and a pressure relief valve. Grade vent valve with rollover protection, fitted to the fuel vapor vent valve housing and with an outlet pipe connected to the fuel level vent valve vapor outlet pipe. Large bore vapor vent pipes. The fuel filler pipe has a reduced diameter between the nozzle guide and the tank, providing a liquid seal when refueling and preventing the fuel vapor venting directly to atmosphere. There is no breather tube fitted between the tank and the filler nozzle. To prevent spit back when refueling , a check valve is fitted at the lower end of the filler pipe inside the tank (see Figure). During refueling, the tank is vented via the fuel level vent valve, large bore vapor pipes and the charcoal canisters. The fuel level vent valve incorporates a float valve which is closed by the rising fuel level, creating a back pressure and causing the fuel delivery to stop. In the closed position, the fuel level vent valve also sets the fuel level. With the fuel level vent valve closed (tank full), any increase in pressure or overfilling is relieved by a separate rollover protected grade vent valve. The outlet from this valve feeds into the main fuel level vent valve vapor outlet pipe, bypassing the closed fuel level vent valve. When the fuel level is below full, the fuel level vent valve opens to allow unrestricted venting via the canisters. A pressure relief valve is incorporated into the fuel level vent valve assembly and has an outlet pipe to the filler nozzle,. If a blockage or other restriction (eg, evaporative emission canister vent solenoid in the closed position) occurs in the vapor vent system, the pressure relief valve opens to allow venting to atmosphere via the filler nozzle guide and fuel filler cap. Canister purge operation is as described in Evaporative Emissions.
2012-07-19

Fuel Vapor Vent Valve Housing - Vehicles With On-Board Refueling Vapor Recovery
www.JagDocs.com
Item 1 2 3 4 5
Description Grade vent valve Fuel pump module electrical connector Fuel tank pressure sensor Fuel level vent valve Fuel vapor vent valve housing locking ring
The fuel vapor vent valve housing is fitted to the top of the tank via a seal and locking ring arrangement identical to that used for vehicles without on-board refueling vapor recovery. The fuel vapor vent valve housing is removable complete with the fitted components. The fuel level vent valve is mounted in the fuel vapor vent valve housing via a bayonet fitting : it is turned approximately 90 clockwise to release. The grade vent valve and pressure sensor are push in fits via sealing grommets : note that, due to the tight fit, removal of these components may require cutting the grommets. The fuel pump connector is push fitted and crimped into a location tube on the underside of the flange.
Evaporative Emission Canister, Evaporative Emission Canister Vent Solenoid and Fittings
The evaporative emission canisters are fixed to the underside of the vehicle either via semi-enclosed mounting brackets. Two fixing bolts are used at the front of the bracket and a single rear bolt supports the evaporative emission canister and the evaporative emission canister vent solenoid. The vapor pipes to the canisters, other than the evaporative emission canister vent solenoid, use multi-tang connectors which are push fitted and pulled out without the use of tools. The evaporative emission canister vent solenoid has a stub pipe with 'O' ring seal which is a simple push fit into the canister. A mounting bracket on the evaporative emission canister vent solenoid enables it to be secured to the underbody via the canister rear mounting bolt. A hose connects the evaporative emission canister vent solenoid to the bracket mounted adaptor into which the vent system air filter is screwed.
2012-07-19
Vehicles Without On-board Refueling Vapor Recovery.
Item 1 2 3
Description Evaporative emission canister purge valve Fuel vapor vent valve housing Evaporative emission canister
This system uses one evaporative emission canister (two evaporative emission canisters and rochester valve fitted on vehicles used in high altitude environments). The vapor outlet from the fuel tank is taken via a rollover valve fitted to the removable flange at the top of the tank. Canister purge operation is as described in Evaporative Emissions.
2012-07-19
Fuel Vapor Vent Valve Housing - Vehicles Without On-board Refueling Vapor Recovery
www.JagDocs.com
Item 1 2 3
Description Vapor vent / rollover protection valve Fuel pump electrical connector fuel vapor vent valve housing locking ring
The fuel vapor vent valve housing is fitted to the top of the tank via a seal and locking ring. The fuel vapor vent valve housing is removable complete with the fitted components. The vapor vent / rollover valve is a push fit via a sealing grommet. The fuel pump electrical connector is push fitted and crimped into a location tube on the underside of the flange.
2012-07-19
Evaporative Emissions
Preliminary Inspection
1. Visually inspect for obvious signs of mechanical or electrical damage. Visual Inspection Chart Mechanical Engine oil level Cooling system coolant level Fuel level Throttle body Poly-vee belt 2. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 3. If the concern is not visually evident, verify the symptom and proceed with diagnosis, using the Jaguar approved diagnostic system, where available. 4. Where K-Line or Vacutec equipment is available, it should be used as an aid to diagnosis. The equipment must be capable of testing to the 0.020 thou standard. (2001 my on). Electrical Fuses Wiring harness Electrical connector(s) Engine control module (ECM)
Fuel Contamination/grade/quality Sensor(s)
Diagnostic Drive Cycles

Following the setting of a DTC, the appropriate repairs must be carried out, and the normal operation of the system checked. This will be done by performing a series of drive cycles which will enable the vehicle to operate the Evaporative Emissions system as a function check. For details of the drive cycles, <<303-14>> ECM adaptations.
Diagnostic Trouble Code (DTC) index/Symptom Chart

1. Where the Jaguar approved diagnostic system is available, complete the S93 report before clearing any or all fault codes from the vehicle. NOTE: If a DTC cannot be cleared, then there is a permanent fault present that flags again as soon as it is cleared. (The exception to this is P1260, which will only clear following an ignition OFF/ON cycle after rectification.) 2. If the cause is not visually evident and the Jaguar approved diagnostic system is not available, use a fault code reader to retrieve the fault codes before proceeding to the Diagnostic Trouble Code (DTC) Index Chart, or the Symptom Chart if no DTCs are set. 3. Using the Jaguar approved diagnostic system where available, and a scan tool where not, check the freeze frame data for information on the conditions applicable when the fault was flagged. The format of this will vary, depending on the tool used, but can provide information useful to the technician in diagnosing the fault. CAUTION: When probing connectors to take measurements in the course of the pinpoint tests, use the adaptor kit, part number 3548-1358-00. NOTE:
2012-07-19
When performing electrical voltage or resistance tests, always use a digital multimeter (DMM) accurate to 3 decimal places, and with an up-to-date calibration certificate. When testing resistance, always take the resistance of the DMM leads into account. NOTE: Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests. Symptom Chart Symptom Difficulty in filling Possible Source Restriction in the vapor line between the fuel tank and the carbon canister outlet/atmospheric port Adaptations incomplete Purge valve inoperative Message centre display (see below) Fuel filler cap missing/not tightened after refuelling Action Check for free flow of air
Fuel smell
Carry out the adaptations procedure, <<303-14>> Check purge valve operation Check fuel filler cap condition and fitment
www.JagDocs.com
Driver Information NOTE: Use this table to identify DTCs associated with the message centre display, then refer to the DTC index for possible sources and actions. NOTE: A trip is an ignition OFF, 30 seconds delay, ignition ON cycle, plus a minimum coolant temperature increase of 22C (40F) after which the coolant temperature should reach a minmum 71C (160F) Warning Light Red Red Message Check Engine (after two trips) Check Engine (after two trips) Default Mode ECM default. (canister purge inhibited, adaptive fuel metering inhibited) None DTC P0442, P0444, P0445, P0447, P0448 P0452, P0453
2012-07-19

Diagnostic Trouble Code (DTC) index Diagnostic Trouble Code P0442 Description System leak detected (small) Possible Source Fuel tank filler cap seal defective System leak (canister damage, pipework damage) Canister close valve leaking Fuel tank leak P0443 Canister purge valve malfunction Canister purge valve failure (not fully closed) For canister purge valve test, Goto <<B>> . For purge valve circuit tests, Goto <<C>> . For purge valve circuit tests, Goto <<C>> . For system checks, Goto <<D>> . For CCV circuit tests, Goto <<E>> . Action Check filler cap, system pipework, fuel tank, Goto <<A>> .
P0444
Canister purge valve circuit open circuit
Canister purge valve to ECM drive circuit; open circuit, high resistance Canister purge valve failure.
P0445
Canister purge valve circuit short circuit
Canister purge valve to ECM drive circuit; short circuit to ground Canister purge valve failure.
P0446
Canister Close Valve (CCV) malfunction
Fuel tank to atmospheric port line restricted CCV failure (stuck closed)
P0447
Canister Close Valve (CCV) circuit open circuit.
CCV power supply circuit; open circuit, short circuit CCV to ECM drive circuit; open circuit, high resistance, short circuit to B+ voltage CCV failure Canister close valve to ECM drive circuit; short circuit to ground Canister close valve failure FTP sensor failure
P0448
Canister Close Valve (CCV) circuit short circuit Fuel Tank Pressure (FTP) sensor malfunction
For CCV circuit tests, Goto <<E>> . For FTP sensor test, Goto <<F>> . For FTP sensor circuit tests, Goto <<G>> .
P0450
P0452
Fuel tank Pressure (FTP) sensor circuit; low voltage (low pressure)
FTP sensor disconnected FTP sensor to ECM sense circuit; open circuit, short circuit to ground FTP sensor to splice in sensor supply circuit; open circuit, high resistance FTP sensor failure
P0453
Fuel tank Pressure (FTP) sensor circuit; high voltage (high pressure)
FTP sensor to splice in sensor ground circuit; open circuit, high resistance FTP sensor to ECM sense circuit; open circuit, short circuit to high voltage FTP sensor failure
For FTP sensor circuit tests, Goto <<G>> .
2012-07-19
P0455
Leak detected (large)
Filler cap missing Filler cap seal defective System leak (canister/pipework damage) CCV stuck open Purge valve to engine purge pipe, damaged/blocked/leaking Purge valve operating vacuum hose leak/blockage Purge valve failure Fuel tank leak
Check filler cap, system pipework, fuel tank, Goto <<A>> .
Pinpoint Tests A : P0442, P0455; SYSTEM LEAK DETECTED

NOTE: For K-Line or Vacutec equipment connection, see bulletin 05.1-29, or Vacutec operating instructions
www.JagDocs.com
A1 : CHECK PIPEWORK, ETC FOR LEAKS

1. Carry out a visual inspection of all accessible pipes, connectors and components. Rectify any faults noted. 2. Using K-line or Vacutec equipment, check the joints/connections in the following order; Filler cap Canister purge valve Underfloor purge line connectors Carbon canister connections and vapor hoses Canister close valve and it's atmospheric port (disconnect the air vent tube if necessary). Was a fault found? -> Yes Rectify the fault as necessary. Repeat the K-line or Vacutec test. CLEAR the DTC. Carry out a full Evaporative system monitor drive cycle. Recheck DTCs. For additional information, see 'diagnostic drive cycles' above. -> No Goto <<A2>>
A2 : CHECK THE CANISTER PURGE VALVE FOR FLOW

1. Run the engine. 2. Make sure the canister purge valve is operating. 3. Using a flowmeter (or a small piece of paper) at the CCV inlet tube, confirm flow through the canister purge valve. Is there flow through the canister purge valve? -> Yes Possible intermittent fault with vapor hoses, 'O' ring seals. Carefully check condition of hoses and seals. Replace any suspect seals. Repeat the K-line or Vacutec test. CLEAR the DTC. Carry out a full
2012-07-19
Evaporative system monitor drive cycle. Recheck DTCs. For additional information, see 'diagnostic drive cycles' above. -> No INSTALL a new canister purge valve. <<Evaporative Emission Canister Purge Valve - >> CLEAR the DTC. Carry out a full Evaporative system monitor drive cycle.
B : P0443; CANISTER PURGE VALVE MALFUNCTION B1 : CHECK THE CANISTER PURGE VALVE FOR INTERNAL LEAKS
1. Disconnect the outlet pipe from the canister purge valve. (Pipe from purge valve to crankcase breather tube). 2. Using a hand-held vacuum pump, apply a vacuum to the outlet port of the canister purge valve Does the canister purge valve hold vacuum? -> Yes No fault found with canister purge valve. CLEAR the DTC. Carry out a full Evaporative system monitor drive cycle. Recheck DTCs. For additional information, see 'diagnostic drive cycles' above. -> No INSTALL a new canister purge valve. <<Evaporative Emission Canister Purge Valve - >> CLEAR the DTC. Carry out a full Evaporative system monitor drive cycle. Recheck DTCs. For additional information, see 'diagnostic drive cycles' above.
C : P0444, P0445; PURGE VALVE CIRCUIT OPEN/SHORT CIRCUIT C1 : CHECK THE PURGE VALVE DRIVE CIRCUIT FOR HIGH RESISTANCE
1. Turn the ignition switch to the OFF position. 2. Disconnect the battery negative terminal. 3. Disconnect the ECM electrical connector, EM80. 4. Disconnect the purge valve electrical connector, LF58. 5. Measure the resistance between EM80, pin 01, (PN) and LF58, pin 02 (PN). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. Carry out a full Evaporative system monitor drive cycle. For additional information, see 'diagnostic drive cycles' above. -> No Goto <<C2>>
C2 : CHECK THE PURGE VALVE DRIVE CIRCUIT FOR SHORT TO GROUND

1. Reconnect the battery negative terminal. 2. Measure the resistance between LF58, pin 02 (PN) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. Carry out a full Evaporative system monitor drive cycle.
2012-07-19
-> No INSTALL a new purge valve, CLEAR the DTC. Carry out a full Evaporative system monitor drive cycle. Recheck DTCs. For additional information, see 'diagnostic drive cycles' above. If the DTC is repeated, contact dealer technical support for advice on possible ECM failure.
D : P0446; CANISTER CLOSE VALVE (CCV) STUCK CLOSED OR RESTRICTED FLOW

NOTE: Depending on the severity of the blockage, it is possible that some level of difficulty has been experienced during a fuel fill operation.
D1 : CHECK FOR FREE FLOW OF AIR

1. Check for free flow of air through the following, paying particular attention to kinked or flattened pipes; Filter Interconnecting pipe (filter to CCV) Canister Close Valve (CCV) Interconnecting pipe (CCV to carbon canister) Carbon canister Interconnecting pipe between carbon canisters and to fuel tank Fuel tank vapor port Was a fault found? -> Yes Rectify the fault as necessary. CLEAR the DTC. Carry out a full Evaporative system monitor drive cycle. -> No Recheck the DTCs. Carry out a full Evaporative system monitor drive cycle.
www.JagDocs.com
E : P0447, P0448; CANISTER CLOSE VALVE CIRCUIT OPEN/SHORT CIRCUIT E1 : CHECK THE CCV DRIVE CIRCUIT FOR HIGH RESISTANCE
1. Turn the ignition switch to the OFF position. 2. Disconnect the battery negative terminal. 3. Disconnect the ECM electrical connector, EM80. 4. Disconnect the CCV electrical connector, BT14. 5. Measure the resistance between EM80, pin 02, (OK) and BT14, pin 01 (OK). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. Carry out a full Evaporative system monitor drive cycle. For additional information, see 'diagnostic drive cycles' above. -> No Goto <<E2>>
E2 : CHECK THE CCV DRIVE CIRCUIT FOR SHORT CIRCUIT TO GROUND
2012-07-19
1. Reconnect the battery negative terminal. 2. Measure the resistance between BT14, pin 01, (OK) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. Carry out a full Evaporative system monitor drive cycle. -> No INSTALL a new CCV. CLEAR the DTC. Carry out a full Evaporative system monitor drive cycle. Recheck DTCs. For additional information, see 'diagnostic drive cycles' above. If the DTC is repeated, contact dealer technical support for advice on possible ECM failure.
F : P0450; FUEL TANK PRESSURE (FTP) SENSOR MALFUNCTION

NOTE: This test will involve the use of a scan tool capable of reading fuel tank pressure.
F1 : CHECK FTP SENSOR FUNCTION

1. Turn the ignition switch to the OFF position. 2. Disconnect the FTP sensor electrical connector, FT02. 3. Connect a slave sensor to the harness. 4. Turn the ignition switch to the ON position. 5. Monitor the fuel tank pressure. 6. Close the sensor port with a finger, and press lightly. Does the pressure alter? -> Yes INSTALL a new fuel tank pressure sensor. CLEAR the DTC. Carry out a full Evaporative system monitor drive cycle. -> No Check the circuit between the FTP sensor and the ECM. For additional information, refer to the wiring diagrams. CLEAR the DTC. Carry out a full Evaporative system monitor drive cycle.
G : P0452, P0453; FUEL TANK PRESSURE (FTP) SENSOR LOW/HIGH VOLTAGE G1 : CHECK THE FTP SENSOR SENSE CIRCUIT FOR HIGH RESISTANCE
1. Turn the ignition switch to the OFF position. 2. Disconnect the battery negative terminal. 3. Disconnect the ECM electrical connector, EM81. 4. Disconnect the FTP sensor electrical connector, BT05. 5. Measure the resistance between EM81, pin 16 (RG) and FT02, pin 02 (RG). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. Carry out a full Evaporative system monitor drive cycle. For additional information, see 'diagnostic drive cycles' above.
2012-07-19
-> No Goto <<G2>>
G2 : CHECK THE FTP SENSOR SENSE CIRCUIT FOR SHORT CIRCUIT TO GROUND
1. Reconnect the battery negative terminal. 2. Measure the resistance between EM81, pin 16 (RG) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. Carry out a full Evaporative system monitor drive cycle. -> No Goto <<G4>>
G3 : CHECK THE FTP SENSOR SENSE CIRCUIT FOR SHORT CIRCUIT TO HIGH VOLTAGE
1. Turn the ignition switch to the ON position. 2. Measure the voltage between FT02, pin 02 (RG) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. Carry out a full Evaporative system monitor drive cycle. -> No Goto <<G4>>
www.JagDocs.com
G4 : CHECK THE FTP SENSOR SIGNAL GROUND CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Reconnect the ECM electrical connector, EM81. 3. Disconnect the ECM electrical connector, EM82. 4. Disconnect the ECM electrical connector, EM83. 5. Measure the resistance between EM82, pin 07 (BG) and FT02, pin 01 (BG). 6. Measure the resistance between EM83, pin 13 (BG) and FT02, pin 01 (BG). Is either resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. This circuit includes harness splice, EMS02. For additional information, refer to the wiring diagrams. CLEAR the DTC. Carry out a full Evaporative system monitor drive cycle. For additional information, see 'diagnostic drive cycles' above. -> No Goto <<G5>>
G5 : CHECK THE FTP SENSOR SIGNAL GROUND CIRCUIT FOR SHORT CIRCUIT TO GROUND
1. Reconnect the battery negative terminal. 2. Measure the resistance between FT02, pin 01 (BG) and GROUND.
2012-07-19
Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. Carry out a full Evaporative system monitor drive cycle. -> No Goto <<G6>>
G6 : CHECK THE FTP SENSOR POWER SUPPLY CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Measure the resistance between EM82, pin 01 (UW) and FT02, pin 03 (UW). 3. Measure the resistance between EM83, pin 05 (UW) and FT02, pin 03 (UW). Is either resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. This circuit includes harness splice, EMS01. For additional information, refer to the wiring diagrams. CLEAR the DTC. Carry out a full Evaporative system monitor drive cycle. For additional information, see 'diagnostic drive cycles' above. -> No Goto <<G7>>
G7 : CHECK THE FTP SENSOR WIRING FOR SHORT CIRCUIT TO EACH OTHER
1. Measure the resistance between FT02, pins 01 (BG) and 02 (RG). 2. Measure the resistance between FT02, pins 02 (RG) and 03 (UW). Is either resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. Carry out a full Evaporative system monitor drive cycle. -> No INSTALL a new FTP sensor. CLEAR the DTC. Carry out a full Evaporative system monitor drive cycle. For additional information, see 'diagnostic drive cycles' above.
2012-07-19
Evaporative Emission Canister 17.15.13

Removal WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE VAPORS ARE ALWAYS PRESENT AND MAY IGNITE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Remove the left-hand fender splash shield. <<501-02>>
www.JagDocs.com
2. Disconnect the evaporative emission canister tubes. Remove and discard the evaporative emission canister tube O-ring seals. Cap the evaporative emission canister and tubes to prevent contamination.
3. Remove the evaporative emission canister.

1 2012-07-19
Installation
1. NOTE: Install new evaporative emission canister tube O-ring seals. To install, reverse the removal procedure. Tighten to 6 Nm.
2012-07-19
Evaporative Emission Canister Purge Valve 17.15.30

Removal WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE VAPORS ARE ALWAYS PRESENT AND MAY IGNITE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WARNING: DO NOT CARRY OR OPERATE CELLULAR PHONES WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE VAPOURS ARE ALWAYS PRESENT AND MAY IGNITE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Remove the left-hand fender splash shield. <<501-02>>
www.JagDocs.com
2. Disconnect the evaporative emission canister purge valve electrical connector.
2012-07-19
3. Disconnect the evaporative emission canister purge valve vacuum hose.
4. Disconnect the evaporative emission canister tube. Remove and discard the evaporative emission canister tube O-ring seal. Cap the evaporative emission canister and tube to prevent contamination.
2012-07-19
www.JagDocs.com
5. Disconnect the evaporative emission canister tubes. Remove and discard the evaporative emission canister tube O-ring seals. Cap the evaporative emission canister tubes to prevent contamination.
6. Detach the side repeater wiring harness.
2012-07-19
7. Remove the evaporative emission canisters.
8. Disconnect the evaporative emission canister purge valve hoses. Cap the hoses and evaporative emission canister purge valve to prevent contamination.
2012-07-19
9. Remove the evaporative emission canister purge valve.
www.JagDocs.com
Installation
1. To install, reverse the removal procedure. Tighten to 6 Nm. 2. Install a new O-ring seal
2012-07-19
3. Tighten to 6 Nm.
2012-07-19
Fuel Vapor Vent Valve Housing 19.55.24

Fuel Tank Sender Unit Wrench 310-001
www.JagDocs.com
Quick Fit Connector Release Tool 310-054
Evaporative Loss Flange Lock Ring Wrench 412-070 Removal
2012-07-19
1.
Remove the fuel tank. Refer to operation 19.55.15. Do not install the fuel level sender unit, at this stage. 2. Tape back the insulation pads on top of the tank, to gain access to the evaporative loss flange.
3. Release the hose clip and disconnect the breather hose from the evaporative loss flange. Slide the hose along the pipe.
4. Remove the evaporative loss flange from the tank. Remove the locking ring (Tool 412-070) from the evaporative loss flange. Reposition the flange from the tank.
2012-07-19
5. Remove the evaporative loss flange from the tank. Disconnect the fuel pump electrical link lead. Remove the flange and the flange to tank seal. Discard the seal.
www.JagDocs.com
Installation 1. Installation is the reverse of the removal procedure. Install a new sealing ring to the evaporative loss flange; refer to 19.55.25. Install the fuel level sender unit.
2012-07-19
1999 XK RANGE - Electronic Engine Controls - 303-14
Torque specification Description Camshaft position (CMP) sensor retaining bolt Catalyst monitor sensor Crankshaft position (CKP) sensor retaining bolt Engine coolant temperature (ECT) sensor Fuel injection supply manifold retaining bolts - vehicles with supercharger Fuel injection supply manifold retaining bolts - vehicles without supercharger Fuel injection supply manifold wiring harness retaining nuts - vehicles with supercharger Heated oxygen sensor (H02S) Intake air temperature (IAT) sensor - vehicles with supercharger Knock sensor retaining nut - vehicles without supercharger Knock sensor retaining nut - vehicles with supercharger Mass air flow (MAF) sensor retaining screws Variable camshaft timing oil control solenoid retaining bolt Nm 7 45 7 17 21 20 5 45 35 20 36 2 10 lb-ft 33 13 15 15 33 26 14 27 7 lb-in 62 62 44 17 -
2012-07-19

Engine Control Module (ECM) Adaptation Vehicles Without: Supercharger
When to carry out adaptations

1. Whenever the battery is disconnected, the Engine Control Module (ECM) adaptations are reset to a 'green' ECM condition. In this condition, certain functions of the ECM are inhibited, and the ECM must 'relearn' these functions. To enable the ECM to do this, the vehicle will have to perform some maneuvres which it may, or may not, do during a normal road test. The routine in this procedure should be carried out at Pre-Delivery Inspection, and after any emissions related rectification work involving the disconnection of the battery.
DTCs P1000/P1111
1. When the DTCs relating to a rectified concern are cleared, P1000 (system checks not complete since last memory clear) will be flagged. This DTC does not indicate a failure, just that diagnostic drive cycles need to be performed. The vehicle's on-board diagnostic system will confirm that all the diagnostic drive cycles are complete by flagging P1111, (system checks complete since last memory clear)
www.JagDocs.com
Conditions for adaptation

1. Make sure these conditions are checked and corrected, if necessary, before carrying out the adaptation procedure. Mechanical Engine oil level correct Coolant level correct Fuel level greater than 30%, less than 80% Fuel filler cap correctly fitted/secure, seal in good condition All rectification work relating to DTCs completed Fuel, ignition and cooling systems in good order Electrical All Diagnostic Trouble Codes (DTCs) cleared All rectification work relating to DTCs completed Fuses Harnesses Electrical connectors
2012-07-19
Fuelling Adaptations Drive Cycle

NOTE: Make sure the engine is at normal operating temperature. (75C, 167F) 1. Either the Jaguar approved diagnostic system (where available), or a scan tool should be connected to measure the Mass Air Flow rate. Most generic scan tools should be capable of reading this parameter. Site 1 2 3 4 Mass Air Flow (grams/second) Up to 7 g/s 10 to 14 g/s 18 to 22 g/s 25 to 30 g/s Driving Conditions Idle in P for 2 minutes Open throttle in P for 2 minutes Open throttle in P or D with guidance * for 2 minutes Drive with guidance * for 2 minutes
Depending on road conditions and dealer location, it may be difficult to achieve the road speeds necessary to reach the air flow indicated. It is possible to reach these air flow figures by inducing a load on the vehicle, (making use of hills, using a lower gear ratio, etc) or, if no alternative is possible, by restraining WARNING: the vehicle and reaching the air flow figure stationery in D. THIS SHOULD NOT BE ATTEMPTED WITHOUT THE VEHICLE BEING IN A SAFE AREA AND SUITABLY CHOCKED. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN PERSONAL INJURY. Without using the Jaguar approved diagnostic system or a scan tool with system readiness capability, it will not be possible to confirm when the adaptations are complete, unless P1111, (system checks complete since last memory clear) is flagged. If such equipment is not available, ALL the diagnostic monitors will have to run to enable DTC P1111 to be flagged. In some US states, this code is a requirement for annual emissions tests.
Diagnostic Monitor Completion

1. The drive cycles detailed here will enable the monitors to run, but only after fuelling adaptations are complete. Entry Conditions
2012-07-19

Diagnostic Catalyst Monitor HO2S Engine Speed 1100 to 1600 rpm 600 to 2500 rpm N/A N/A N/A 1800 to 2200 rpm N/A Vehicle Speed 50 to 72 kph (31 to 45 mph) 29 to 113 kph (18 to 70 mph) N/A N/A 61 to 121 kph (38 to 75 mph) 80 to 101 kph (50 to 63 mph) 48 to 89 kph (30 to 55 mph) and idle Mass Air Flow (grams/second) 5 to 30 g/s 4 to 16 g/s Time to Completion 23 seconds Fuel cut for more than 10 seconds, but less than 30 seconds * 140 seconds 33 seconds Fuel cut for 2 seconds * 31 seconds Refer to drive cycles for leak tests in this section
Catalyst Monitor Sensor Fuel System AACV P/N switch Evaporative emissions
10 to 90 g/s More than 6 g/s 4 to 16 g/s N/A Refer to drive cycles for leak tests in this section
www.JagDocs.com
2. During the drive cycle, drive gently, avoiding hard acceleration, braking or cornering and rough roads. 1. Drive at 84 to 97 kph (52 to 60 mph) for 40 seconds. 2. Accelerate to 113 kph (70 mph). 3. Close the throttle, (ideally at the start of a descent) continue with closed throttle for 10 seconds. (* Fuel cut) 4. Drive at 56 to 64 kph (35 to 40 mph), holding the throttle as steady as possible, on a flat level road for 30 seconds minimum.
Drive Cycle for 40 thou leak test

1. Make sure the 'conditions for adaptation' detailed at the start of this section are met. 1. Avoiding high engine loads, drive the vehicle steadily between 48 and 89 kph (30 and 55 mph) for 15 to 20 minutes after starting the engine. (Depending on the amount of fuel vapor generated, the test may take longer than this). 2. Where possible, avoid body roll to minimise fuel movement. 3. If the scan tool being used is able to read TIDs, check TID 08 in mode 6. If the test has not completed, this TID will display '0'. Any other value indicates that the test has successfully completed. 4. If the test has not completed, the drive cycle must be repeated. 5. If the scan tool being used is not able to read TIDs, the only way to confirm that the test has run is to check for P1111 after running the 20 thou test, where applicable.
3 2012-07-19
Drive Cycle for 20 thou leak test (2001 my on only)

1. This test needs to be completed within 50 minutes of starting the engine from cold. It should be run following the 40 thou test. 1. Continue driving the vehicle steadily between 48 and 89 kph, (30 and 55 mph) avoiding high engine loads for a further 15 minutes. 2. Avoiding excessive fuel movement, bring the vehicle to rest. 3. Allow to idle for two minutes. 4. Provided the vapor conditions are suitable, the test will complete. 5. If the scan tool being used is able to read TIDs, check TID 06 in mode 6. If the test has not completed, this TID will display '0'. Any other value indicates that the test has successfully completed. 6. If the test has not completed, the drive cycle must be repeated. 7. Check for DTCs. P1111 will be flagged if all monitors have run. 8. Leak check drive cycles will only normally be necessary if an Evaporative Emissions related DTC is flagged. 9. Unless P1111 is required for the State inspection, fuelling adaptations will normally be all that is required for the vehicle to adapt itself and complete diagnostic drive cycles in the course of it's normal use.
2012-07-19

Electronic Engine Controls
Engine Sensors Vehicles Without Supercharger
www.JagDocs.com
2012-07-19
Parts List Item 1 2 3 4 5 6 7 Description Knock sensors (KS) Engine coolant temperature (ECT) sensor Variable camshaft timing oil control solenoid Crankshaft position (CKP) sensor Catalyst monitor sensor Heated oxygen (HO2) sensor Camshaft position (CMP) sensor
Electronic Engine Control

The engine management system provides optimum control of the engine under all operating conditions using several strategically placed sensors and any necessary actuators. Electronic engine control consists of: engine control module throttle position sensor engine coolant temperature sensor camshaft position sensor crankshaft position sensor mass air flow sensor charge air cooler intake air temperature sensor (vehicles with supercharger) knock sensor heated oxygen sensor Catalyst monitor sensor
2012-07-19

Engine Control Module (ECM)
www.JagDocs.com
The ECM incorporates a comprehensive monitoring and diagnostic capability including software variations to ensure system compliance with the latest diagnostic and emissions legislation in different markets. The engine control module controls the coil on plug ignition system, electronic fuel system, cruise control and the electronic throttle control system. The ECM responds to input signals received from sensors relating to engine operating conditions and provides output signals to the appropriate actuators. These output signals are based on the evaluated input signals which are compared with calibrated data tables or maps held within the ECM before the output signal is generated. The ECM needs the following inputs to calibrate the engine properly: camshaft position engine rpm engine coolant temperature amount of engine detonation
2012-07-19

Throttle Position (TP) Sensor Location
Parts List Item 1 2 Description Throttle body Throttle position (TP) sensor
sends the ECM a signal indicating throttle plate angle is the main input to the ECM from the driver is mounted on the motor end of the throttle body The throttle body also has an accelerator pedal position (APP) sensor consisting of twin potentiometers which provide separate analogue input signals, proportional to driver demand to the ECM. As a further safety feature the two potentiometers have different input/output characteristics for unique signal identifications and any corrupt signal between the expected outputs will cause the ECM to switch the throttle to limp home mode.
2012-07-19
Camshaft Position (CMP) Sensor

sends the ECM a signal indicating camshaft position for fuel synchronization purposes is a variable reluctance device mounted on each cylinder head generates a signal when the ring fitted to each intake camshaft passes the sensor
Crankshaft Position (CKP) Sensor

is a variable reluctance device mounted on the engine oil pan generates a signal when the drive plate passes the sensor sends the ECM signals indicating crankshaft position and engine speed is essential for calculating spark timing
Engine Coolant Temperature (ECT) Sensor

sends the ECM a signal indicating the temperature of the engine coolant is a temperature dependent resistor with a negative temperature coefficient (resistance changes inversely with respect to temperature) and is constantly monitored by the ECM
www.JagDocs.com
Knock Sensor (KS)

is a piezo-electric device which sends a signal to the ECM indicating engine detonation Between 700 and 6800 rpm, the ECM will retard individual cylinder ignition timing when detonation occurs while allowing the other cylinders to continue operating normally. During acceleration, at critical load and speed conditions, the ECM retards ignition timing to prevent the onset of detonation.
Heated Oxygen Sensor (HO2S)

are positioned upstream of the catalytic convertor is equipped with a heating element which improves the response time of the sensors during engine warm-up has the ability to generate a voltage signal proportional to the oxygen content of the exhaust gases leaving the engine provides feedback information to the ECM used to calculate fuel delivery and provide optimum gas emissions
Catalyst monitor sensor

are positioned downstream of the catalytic convertor has the ability to generate a voltage signal proportional to the oxygen content of the exhaust gases leaving the catalytic convertor provides feedback information to the ECM used to calculate fuel delivery
Variable Camshaft Timing Oil Control Solenoid - Vehicles Without Supercharger.

The variable camshaft timing oil control solenoid is a hydraulic actuator, which advances and retards the inlet camshaft timing, thereby altering the camshaft to crankshaft phasing for optimum engine performance.
2012-07-19
Mass Air Flow (MAF) Sensor
Location
The MAF sensor informs the ECM of the rate of air flow entering the engine by producing a voltage which is proportional to the rate of air flow into the engine. The voltage produced by the MAF sensor increases as the rate of air flow increases. The ECM takes into account the density of the air entering the air intake system so that it is possible to maintain the required air to fuel ratio, and to compensate for variations in atmospheric pressure. Integral to the MAF sensor is the intake air temperature sensor (IAT) which measures the temperature of the air entering the air intake system. The ECM uses this information to compensate for higher than normal air intake
2012-07-19
temperatures.
Intake Air Temperature (IAT) Sensor - Vehicles with supercharger.

Vehicles with supercharger have an additional intake air temperature (IAT) sensor located on the right-hand charge air cooler. The IAT sensor measures the temperature of the air entering the charge air cooler. The ECM uses this information to compensate for higher than normal air intake temperatures.
www.JagDocs.com
2012-07-19

Electronic Engine Controls Vehicles Without: Supercharger
1. Verify the customer concern. 2. Confirm which, if any, warning lights and/or messages were displayed on the instrument cluster. NOTE: If any warning lights and/or messages were displayed when the fault occurred, refer to the Driver Information table for DTCs associated with the display, then to the DTC index table for possible sources and actions. Some warnings will appear to clear when the ignition is cycled. This is often because the warning has flagged as a result of one of the vehicle's on-board diagnostic routines having run to detect the fault. If the same routine is not run when the ignition is switched ON, the warning will not reflag until the routine does run. See the DTC summaries for drive cycle routines. 3. Visually inspect for obvious signs of mechanical or electrical damage. Visual Inspection Chart Mechanical Engine oil level Cooling system coolant level Fuel Contamination Throttle body Poly-vee belt Electrical Fuses Wiring harness Electrical connector(s) Sensor(s) Engine control module (ECM) Transmission control module Check spark plug type. Only resisted plugs should be fitted. Refer to specifications section for gap Relay date codes. If the date on the relay is between R6 k1 and R6 k8, replace the relay 4. Verify the following systems are working correctly: Air intake system Cooling system Charging system Fuel charging system 5. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
2012-07-19

6. Where the Jaguar approved diagnostic system is available, complete the S93 report before clearing any or all fault codes from the vehicle. NOTE: If a DTC cannot be cleared, then there is a permanent fault present that flags again as soon as it is cleared. (The exception to this is P1260, which will only clear following an ignition OFF/ON cycle after rectification.) 7. If the cause is not visually evident and the Jaguar approved diagnostic system is not available, use a fault code reader to retrieve the fault codes before proceeding to the Diagnostic Trouble Code (DTC) Index Chart, or the Symptom Chart if no DTCs are set. NOTE: If the DTC flagged was not present for two or more consecutive cycles, it is classed as temporary, and will be deleted following three cycles during which no fault was present. This could result in a reported warning light/message with no stored DTCs. If a fault is present for three consecutive cycles, the DTC becomes permanent, and will remain in the module's memory for 40 drive cycles. (A cycle is an ignition ON/OFF, which will occur during the owner's normal use of the vehicle. No action on the part of the technician is necessary to perform this cycle. A drive cycle is a series of conditions needed to make the on-board diagnostic routine run, and may need a specific action on the part of the technician. See the DTC summaries for drive cycle routines) 8. Using the Jaguar approved diagnostic system where available, and a scan tool where not, check the freeze frame data for information on the conditions applicable when the fault was flagged. The format of this will vary, depending on the tool used, but can provide information useful to the technician in diagnosing the fault.
www.JagDocs.com
CAUTION: When probing connectors to take measurements in the course of the pinpoint tests, use the adaptor kit, part number 3548-1358-00. NOTE: When performing electrical voltage or resistance tests, always use a digital multimeter (DMM) accurate to 3 decimal places, and with an up-to-date calibration certificate. When testing resistance, always take the resistance of the DMM leads into account. NOTE: Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.
2012-07-19

Symptom Chart Symptom (general) Non-Start Symptom (specific) Engine does not crank Possible source Starter relay ECM relay Battery Park/Neutral switch Starting system Harness damage Engine siezed ' Engine cranks, but does not fire Security system /Immobiliser engaged Harness damage Fuel system ECM fault ' Engine cranks and fires, but will not start Fuel pump relay Fuel pump Cylinder compression loss (short-term. Refer to bulletin; 303-52) Engine coolant temperature (ECT) sensor Spark plugs fouled Ignition coil failure(s) HT short to ground (tracking) check rubber boots for cracks/damage Difficult to start Difficult to start cold Battery Fuel pump Cylinder compression loss (short-term. Refer to bulletin; 303-52) Spark plugs fouled For battery information, <<414-01>> Check fuel pressure. Refer to Technical service bulletins. For ignition system, <<303-07>> For fuel pump relay tests, Goto <<AB>> . Check fuel pressure. Refer to Technical service bulletins. For ECT sensor tests, Goto <<C>> . For ignition system, <<303-07>> Contact Dealer technical support for information on security system. For fuel system, <<303-04>> Contact Dealer technical support for advice on possible ECM failure Action Check relay dates. Check for DTCS. For starting system, <<303-06>> For ECM relay tests, Goto <<AL>> . For battery information, <<414-01>> For Park/Neutral tests, Goto <<AJ>> . For engine information, <<303-01>>
2012-07-19

' Difficult to start hot Rochester valve Injector leak Purge valve Fuel pump Engine coolant temperature (ECT) sensor ' ' Difficult to start after hot soak (vehicle standing after engine has reached operating temperature) For Rochester valve test, Goto <<AO>> . For injector leak test, REFER to technical service bulletin; 303-39. For evaporative emissions components, <<303-13>> Check fuel pressure. For ECT sensor tests, Goto <<C>> . Rochester valve Injector leak Purge valve Fuel pump Engine coolant temperature (ECT) sensor ' Engine cranks too fast/slow Battery Starting system Cylinder compression loss (NA short term only. Refer to technical service bulletin; 303-39) For battery information, <<414-01>> For starting system. <<303-06>> Refer to technical service bulletins.
www.JagDocs.com
2012-07-19

Engine stalls Engine stalls soon after start Fuel pump relay ECM relay Harness Coolant sensor Fuel lines Fuel pressure regulator Air leakage Cylinder compression loss (NA short term only. Refer to technical service bulletin; 303-39) ' Engine stalls on overrun ECM relay Fuel pump relay Throttle sensors Check relay dates; For ECM relay tests, Goto <<AL>> . For fuel pump relay tests, Goto <<AB>> . For throttle sensor tests, Goto <<D>> , and Goto <<N>> . For ECM relay circuit tests, Goto <<AL>> . For fuel pump relay circuit tests, Goto <<AB>> . For stop lamp switch circuit information, refer to the electrical guides. Check relay dates. Check for DTCS. For fuel pump relay tests, Goto <<AB>> . For ECM relay tests, Goto <<AL>> . For ECT sensor tests, Goto <<C>> . For fuel system, <<303-04>> For intake system information, <<303-12>> Refer to technical service bulletins.
'
Engine stalls at steady speed, with or without cruise enabled
ECM relay Fuel pump relay Stop lamp switch Harness
2012-07-19

' Engine stalls when maneuvering ECM relay Fuel pump relay Throttle sensors For ECM relay tests, Goto <<AL>> . For fuel pump relay tests, Goto <<AB>> . For throttle position sensor tests, Goto <<D>> , and Goto <<N>> . Check fuel pressure. For intake system information, <<303-12>> For fuel pressure regulator, <<303-04>> For fuel lines information, <<310-01>> For throttle position sensor tests, Goto <<D>> , and Goto <<N>> . For throttle motor relay tests, Goto <<AM>> , and Goto <<AN>> . For ignition system, <<303-07>>
Poor driveability
Fuel pump Air leakage Fuel pressure regulator Fuel lines Harness damage Throttle sensors Throttle motor Spark plugs fouled Ignition coil failure(s) HT short to ground (tracking) check rubber boots for cracks/damage
www.JagDocs.com
2012-07-19

' Engine backfires Fuel pump Fuel lines Air leakage MAF sensor Spark plugs HT short to ground (tracking) check rubber boots for cracks/damage Ignition coil failure(s) ' Engine surges Air leakage Fuel pump Fuel lines MAF sensor Harness Throttle sensors Throttle motor Spark plugs HT short to ground (tracking) check rubber boots for cracks/damage For intake system, <<303-12>> For fuel pump and lines tests, <<303-04>> For MAF sensor tests, Goto <<A>> . For throttle position sensor tests, Goto <<D>> , and Goto <<N>> . For ignition system, <<303-07>> For fuel pump and lines, <<310-01>> For intake system, <<303-12>> For MAF sensor tests, Goto <<A>> . For ignition system, <<303-07>>
2012-07-19

' Engine detonates/knocks Fuel lines Fuel pressure regulator Air leakage Mass air flow (MAF) sensor Oxygen sensors Fuel pump ' No throttle response Traction control invoked Throttle sensors Throttle motor For throttle position sensor tests, Goto <<D>> , and Goto <<N>> . For throttle motor relay tests, Goto <<AM>> , and Goto <<AN>> . For cruise control switches, <<310-03>> For throttle position sensor tests, Goto <<D>> , and Goto <<N>> . Check electrical guides for stop light switch information. For fuel lines, <<310-01>> For fuel pressure regulator, <<303-04>> For intake system, <<303-12>> For MAF sensor tests, Goto <<A>> . For oxygen sensor tests, check for DTCs and refer to the pinpoint tests listed for the DTCs flagged. Check fuel pressure.
www.JagDocs.com
'
Cruise control inhibited or disabled
Cruise control switch Throttle sensors Stop lamp switch
2012-07-19

' Poor throttle response Throttle sensors Throttle motor Air leakage Mass air flow (MAF) sensor For throttle position sensor tests, Goto <<D>> , and Goto <<N>> . For throttle motor relay tests, Goto <<AM>> , and Goto <<AN>> . For MAF sensor tests, Goto <<A>> . For transmission tests, <<307-01A>><<307-01B>> For Park/Neutral tests, Goto <<AJ>> . For throttle position sensor tests, Goto <<D>> , and Goto <<N>> . For MAF sensor tests, Goto <<A>> . For ECT sensor tests, Goto <<C>> . For knock sensor tests, Goto <<O>> , and Goto <<P>> .
'
Engine defaults, warning light and messages. Refer to the Driver Information table
Engine misfire Transmission fault Park/Neutral switch Throttle sensors MAF sensor Engine coolant temperature (ECT) sensor Knock sensors Harness

2012-07-19

Warning light Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Amber Amber Amber Amber Amber Amber Amber Amber Amber Amber Message Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Default Mode Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Engine shut-down when combined with other throttle failures Engine shut-down when combined with other throttle failures Cruise inhibited Cruise inhibited Cruise inhibited Cruise inhibited Cruise inhibited Cruise inhibited Cruise inhibited Cruise inhibited Cruise inhibited Cruise inhibited DTC P1224 P1229 P0122, P0123, P0222, P0223 P0121 P1122, P1123 P1222, P1223 P1121, P1632 P1251, P0560, P1658 P1631 P1611 P1633 P1609 P0506, P0507 P1656 P1254 P1250 P1516 P1517 P1571 P1696 P0568 P0570 P0569 P0567 P0566 P1697
www.JagDocs.com
2012-07-19

Red Amber Red Amber Amber Amber Amber Amber Amber Amber Amber Amber Amber Amber Amber Amber Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Limp-Home unavailable. Reverse throttle progression enabled Limp-Home unavailable. Reverse throttle progression enabled. High idle speed Limp-Home unavailable. Reverse throttle progression enabled Engine Speed Limit (runs normally, limited to 3000 RPM) Engine Speed Limit (runs normally, limited to 3000 RPM) Engine Speed Limit (runs normally, limited to 3000 RPM) Engine Speed Limit (runs normally, limited to 3000 RPM) Reverse throttle progression enabled Engine Speed Limit (runs normally, limited to 3000 RPM) Engine Speed Limit (runs normally, limited to 3000 RPM) Engine Speed Limit (runs normally, limited to 3000 RPM) Gearbox default to 4th gear Gearbox default to 4th gear Gearbox default to 4th gear Gearbox default to 4th gear Gearbox default to 4th gear P0560, P1254 P1250, P1254 P1250 P0116, P0117, P0118, P0125 P0101, P0102, P0103, P0104 P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P1313, P1314 P0327, P0328, P0332, P0333, P1648 P1474 P1230 P1671 P1112, P1113 P1601 (SC only) P1605 (NA only) P0702 P1795 P1796
2012-07-19

Amber Amber Amber Amber Amber Restricted Performance Restricted Performance None None None Gearbox default to 4th gear Gearbox default to 4th gear Gearbox default to 4th gear Gearbox default to 4th gear Gearbox default to 4th gear P1797 P1605 P0705 (SC only) P0706 P1720

MECHANICAL LIMP-HOME MODE No electronic throttle operation. (Mechanical operation for last quarter of pedal travel) Maximum 25 throttle opening, depending on adjustment of throttle mechanical linkage. Engine speed restricted to 3000 RPM maximum, by fuel cut-off. High idle speed. (1200 RPM approx.) Misfire at idle, due to cylinder cut as a means of controlling idle speed. (The misfire will switch cylinders, as the strategy varies the cylinder cut) Cruise Control Inhibited REVERSE THROTTLE PROGRESSION ENABLED Electronic throttle operation, limited to maximum 25 Cruise Control Inhibited NOTE: The throttle operation uses the same map as for reverse gear. ENGINE SPEED LIMIT Engine runs normally, up to 3000 RPM. Engine speed restricted to 3000 RPM maximum, by fuel cut-off. Cruise Control Inhibited LIMP-HOME UNAVAILABLE Cruise Control Inhibited
www.JagDocs.com
2012-07-19
DTC P0010
Description Right-hand variable camshaft timing (VCT) oil control solenoid circuit malfunction
Possible Source VCT solenoid valve to ECM PWM drive circuit fault VCT solenoid valve to ECM ground circuit fault VCT solenoid failure
Action For Right-hand VCT oil control solenoid circuit tests, Goto <<AH>> . For Left-hand VCT oil control solenoid circuit tests, Goto <<AI>> . For MAF sensor circuit tests, Goto <<A>> .
P0020
Left-hand variable camshaft timing (VCT) oil control solenoid circuit malfunction
VCT solenoid valve to ECM PWM drive circuit fault VCT solenoid valve to ECM ground circuit fault VCT solenoid failure
P0101
Mass air flow (MAF) sensor range/performance
Blocked air filter Air intake leak Engine breather leak Throttle control malfunction MAF sensor to ECM sensing circuit high resistance MAF sensor to ECM sensing circuit intermittent short circuit to ground MAF sensor supply circuit high resistance MAF sensor failure
P0102
Mass air flow (MAF) sensor sense circuit low voltage
Blocked air filter MAF sensor to ECM sensing circuit high resistance or open circuit MAF sensor to ECM sensing circuit intermittent short circuit to ground MAF sensor supply circuit open circuit or short circuit to ground MAF sensor failure
For MAF sensor circuit tests, Goto <<A>> .
P0103
Mass air flow (MAF) sensor sense circuit high voltage
MAF sensor to ECM reference ground circuit open circuit MAF sensor to ECM sensing circuit short circuit to high voltage MAF sensor failure
For MAF sensor circuit tests, Goto <<A>> . Contact dealer technical support for aadvice on possible ECM failure Contact dealer technical support for aadvice on possible ECM failure Check the air filter element and intake system, <<303-12>> Check for engine breather leaks, <<303-08>> For IAT sensor circuit tests, Goto <<B>> .
P0107 P0108 P0111
BARO circuit, low voltage BARO circuit, high voltage Intake air temperature (IAT) sensor range/performance (2 part monitoring)
BARO failure (internal ECM fault) BARO failure (internal ECM fault) Blocked air filter Air intake leak Engine breather leak IAT sensor to ECM wiring open circuit or high resistance IAT sensor to ECM sensing circuit short circuit to high voltage IAT sensor failure
P0112
Intake air temperature (IAT) sensor sense circuit high voltage (low air temperature)
IAT sensor to ECM wiring open circuit or high resistance IAT sensor to ECM sensing circuit short circuit to high voltage IAT sensor failure
For IAT sensor circuit tests, Goto <<B>> . For IAT sensor circuit tests, Goto <<B>> . For ECT sensor circuit tests, Goto <<C>> .
P0113
Intake air temperature (IAT) sensor sense circuit low voltage (high air temperature)
IAT sensor to ECM wiring short circuit to ground IAT sensor failure
P0116
Engine coolant temperature (ECT) sensor range/ performance (2 part monitoring)
Low/contaminated coolant Thermostat failure ECT sensor to ECM sensing circuit high resistance when hot ECT sensor to ECM sensing circuit intermittent high resistance ECT sensor failure
Engine coolant temperature (ECT) sensor sense circuit high voltage (low coolant temperature) P0117
ECT sensor disconnected ECT sensor to ECM sensing circuit high resistance, open circuit or short circuit to battery + voltage ECT sensor failure
For ECT sensor circuit tests, Goto <<C>> .
P0118
Engine coolant temperature (ECT) sensor sense circuit low voltage (high coolant temperature)
Engine overheat condition ECT sensor to ECM wiring short circuit to ground ECT sensor failure
For ECT sensor circuit tests, Goto <<C>> . For TP sensor circuit tests, Goto <<D>> , and Goto <<N>> . For TP sensor circuit tests, Goto <<D>> , and Goto <<N>> . For TP sensor circuit tests, Goto <<D>> , and Goto <<N>> .
P0121
Throttle position (TP) sensor circuit range/performance
TP sensor to ECM wiring open circuit or high resistance TP sensor to ECM sensing circuits 1 or 2 short circuit to battery + voltage TP sensor failure
P0122
Throttle position (TP) sensor 1 low voltage
TP sensor to ECM sensing circuit 1 (TP sensor pin 3) open circuit or high resistance TP sensor failure
P0123
Throttle position (TP) sensor 1 high voltage
TP sensor to ECM sensing circuit 1 (TP sensor pin 3) short circuit to high voltage TP sensor failure
2012-07-19
P0125
Engine coolant temperature (ECT) sensor response (for closed loop fuel control)
Low/contaminated coolant Thermostat failure ECT sensor to ECM sensing circuit high resistance, open circuit or short circuit to high voltage
For ECT sensor circuit tests, Goto <<C>> .
P0131
Right-hand H02S sense circuit low current (universal oxygen sensor; lean condition at ECM - high current at sensor)
H02S disconnected H02S to ECM variable current circuit fault. (HO2S pin 3) ECM to HO2S constant current circuit fault (HO2S pin 4) H02S failure
For Right-hand HO2S circuit tests, Goto <<E>> .
P0132
Right-hand H02S sense circuit high current (universal oxygen sensor; rich condition at ECM - low current at sensor)
H02S disconnected H02S to ECM variable current circuit fault. (HO2S pin 3) ECM to HO2S constant current circuit fault (HO2S pin 4) H02S failure
For Right-hand HO2S circuit tests, Goto <<E>> .
P0133
Right-hand H02S sense circuit slow response
Engine misfire H02S disconnected H02S mechanical damage H02S to ECM wiring intermittent open circuit H02S sensing circuit short circuit to high voltage H02S short circuit to ground H02S ground braided shield open circuit H02S heater circuit fault Exhaust leak Low exhaust temperature Injector flow partially blocked Catalyst efficiency decrease H02S failure
For Right-hand HO2S circuit tests, Goto <<E>> . For heater circuit tests, Goto <<F>> .
www.JagDocs.com
P0135
Right-hand H02S heater circuit malfunction
H02S disconnected H02S heater power supply open circuit H02S heater to ECM wiring short circuit or open circuit H02S heater failure
For Right-hand H02S heater circuit tests, Goto <<F>> .
P0137
Right-hand catalyst monitor sensor sense circuit low voltage
Catalyst monitor sensor disconnected Catalyst monitor sensor to ECM wiring open circuit Catalyst monitor sensor short circuit to ground Catalyst monitor sensor failure
For Right-hand catalyst monitor circuit tests, Goto <<H>> .
P0138
Right-hand catalyst monitor sensor sense circuit high voltage
Catalyst monitor sensor sensing circuit short circuit to high voltage Catalyst monitor sensor ground braided shield open circuit Catalyst monitor sensor failure
For Right-hand catalyst monitor circuit tests, Goto <<G>> . For Right-hand catalyst monitor circuit tests, Goto <<G>> .
P0140
Right-hand catalyst monitor sensor sense circuit no activity
Catalyst monitor sensor disconnected Catalyst monitor sensor mechanical damage Catalyst monitor sensor to ECM wiring open circuit Catalyst monitor sensor sensing circuit short circuit to high voltage Catalyst monitor sensor short circuit to ground Catalyst monitor sensor ground braided shield open circuit Exhaust leak Low exhaust temperature Catalyst monitor sensor failure
P0141
Right-hand catalyst monitor sensor heater circuit malfunction
Catalyst monitor sensor disconnected Catalyst monitor sensor mechanical damage Catalyst monitor sensor to ECM wiring fault Catalyst monitor sensor heater failure
For Right-hand catalyst monitor sensor heater circuit tests, Goto <<H>> .
P0151
Left-hand HO2S sense circuit low current (universal oxygen sensor; lean condition at ECM - high current at sensor)
H02S disconnected H02S to ECM variable current circuit fault (HO2S pin 3) ECM to HO2S constant current circuit fault (HO2S pin 4) H02S failure
For Left-hand catalyst monitor sensor circuit tests, Goto <<M>> .
P0152
Left-hand H02S sense circuit high current (universal oxygen sensor; rich condition at ECM - low current at sensor)
H02S disconnected H02S to ECM variable current circuit fault (HO2S pin 3) ECM to HO2S constant current circuit fault (HO2S pin 4)
2012-07-19
P0153
Left-hand HO2S sense circuit slow response
Engine misfire H02S disconnected H02S mechanical damage H02S to ECM wiring fault H02S short circuit to ground H02S to ECM variable current circuit shielding open circuit H02S heater circuit fault Exhaust leak Low exhaust temperature Injector flow partially blocked Catalyst efficiency decrease H02S failure
For Left-hand HO2S circuit tests, Goto <<J>> .
P0155
Left-hand HO2S heater circuit malfunction
For Left-hand HO2S heater circuit tests, Goto <<J>> .
P0157
Left-hand catalyst monitor sensor sense circuit low voltage
P0158
Left-hand catalyst monitor sensor sense circuit high voltage
For Left-hand catalyst monitor sensor circuit tests, Goto <<M>> . For Left-hand catalyst monitor sensor circuit tests, Goto <<M>> .
P0160
Left-hand catalyst monitor sensor sense circuit no activity
P0161
Left-hand catalyst monitor sensor heater circuit malfunction
Catalyst monitor sensor disconnected Catalyst monitor sensor mechanical damage Catalyst monitor sensor to ECM wiring fault Catalyst monitor sensor heater failure
For Left-hand catalyst monitor sensor heater circuit tests, Goto <<K>> .
P0171
Right-hand cylinders combustion too lean
Air intake leak between MAF sensor and throttle Fuel filter system blockage Fuel injector blockage Fuel pressure regulator failure (low fuel pressure) Low fuel pump output H02S harness wiring fault Exhaust leak (before catalyst) ECM receiving incorrect signal from one or more of the following sensors - ECT, MAF, IAT, TP
Check air intake system, <<303-12>> Check fuel filter, <<310-00>> Check fuel injectors, fuel pressure and regulator, <<303-04>><<309-00>> Refer to pinpoint tests for HO2S and other sensors listed.
P0172
Right-hand cylinders combustion too rich
Engine misfire Blocked air filter Fuel system return blockage Leaking fuel injector(s) Fuel pressure regulator failure (high fuel pressure) ECM receiving incorrect signal from one or more of the following sensors - ECT, MAF, IAT, TP
Check for misfire detected DTCs. Check air intake system, <<303-12>> Check fuel filter, <<310-00>> Check fuel injectors, fuel pressure and regulator, <<303-04>><<309-00>> Refer to pinpoint tests for sensors listed.
2012-07-19
P0174
Left-hand cylinders combustion too lean
Air intake leak between MAF sensor and throttle Fuel filter system blockage Fuel injector blockage Fuel pressure regulator failure (low fuel pressure) Low fuel pump output H02S harness wiring fault Exhaust leak (before catalyst) ECM receiving incorrect signal from one or more of the following sensors - ECT, MAF, IAT, TP
Check air intake system, <<303-12>> Check fuel filter, <<310-00>> Check fuel injectors, fuel pressure and regulator, <<303-04>><<309-00>> Refer to pinpoint tests for HO2S and other sensors listed.
P0175
Left-hand cylinders combustion too rich
Engine misfire Blocked air filter Fuel system return blockage Leaking fuel injector(s) Fuel pressure regulator failure (high fuel pressure) ECM receiving incorrect signal from one or more of the following sensors - ECT, MAF, IAT, TP
Check for misfire detected DTCs. Check air intake system, <<303-12>> Check fuel filter, <<310-00>> Check fuel injectors, fuel pressure and regulator, <<303-04>><<309-00>> Refer to pinpoint tests for sensors listed.
P0196
Engine oil temperature (EOT) sensor range/performance
EOT sensor to ECM sensing circuit high resistance when hot EOT sensor to ECM sensing circuit intermittent high resistance EOT sensor failure
For EOT sensor circuit tests, Goto <<L>> . For EOT sensor circuit tests, Goto <<L>> . For EOT sensor circuit tests, Goto <<L>> .
P0197
Engine oil temperature (EOT) sensor sense circuit low voltage (high oil temperature)
EOT sensor to ECM wiring short circuit to ground EOT sensor failure
P0198
Engine oil temperature (EOT) sensor sense circuit high voltage (low oil temperature)
EOT sensor disconnected EOT sensor to ECM sensing circuit high resistance, open circuit or short circuit to battery voltage EOT sensor failure
www.JagDocs.com
P0201
Fuel injector circuit malfunction, Cyl 1
Injector disconnected Injector wiring open or short circuit Injector failure
For fuel injector circuit tests, <<303-04>>
' ' ' ' ' ' ' P0222
' ' ' ' ' ' ' Throttle position (TP) sensor circuit 2 low voltage
P0202 P0203 P0204 P0205 P0206 P0207 P0208 TP sensor to ECM sensing circuit 2 (TP sensor pin 2) open circuit or high resistance TP sensor failure
Fuel injector circuit malfunction, Cyl 3 Fuel injector circuit malfunction, Cyl 5 Fuel injector circuit malfunction, Cyl 7 Fuel injector circuit malfunction, Cyl 2 Fuel injector circuit malfunction, Cyl 4 Fuel injector circuit malfunction, Cyl 6 Fuel injector circuit malfunction, Cyl 8 For TP sensor circuit tests, Goto <<D>> , and Goto <<N>> . For TP sensor circuit tests, Goto <<D>> , and Goto <<N>> .
P0223
Throttle position (TP) sensor circuit 2 high voltage
TP sensor to ECM sensing circuit 2 (TP sensor pin 2) short circuit to battery voltage TP sensor failure
2012-07-19
P0300
Random misfire detected
ECM to ignition coil primary circuit faults (cylinder misfire detected DTCs also logged) Ignition coil ground circuit; open circuit, high resistance Fuel injector circuit fault(s) [injector DTCs also logged] Ignition coil failure(s) HT short to ground (tracking) check rubber boots for cracks/damage Spark plug failure/fouled/incorrect gap Cylinder compression low Fuel delivery pressure (low/high) Fuel injectors restricted/leaking Fuel contamination PAS pulley bolts loose (see Service Action S462) Worn camshaft/broken valve springs
For ignition system, <<303-07>> For injector circuit tests, <<303-04>> Check compressions. Check fuel pressure. For fuel injectors, <<303-04>> For fuel tank and lines information, <<310-01>> Check PAS pulley bolt torque. (see Service Action S462) For engine information, <<303-01>>
P0301 ' ' ' ' ' ' ' P0327
Misfire detected, Cyl 1 ' ' ' ' ' ' ' Right-hand knock sensor (KS) sense circuit out of range (low voltage)
Refer to possible sources for P0300 P0302 P0303 P0304 P0305 P0306 P0307 P0308 Poor sensor contact with cylinder block KS to ECM sense circuit short circuit to ground KS failure
Refer to actions for P0300 Misfire detected, Cyl 3 Misfire detected, Cyl 5 Misfire detected, Cyl 7 Misfire detected, Cyl 2 Misfire detected, Cyl 4 Misfire detected, Cyl 6 Misfire detected, Cyl 8 For Right-hand KS circuit tests, Goto <<O>> . For Right-hand KS circuit tests, Goto <<O>> .
P0328
Right-hand knock sensor (KS) sense circuit out of range (high voltage)
Poor sensor contact with cylinder block KS to ECM sense circuit high resistance or open circuit KS to ECM sense circuit short circuit to high voltage KS failure
P0332
Left-hand knock sensor (KS) sense circuit out of range (low voltage)
Poor sensor contact with cylinder block KS to ECM sense circuit short circuit to ground KS failure
For Left-hand KS circuit tests, Goto <<P>> . For Left-hand KS circuit tests, Goto <<P>> .
P0333
Left-hand knock sensor (KS) sense circuit out of range (high voltage)
P0335
Crankshaft position (CKP) sensor circuit malfunction
CKP sensor disconnected CKP sensor air gap incorrect/foreign matter on face CKP sensor sensing circuit open circuit, short circuit to ground, short circuit to high voltage CKP sensor failure
For CKP sensor circuit tests, Goto <<Q>> .
P0336
Crankshaft position (CKP) sensor range/performance
CKP sensor reluctor (on drive plate) foreign matter/damaged teeth CKP sensor sensing circuit intermittent open circuit, short circuit to ground, short circuit to high voltage CKP sensor failure
For CKP sensor circuit tests, Goto <<Q>> .
P0340
Right-hand camshaft position (CMP) sensor circuit malfunction
CMP sensor disconnected CMP sensor air gap incorrect/foreign matter on face CMP sensor sensing circuit open circuit, short circuit to ground, short circuit to high voltage CMP sensor failure
For Right-hand CMP sensor circuit tests, Goto <<R>> .
P0341
Right-hand camshaft position (CMP) sensor range/performance (CMP sensor pulse not detected at CKP sensor missing tooth)
For Right-hand CMP sensor circuit tests, Goto <<R>> .
P0351
ECM to ignition coil circuit open circuit, short circuit to ground, high resistance Ignition coil ground circuit open circuit, high resistance Ignition coil failure
For ignition system pinpoint tests, <<303-07>>
2012-07-19
' ' ' ' ' ' ' P0420
' ' ' ' ' ' ' Right-hand catalytic converter efficiency below threshold
P0352 P0353 P0354 P0355 P0356 P0357 P0358 HO2S/catalyst monitor sensor disconnected. HO2S/catalyst monitor sensor to ECM wiring fault. HO2S/catalyst monitor sensor heater to ECM wiring fault. HO2S/catalyst monitor sensor heater failure. HO2S failure. Catalyst monitor sensor failure. HO2 sensor/Catalyst monitor sensor failure Catalytic converter failure.
Ignition coil primary/secondary circuit malfunction, cyl 3 Ignition coil primary/secondary circuit malfunction, cyl 5 Ignition coil primary/secondary circuit malfunction, cyl 7 Ignition coil primary/secondary circuit malfunction, cyl 2 Ignition coil primary/secondary circuit malfunction, cyl 4 Ignition coil primary/secondary circuit malfunction, cyl 6 Ignition coil primary/secondary circuit malfunction, cyl 8 Refer to pinpoint tests for components listed. Visually inspect catalytic converters.
P0430
Left-hand catalytic converter efficiency below threshold
HO2S/catalyst monitor sensor disconnected. HO2S/catalyst monitor sensor to ECM wiring fault. HO2S/catalyst monitor sensor heater to ECM wiring fault. HO2S/catalyst monitor sensor heater failure. HO2S failure. Catalyst monitor sensor failure. Catalytic converter failure.
Refer to pinpoint tests for components listed. Visually inspect catalytic converters.
P0442
Evaporative emissions system (EVAP) leak detected - small (0.040 in)
Fuel cap seal defective EVAP system leak (canister damage, pipework damage, CCV leaking) Fuel tank leak
For evaporative emissions pinpoint tests, <<303-13>>
www.JagDocs.com
P0443 P0444 P0445 P0446 P0447
Evaporative emissions system (EVAP) valve control malfunction Evaporative emissions system (EVAP) valve circuit open circuit Evaporative emissions system (EVAP) valve circuit short circuit Canister close valve (CCV) malfunction Canister close valve (CCV) circuit opened failure
EVAP valve not fully closed EVAP to ECM drive circuit open circuit or high resistance EVAP failure EVAP to ECM drive circuit short circuit to ground EVAP failure Tank to atmospheric port line restricted CCV stuck closed CCV B+ power supply circuit fault CCV to ECM drive circuit open circuit, high resistance, or short circuit to high voltage CCV failure
For evaporative emissions pinpoint tests, <<303-13>> For evaporative emissions pinpoint tests, <<303-13>> For evaporative emissions pinpoint tests, <<303-13>> For evaporative emissions pinpoint tests, <<303-13>> For evaporative emissions pinpoint tests, <<303-13>>
P0448 P0450 P0452
Canister close valve (CCV) circuit short circuit Fuel tank pressure (FTP) sensor malfunction Fuel tank pressure (FTP) sensor circuit low voltage
CCV to ECM drive circuit short circuit to high voltage CCV failure FTP sensor disconnected FTP sensor failure FTP sensor disconnected FTP sensor to ECM sense circuit open circuit or short circuit to ground FTP sensor to ECM power supply circuit open circuit or short circuit to ground FTP sensor failure
For evaporative emissions pinpoint tests, <<303-13>> For evaporative emissions pinpoint tests, <<303-13>> For evaporative emissions pinpoint tests, <<303-13>>
P0453
Fuel tank pressure (FTP) sensor circuit high voltage
FTP sensor to ECM signal ground circuit open circuit FTP sensor to ECM wiring (supply, sense, signal, ground) short circuit to each other FTP sensor to ECM sense circuit short circuit to B+ voltage FTP sensor failure
2012-07-19
P0455
EVAP system leak detected - large
Fuel filler cap missing Fuel filler cap seal defective EVAP system leak (canister damage, pipework damage) CCV leaking/stuck open EVAP valve to engine purge pipe damaged/blocked/leaking/disconnected EVAP valve operating vacuum hose leak/blockage/disconnected (stuck closed) EVAP valve failure Fuel tank leak
P0460
Fuel level sense signal performance
Fuel level sensor to instrument cluster circuits intermittent short or open circuit Fuel level sensor failure Instrument cluster fault (incorrect fuel level data)
For fuel level sensor circuit tests, <<303-04>>
P0480
Radiator fans slow (series) circuit malfunction
Radiator fan control relay module to ECM 'series' drive circuit (relay pin 9) fault Relay coil ignition power supply open circuit ECM ground circuit fault (relay coil drive) ECT sensor circuit malfunction (refer to P0116)
For radiator fan series circuit tests, Goto <<S>> .
P0482
Radiator fans fast (parallel) circuit malfunction
Radiator fan control relay module to ECM 'parallel' drive circuit (relay pin 7) fault Relay coil ignition power supply open circuit ECM ground circuit fault (relay coil drive) ECT sensor circuit malfunction (refer to P0116)
For radiator fan parallel circuit tests, Goto <<T>> .
P0506
Idle RPM lower than expected
Air intake blockage Accessory drive overload (defective/siezed component) Throttle valve stuck closed Throttle assembly failure
Inspect air intake system. <<303-12>> For accessory drive information, <<303-05>> For throttle body information, <<303-04>>
P0507
Idle RPM higher than expected
Intake air leak between MAF sensor and throttle Intake air leak between throttle and engine Engine breather leak Cruise control vacuum failure Throttle valve stuck open Throttle assembly failure
Inspect air intake system. <<303-12>> Check engine breather system, <<303-08>> For cruise control, <<310-03>> For throttle body information, <<303-04>>
P0560
Vehicle voltage malfunction
ECM battery power supply open circuit, high resistance
For ECM power supply tests, Goto <<U>> . For cruise control pinpoint tests, <<310-03>>
P0566
Cruise control CANCEL switch ON fault
Cruise control switches internal steering wheel short circuit to ground Steering wheel cassette reel short circuit to ground Cassette reel to ECM circuit short circuit to ground CANCEL switch failure (stuck ON)
P0567
Cruise control RESUME switch ON fault
Cruise control switches internal steering wheel short circuit to ground Steering wheel cassette reel short circuit to ground Cassette reel to ECM circuit short circuit to ground RESUME switch failure (stuck ON)
For cruise control pinpoint tests, <<310-03>>
P0568
Cruise control switch ground malfunction
Cruise control switches internal steering wheel open circuit Steering wheel cassette reel open circuit or high resistance Cassette reel to ECM circuit (ACCEL/DECEL) open circuit or high resistance (ACCEL/DECEL) switch failure
P0569
Cruise control DECEL/SET (SET-) switch ON fault
Cruise control switches internal steering wheel short circuit to ground Steering wheel cassette reel short circuit to ground Cassette reel to ECM circuit short circuit to ground DECEL/SET- switch failure (stuck ON)
2012-07-19
P0570
Cruise control ACCEL/SET (SET+) switch ON fault
Cruise control switches internal steering wheel short circuit to ground Steering wheel cassette reel short circuit to ground Cassette reel to ECM circuit short circuit to ground ACCEL/SET (SET+) switch failure (stuck ON)
P0603 P1000 P1104
ECM data corrupted System checks not complete since last memory clear Mass air flow (MAF) sensor ground malfunction
ECM OBD diagnostic monitors have not completed MAF sensor to ECM reference ground circuit open circuit, short circuit to high voltage, high resistance MAF sensor to ECM sensing circuit open circuit MAF sensor failure
Contact dealer technical support for advice on possible ECM failure Carry out comprehensive component monitor drive cycle. Refer to the DTC section of JTIS, accessed by the icon on the opening page. For MAF ground circuit tests, Goto <<V>> , For MAF sensor sense circuit tests, Goto <<A>> . No action necessary Check cable adjustment (refer to technical bulletins), for APP sensor circuit tests, Goto <<W>> , and Goto <<Z>> . For sensor power supply circuit tests, Goto <<AC>> . For sensor ground circuit tests, Goto <<AD>> . For APP sensor circuit tests, Goto <<W>> , and Goto <<Z>> . For sensor power supply circuit tests, Goto <<AC>> . For APP sensor circuit tests, Goto <<W>> , and Goto <<Z>> . For module cooling fan circuit tests, Goto <<X>> . Check AACV pipework and air channels, for AACV circuit tests, Goto <<Y>> . For AACV circuit tests, Goto <<Y>> .
P1111 P1121
System checks complete since last memory clear Accelerator pedal position (APP) sensor circuit range/performance
OBD diagnostic monitors have completed Accelerator pedal to APP sensor cable adjustment incorrect APP sensor to ECM sense circuits 1 and 2 open circuit, short circuit or high resistance Sensor power supply fault Sensor reference ground fault APP sensor failure
P1122
Accelerator pedal position (APP) sensor circuit '1' low voltage
APP sensor to ECM sense circuit '1' (sensor pin 4) open circuit or high resistance Sensor power supply fault APP sensor failure
P1123
Accelerator pedal position (APP) sensor circuit '1' high voltage
www.JagDocs.com
APP sensor to ECM sense circuit '1' (sensor pin 4) short circuit to battery voltage APP sensor failure
P1136
'Cool box' malfunction
Cooling fan power supply fault Cooling fan drive circuit fault Cooling fan motor failure
P1143
Air assist close valve (AACV) range/performance
AAI piping blocked Throttle body air channel blocked AACV stuck
P1144
Air assist close valve (AACV) circuit malfunction
AACV B+ power supply circuit fault AACV ground circuit fault AACV to ECM PWM drive circuit open circuit, short circuit or high resistance AACV failure
P1222
Accelerator pedal position (APP) sensor circuit '2' low voltage
APP sensor to ECM sense circuit '2' (sensor pin 2) open circuit or high resistance Sensor power supply fault APP sensor failure
For APP sensor circuit tests, Goto <<W>> , and Goto <<Z>> . For APP sensor circuit tests, Goto <<W>> , and Goto <<Z>> . Carry out throttle adaptation procedure. For TP sensor circuit tests, Goto <<D>> , and Goto <<N>> . For throttle motor relay circuit tests, Goto <<AM>> , and Goto <<AN>> . For throttle body information, <<303-04>>
P1223
Accelerator pedal position (APP) sensor circuit '2' high voltage
APP sensor to ECM sense circuit '2' (sensor pin 2) short circuit to battery voltage APP sensor failure
P1224
Throttle control position error
Throttle position adaptions not performed after battery disconnect TP sensor disconnected TP sensor to ECM sense circuits open circuit, high resistance Throttle motor power relay failure Throttle motor power relay to ECM circuit fault Throttle motor power relay power supply open circuit ECM ground circuit fault (relay coil drive) Throttle motor to ECM drive circuits open circuit, short circuit, high resistance Throttle motor failure Throttle assembly failure
2012-07-19
P1229
Throttle motor control circuit mallfunction
Throttle motor disconnected Throttle motor to ECM drive circuits short circuit or open circuit Throttle motor failure
For throttle motor circuit tests, Goto <<AM>> , and Goto <<AN>> . For fuel pump relay circuit tests, Goto <<AB>> .
P1230
Fuel pump relay malfunction
Fuel pump relay failure Fuel pump to ECM circuit fault Fuel pump relay coil power supply open circuit ECM ground circuit fault (relay coil drive)
P1240
Sensor reference voltage malfunction (throttle sensors, fuel tank pressure sensor) (ECM pins EM82-01; EM83-05) Sensor reference voltage low (throttle sensors, fuel tank pressure sensor) (ECM pins EM82-01; EM83-05) Sensor reference voltage high (throttle sensors, fuel tank pressure sensor) (ECM pins EM82-01; EM83-05) Sensor reference ground malfunction (throttle sensors, fuel tank pressure sensor, ECT sensor, IAT sensor) (ECM pins EM82-01; EM83-13) Engine crank signal low voltage
ECM to sensors reference voltage short circuit to ground, short circuit to high voltage, open circuit, high resistance TP sensor, APP sensor, FTP sensor failure(s) ECM to sensors reference voltage short circuit to ground TP sensor, APP sensor, FTP sensor failure(s) ECM to sensors reference voltage circuit open circuit, high resistance, short circuit to high voltage TP sensor, APP sensor, FTP sensor failure(s) ECM to sensors reference ground circuit open circuit, high resistance TP, APP, ECT, IAT, FTP sensor failure(s) Starter relay coil to ECM/BPM circuit open circuit
For sensor reference voltage circuit tests, Goto <<AC>> . For sensor reference voltage circuit tests, Goto <<AC>> . For sensor reference voltage circuit tests, Goto <<AC>> . For sensor reference ground circuit tests, Goto <<AD>> . For starter relay circuit tests, Goto <<AE>> . For starter relay circuit tests, Goto <<AE>> . INSTALL a new throttle body. <<303-04>> For throttle motor control circuit tests, Goto <<AA>> .
P1241
P1242
P1243
P1245
P1246
P1250 P1251
Throttle valve return spring malfunction Throttle motor power relay malfunction
Throttle return spring failure (throttle failure) Throttle motor power relay failure Throttle motor power relay to ECM circuit fault Throttle motor power relay coil power supply open circuit ECM ground circuit fault (relay coil drive)
P1254 P1260
Throttle 'limp-home' spring malfunction Security input malfunction
Throttle limp-home spring failure (throttle failure) KTM to ECM circuit short circuit, high resistance or open circuit Loss of ignition switched power supply to the ECM, pin EM82-09 for greater than 16 milliseconds KTM failure Security system incorrectly configured (KTM/ECM)
INSTALL a new throttle body <<303-04>> For KTM to ECM circuit tests, Goto <<AF>> . Check the ignition supply to the ECM. Contact dealer technical support for information on security system.
P1313 ' ' P1340
Misfire rate catalyst damage, Right-hand cylinders. NOTE. This DTC will flag only when accompanied by a random or individual cylinder misfire DTC; P0300, P0301 to P0308 ' ' Left-hand camshaft position (CMP) sensor circuit malfunction
Refer to possible causes for P0300-P0308 P1314 P1316 CMP sensor disconnected CMP sensor gap incorrect/foreign matter on sensor face CMP sensor sensing circuit open circuit, short circuit to ground, short circuit to high voltage CMP sensor failure
Refer to actions for P0300-P0308 Misfire rate catalyst damage, Left-hand cylinders. NOTE. This DTC will flag only when accompanied by a random or individual cylinder misfire DTC; P0300 to P0308 Misfire excess emission. NOTE. This DTC will flag only when accompanied by an individual cylinder misfire DTC; P0300 to P0308 For Left-hand CMP sensor circuit tests, Goto <<AG>> .
P1341
Left-hand camshaft position (CMP) sensor range/performance (CMP sensor pulse not detected)
CMP sensor disconnected CMP sensor gap incorrect/foreign matter on sensor face CMP sensor sensing circuit open circuit, short circuit to ground, short circuit to high voltage CMP sensor failure
For Left-hand CMP sensor circuit tests, Goto <<AG>> .
2012-07-19
P1367
Ignition monitor; Group 1 Cylinders 1, 4, 6, and 7
Ignition monitoring circuit between splice and ECM open circuit, short circuit to ground or short circuit to B+ voltage Ignition coil group ground circuit fault Ignition coil relay failure
P1368
Ignition monitor; Group 2 Cylinders 2, 3, 5, and 8
Ignition monitoring circuit between splice and ECM open circuit, short circuit to ground or short circuit to B+ voltage Ignition coil group ground circuit fault Ignition coil relay failure
P1384
Right-hand variable camshaft timing (VCT) oil control solenoid malfunction
VCT solenoid valve to ECM PWM drive circuit fault VCT solenoid valve to ECM ground circuit fault VCT solenoid failure VCT oil flow fault VCT/camshaft mechanical failure
For Right-hand VCT circuit tests, Goto <<AH>> .
P1396
Left-hand variable camshaft timing (VCT) oil control solenoid malfunction
VCT solenoid valve to ECM PWM drive circuit fault VCT solenoid valve to ECM ground circuit fault VCT solenoid failure VCT oil flow fault VCT/camshaft mechanical failure
For Right-hand VCT circuit tests, Goto <<AG>> .
P1516
Gear change PARK/NEUTRAL driving malfunction
Gear selector cable setting incorrect Transmission rotary switch (TR sensor) to ECM circuit open circuit or high resistance TR sensor failure D-4 switch to TCM circuit open circuit or high resistance D-4 switch fault
Check selector cable adjustment. For TR sensor circuit tests, Goto <<AJ>> .
www.JagDocs.com
P1517
Engine PARK/NEUTRAL cranking malfunction
Gear selector cable setting incorrect TR sensor to ECM circuit open circuit or high resistance TR sensor failure
Check selector cable adjustment. For TR sensor circuit tests, Goto <<AJ>> . For cruise control pinpoint tests, <<310-03>>
P1571
Brake switch malfunction
Brake switch to ECM circuit open circuit, short circuit to ground, high resistance Brake switch ignition switched ground circuit open circuit Brake switch failure Brake cancel switch to ECM circuit open circuit, short circuit to ground, high resistance Brake cancel switch to cruise control switch circuit open circuit, short circuit to ground, high resistance Brake cancel switch ignition switched power supply open circuit Brake cancel switch failure Cruise control switch failure
P1582
Throttle monitor data available or inertia switch malfunction
DTC indicates that the inertia switch has tripped (vehicle impact) If no vehicle impact; Inertia switch to ECM circuit short circuit to ground Inertia switch failure
For inertia switch fault circuit tests, Goto <<AK>> .
P1606
Engine management system (EMS) control relay malfunction
ECM control relay failure ECM control relay to ECM circuit fault ECM control relay coil power supply open circuit ECM ground circuit fault (relay coil drive)
For ECM control relay circuit tests, Goto <<AL>> .
P1609 P1611 P1631
ECM microprocessor-to-microprocessor communication failure ECM CPU 2 failure Throttle motor power relay coil activation circuit failure
ECM failure ECM failure Throttle motor relay coil to ECM circuit open circuit, short circuit to ground or short circuit to B+ voltage ECM failure Contact dealer technical support for advice on possible ECM failure For throttle motor relay circuit tests, Goto <<AM>> , and Goto <<AN>> . Contact dealer technical support for advice on possible ECM failure Contact dealer technical support for advice on possible ECM failure
P1633 P1634
ECM CPU 1 memory failure Throttle 'watchdog' circuit malfunction
ECM failure ECM failure
2012-07-19
P1637
CAN ABS/TCCM token missing
CAN open circuit fault - ABS/TCCM to ECM CAN short circuit fault ABS/TCCM failure ECM failure
For network circuit tests, <<418-00>>
P1638
CAN INST token missing
CAN open circuit fault - INST to ECM CAN short circuit fault INST failure ECM failure
P1642
CAN circuit malfunction
CAN short circuit fault Control module failure - check for additional logged DTCs to locate control module source
P1643
CAN TCM token missing
CAN open circuit fault - TCM to ECM CAN short circuit fault TCM failure ECM failure
P1646
ECM Right-hand HO2S control malfunction
HO2S heater failure HO2S sensing circuit short circuit to ground or high voltage HO2S sensing circuit open circuit ECM failure
For Right-hand HO2S circuit tests, Goto <<I>> .
P1647
ECM Left-hand HO2S control malfunction
HO2S heater failure HO2S sensing circuit short circuit to ground or high voltage HO2S sensing circuit open circuit ECM failure
For Left-hand HO2S circuit tests, Goto <<J>> .
P1648 P1649 P1656 P1657 P1658
ECM KS self-test failure ECM flash programming circuit malfunction Throttle position (TP) sensor amplifier circuit malfunction Throttle motor power relay coil circuit ON failure Throttle motor power relay ON failure
ECM failure ECM to DLC circuit, short circuit to ground or short circuit to battery voltage ECM failure ECM failure Throttle motor power relay failure (contacts stuck on) Throttle motor power relay to ECM coil circuit, short circuit to ground Throttle motor power relay to ECM supply circuit, short circuit to B+ voltage
Contact dealer technical support for advice on possible ECM failure For network circuit tests, <<418-00>> Contact dealer technical support for advice on possible ECM failure Contact dealer technical support for advice on possible ECM failure For throttle motor relay circuit tests, Goto <<AM>> , and Goto <<AN>> .
Pinpoint Tests A : DTC P0101, P0102, P0103; MASS AIR FLOW (MAF) SENSOR RANGE/PERFORMANCE, HIGH/LOW VOLTAGE
NOTE: Before commencing this test, check the air filter for blockage, the engine air intake and breather systems for leaks, and the TP sensor for additional DTCs.
A1 : CHECK THE MAF SENSOR SENSE CIRCUIT FOR HIGH RESISTANCE

1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM83. 3. Disconnect the MAF sensor electrical connector, PI35.
2012-07-19

4. Measure the resistance between EM83, pin 28 (GY) and PI35, pin 03 (GY). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<A2>>
A2 : CHECK THE MAF SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between the MAF sensor electrical connector, PI35, pin 03 (GY) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<A3>>
www.JagDocs.com
A3 : CHECK THE MAF SENSOR SENSE CIRCUIT FOR SHORT TO GROUND

NOTE: The short to GROUND may be intermittent. Move the wiring to attempt to reproduce the conditions under which the DTC was logged, and visually inspect the harness for any signs of chafing, see 'visual inspection chart'. 1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI35, pin 03 (GY) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation -> No Goto <<A4>>
2012-07-19
A4 : CHECK THE MAF SENSOR SUPPLY CIRCUIT VOLTAGE

1. Reconnect the ECM electrical connector, EM83. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between the MAF sensor electrical connector, PI35, pin 01 (WU) and GROUND. Is the voltage greater than 10 volts? -> Yes Goto <<A5>> -> No REPAIR the circuit between the MAF sensor electrical connector, PI35, pin 01 (WU) and BATTERY. This circuit includes the EMS control relay, fuse 12 of the EMS fuse board, and splices in the harness. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
A5 : CHECK THE MAF SENSOR SUPPLY CIRCUIT FOR HIGH RESISTANCE

1. Disconnect the battery negative terminal. 2. Disconnect the EMS fuse board electrical connector, EM20. 3. Measure the resistance between EM20, pin 10 (WU) and PI35, pin 01 (WU). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<A6>>
A6 : CHECK THE MAF SENSOR SUPPLY CIRCUIT FOR SHORT TO GROUND

1. Reconnect the battery negative terminal. 2. Measure the resistance between EM20, pin 10 (WU) and GROUND. Is the resistance less than 10,000 ohms?
2012-07-19

-> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new MAF sensor. CLEAR the DTC. TEST the system for normal operation.
B : DTC P0111, P0112, P0113; INTAKE AIR TEMPERATURE (IAT) SENSOR RANGE/PERFORMANCE, HIGH/LOW VOLTAGE
NOTE: Before commencing this test, check the air filter for blockage and the engine air intake and breather systems for leaks.
B1 : CHECK THE IAT SENSOR SENSE CIRCUIT FOR HIGH RESISTANCE

1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM82. 3. Disconnect the MAF sensor electrical connector, PI35. 4. Measure the resistance between EM82, pin 17 (UP) and PI35, pin 04 (UP). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<B2>>
www.JagDocs.com
B2 : CHECK THE IAT SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between PI35, pin 04 (UP) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No
2012-07-19

Goto <<B3>>
B3 : CHECK THE IAT SENSOR SENSE CIRCUIT FOR SHORT TO GROUND

1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI35, pin 04 (UP) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new MAF sensor. CLEAR the DTC. TEST the system for normal operation.
C : DTC P0116, P0117, P0118, P0125; ENGINE COOLANT TEMPERATURE (ECT) SENSOR RANGE/PERFORMANCE, HIGH/LOW VOLTAGE, RESPONSE
NOTE: Before commencing this test, check the coolant level and condition, check the operation of the thermostat, rectify as necessary.
C1 : CHECK THE ECT SENSOR SENSE CIRCUIT FOR HIGH RESISTANCE

1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM82. 3. Disconnect the ECT sensor electrical connector, PI04. 4. Measure the resistance between EM82. pin 14 (UY) and PI04, pin 02 (UY). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<C2>>
2012-07-19
C2 : CHECK THE ECT SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between PI04, pin 02 (UY) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<C3>>
www.JagDocs.com
C3 : CHECK THE ECT SENSOR SENSE CIRCUIT FOR SHORT TO GROUND

1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI04, pin 02 (UY) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new ECT sensor. <<Engine Coolant Temperature (ECT) Sensor - >> CLEAR the DTC. TEST the system for normal operation.
D : DTC P0121, P0122, P0123; THROTTLE POSITION (TP) SENSOR RANGE/PERFORMANCE, HIGH/LOW VOLTAGE D1 : CHECK THE TP SENSOR SENSE CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM81. 3. Disconnect the TP sensor electrical connector, PI06.
2012-07-19

4. Measure the resistance between EM81, pin 10 (U) and PI06, pin 03 (U). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<D2>>
D2 : CHECK THE TP SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE

1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between PI06, pin 03 (U) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<D3>>
D3 : CHECK THE TP SENSOR SENSE CIRCUIT FOR SHORT TO GROUND

1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI06, pin 03 (U) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new TP sensor. CLEAR the DTC. TEST the system for normal operation.
E : DTC P0131, P0132, P0133, P1646; RIGHT-HAND H02S LOW/HIGH VOLTAGE, SLOW RESPONSE/ECM CONTROL MALFUNCTION
2012-07-19

NOTE: Before commencing this test, check the sensor connections and harness, check for exhaust leaks, engine misfire, etc. See 'visual inspection chart' and 'possible causes'.
E1 : CHECK THE H02S VARIABLE CIRCUIT FOR HIGH RESISTANCE

1. Disconnect the battery negative terminal. 2. Disconnect the H02S electrical connector, EM21. 3. Disconnect the ECM electrical connector, EM82. 4. Measure the resistance between EM21, pin 03 (R) and EM82, pin 04 (R). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<E2>>
www.JagDocs.com
E2 : CHECK THE H02S VARIABLE CIRCUIT FOR SHORT TO HIGH VOLTAGE

1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between EM82, pin 04 (R) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<E3>>
E3 : CHECK THE H02S VARIABLE CIRCUIT FOR SHORT TO GROUND

1. Turn the ignition switch to the OFF position. 2. Measure the resistance between EM82, pin 04 (R) and GROUND.
2012-07-19

Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<E4>>
E4 : CHECK THE H02S CONSTANT CIRCUIT FOR HIGH RESISTANCE

1. Measure the resistance between EM21, pin 04 (Y) and EM82, pin 10 (Y). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<E5>>
E5 : CHECK THE H02S CONSTANT CIRCUIT FOR SHORT TO HIGH VOLTAGE

1. Measure the voltage between EM21, pin 04 (Y) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<E6>>
E6 : CHECK THE H02S CONSTANT CIRCUIT FOR SHORT TO GROUND

1. Measure the resistance between EM21, pin 04 (Y) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
53
2012-07-19

-> No INSTALL a new H02S. CLEAR the DTC. TEST the system for normal operation. If the DTC is repeated, contact dealer technical support for advice on possible ECM failure.
F : DTC P0133, P0135, P1646; RIGHT-HAND H02S HEATER CIRCUIT MALFUNCTION/ECM CONTROL MALFUNCTION F1 : CHECK H02S HEATER POWER SUPPLY CIRCUIT
1. Disconnect the H02S electrical connector, EM21. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between EM21, pin 02 (WG) and GROUND. Is the voltage greater than 10 volts? -> Yes Goto <<F2>> -> No REPAIR the power supply circuit to the H02S heater. This circuit includes the O2S heater relay, the EMS control relay and fuse 14 of the EMS fuse board. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
www.JagDocs.com
F2 : CHECK H02S HEATER CONTROL CIRCUIT FROM ECM FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM85. 3. Measure the resistance between EM85, pin 01 (PU) and EM21, pin 01 (PU). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<F3>>
54
2012-07-19
F3 : CHECK H02S HEATER CONTROL CIRCUIT FROM ECM FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between EM21, pin 01 (PU) and GROUND. Is the voltage greater than 10 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<F4>>
F4 : CHECK H02S HEATER CONTROL CIRCUIT FROM ECM FOR SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between EM21, pin 01 (PU) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new H02S. CLEAR the DTC. TEST the system for normal operation. If the DTC is repeated, contact dealer technical support for advice on possible ECM failure.
G : DTC P0137, P0138, P0140; RIGHT-HAND CATALYST MONITOR SENSOR LOW/HIGH VOLTAGE, NO ACTIVITY G1 : CHECK THE CATALYST MONITOR SENSOR SENSE CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the catalyst monitor sensor electrical connector, EM22. 3. Disconnect the ECM electrical connector, EM83.
55 2012-07-19

4. Measure the resistance between EM22, pin 04 (U) and EM83, pin 21 (U). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<G2>>
G2 : CHECK THE CATALYST MONITOR SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between EM83, pin 21 (U) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<G3>>
www.JagDocs.com
G3 : CHECK THE CATALYST MONITOR SENSOR SENSE CIRCUIT FOR SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between EM83, pin 21 (U) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<G4>>
G4 : CHECK THE CATALYST MONITOR SENSOR GROUND CIRCUIT FOR OPEN CIRCUIT
56
2012-07-19

1. Reconnect the ECM electrical connector, EM83. 2. Measure the resistance between EM22, pin 03 (BRD) and GROUND. Is the resistance greater than 5 ohms? -> Yes REPAIR the circuit. (This is a braided lead which would require different repair techniques to standard wiring). For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new catalyst monitor sensor. CLEAR the DTC. TEST the system for normal operation.
H : DTC P0141; RIGHT-HAND CATALYST MONITOR SENSOR HEATER CIRCUIT MALFUNCTION H1 : CHECK THE POWER SUPPLY TO THE CATALYST MONITOR HEATER
1. Disconnect the catalyst monitor sensor electrical connector, EM22. 2. Turn the ignition switch to the ON position. 3. Make sure the O2S heater relay is engaged. 4. Measure the voltage between EM22, pin 02 (WG). Is the voltage greater than 10 volts? -> Yes Goto <<H2>> -> No REPAIR the circuit between the O2S heater and battery. This circuit includes the engine management fuse box, (fuse 01) the engine management relay, O2S heater relay, and the high power protection module. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
H2 : CHECK THE CATALYST MONITOR HEATER CONTROL CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM84. 3. Measure the resistance between EM22, pin 01 (PG) and EM84, pin 07 (PG).
57
2012-07-19

Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new catalyst monitor sensor. CLEAR the DTC. TEST the system for normal operation. If the DTC is repeated, contact dealer technical support for advice on possible ECM failure.
I : DTC P0151, P0152, P0153, P1647; RIGHT-HAND H02S LOW/HIGH VOLTAGE, SLOW RESPONSE/ECM CONTROL MALFUNCTION
www.JagDocs.com
I1 : CHECK THE H02S VARIABLE CIRCUIT FOR HIGH RESISTANCE

1. Disconnect the battery negative terminal. 2. Disconnect the H02S electrical connector, EM23. 3. Disconnect the ECM electrical connector, EM82. 4. Measure the resistance between EM23, pin 03 (G) and EM82, pin 05 (G). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<E2>>
I2 : CHECK THE H02S VARIABLE CIRCUIT FOR SHORT TO HIGH VOLTAGE

1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between EM82, pin 05 (G) and GROUND. Is the voltage greater than 3 volts?
58
2012-07-19

-> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<E3>>
I3 : CHECK THE H02S VARIABLE CIRCUIT FOR SHORT TO GROUND

1. Turn the ignition switch to the OFF position. 2. Measure the resistance between EM82, pin 05 (G) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<E4>>
I4 : CHECK THE H02S CONSTANT CIRCUIT FOR HIGH RESISTANCE

1. Measure the resistance between EM23, pin 04 (W) and EM82, pin 11 (W). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<I5>>
I5 : CHECK THE H02S CONSTANT CIRCUIT FOR SHORT TO HIGH VOLTAGE

1. Measure the voltage between EM23, pin 04 (W) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
59
2012-07-19

-> No Goto <<I6>>
I6 : CHECK THE H02S CONSTANT CIRCUIT FOR SHORT TO GROUND

1. Measure the resistance between EM23, pin 04 (W) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new H02S. CLEAR the DTC. TEST the system for normal operation. If the DTC is repeated, contact dealer technical support for advice on possible ECM failure.
www.JagDocs.com
J : DTC P0153, P0155, P1647; LEFT-HAND H02S HEATER CIRCUIT MALFUNCTION/ECM CONTROL MALFUNCTION J1 : CHECK H02S HEATER POWER SUPPLY CIRCUIT
1. Disconnect the H02S electrical connector, EM23. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between EM23, pin 02 (WP) and GROUND. Is the voltage greater than 10 volts? -> Yes Goto <<J2>> -> No REPAIR the power supply circuit to the H02S heater. This circuit includes the EMS control relay and fuse 14 of the EMS fuse board. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
J2 : CHECK H02S HEATER CONTROL CIRCUIT FROM ECM FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal.
60
2012-07-19

2. Disconnect the ECM electrical connector, EM85. 3. Measure the resistance between EM85, pin 02 (PS) and EM23, pin 01 (PS). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<J3>>
J3 : CHECK H02S HEATER CONTROL CIRCUIT FROM ECM FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between EM23, pin 01 (PS) and GROUND. Is the voltage greater than 10 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<J4>>
J4 : CHECK H02S HEATER CONTROL CIRCUIT FROM ECM FOR SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between EM23, pin 01 (PS) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new H02S. CLEAR the DTC. TEST the system for normal operation. If the DTC is repeated, contact dealer technical support for advice on possible ECM failure.
61
2012-07-19
K : DTC P0161; LEFT-HAND CATALYST MONITOR SENSOR HEATER CIRCUIT MALFUNCTION K1 : CHECK THE POWER SUPPLY TO THE CATALYST MONITOR HEATER
1. Disconnect the catalyst monitor sensor electrical connector, EM24. 2. Turn the ignition switch to the ON position. 3. Make sure the O2S heater relay is engaged. 4. Measure the voltage between EM24, pin 02 (WG). Is the voltage greater than 10 volts? -> Yes Goto <<K2>> -> No REPAIR the circuit between the O2S heater and battery. This circuit includes the engine management fuse box, (fuse 01) the engine management relay, O2S heater relay, and the high power protection module. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
www.JagDocs.com
K2 : CHECK THE CATALYST MONITOR HEATER CONTROL CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM84. 3. Measure the resistance between EM22, pin 01 (PR) and EM84, pin 15 (PR). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new catalyst monitor sensor. CLEAR the DTC. TEST the system for normal operation. If the DTC is repeated, contact dealer technical support for advice on possible ECM failure.
62
2012-07-19
L : DTC P0196, P0197, P0198; ENGINE OIL TEMPERATURE (EOT) SENSOR RANGE/PERFORMANCE, HIGH/LOW VOLTAGE L1 : CHECK THE EOT SENSOR SENSE CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the EOT sensor electrical connector, PI38. 3. Disconnect the ECM electrical connector, EM80. 4. Measure the resistance between PI38, pin 01 (SG) and EM80, pin 15 (SG). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<L2>>
L2 : CHECK THE EOT SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between PI38, pin 01 (SG) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<L3>>
L3 : CHECK THE EOT SENSOR SENSE CIRCUIT FOR SHORT TO GROUND

1. Turn the ignition switch to the OFF position.
63
2012-07-19

2. Measure the resistance between PI38, pin 01 (SG) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<L4>>
L4 : CHECK THE EOT SENSOR GROUND

1. Measure the resistance between PI38, pin 02 (BG) and GROUND. Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. This circuit includes harness splices, PIS1 and EMS2, and the ECM. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new EOT sensor. CLEAR the DTC. TEST the system for normal operation.
www.JagDocs.com
M : DTC P0157, P0158, P0160; LEFT-HAND CATALYST MONITOR SENSOR LOW/HIGH VOLTAGE, NO ACTIVITY M1 : CHECK THE CATALYST MONITOR SENSOR SENSE CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the catalyst monitor sensor electrical connector, EM24. 3. Disconnect the ECM electrical connector, EM83. 4. Measure the resistance between EM24, pin 04 (N) and EM83, pin 22 (N). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<M2>>
64
2012-07-19
M2 : CHECK THE CATALYST MONITOR SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between EM83, pin 22 (N) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<M3>>
M3 : CHECK THE CATALYST MONITOR SENSOR SENSE CIRCUIT FOR SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between EM83, pin 22 (N) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<M4>>
M4 : CHECK THE CATALYST MONITOR SENSOR GROUND CIRCUIT FOR OPEN CIRCUIT
1. Reconnect the ECM electrical connector, EM83. 2. Measure the resistance between EM24, pin 03 (BRD) and GROUND. Is the resistance greater than 5 ohms? -> Yes REPAIR the circuit. (This is a braided lead which would require different repair techniques to standard wiring). For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
65
2012-07-19

-> No INSTALL a new catalyst monitor sensor. CLEAR the DTC. TEST the system for normal operation.
N : DTC P0222, P0223; THROTTLE POSITION (TP) SENSOR CIRCUIT #2 LOW VOLTAGE N1 : CHECK TP SENSOR #2 SENSE CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the TP sensor electrical connector, PI06. 3. Disconnect the ECM electrical connector, EM81. 4. Measure the resistance between PI06, pin 02 (G) and EM81, pin 19 (G). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<N2>>
www.JagDocs.com
N2 : CHECK TP SENSOR #2 SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE

1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between PI06, pin 02 (G) and GROUND. Is the voltage greater than 5 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new TP sensor. CLEAR the DTC. TEST the system for normal operation.
O : DTC P0327, P0328; RIGHT-HAND KNOCK SENSOR (KS) CIRCUIT OUT OF RANGE (LOW VOLTAGE)
66
2012-07-19

NOTE: Before commencing this test, make sure that the sensor is making a good electrical contact with the cylinder block. See 'possible causes'.
O1 : CHECK KS SENSE CIRCUIT FOR HIGH RESISTANCE

1. Disconnect the battery negative terminal. 2. Disconnect the KS electrical connector, PI26. 3. Disconnect the ECM electrical connector, EM83. 4. Measure the resistance between PI26, pin 01 (S) and EM83, pin 14 (S). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<O2>>
O2 : CHECK KS SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE

1. Turn the ignition switch to the ON position. 2. Reconnect the battery negative terminal. 3. Measure the voltage between PI26, pin 01 (S) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit to high voltage. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<O3>>
O3 : CHECK KS SENSE CIRCUIT FOR SHORT TO GROUND

1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI26, pin 01 (S) and GROUND.
67
2012-07-19

Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new KS. CLEAR the DTC. TEST the system for normal operation.
P : DTC P0332, P0333; LEFT-HAND KNOCK SENSOR (KS) CIRCUIT OUT OF RANGE (LOW VOLTAGE)
www.JagDocs.com
P1 : CHECK KS SENSE CIRCUIT FOR HIGH RESISTANCE

1. Disconnect the battery negative terminal. 2. Disconnect the KS electrical connector, PI27. 3. Disconnect the ECM electrical connector, EM83. 4. Measure the resistance between PI27, pin 01 (N) and EM83, pin 23 (N). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<P2>>
P2 : CHECK KS SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE

1. Turn the ignition switch to the ON position. 2. Reconnect the battery negative terminal. 3. Measure the voltage between PI27, pin 01 (N) and GROUND. Is the voltage greater than 5 volts? -> Yes REPAIR the short circuit to high voltage. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
68
2012-07-19

-> No Goto <<P3>>
P3 : CHECK KS SENSE CIRCUIT FOR SHORT TO GROUND

1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI27, pin 01 (N) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new KS. CLEAR the DTC. TEST the system for normal operation.
Q : DTC P0335, P0336; CRANKSHAFT POSITION (CKP) SENSOR CIRCUIT MALFUNCTION Q1 : CHECK THE CKP SENSOR FOR CORRECT INSTALLATION
1. Turn the ignition switch to the OFF position. 2. Check the CKP sensor for correct installation. Is the CKP sensor correctly installed? -> Yes Goto <<Q2>> -> No INSTALL the CKP sensor correctly. Reconnect the sensor. CLEAR the DTCs. TEST the system for normal operation.
Q2 : CHECK THE CKP SENSOR FOR DEBRIS

1. Remove the CKP sensor and inspect for debris. Is the CKP sensor free of debris? -> Yes
69 2012-07-19

Goto <<Q3>> -> No CLEAN the sensor and wheel. INSTALL the sensor. Reconnect the sensor. CLEAR the DTCs. TEST the system for normal operation.
Q3 : CHECK THE CKP SENSOR SENSE CIRCUIT FOR HIGH RESISTANCE

1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM83. 3. Measure the resistance between EM83, pin 08 (Y) and PI17, pin 02 (Y). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<Q4>>
www.JagDocs.com
Q4 : CHECK THE CKP SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between PI17, pin 02 (Y) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<Q5>>
Q5 : CHECK THE CKP SENSOR SENSE CIRCUIT FOR SHORT TO GROUND

1. Turn the ignition switch to the OFF position. 2. Measure the resistance between EM83, pin 08 (Y) and GROUND.
70
2012-07-19

Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new CKP sensor. CLEAR the DTC. TEST the system for normal operation.
R : DTC P0340, P0341; RIGHT-HAND CAMSHAFT POSITION (CMP) SENSOR CIRCUIT MALFUNCTION R1 : CHECK THE CMP SENSOR FOR CORRECT INSTALLATION
1. Turn the ignition switch to the OFF position. 2. Check the CMP sensor for correct installation. Is the CMP sensor correctly installed? -> Yes Goto <<R2>> -> No INSTALL the CMP sensor correctly. CLEAR the DTCs. TEST the system for normal operation.
R2 : CHECK THE CMP SENSOR FOR FOREIGN DEBRIS

1. Remove the CMP sensor and inspect for foreign debris. Is the CMP sensor free of foreign debris? -> Yes Goto <<Q3>> -> No CLEAN the sensor and wheel. INSTALL the sensor. CLEAR the DTCs. TEST the system for normal operation.
R3 : CHECK THE CMP SENSOR SENSE CIRCUIT FOR HIGH RESISTANCE

71
2012-07-19

2. Disconnect the CMP sensor electrical connector, PI16. 3. Disconnect the ECM electrical connector, EM83. 4. Measure the resistance between EM83, pin 19 (G) and PI16, pin 01 (G). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<R3>>
R4 : CHECK THE CMP SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between EM83, pin 19 (G) and GROUND. Is the voltage greater than 5 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<R5>>
www.JagDocs.com
R5 : CHECK THE CMP SENSOR SENSE CIRCUIT FOR SHORT TO GROUND

1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI16, pin 01 (G) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new CMP sensor. CLEAR the DTC. TEST the system for normal operation.
72
2012-07-19
S : DTC P0480; RADIATOR FANS SLOW (SERIES) CIRCUIT MALFUNCTION S1 : CHECK THE RADIATOR FAN MODULE TO ECM 'SERIES' DRIVE CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM81. 3. Disconnect the fan module electrical connector, LF09. 4. Measure the resistance between EM81, pin 05 (W) and LF09, pin 09 (W). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<S2>>
S2 : CHECK THE RADIATOR FAN MODULE TO ECM 'SERIES' DRIVE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between EM81, pin 05 (W) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<S3>>
S3 : CHECK THE RADIATOR FAN MODULE TO ECM 'SERIES' DRIVE CIRCUIT FOR SHORT TO GROUND
73
2012-07-19

2. Measure the resistance between EM81, pin 05 (W) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<S4>>
S4 : CHECK THE RADIATOR FAN MODULE IGNITION SUPPLY

1. Reconnect the ECM electrical connector, EM81. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between LF09, pin 08 (WU) and GROUND. Is the voltage greater than 10 volts? -> Yes INSTALL a new radiator fan module. <<303-03A>><<303-03B>> CLEAR the DTC. TEST the system for normal operation. -> No REPAIR the circuit between LF09, pin 08 (WU) and battery. This circuit includes the EMS fuse box, (fuse 12), the EMS relay, etc. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
www.JagDocs.com
T : DTC P0482; RADIATOR FANS FAST (PARALLEL) CIRCUIT MALFUNCTION T1 : CHECK THE RADIATOR FAN MODULE TO ECM 'PARALLEL' DRIVE CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM81. 3. Disconnect the fan module electrical connector, LF09. 4. Measure the resistance between EM81, pin 04 (WU) and LF09, pin 07 (WU). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
74
2012-07-19

-> No Goto <<S2>>
T2 : CHECK THE RADIATOR FAN MODULE TO ECM 'PARALLEL' DRIVE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between EM81, pin 04 (WU) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<T3>>
T3 : CHECK THE RADIATOR FAN MODULE TO ECM 'PARALLEL' DRIVE CIRCUIT FOR SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between EM81, pin 04 (WU) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<S4>>
T4 : CHECK THE RADIATOR FAN MODULE IGNITION SUPPLY

1. Reconnect the ECM electrical connector, EM81. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between LF09, pin 08 (WP) and GROUND. Is the voltage greater than 10 volts?
75 2012-07-19

-> Yes INSTALL a new radiator fan module. <<303-03A>><<303-03B>> CLEAR the DTC. TEST the system for normal operation. -> No REPAIR the circuit between LF09, pin 08 (WP) and battery. This circuit includes the EMS fuse box, (fuse 12), the EMS relay, etc. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
U : DTC P0560; VEHICLE VOLTAGE MALFUNCTION

NOTE: When checking the EMS switched supplies to the ECM in test P3, the EMS relay must be energised when testing EM10, pin 01 and EM14, pin 03.
www.JagDocs.com
U1 : CHECK THE BATTERY POWER SUPPLY TO THE ECM

1. Disconnect the ECM electrical connector, EM83. 2. Measure the voltage between EM83, pin 20 (NO) and GROUND. Is the voltage greater than 10 volts? -> Yes Reconnect the ECM electrical connector, EM83. Goto <<U2>> -> No REPAIR the battery power supply circuit. This circuit includes fuse 4 of the EMS fuse board. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
U2 : CHECK THE IGNITION SWITCHED POWER SUPPLY TO THE ECM

1. Disconnect the ECM electrical connector, EM82. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between EM82, pin 09 (WK) and GROUND. Is the voltage greater than 10 volts? -> Yes Goto <<U3>>
76
2012-07-19

-> No REPAIR the ignition switched power supply circuit. This circuit includes fuse 9 of the Right-Hand heelboard fuse box. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
U3 : CHECK THE EMS SWITCHED POWER SUPPLIES TO THE ECM

1. Disconnect the ECM electrical connector, EM81. 2. Turn the ignition switch to the ON position. 3. Make sure the EMS relay is energised. 4. Measure the voltage between EM82, pin 13 (WR) and GROUND. 5. Measure the voltage between EM81, pin 17 (WR) and GROUND. Are both voltages greater than 10 volts? -> Yes Contact dealer technical support for advice on possible ECM failure. -> No REPAIR the EMS switched power supply circuits. The supply circuit to EM82, pin 13 includes fuse 10 of the EMS fuse box, the supply circuit to EM81, pin 17 includes fuse 01 of the trunk fuse box. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
V : DTC P1104; MASS AIR FLOW (MAF) SENSOR GROUND MALFUNCTION V1 : CHECK THE MAF SENSOR REFERENCE GROUND
1. Disconnect the MAF sensor electrical connector, PI35. 2. Turn the ignition switch to the ON position. 3. Measure the resistance between PI35, pin 02 (BY) and GROUND. Is the resistance greater than 5 ohms? -> Yes Goto <<V2>> -> No INSTALL a new MAF sensor. CLEAR the DTC. TEST the system for normal operation.
77
2012-07-19
V2 : CHECK THE MAF SENSOR REFERENCE GROUND CIRCUIT FOR HIGH RESISTANCE
1. Turn the ignition switch to the OFF position. 2. Disconnect the battery negative terminal. 3. Disconnect the ECM electrical connector, EM83. 4. Measure the resistance between PI35, pin 02 (BY) and EM83, pins 26 and 27 (BY). Is either resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Contact dealer technical support for advice on possible ECM failure.
www.JagDocs.com
W : DTC P1121, P1122, P1123; ACCELERATOR PEDAL POSITION (APP) SENSOR CIRCUIT '1' RANGE/PERFORMANCE, HIGH/LOW VOLTAGE W1 : CHECK THE APP SENSOR SENSE CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM81. 3. Disconnect the APP sensor electrical connector, PI42. 4. Measure the resistance between EM81, pin 09 (K) and PI42, pin 04 (K). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<W2>>
W2 : CHECK THE APP SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
78
2012-07-19

1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between PI42, pin 04 (K) and GROUND. Is the voltage greater than 5 volts? -> Yes REPAIR the short circuit to high voltage. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<W3>>
W3 : CHECK THE APP SENSOR SENSE CIRCUIT FOR SHORT TO GROUND

1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI42, pin 04 (K) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<W4>>
W4 : CHECK THE APP SENSOR SUPPLY VOLTAGE AT THE SENSOR

1. Reconnect the ECM electrical connector, EM81. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between PI42, pin 01 (UW) and GROUND. Is the voltage less than 4 volts? -> Yes Goto <<W5>> -> No Goto <<W6>>
79
2012-07-19
W5 : CHECK THE APP SENSOR SUPPLY VOLTAGE CIRCUIT

1. Turn the ignition switch to the OFF position. 2. Disconnect the ECM electrical connector, EM83. 3. Measure the resistance between EM83, pin 05 (UW) and PI42, pin 01 (UW). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Check the ECM power supplies.
www.JagDocs.com
W6 : CHECK THE APP SENSOR COMMON SIGNAL GROUND

1. Measure the resistance between PI42, pin 03 (BG) and GROUND. Is the resistance greater than 5 ohms? -> Yes Goto <<W7>> -> No INSTALL a new APP sensor. CLEAR the DTC. TEST the system for normal operation.
W7 : CHECK THE APP SENSOR COMMON SIGNAL GROUND CIRCUIT

1. Disconnect the ECM electrical connector, EM83. 2. Measure the resistance between EM83, pin 13 (BG) and PI42, pin 03 (BG). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Check the ECM GROUND circuits. If the GROUND circuits are sound, contact dealer technical support for advice on possible ECM failure.
80
2012-07-19
X : DTC P1136; 'COOL BOX' MALFUNCTION X1 : CHECK THE POWER SUPPLY TO THE ECM/TCM COOLING FAN MOTOR
1. Disconnect the ECM/TCM fan motor electrical connector, EM64. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between EM64, pin 02 (WY) and GROUND. Is the voltage greater than 10 volts? -> Yes Goto <<X2>> -> No REPAIR the circuit between EM64, pin 02 and battery. This circuit includes the EMS fuse box, (fuse 16) the EMS control relay, and the high power protection module. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
X2 : CHECK THE ECM/TCM COOLING FAN MOTOR TO ECM CIRCUIT

1. Turn the ignition switch to the OFF position. 2. Disconnect the battery negative terminal. 3. Disconnect the ECM electrical connector, EM85. 4. Measure the resistance between EM85, pin 05 (U) and EM64, pin 01 (U). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new ECM/TCM cooling fan motor. CLEAR the DTC. TEST the system for normal operation. If the DTC is repeated, contact dealer technical support for advice on possible ECM failure.
Y : DTC P1144; AIR ASSIST CLOSE VALVE (AACV) CIRCUIT MALFUNCTION
81
2012-07-19
Y1 : CHECK THE AACV POWER SUPPLY

1. Disconnect the AACV electrical connector, PI29. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between PI29, pin 02 (WU) and GROUND. Is the voltage less than 10 volts? -> Yes REPAIR the circuit between PI29, pin 02 and battery. This circuit includes the EMS fuse box, (fuse 12) the EMS control relay, and the high power protection module. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<Y2>>
www.JagDocs.com
Y2 : CHECK THE AACV SIGNAL GROUND

1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI29, pin 03 (BK) and GROUND. Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<Y3>>
Y3 : CHECK THE AACV ACTIVATE CIRCUIT FOR HIGH RESISTANCE

1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM83. 3. Measure the resistance between PI29, pin 01 (PU) and EM83, pin 03 (PU). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
82
2012-07-19

-> No Goto <<Y4>>
Y4 : CHECK THE AACV ACTIVATE CIRCUIT FOR SHORT TO HIGH VOLTAGE

1. Reconnect the battery negative terminal. 2. Measure the voltage between PI29, pin 01 (PU) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<Y5>>
Y5 : CHECK THE AACV ACTIVATE CIRCUIT FOR SHORT TO GROUND

1. Measure the resistance between PI29, pin 01 (PU) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new AACV. CLEAR the DTC. TEST the system for normal operation. If the DTC is repeated, contact dealer technical support for advice on possible ECM failure.
Z : DTC P1222, P1223; ACCELERATOR PEDAL POSITION (APP) SENSOR CIRCUIT '2' RANGE/PERFORMANCE, HIGH/LOW VOLTAGE Z1 : CHECK THE APP SENSOR SENSE CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM81. 3. Disconnect the APP sensor electrical connector, PI42.
83
2012-07-19

4. Measure the resistance between EM81, pin 18 (R) and PI42, pin 02 (R). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<Z2>>
Z2 : CHECK THE APP SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between PI42, pin 02 (R) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<Z3>>
www.JagDocs.com
Z3 : CHECK THE APP SENSOR SENSE CIRCUIT FOR SHORT TO GROUND

1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI42, pin 02 (R) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<Z4>>
Z4 : CHECK THE APP SENSOR SUPPLY VOLTAGE AT THE SENSOR
84
2012-07-19

1. Reconnect the ECM electrical connector, EM81. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between PI42, pin 01 (UW) and GROUND. Is the voltage less than 4 volts? -> Yes Goto <<Z5>> -> No Goto <<Z6>>
Z5 : CHECK THE APP SENSOR SUPPLY VOLTAGE CIRCUIT

Z6 : CHECK THE APP SENSOR SIGNAL GROUND

1. Measure the resistance between PI42, pin 02 (BG) and GROUND. Is the resistance greater than 5 ohms? -> Yes Goto <<Z7>> -> No INSTALL a new APP sensor. CLEAR the DTC. TEST the system for normal operation.
85
2012-07-19
Z7 : CHECK THE APP SENSOR COMMON REFERENCE GROUND CIRCUIT

1. Disconnect the ECM electrical connector, EM83. 2. Measure the resistance between EM83, pin 13 (BG) and PI42, pin 03 (BG). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Check the ECM GROUND circuits. If the GROUND circuits are sound, contact Dealer technical support for advice on possible ECM failure.
www.JagDocs.com
AA : DTC P1224, P1229, P1251; THROTTLE CONTROL POSITION SENSOR ERROR/THROTTLE MOTOR CONTROL CIRCUIT MALFUNCTION/THROTTLE MOTOR POWER RELAY MALFUNCTION
NOTE: Before commencing this test, check the TP sensor connections, perform the throttle adaptions procedure.
AA1 : CHECK THE TP SENSOR TO ECM SENSE CIRCUIT #1 FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the TP sensor electrical connector, PI06. 3. Disconnect the ECM electrical connector, EM81. 4. Measure the resistance between PI06, pin 03 (U) and EM81, pin 10 (U). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AA2>>
AA2 : CHECK THROTTLE MOTOR RELAY CONSTANT SUPPLY

86 2012-07-19

1. Reconnect the battery negative terminal. 2. Remove the throttle motor relay. 3. Measure the voltage between the throttle motor relay base, pin 3 and GROUND. Is the voltage greater than 10 volts? -> Yes Goto <<AA3>> -> No REPAIR the circuit between the throttle motor relay base, pin 3 and the battery. This circuit includes the EMS fuse box, fuse 09. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
AA3 : CHECK THROTTLE MOTOR RELAY EMS SWITCHED SUPPLY

1. Turn the ignition switch to the ON position. 2. Measure the voltage between the throttle motor relay base, pin 1 and GROUND. Is the voltage greater than 10 volts? -> Yes Goto <<AA4>> -> No REPAIR the circuit between the throttle motor relay base, pin 1 and the battery. This circuit includes the EMS fuse box, fuse 14, and the EMS control relay. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
AA4 : CHECK THROTTLE MOTOR RELAY TO ECM CIRCUIT FOR HIGH RESISTANCE
1. Turn the ignition switch to the OFF position. 2. Disconnect the battery negative terminal. 3. Disconnect the ECM electrical connector, EM82. 4. Measure the resistance between EM82, pin 06 (GR) and throttle motor relay base, pin 2. Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
87
2012-07-19

-> No Goto <<AA5>>
AA5 : CHECK THROTTLE MOTOR RELAY OUTPUT TO ECM

1. Reconnect the ECM electrical connector, EM82. 2. Disconnect the ECM electrical connector, EM80. 3. INSTALL the throttle motor relay. 4. Reconnect the battery negative terminal. 5. Turn the ignition switch to the ON position. 6. Measure the voltage between EM80, pins 08 and 09, (GY) and GROUND. Is the voltage greater than 10 volts? -> Yes Goto <<AA6>> -> No INSTALL a new throttle motor relay. For additional information, refer to the electrical guide. CLEAR the DTC. TEST the system for normal operation.
www.JagDocs.com
AA6 : CHECK THROTTLE MOTOR TO ECM DRIVE SUPPLY CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the throttle motor electrical connector, PI33. 2. Measure the resistance between PI33, pin 01 (R) and EM80, pins 06 and 07 (R). Is either resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AA7>>
AA7 : CHECK THROTTLE MOTOR TO ECM DRIVE GROUND CIRCUIT FOR HIGH RESISTANCE
1. Measure the resistance between PI33, pin 02 (G) and EM80, pins 04 and 05 (G).
88 2012-07-19

Is either resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AA8>>
AA8 : CHECK THROTTLE MOTOR TO ECM DRIVE SUPPLY CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the ECM electrical connector, EM80. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between PI33, pin 01 (R) and GROUND. Is the voltage greater than 10 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AA9>>
AA9 : CHECK THROTTLE MOTOR TO ECM DRIVE SUPPLY CIRCUIT FOR SHORT TO GROUND
1. Disconnect the ECM electrical connector, EM80. 2. Turn the ignition switch to the OFF position. 3. Measure the resistance between PI33, pin 01 (R) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new throttle motor. <<303-04>> CLEAR the DTC. TEST the system for normal operation.
AB : DTC P1230; FUEL PUMP RELAY MALFUNCTION
89
2012-07-19
AB1 : CHECK THE FUEL PUMP RELAY TO ECM CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Remove the fuel pump relay. 3. Disconnect the ECM electrical connector, EM83. 4. Measure the resistance between EM83, pin 04 (KN) and the relay base, pin 02. Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AB2>>
www.JagDocs.com
AB2 : CHECK THE FUEL PUMP RELAY TO ECM CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between EM83, pin 04 (KN) and GROUND. Is the voltage greater than 10 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AB3>>
AB3 : CHECK THE FUEL PUMP RELAY TO ECM CIRCUIT FOR SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between EM83, pin 04 (KN) and GROUND. Is the resistance less than 10,000 ohms? -> Yes
90
2012-07-19

REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AB4>>
AB4 : CHECK THE FUEL PUMP RELAY CONSTANT POWER SUPPLY

1. Reconnect the ECM electrical connector, EM83. 2. Measure the voltage between the relay base, pin 03 and GROUND. Is the voltage less than 10 volts? -> Yes REPAIR the circuit between the relay base, pin 03 and the battery power bus. This circuit includes the trunk fuse box and the high power protection module. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AB5>>
AB5 : CHECK THE FUEL PUMP RELAY IGNITION SWITCHED POWER SUPPLY
1. Turn the ignition switch to the ON position. 2. Measure the voltage between the relay base, pin 01 and GROUND. Is the voltage less than 10 volts? -> Yes REPAIR the circuit between the relay base, pin 01 and battery. This circuit includes the trunk fuse box, fuse 16 of the Left-Hand fuse box, the ignition positive relay and the high power protection module. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AB6>>
AB6 : CHECK THE FUEL PUMP RELAY ECM SWITCHED GROUND SUPPLY
1. Turn the ignition switch to the ON position. 2. Make sure the ignition positive relay is engaged.
91
2012-07-19

3. Check the resistance between the fuel pump relay base, pin 02 and GROUND. Is the resistance greater than 5 ohm? -> Yes Contact dealer technical support for advice on possible ECM failure. -> No INSTALL a new fuel pump relay. For additional information, refer to the electrical guide. CLEAR the DTC. TEST the system for normal operation.
AC : DTC P1240, P1241, P1242; SENSOR REFERENCE VOLTAGE MALFUNCTION, HIGH/LOW VOLTAGE (THROTTLE SENSORS, APP SENSOR, FTP SENSOR) AC1 : CHECK THE REFERENCE VOLTAGE AT THE APP SENSOR
1. Disconnect the APP sensor electrical connector, PI42. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between PI42, pin 04 (UW) and GROUND. Is the voltage less than 5 volts? -> Yes Goto <<AC2>> -> No Goto <<AC3>>
www.JagDocs.com
AC2 : CHECK THE APP SENSOR REFERENCE VOLTAGE CIRCUIT FOR HIGH RESISTANCE
1. Turn the ignition switch to the OFF position. 2. Disconnect the ECM electrical connector, EM83. 3. Measure the resistance between PI42, pin 01 (UW) and EM83, pin 05 (UW). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No
92
2012-07-19

Goto <<AC3>>
AC3 : CHECK THE APP SENSOR REFERENCE VOLTAGE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the ECM electrical connector, EM83. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between PI42, pin 01 (UW) and GROUND. Is the voltage greater than 6 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AC4>>
AC4 : CHECK THE APP SENSOR REFERENCE VOLTAGE CIRCUIT FOR SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI42, pin 01 (UW) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AC5>>
AC5 : CHECK THE REFERENCE VOLTAGE AT THE TP SENSOR

1. Disconnect the TP sensor electrical connector, PI06. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between PI06, pin 04 (UW) and GROUND. Is the voltage less than 5 volts? -> Yes
93 2012-07-19

Goto <<AC6>> -> No Goto <<AC7>>
AC6 : CHECK THE TP SENSOR REFERENCE VOLTAGE CIRCUIT FOR HIGH RESISTANCE
1. Turn the ignition switch to the OFF position. 2. Disconnect the ECM electrical connector, EM83. 3. Measure the resistance between PI06, pin 04 (UW) and EM83, pin 05 (UW). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AC7>>
www.JagDocs.com
AC7 : CHECK THE TP SENSOR REFERENCE VOLTAGE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Turn the ignition switch to the ON position. 2. Measure the voltage between PI06, pin 04 (UW) and GROUND. Is the voltage greater than 6 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AC8>>
AC8 : CHECK THE TP SENSOR REFERENCE VOLTAGE CIRCUIT FOR SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI06, pin 04 (UW) and GROUND. Is the resistance less than 10,000 ohms?
94
2012-07-19

-> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AC9>>
AC9 : CHECK THE REFERENCE VOLTAGE AT THE FUEL TANK PRESSURE SENSOR
1. Disconnect the fuel tank pressure sensor electrical connector, FT02. 2. Reconnect the ECM electrical connector, EM83. 3. Turn the ignition switch to the ON position. 4. Measure the voltage between FT02, pin 03 (UW) and GROUND. Is the voltage less than 5 volts? -> Yes Goto <<AC10>> -> No CHECK for DTCs associated with TP sensor, APP sensor, or FTP sensor. INSTALL a new sensor as indicated by the DTC. CLEAR the DTC. TEST the system for normal operation.
AC10 : CHECK THE FUEL TANK PRESSURE SENSOR REFERENCE VOLTAGE CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the ECM electrical connector, EM83. 2. Measure the resistance between FT02, pin 03 (UW) and EM83, pin 05 (UW). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AC11>>
AC11 : CHECK THE FUEL TANK PRESSURE SENSOR REFERENCE VOLTAGE CIRCUIT FOR SHORT TO HIGH VOLTAGE
95
2012-07-19

1. Turn the ignition switch to the ON position. 2. Measure the voltage between FT02, pin 03 (UW) and GROUND. Is the voltage greater than 6 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AC12>>
AC12 : CHECK THE FUEL TANK PRESSURE SENSOR REFERENCE VOLTAGE CIRCUIT FOR SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between FT02, pin 03 (UW) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No CHECK for DTCs associated with TP sensor, APP sensor, or FTP sensor. INSTALL a new sensor as indicated by the DTC. CLEAR the DTC. TEST the system for normal operation.
www.JagDocs.com
AD : DTC P1243; SENSOR REFERENCE GROUND MALFUNCTION (THROTTLE SENSORS, FUEL TANK PRESSURE SENSOR, ECT SENSOR, IAT SENSOR) AD1 : CHECK THE SENSOR REFERENCE GROUND AT THE THROTTLE SENSORS
1. Disconnect the throttle sensor electrical connector, PI06. 2. Measure the resistance between PI06, pin 01 (BG) and GROUND. Is the resistance greater than 5 ohms? -> Yes Goto <<AD2>> -> No
96
2012-07-19

Goto <<AD3>>
AD2 : CHECK THE THROTTLE SENSOR REFERENCE GROUND CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connectors, EM82 and EM83. 3. Measure the resistance between PI06, pin 01 (BG) and EM82, pin 07 (BG). 4. Measure the resistance between PI06, pin 01 (BG) and EM83, pin 13 (BG). Is either resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AD3>>
AD3 : CHECK THE SENSOR REFERENCE GROUND AT THE APP SENSOR

1. Disconnect the APP sensor electrical connector, PI42. 2. Reconnect the ECM electrical connectors, EM82 and EM83. 3. Reconnect the ECM electrical connectors, EM82 and EM83. 4. Measure the resistance between PI42, pin 03 (BG) and GROUND. Is the resistance greater than 5 ohms? -> Yes Goto <<AD4>> -> No Goto <<AD5>>
AD4 : CHECK THE APP SENSOR REFERENCE GROUND CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connectors, EM82 and EM83.
97 2012-07-19

3. Measure the resistance between PI42, pin 03 (BG) and EM82, pin 07 (BG). 4. Measure the resistance between PI42, pin 03 (BG) and EM83, pin 13 (BG). Is either resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AD5>>
AD5 : CHECK THE SENSOR REFERENCE GROUND AT THE FUEL TANK PRESSURE SENSOR
1. Disconnect the FTP sensor electrical connector, FT02. 2. Reconnect the ECM electrical connectors, EM82 and EM83. 3. Reconnect the battery negative terminal. 4. Measure the resistance between FT02, pin 01 (BG) and GROUND. Is the resistance greater than 5 ohms? -> Yes Goto <<AD6>> -> No Goto <<AD7>>
www.JagDocs.com
AD6 : CHECK THE FUEL TANK PRESSURE SENSOR REFERENCE GROUND CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connectors, EM82 and EM83. 3. Measure the resistance between FT02, pin 01 (BG) and EM82, pin 07 (BG). 4. Measure the resistance between FT02, pin 01 (BG) and EM83, pin 13 (BG). Is either resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No
98
2012-07-19

Goto <<AD7>>
AD7 : CHECK THE SENSOR REFERENCE GROUND AT THE ECT SENSOR

1. Reconnect the ECM electrical connectors, EM82 and EM83. 2. Reconnect the battery negative terminal. 3. Disconnect the ECT sensor electrical connector, PI04. 4. Measure the resistance between PI04, pin 01 (BG) and GROUND. Is the resistance greater than 5 ohms? -> Yes Goto <<AD8>> -> No Goto <<AD9>>
AD8 : CHECK THE ECT SENSOR REFERENCE GROUND CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connectors, EM82 and EM83. 3. Measure the resistance between PI04, pin 01 (BG) and EM82, pin 07 (BG). 4. Measure the resistance between PI04, pin 01 (BG) and EM83, pin 13 (BG). Is either resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AD9>>
AD9 : CHECK THE SENSOR REFERENCE GROUND AT THE IAT SENSOR (MAF)
1. Reconnect the ECM electrical connectors, EM82 and EM83. 2. Reconnect the battery negative terminal.
99 2012-07-19

3. Disconnect the IAT sensor (MAF) electrical connector, PI35. 4. Measure the resistance between PI35, pin 05 (BG) and GROUND. Is the resistance greater than 5 ohms? -> Yes Goto <<AD10>> -> No CHECK for DTCs associated with TP sensor, APP sensor, FTP sensor , ECT sensor, IAT sensor. INSTALL a new sensor as indicated by the DTC. CLEAR the DTC. TEST the system for normal operation.
AD10 : CHECK THE IAT SENSOR REFERENCE GROUND CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connectors, EM82 and EM83. 3. Measure the resistance between PI35, pin 05 (BG) and EM82, pin 07 (BG). 4. Measure the resistance between PI35, pin 05 (BG) and EM83, pin 13 (BG). Is either resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No CHECK for DTCs associated with TP sensor, APP sensor, FTP sensor , ECT sensor, IAT sensor. INSTALL a new sensor as indicated by the DTC. CLEAR the DTC. TEST the system for normal operation.
www.JagDocs.com
AE : DTC P1245, P1246; ENGINE CRANK SIGNAL LOW/HIGH VOLTAGE AE1 : CHECK THE STARTER RELAY SIGNAL CIRCUIT FROM ECM AND BPM FOR SHORT TO B+
1. Remove the starter relay. 2. Measure the voltage between the starter relay base, pin 02 and GROUND. Is the voltage greater than 3 volts? -> Yes
100
2012-07-19

REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AE2>>
AE2 : CHECK THE STARTER RELAY SIGNAL CIRCUIT FROM ECM AND BPM FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM82. 3. Disconnect the BPM electrical connector, FC14. 4. Measure the resistance between EM82, pin 02 (GO) and the starter relay base, pin 02. 5. Measure the resistance between FC14, pin 79 (GO) and the starter relay base, pin 02. Is either resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new BPM. CLEAR the DTC. TEST the system for normal operation.
AF : DTC P1260; SECURITY INPUT MALFUNCTION

NOTE: This DTC can only be cleared following an ignition OFF/ON cycle after rectification. Attempts to clear without cycling the ignition will result in the DTC reflagging 3-4 seconds after clearing. NOTE: P1260 can be flagged as a result of a time-out situation within the security system. If the engine cranks with P1260 flagged, clear the code and recheck the DTCs.
AF1 : CHECK THE KTM TO ECM CIRCUIT FOR HIGH RESISTANCE

1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM82. 3. Disconnect the KTM electrical connector, FC22.
101
2012-07-19

4. Measure the resistance between EM82, pin 16 (Y) and FC22, pin 17 (Y). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new KTM. CLEAR the DTC. TEST the system for normal operation.
AG : DTC P1340, P1341; LEFT-HAND CAMSHAFT POSITION (CMP) SENSOR CIRCUIT MALFUNCTION AG1 : CHECK THE CMP SENSOR FOR CORRECT INSTALLATION
1. Check the CMP sensor for correct installation. Is the CMP sensor correctly installed? -> Yes Goto <<AG2>> -> No INSTALL the CMP sensor correctly. CLEAR the DTCs. TEST the system for normal operation.
www.JagDocs.com
AG2 : CHECK THE CMP SENSOR FOR FOREIGN DEBRIS

1. Remove the CMP sensor and inspect for foreign debris. Is the CMP sensor free of foreign debris? -> Yes Goto <<AG3>> -> No CLEAN the sensor and wheel. INSTALL the sensor. CLEAR the DTCs. TEST the system for normal operation.
AG3 : CHECK THE CMP SENSOR SENSE CIRCUIT FOR HIGH RESISTANCE
102
2012-07-19

2. Disconnect the CMP sensor electrical connector, PI15. 3. Disconnect the ECM electrical connector, EM83. 4. Measure the resistance between EM83, pin 18 (B) and PI15, pin 01 (B). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AG4>>
AG4 : CHECK THE CMP SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between EM83, pin 18 (B) and GROUND. Is the voltage greater than 6 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AG5>>
AG5 : CHECK THE CMP SENSOR SENSE CIRCUIT FOR SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI15, pin 01 (B) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new CMP sensor. CLEAR the DTC. TEST the system for normal operation.
103
2012-07-19
AH : DTC P0010, P1384; RIGHT-HAND VARIABLE CAMSHAFT TIMING (VCT) OIL CONTROL SOLENOID CIRCUIT OPEN/SHORT CIRCUIT AH1 : CHECK ECM TO VCT SOLENOID VALVE + CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the VCT electrical connector, PI31. 3. Disconnect the ECM electrical connector, EM81. 4. Measure the resistance between PI31, pin 01 (OY) and EM81, pin 01 (OY). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AH2>>
www.JagDocs.com
AH2 : CHECK ECM TO VCT SOLENOID VALVE + CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between PI31, pin 01 (OY) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AH2>>
AH3 : CHECK ECM TO VCT SOLENOID VALVE + CIRCUIT FOR SHORT TO GROUND
104
2012-07-19

2. Measure the resistance between PI31, pin 01 (OY) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AH4>>
AH4 : CHECK ECM TO VCT SOLENOID VALVE - CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Measure the resistance between PI31, pin 02 (RY) and EM81, pin 02 (RY). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AH5>>
AH5 : CHECK ECM TO VCT SOLENOID VALVE - CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between PI31, pin 02 (RY) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new VCT solenoid. CLEAR the DTC. TEST the system for normal operation.
AI : DTC P0020, P1396; LEFT-HAND VARIABLE CAMSHAFT TIMING (VCT) OIL CONTROL SOLENOID CIRCUIT OPEN/SHORT CIRCUIT
105
2012-07-19
AI1 : CHECK ECM TO VCT SOLENOID VALVE + CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the VCT electrical connector, PI32. 3. Disconnect the ECM electrical connector, EM81. 4. Measure the resistance between PI32, pin 01 (OG) and EM81, pin 06 (OG). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AI2>>
www.JagDocs.com
AI2 : CHECK ECM TO VCT SOLENOID VALVE + CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between PI32, pin 01 (OG) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AI3>>
AI3 : CHECK ECM TO VCT SOLENOID VALVE + CIRCUIT FOR SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI32, pin 01 (OG) and GROUND. Is the resistance less than 10,000 ohms? -> Yes
106
2012-07-19

REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AI4>>
AI4 : CHECK ECM TO VCT SOLENOID VALVE - CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Measure the resistance between PI32, pin 02 (RG) and EM81, pin 07 (RG). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AI5>>
AI5 : CHECK ECM TO VCT SOLENOID VALVE - CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between PI32, pin 02 (RG) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new VCT solenoid. CLEAR the DTC. TEST the system for normal operation.
AJ : DTC P1516, P1517; GEAR CHANGE PARK/NEUTRAL DRIVING MALFUNCTION AJ1 : CHECK THE TRANSMISSION RANGE (TR) SENSOR TO ECM CIRCUIT FOR HIGH RESISTANCE
107
2012-07-19

2. Disconnect the TR sensor electrical connector, EM47. 3. Disconnect the ECM electrical connector, EM10. 4. Measure the resistance between EM47, pin K (RU) and EM10, pin 15 (RU). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AJ2>>
AJ2 : CHECK THE TRANSMISSION RANGE (TR) SENSOR PARK/NEUTRAL SWITCHING ACTION
1. Measure the resistance between pins J and K of the TR sensor. 2. Move the selector lever from PARK to NEUTRAL and back. Does the resistance switch between open circuit and continuity as the lever moves? -> Yes Goto <<AJ3>> -> No INSTALL a new TR sensor. <<307-05A>><<307-05B>> CLEAR the DTC. TEST the system for normal operation.
www.JagDocs.com
AJ3 : CHECK THE D-4 SWITCH TO TCM CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the D-4 switch electrical connector, FC83. 2. Disconnect the TCM electrical connector, EM07. 3. Measure the resistance between FC83, pin 01 (US) and EM07, pin 13 (US). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new TR sensor. <<307-05A>><<307-05B>> CLEAR the DTC. TEST the system for normal operation.
108
2012-07-19
AK : DTC P1582; THROTTLE MONITOR DATA AVAILABLE OR INERTIA SWITCH MALFUNCTION AK1 : CHECK THE INERTIA SWITCH TO ECM CIRCUIT FOR SHORT CIRCUIT TO GROUND
1. Make sure the inertia switch is not tripped. 2. Disconnect the inertia switch electrical connector, FC46. 3. Disconnect the ECM electrical connector, EM82. 4. Measure the resistance between FC46, pin 02 (GP) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new inertia switch. CLEAR the DTC. TEST the system for normal operation.
AL : DTC P1606; EMS CONTROL RELAY MALFUNCTION AL1 : CHECK THE EMS RELAY PERMANENT B+SUPPLY
1. Remove the EMS relay. 2. Measure the voltage between the relay base, pins 02 and 03. Are both voltages greater than 10 volts? -> Yes Goto <<AL2>> -> No REPAIR the circuit between the relay base and battery. This circuit includes the high power protection module. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
AL2 : CHECK THE EMS RELAY TO ECM CIRCUIT FOR HIGH RESISTANCE
109
2012-07-19

1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM81. 3. Measure the resistance between the relay base, pin 01 and EM81, pin 03 (PK). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new EMS relay. CLEAR the DTC. TEST the system for normal operation.
AM : DTC P1631; THROTTLE MOTOR POWER RELAY COIL ACTIVATION CIRCUIT FAILURE AM1 : CHECK THE THROTTLE MOTOR RELAY TO ECM CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Remove the throttle motor relay. 3. Disconnect the ECM electrical connector, EM80. 4. Measure the resistance between the throttle motor relay base, pin 05 and EM80, pins 08 and 09. Is either resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AM2>>
www.JagDocs.com
AM2 : CHECK THE THROTTLE MOTOR RELAY TO ECM CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between the throttle motor relay base, pin 05 and GROUND. Is the voltage greater than 3 volts?
110
2012-07-19

-> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AM3>>
AM3 : CHECK THE THROTTLE MOTOR RELAY TO ECM CIRCUIT FOR SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between the throttle motor relay base, pin 05 and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new throttle body. <<303-04>> CLEAR the DTC. TEST the system for normal operation.
AN : DTC P1658; THROTTLE MOTOR POWER RELAY 'ON' FAILURE

NOTE: Before beginning this test, make sure the relay contacts are not stuck on.
AN1 : CHECK THE THROTTLE MOTOR RELAY TO ECM COIL CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Remove the throttle motor power relay. 3. Disconnect the ECM electrical connector, EM82. 4. Measure the resistance between the relay base, pin 02 and EM82, pin 06 (GR). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AN2>>
111
2012-07-19
AN2 : CHECK THE THROTTLE MOTOR RELAY TO ECM COIL CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between the relay base, pin 02 and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AN3>>
www.JagDocs.com
AN3 : CHECK THE THROTTLE MOTOR RELAY TO ECM COIL CIRCUIT FOR SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between the relay base, pin 02 and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AN4>>
AN4 : CHECK THE THROTTLE MOTOR RELAY TO ECM SUPPLY CIRCUIT FOR SHORT TO BATTERY +
1. Disconnect the ECM electrical connector, EM80. 2. Measure the voltage between the relay base, pin 05 and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No
112 2012-07-19

Contact dealer technical support for advice on possible ECM failure.
AO : CHECK ROCHESTER VALVE FUNCTION AO1 : CHECK VACUUM INTEGRITY OF ROCHESTER VALVE
1. Disconnect hoses from rochester valve. 2. Blank off outlet side of valve. 3. Connect a hand-held vacuum pump to the vacuum inlet of the valve. 4. Apply a vacuum to the valve and monitor the reading for 2 minutes. Does the valve hold vacuum? -> Yes Inspect the pipes at either side of the valve for leaks/damage. Rectify as necessary. -> No INSTALL a new rochester valve. TEST the system for normal operation.
113
2012-07-19
Electronic Engine Controls Vehicles With: Supercharger

1. Verify the customer concern. 2. Confirm which, if any, warning lights and/or messages were displayed on the instrument cluster. NOTE: If any warning lights and/or messages were displayed when the fault occurred, refer to the Driver Information table for DTCs associated with the display, then to the DTC index table for possible sources and actions. Some warnings will appear to clear when the ignition is cycled. This is often because the warning has flagged as a result of one of the vehicle's on-board diagnostic routines having run to detect the fault. If the same routine is not run when the ignition is switched ON, the warning will not reflag until the routine does run. See the DTC summaries for drive cycle routines. 3. Visually inspect for obvious signs of mechanical or electrical damage. Visual Inspection Chart Mechanical Engine oil level Cooling system coolant level Fuel Contamination Throttle body Poly-vee belt Electrical Fuses Wiring harness Electrical connector(s) Sensor(s) Engine control module (ECM) Transmission control module Check spark plug type. Only resisted plugs should be fitted. Refer to specifications section for gap Relay date codes. If the date on the relay is between R6 k1 and R6 k8, replace the relay 4. Verify the following systems are working correctly: Air intake system Cooling system Charging system Fuel charging system 5. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 6. Where the Jaguar approved diagnostic system is available, complete the S93 report before clearing any or all fault codes from the vehicle. NOTE: If a DTC cannot be cleared, then there is a permanent fault present that flags again as soon as it is cleared. (The exception to this is P1260, which will only clear following an ignition OFF/ON cycle after rectification.) 7. If the cause is not visually evident and the Jaguar approved diagnostic system is not available, use a fault code reader to retrieve the fault codes before proceeding to the Diagnostic Trouble Code (DTC) Index Chart, or the Symptom Chart if no DTCs are set. NOTE: If the DTC flagged was not present for two or more consecutive cycles, it is classed as temporary, and will be
www.JagDocs.com
2012-07-19
deleted following three cycles during which no fault was present. This could result in a reported warning light/message with no stored DTCs. If a fault is present for three consecutive cycles, the DTC becomes permanent, and will remain in the module's memory for 40 drive cycles. (A cycle is an ignition ON/OFF, which will occur during the owner's normal use of the vehicle. No action on the part of the technician is necessary to perform this cycle. A drive cycle is a series of conditions needed to make the on-board diagnostic routine run, and may need a specific action on the part of the technician. See the DTC summaries for drive cycle routines) 8. Using the Jaguar approved diagnostic system where available, and a scan tool where not, check the freeze frame data for information on the conditions applicable when the fault was flagged. The format of this will vary, depending on the tool used, but can provide information useful to the technician in diagnosing the fault.
CAUTION: When probing connectors to take measurements in the course of the pinpoint tests, use the adaptor kit, part number 3548-1358-00. NOTE: When performing electrical voltage or resistance tests, always use a digital multimeter (DMM) accurate to 3 decimal places, and with an up-to-date calibration certificate. When testing resistance, always take the resistance of the DMM leads into account. NOTE: Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests. Symptom Chart Symptom (general) Non-Start Symptom (specific) Engine does not crank Possible source Starter relay ECM relay Battery Park/Neutral switch Starting system Harness damage Engine siezed ' Engine cranks, but does not fire Security system /Immobiliser engaged Throttle contaminated Harness damage Fuel pump relay Fuel system Refer to service action S491 Contact dealer technical support for information on security system. For fuel system, <<303-04>> Check bulletins for throttle cleaning procedure. Check service actions. Action Check relay dates. Check for DTCS. For starting system, <<303-06>> For ECM relay tests, Goto <<BT>> . For battery information, <<414-01>> For Park/Neutral tests, Goto <<BS>> . For engine information, <<303-01>>
2012-07-19
'
Engine cranks and fires, but will not start
Rochester valve Fuel pump relay Throttle contaminated Purge valve Fuel pump Engine coolant temperature (ECT) sensor Spark plugs fouled Cylinder compression loss (short-term. Refer to bulletin; 303-52) Refer to service action S491
For rochester valve tests, Goto <<BV>> For fuel pump relay tests, Goto <<BK>> . Check bulletins for throttle cleaning procedure. Check fuel pressure. Refer to Technical service bulletins. For ECT sensor tests, Goto <<AR>> . For ignition system, <<303-07>> Check bulletins and service actions.
Difficult to start
Difficult to start cold
Throttle contaminated Rochester valve Blocked part-load breather (service action S474) Cylinder compression loss (short-term. Refer to bulletin; 303-52) Fuel pump Battery Engine coolant temperature (ECT) sensor Purge valve Refer to service action S491
www.JagDocs.com
For Rochester valve test, Goto <<BV>> . For battery information, <<414-01>> Check bulletins for throttle cleaning procedure. Check fuel pressure. For ECT sensor circuit tests, Goto <<AR>> . For evaporative emissions tests, <<303-13>> Refer to bulletins for compression information, and service actions for part-load breather procedure and compressions.
'
Difficult to start hot
Rochester valve Throttle contaminated Injector leak Purge valve Fuel pump Engine coolant temperature (ECT) sensor Blocked part-load breather (service action S474)
For Rochester valve test, Goto <<BV>> . For evaporative emissions tests, <<303-13>> Check bulletins for throttle cleaning procedure. Check fuel pressure. For ECT sensor circuit tests, Goto <<AR>> . Refer to Service action S474 for part-load breather procedure. For injector leak test, Refer to technical service bulletin 303-39.
2012-07-19
'
'
Difficult to start after hot soak (vehicle standing after engine has reached operating temperature)
Rochester valve Throttle contaminated Injector leak Purge valve Fuel pump Engine coolant temperature (ECT) sensor Blocked part-load breather (service action S474)
'
Engine cranks too fast/slow
Battery Starter relay Harness Cylinder compression loss (NA short term only. Refer to technical service bulletin; 303-39) Refer to service action S491
For battery information, <<414-01>> For starting system. <<303-06>> Refer to technical service bulletins and service actions.
Engine stalls
Engine stalls soon after start
Throttle contaminated Fuel pressure regulator Air leakage ECM relay Fuel pump relay Fuel pump Engine coolant temperature (ECT) sensor CMP/CKP sensor synchronization malfunction Harness Fuel lines
Check relay dates. Check for DTCS. For fuel pump relay tests, Goto <<BK>> . For ECM relay tests, Goto <<BT>> . Check bulletins for throttle cleaning procedure. For CMP sensor circuit tests, Goto <<BD>> , for CKP sensor circuit tests, Goto <<BC>> . Check fuel pressure. For MAF sensor circuit tests, Goto <<AP>> . For ECT sensor tests, Goto <<AR>> . For fuel system, <<303-04>> and <<310-01>> For intake system information, <<303-12>>
2012-07-19
'
Engine stalls on overrun
Throttle contaminated ECM relay Fuel pump relay CMP/CKP sensor synchronization malfunction
Check bulletins for throttle cleaning procedure. Check relay dates. For ECM relay tests, Goto <<BT>> . For fuel pump relay tests, Goto <<BK>> . For CMP sensor circuit tests, Goto <<BD>> , for CKP sensor circuit tests, Goto <<BC>> . Check bulletins for throttle cleaning procedure. Check relay dates. For ECM relay circuit tests, Goto <<BT>> . For fuel pump relay circuit tests, Goto <<BK>> . For CMP sensor circuit tests, Goto <<BD>> , for CKP sensor circuit tests, Goto <<BC>> . Check service actions. Check relay dates. For ECM relay circuit tests, Goto <<BT>> . For fuel pump relay circuit tests, Goto <<BK>> . For CMP sensor circuit tests, Goto <<BD>> , for CKP sensor circuit tests, Goto <<BC>> .
'
Engine stalls at steady speed, with or without cruise enabled
Throttle contaminated ECM relay Fuel pump relay CMP/CKP sensor synchronization malfunction Harness Blocked part-load breather (service action S474)
www.JagDocs.com
'
Engine stalls when maneuvering
ECM relay Fuel pump relay CMP/CKP sensor synchronization malfunction
2012-07-19
Poor driveability
Exhaust gas recirculation (EGR) where fitted Fuel pump Air leakage Spark plugs fouled HT short to ground (tracking) check rubber boots for cracks/damage Ignition coil failure(s) Throttle sensors Throttle motor
Check fuel pressure. For EGR information, <<303-08>> For intake system information, <<303-12>> For stop lamp switch information, refer to the wiring diagrams. For throttle position sensor tests, Goto <<AS>> . For throttle motor control circuit tests, Goto <<BI>> . For ignition system, <<303-07>> For ECM circuit tests, Goto <<BT>> . Check fuel pressure. For intake system information, <<303-12>> For MAF sensor circuit tests, Goto <<AP>> . For HO2 sensor circuit tests, check for DTC indicating which sensor and follow indicated pinpoint test. For ignition system, <<303-07>>
'
Engine backfires
Fuel pump Air leakage MAF sensor HO2 sensors Spark plugs Check for water ingress into spark plug wells (SC only) HT short to ground (tracking) check rubber boots for cracks/damage Ignition coil failure(s)
2012-07-19
'
Engine surges
Air leakage Fuel pump Stop lamp switch MAF sensor Harness Throttle sensors Throttle motor Spark plugs Check for water ingress into spark plug wells (SC only) HT short to ground (tracking) check rubber boots for cracks/damage ECM failure
For intake system, <<303-12>> Check fuel pressure. For stop lamp information, refer to the wiring diagrams. For MAF sensor tests, Goto <<AP>> . For throttle position sensor tests, Goto <<AS>> , and Goto <<AZ>> . For throttle motor circuit tests, Goto <<BI>> . For ignition system, <<303-07>> For ECM circuit tests, Goto <<BT>> .
'
Engine detonates/knocks
Fuel pump HO2 sensors Air leakage Blocked part-load breather (service action S474) Mass air flow (MAF) sensor
www.JagDocs.com
Check fuel pressure. For HO2 sensor circuit tests, check for DTC indicating which sensor and follow indicated pinpoint test. For intake system information, <<303-12>> Check service action S474. For MAF sensor tests, Goto <<AP>> .
'
No throttle response
Traction control invoked Throttle sensors Throttle motor
For throttle position sensor tests, Goto <<AS>> , and Goto <<AZ>> . For throttle motor circuit tests, Goto <<BI>> . For cruise control switches, <<310-03>> For throttle position sensor tests, Goto <<AS>> , and Goto <<AZ>> . For stop light switch information, refer to the wiring diagrams.
'
Cruise control inhibited or disabled
Cruise control switch Throttle sensors Stop lamp switch

2012-07-19
Warning light Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Amber Amber Amber Amber Amber Amber Amber
Message Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode
Default Mode Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Limp-Home Engine shut-down when combined with other throttle failures Engine shut-down when combined with other throttle failures Cruise inhibited Cruise inhibited Cruise inhibited Cruise inhibited Cruise inhibited Cruise inhibited Cruise inhibited
DTC P1224 P1229 P0122, P0123, P0222, P0223 P0121 P1122, P1123 P1222, P1223 P1121, P1632 P1251, P0560, P1658 P1631 P1611 P1633 P1609 P0506, P0507 P1656 P1254 P1250 P1516 P1517 P1571 P1696 P0568 P0570 P0569
2012-07-19
Amber Amber Amber Red Amber
Engine Failsafe Mode Engine Failsafe Mode Engine Failsafe Mode Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance Restricted Performance None None None
Cruise inhibited Cruise inhibited Cruise inhibited Limp-Home unavailable. Reverse throttle progression enabled Limp-Home unavailable. Reverse throttle progression enabled. High idle speed Limp-Home unavailable. Reverse throttle progression enabled Engine Speed Limit (runs normally, limited to 3000 RPM) Engine Speed Limit (runs normally, limited to 3000 RPM) Engine Speed Limit (runs normally, limited to 3000 RPM) Engine Speed Limit (runs normally, limited to 3000 RPM) Reverse throttle progression enabled Engine Speed Limit (runs normally, limited to 3000 RPM) Engine Speed Limit (runs normally, limited to 3000 RPM) Engine Speed Limit (runs normally, limited to 3000 RPM) Gearbox default to 4th gear Gearbox default to 4th gear Gearbox default to 4th gear Gearbox default to 4th gear Gearbox default to 4th gear Gearbox default to 4th gear Gearbox default to 4th gear Gearbox default to 4th gear Gearbox default to 4th gear Gearbox default to 4th gear
P0567 P0566 P1697 P0560, P1254 P1250, P1254
Red Amber Amber Amber
P1250 P0116, P0117, P0118, P0125 P0101, P0102, P0103, P0104 P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P1313, P1314 P0327, P0328, P0332, P0333, P1648 P1474 P1230 P1671 P1112, P1113 P1601 (SC only) P1605 (NA only) P0702 P1795 P1796 P1797 P1605 P0705 (SC only) P0706 P1720
www.JagDocs.com
Amber Amber Amber Amber Amber Amber Amber Amber Amber Amber Amber Amber Amber Amber Amber
2012-07-19


2012-07-19
DTC P0101
Description Mass air flow (MAF) sensor range/performance
Possible Source Blocked air filter Air intake leak Engine breather leak Throttle control malfunction MAF sensor to ECM sensing circuit high resistance MAF sensor to ECM sensing circuit intermittent short circuit to ground MAF sensor supply circuit high resistance MAF sensor failure
Action Check the air filter element, check the air intake system for leaks, <<303-12>> Check the engine breather system for leaks, <<303-08>> For throttle control circuit tests, Goto <<BI>> . For MAF sensor circuit tests, Goto <<AP>> .
P0102
Mass air flow (MAF) sensor sense circuit low voltage
Blocked air filter MAF sensor to ECM sensing circuit high resistance or open circuit MAF sensor to ECM sensing circuit intermittent short circuit to ground MAF sensor supply circuit open circuit or short circuit to ground MAF sensor failure
Check the air filter element, <<303-12>> For MAF sensor circuit tests, Goto <<AP>>
P0103
Mass air flow (MAF) sensor sense circuit high voltage
MAF sensor to ECM reference ground circuit open circuit MAF sensor to ECM sensing circuit short circuit to high voltage MAF sensor failure
For MAF sensor circuit tests, Goto <<AP>>
P0106 P0107 P0111
BARO circuit, low voltage BARO circuit, high voltage Intake air temperature (IAT) sensor range/performance
BARO failure (internal ECM fault) BARO failure (internal ECM fault) Blocked air filter Air intake leak Engine breather leak IAT sensor to ECM wiring open circuit or high resistance IAT sensor to ECM sensing circuit short circuit to high voltage IAT sensor failure
Contact dealer technical support for advice on possible ECM failure. Contact dealer technical support for advice on possible ECM failure. Check the air filter element, check the air intake system for leaks, <<303-12>> Check the engine breather system for leaks, <<303-08>> For IAT sensor circuit tests, Goto <<AQ>> .
www.JagDocs.com
P0112
Intake air temperature (IAT) sensor sense circuit high voltage (low air temperature)
IAT sensor to ECM wiring open circuit or high resistance IAT sensor to ECM sensing circuit short circuit to high voltage IAT sensor failure
For IAT sensor circuit tests, Goto <<AQ>> . For IAT sensor circuit tests, Goto <<AQ>> . Check coolant level and condition. Check thermostat function. For ECT sensor circuit tests, Goto <<AR>> .
P0113
Intake air temperature (IAT) sensor sense circuit low voltage (high air temperature)
IAT sensor to ECM wiring short circuit to ground IAT sensor failure
P0116
Engine coolant temperature (ECT) sensor range / performance
Low/contaminated coolant Thermostat failure ECT sensor to ECM sensing circuit high resistance when hot ECT sensor to ECM sensing circuit intermittent high resistance ECT sensor failure
P0117
Engine coolant temperature (ECT) sensor sense circuit high voltage (low coolant temperature)
ECT sensor disconnected ECT sensor to ECM sensing circuit high resistance, open circuit or short circuit to high voltage ECT sensor failure
For ECT sensor circuit tests, Goto <<AR>> .
P0118
Engine coolant temperature (ECT) sensor sense circuit low voltage (high coolant temperature)
Engine overheat condition ECT sensor to ECM wiring short circuit to ground ECT sensor failure
Check engine for overheating. For ECT sensor circuit tests, Goto <<AR>> . For TP sensor circuit tests, Goto <<AS>> , and Goto <<AZ>> . For TP sensor circuit tests, Goto <<AS>> , and Goto <<AZ>> . For TP sensor circuit tests, Goto <<AS>> , and Goto <<AZ>> . Check coolant level and condition. Check thermostat function. For ECT sensor circuit tests, Goto <<AR>> .
P0121
Throttle position (TP) sensor circuit range/performance
TP sensor to ECM wiring open circuit or high resistance TP sensor to ECM sensing circuits 1 or 2 short circuit to high voltage TP sensor failure
P0122
Throttle position (TP) sensor 1 low voltage
TP sensor to ECM sensing circuit 1 (TP sensor pin 3) open circuit or high resistance TP sensor failure
P0123
Throttle position (TP) sensor 1 high voltage
TP sensor to ECM sensing circuit 1 (TP sensor pin 3) short circuit to high voltage TP sensor failure
P0125
Engine coolant temperature (ECT) sensor response (for closed loop fuel control)
Low/contaminated coolant Thermostat failure ECT sensor to ECM sensing circuit high resistance, open circuit or short circuit to high voltage
2012-07-19
P0131
Right-hand H02S sense circuit low voltage
H02S disconnected H02S to ECM wiring open circuit H02S short circuit to ground H02S failure
For Right-hand HO2S circuit tests, Goto <<AT>>
P0132
Right-hand H02S sense circuit high voltage
H02S sensing circuit short circuit to high voltage H02S ground braided shield open circuit H02S failure
For Right-hand HO2S circuit tests, Goto <<AT>>
P0133
Right-hand H02S sense circuit slow response
Check for 'engine misfire detected' DTCs. For HO2S circuit tests, Goto <<AT>> . Goto <<AU>> . Check for exhaust leaks, <<309-00>> Check injectors, <<303-04>>
P0135
Right-hand H02S heater circuit malfunction
For Right-hand HO2S heater circuit tests, Goto <<AU>>
P0137
Right-hand catalyst monitor sensor sense circuit low voltage
For Right-hand catalyst monitor sensor circuit tests, Goto <<AV>>
P0138
Right-hand catalyst monitor sensor sense circuit high voltage
For Right-hand catalyst monitor sensor circuit tests, Goto <<AV>>
P0140
Right-hand catalyst monitor sensor sense circuit no activity
For Right-hand catalyst monitor sensor circuit tests, Goto <<AV>> Check for exhaust leaks, <<309-00>> Check injectors, <<303-04>>
P0151
Left-hand H02S sense circuit low voltage
H02S disconnected H02S to ECM wiring open circuit H02S short circuit to ground H02S failure
For Left-hand HO2S circuit tests, Goto <<AW>>
P0152
Left-hand H02S sense circuit high voltage
H02S sensing circuit short circuit to high voltage H02S ground braided shield open circuit H02S failure
For Left-hand HO2S circuit tests, Goto <<AW>>
2012-07-19
P0153
Left-hand H02S sense circuit slow response
Check for 'engine misfire detected' DTCs. For HO2S circuit tests, Goto <<AW>> Check for exhaust leaks, <<309-00>> Check injectors, <<303-04>>
P0155
Left-hand H02S heater circuit malfunction
For Left-hand HO2S heater circuit tests, Goto <<AX>>
P0157
Left-hand catalyst monitor sensor sense circuit low voltage
For Left-hand catalyst monitor sensor circuit tests, Goto <<AY>>
P0158
Left-hand catalyst monitor sensor sense circuit high voltage
For Left-hand catalyst monitor sensor circuit tests, Goto <<AY>>
www.JagDocs.com
P0160
Left-hand catalyst monitor sensor sense circuit no activity
For Left-hand catalyst monitor sensor circuit tests, Goto <<AY>> Check for exhaust leaks, <<309-00>>
P0171
Right-hand cylinders combustion too lean
Air intake leak between MAF sensor and throttle Air leak via other systems Fuel pressure regulator failure (low fuel pressure) Fuel filter system blockage Fuel injector blockage Exhaust leak (before catalyst) Low fuel pump output H02S harness wiring fault ECM receiving incorrect signal from one or more of the following sensors - ECT, MAF, IAT, TP.
Check air intake system for leaks, <<303-12>> Check the fuel filter, <<310-01>> Check the fuel injectors and fuel pressure regulator, <<303-04>> Check the fuel pressure. Check the exhaust system for leaks, <<309-00>> Refer to pinpoint tests for sensors listed.
P0172
Right-hand cylinders combustion too rich
Engine misfire Fuel pressure regulator failure (high fuel pressure) Leaking fuel injector(s) Blocked air filter Fuel system return blockage ECM receiving incorrect signal from one or more of the following sensors - ECT, MAF, IAT, TP.
Check for 'engine misfire detected' DTCs. Check the air filter element, <<303-12>> Check the fuel lines, <<310-01>> Check the fuel injectors and fuel pressure regulator, <<303-04>> Refer to pinpoint tests for sensors listed.
2012-07-19
P0174
Left-hand cylinders combustion too lean
Air intake leak between MAF sensor and throttle Air leak via other systems Fuel pressure regulator failure (low fuel pressure) Fuel filter system blockage Fuel injector blockage Exhaust leak (before catalyst) Low fuel pump output H02S harness wiring fault ECM receiving incorrect signal from one or more of the following sensors - ECT, MAF, IAT, TP.
Check the eir intake system for leaks, <<303-12>> Check the fuel filter, <<310-01>> Check the fuel injectors and fuel pressure regulator, <<303-04>> Check the fuel pressure. For HO2S circuit tests, Goto <<AW>> , and Goto <<AX>> . Check the exhaust system for leaks, <<309-00>> Refer to pinpoint tests for sensors listed.
P0175
Left-hand cylinders combustion too rich
Engine misfire Fuel pressure regulator failure (high fuel pressure) Leaking fuel injector(s) Blocked air filter Fuel system return blockage ECM receiving incorrect signal from one or more of the following sensors - ECT, MAF, IAT, TP.
Check for 'engine misfire detected' DTCs. Check air filter element, <<303-12>> Check the fuel lines, <<310-01>> Check the fuel injectors and fuel pressure regulator, <<303-04>> Refer to pinpoint tests for sensors listed.
P0201
Fuel injector circuit malfunction, Cyl 1
Injector disconnected Injector wiring open or short circuit Injector failure
For fuel injector circuit tests, <<303-04>>
' ' ' ' ' ' ' P0222
' ' ' ' ' ' ' Throttle position (TP) sensor circuit 2 low voltage
P0202 P0203 P0204 P0205 P0206 P0207 P0208 TP sensor to ECM sensing circuit 2 (TP sensor pin 2) open circuit or high resistance TP sensor failure TP sensor to ECM sensing circuit 2 (TP sensor pin 2) short circuit to battery voltage TP sensor failure ECM to ignition module primary circuit faults (cylinder misfire detected DTCs also logged) Ignition module to ignition coil primary circuit fault(s) (cylinder misfire DTC also logged) Ignition module ground circuit; open circuit, high resistance Ignition coil failure(s) Ignition module failure(s) Check for water ingress into spark plug wells HT short to ground (tracking) check rubber boots for cracks/damage Spark plug failure/fouled/incorrect gap Cylinder compression low Fuel injector circuit fault(s) [injector DTCs also logged] Fuel delivery pressure (low/high) Fuel injectors restricted/leaking Fuel contamination
Fuel injector circuit malfunction, Cyl 3 Fuel injector circuit malfunction, Cyl 5 Fuel injector circuit malfunction, Cyl 7 Fuel injector circuit malfunction, Cyl 2 Fuel injector circuit malfunction, Cyl 4 Fuel injector circuit malfunction, Cyl 6 Fuel injector circuit malfunction, Cyl 8 For TP sensor circuit tests, Goto <<AZ>> For TP sensor circuit tests, Goto <<AZ>> For ignition circuit tests, <<303-07>> For engine information, <<303-00>> For fuel system information, <<303-04>>
P0223
Throttle position (TP) sensor circuit 2 high voltage
P0300
Random misfire detected
P0301 ' ' ' ' ' '
Misfire detected, Cyl 1 ' ' ' ' ' '
Refer to possible sources for P0300 P0302 P0303 P0304 P0305 P0306 P0307
Refer to actions for P0300 Misfire detected, Cyl 3 Misfire detected, Cyl 5 Misfire detected, Cyl 7 Misfire detected, Cyl 2 Misfire detected, Cyl 4 Misfire detected, Cyl 6
2012-07-19
' P0327
' Right-hand knock sensor (KS) sense circuit out of range (low voltage)
P0308 Poor sensor contact with cylinder block KS to ECM sense circuit short circuit to ground KS failure
Misfire detected, Cyl 8 For Right-hand knock sensor circuit tests, Goto <<BA>>
P0328
Right-hand knock sensor (KS) sense circuit out of range (high voltage)
For Right-hand knock sensor circuit tests, Goto <<BA>>
P0332
Left-hand knock sensor (KS) sense circuit out of range (low voltage)
Poor sensor contact with cylinder block KS to ECM sense circuit short circuit to ground KS failure
For Left-hand knock sensor circuit tests, Goto <<BB>>
P0333
Left-hand knock sensor (KS) sense circuit out of range (high voltage)
For Left-hand knock sensor circuit tests, Goto <<BB>>
P0335
Crankshaft position (CKP) sensor circuit malfunction
CKP sensor disconnected CKP sensor air gap incorrect/foreign matter on face CKP sensor sensing circuit open circuit, short circuit to ground, short circuit to high voltage CKP sensor failure
For CKP sensor circuit tests, Goto <<BC>>
P0340
Camshaft position (CMP) sensor circuit malfunction
For CMP sensor circuit tests, Goto <<BD>>
www.JagDocs.com
P0351
ECM to ignition module primary circuit open circuit, short circuit to ground, high resistance Ignition module to ignition coil primary circuit open circuit, short circuit to ground, high resistance Ignition module ground circuit open circuit, high resistance Ignition coil failure Ignition module failure
For ignition circuit tests, <<303-07>>
' ' ' ' ' ' ' P0400
' ' ' ' ' ' ' Exhaust gas recirculation (EGR) flow malfunction
P0352 P0353 P0354 P0355 P0356 P0357 P0358 EGR valve connector pins high resistance EGR pipe/exhaust manifold leak EGR pipe blocked EGR valve stuck open/closed, blocked EGR valve failure
Ignition coil primary/secondary circuit malfunction, cyl 3 Ignition coil primary/secondary circuit malfunction, cyl 5 Ignition coil primary/secondary circuit malfunction, cyl 7 Ignition coil primary/secondary circuit malfunction, cyl 2 Ignition coil primary/secondary circuit malfunction, cyl 4 Ignition coil primary/secondary circuit malfunction, cyl 6 Ignition coil primary/secondary circuit malfunction, cyl 8 For EGR pinpoint tests, <<303-08>>
P0405
Exhaust gas recirculation (EGR) drive circuits open circuit
EGR valve power supply circuit open circuit EGR valve to ECM drive circuit pair - EGR pins 1/3, 4/6 open circuit, high resistance EGR valve failure (stepper motor open circuit)
For EGR pinpoint tests, <<303-08>>
P0406
Exhaust gas recirculation (EGR) drive circuits short circuit
EGR valve to ECM drive circuit pair - EGR pins 1/3, 4/6 short circuit to ground or high voltage EGR valve failure (stepper motor short circuit) HO2S disconnected. HO2S to ECM wiring fault. HO2S heater to ECM wiring fault. HO2S heater failure. HO2S failure. Catalyst monitor sensor failure. Catalytic converter failure.
<<303-08>>
P0420
Right-hand catalytic converter efficiency below threshold
Refer to pinpoint tests for components listed. Visually inspect catalytic converters.
2012-07-19
P0442
Evaporative emissions system (EVAP) leak detected
Fuel filler cap missing Fuel filler cap seal faulty EVAP system leak (canister damage, pipework damage) EVAP valve to ECM drive circuit open circuit, short circuit, high resistance EVAP valve to engine purge pipe damaged/blocked/leaking EVAP operating vacuum hose leak/blockage EVAP valve failure
P0444 P0445 P0447
Evaporative emissions system (EVAP) valve circuit open circuit Evaporative emissions system (EVAP) valve circuit short circuit Canister close valve (CCV) circuit open circuit
EVAP to ECM drive circuit open circuit or high resistance EVAP failure EVAP to ECM drive circuit short circuit to ground EVAP failure CCV to ECM drive circuit open circuit, high resistance or short circuit to ground EVAP failure CCV to ECM drive circuit short circuit to high voltage CCV failure FTP sensor disconnected FTP sensor to ECM sense circuit open circuit or short circuit to ground FTP sensor to ECM power supply circuit open circuit or short circuit to ground FTP sensor failure
For evaporative emissions pinpoint tests, <<303-13>> For evaporative emissions pinpoint tests, <<303-13>> For evaporative emissions pinpoint tests, <<303-13>>
P0448 P0452
Canister close valve (CCV) circuit short circuit Fuel tank pressure (FTP) sensor circuit low voltage
For evaporative emissions pinpoint tests, <<303-13>> For evaporative emissions pinpoint tests, <<303-13>>
P0453
Fuel tank pressure (FTP) sensor circuit high voltage
FTP sensor to ECM signal ground circuit open circuit FTP sensor to ECM wiring (supply, sense, signal, ground) short circuit to each other FTP sensor to ECM sense circuit short circuit to high voltage FTP sensor failure
<<303-13>>
P0460
Fuel level sense signal performance
Fuel level sensor to instrument cluster circuits intermittent short or open circuit Fuel level sensor failure Instrument cluster fault (incorrect fuel level reading)
For fuel level sensor circuit tests, <<303-04>>
P0506
Idle RPM lower than expected
Air intake blockage Accessory drive overload (defective/siezed component) Throttle valve stuck closed Throttle assembly failure
Check the air intake system. <<303-12>> Check the accessory drive components, <<303-05>> For throttle body information, <<303-04>>
P0507
Idle RPM higher than expected
Intake air leak between MAF sensor and throttle Intake air leak between throttle and engine Engine breather leak Cruise control vacuum failure Throttle valve stuck open Throttle assembly failure
Check the air intake system. <<303-12>> Check the engine breather system, <<303-08>> For cruise control information, <<310-03>> For throttle body information, <<303-04>>
P0560 P0566
Vehicle voltage malfunction Cruise control CANCEL switch ON fault
ECM battery power supply open circuit, high resistance Cruise control switches internal steering wheel short circuit to ground Steering wheel cassette reel short circuit to ground Cassette reel to ECM circuit short circuit to ground CANCEL switch failure (stuck ON)
For ECM power supply circuit tests, Goto <<BE>> For cruise control circuit tests, <<310-03>>
P0567
Cruise control RESUME switch ON fault
Cruise control switches internal steering wheel short circuit to ground Steering wheel cassette reel short circuit to ground Cassette reel to ECM circuit short circuit to ground RESUME switch failure (stuck ON)
For cruise control circuit tests, <<310-03>>
2012-07-19
P0568
Cruise control switch ground malfunction
Cruise control switches internal steering wheel open circuit Steering wheel cassette reel open circuit or high resistance Cassette reel to ECM circuit ACCEL/DECEL open circuit or high resistance ACCEL/DECEL switch failure
P0569
Cruise control DECEL/SET (SET-) switch ON fault
Cruise control switches internal steering wheel short circuit to ground Steering wheel cassette reel short circuit to ground Cassette reel to ECM circuit short circuit to ground DECEL/SET switch failure (stuck ON)
P0570
Cruise control ACCEL/SET (SET+) switch ON fault
Cruise control switches internal steering wheel short circuit to ground Steering wheel cassette reel short circuit to ground Cassette reel to ECM circuit short circuit to ground ACCEL/SET switch failure (stuck ON)
P0603 P1000 P1104
ECM data corrupted System checks not complete since last memory clear Mass air flow (MAF) sensor ground malfunction
ECM failure OBD diagnostic monitors have not completed MAF sensor to ECM reference ground circuit open circuit, short circuit to high voltage, high resistance MAF sensor to ECM sensing circuit open circuit MAF sensor failure
Contact dealer technical support for advice on possible ECM failure. Carry out comprehensive component monitor drive cycle. Refer to the DTC section of JTIS, accessed by the icon on the opening page. For MAF sensor circuit tests, Goto <<AP>>
P1111 P1112
System checks complete since last memory clear Intake air temperature (IAT) sensor 2 sense circuit high voltage (low charge air temperature)
OBD diagnostic monitors have completed IAT sensor 2 disconnected IAT sensor 2 to ECM sensing circuit high resistance, open circuit or short circuit to high voltage IAT sensor 2 failure
No action necessary For IAT sensor 2 circuit tests, Goto <<BF>>
www.JagDocs.com
P1113
Intake air temperature (IAT) sensor 2 sense circuit low voltage (high charge air temperature)
Supercharger intercooler failure IAT sensor 2 to ECM sensing circuit short circuit to ground IAT sensor 2 failure
For IAT sensor 2 circuit tests, Goto <<BF>>
P1121
Accelerator pedal position (APP) sensor circuit 'A' range/performance
APP sensor to ECM sense circuit 'A' (sensor pin 5) open circuit, short circuit or high resistance Sensor power supply fault Sensor reference ground fault APP sensor failure
For APP sensor circuit tests, Goto <<BG>>
P1122
Accelerator pedal position (APP) sensor circuit 'A' low voltage
APP sensor to ECM sense circuit 'A' (sensor pin 5) open circuit or high resistance Sensor power supply fault APP sensor failure
For APP sensor circuit tests, Goto <<BG>>
P1123
Accelerator pedal position (APP) sensor circuit 'A' high voltage
APP sensor to ECM sense circuit 'A' (sensor pin 5) short circuit to high voltage APP sensor failure APP sensor to ECM sense circuit 'B' (sensor pin 3) open circuit, short circuit or high resistance Sensor power supply fault Sensor reference ground fault APP sensor failure
For APP sensor circuit tests, Goto <<BG>> For APP sensor circuit tests, Goto <<BH>>
P1221
Accelerator pedal position (APP) sensor circuit 'B' range/performance
P1222
Accelerator pedal position (APP) sensor circuit 'B' low voltage
APP sensor to ECM sense circuit 'B' (sensor pin 3) open circuit or high resistance Sensor power supply fault APP sensor failure
For APP sensor circuit tests, Goto <<BH>>
P1223
Accelerator pedal position (APP) sensor circuit 'B' high voltage
APP sensor to ECM sense circuit 'B' (sensor pin 3) short circuit to high voltage APP sensor failure
For APP sensor circuit tests, Goto <<BH>>
2012-07-19
P1224
Throttle control position error
Throttle position adaptations not performed after battery disconnect TP sensor disconnected TP sensor to ECM sense circuits open circuit, high resistance Throttle motor power relay failure Throttle motor power relay to ECM circuit fault Throttle motor power relay power supply open circuit ECM ground circuit fault (relay coil drive) Throttle motor to ECM drive circuits open circuit, short circuit, high resistance Throttle motor failure Throttle assembly failure
Carry out throttle adaptation procedure. For TP sensor circuit tests, Goto <<AS>> , and Goto <<AZ>> . For throttle motor circuit tests, Goto <<BI>> . For throttle body information, <<303-04>>
P1226
Mechanical guard sensor range/performance
Mechanical guard sensor to ECM sense circuit open circuit, short circuit or high resistance Sensor power supply fault Sensor reference ground fault Mechanical guard sensor failure Mechanical guard actuator seized/spring broken
For mechanical guard circuit tests, Goto <<BJ>> . For sensor power supply circuit tests, Goto <<BL>> . For sensor ground circuit tests, Goto <<BM>> . For throttle body information, <<303-04>> For mechanical guard circuit tests, Goto <<BJ>> . For sensor power supply circuit tests, Goto <<BL>> . For throttle body information, <<303-04>> For mechanical guard circuit tests, Goto <<BJ>> . For throttle body information, <<303-04>> For throttle motor circuit tests, Goto <<BI>> . For fuel pump relay circuit tests, Goto <<BK>>
P1227
Mechanical guard sensor circuit low voltage
Mechanical guard sensor to ECM sense circuit open circuit or high resistance Sensor power supply fault Mechanical guard sensor failure
P1228
Mechanical guard sensor circuit high voltage
Mechanical guard sensor to ECM sense circuit short circuit to high voltage Mechanical guard sensor failure Throttle motor disconnected Throttle motor to ECM drive circuits short circuit or open circuit Throttle motor failure
P1229
Throttle motor control circuit mallfunction
P1230
Fuel pump relay malfunction. NOTE. This DTC covers the S/C system fuel pump 1
Fuel pump relay failure Fuel pump to ECM circuit fault Fuel pump relay coil power supply open circuit ECM ground circuit fault (relay coil drive)
P1235
Vacuum switching valve (VSV) 1 circuit range/performance (mechanical guard position)
Vacuum leak/blockage between the throttle elbow and the throttle vacuum actuator Vacuum actuator failure Mechanical guard actuator seized/spring broken
Carry out mechanical checks for vacuum leak/blockage, failed vacuum actuator, and broken/siezed actuator spring
P1236
Vacuum switching valve (VSV) 1 (vacuum) circuit failure
VSV 1 disconnected VSV 1 to ECM drive circuit high resistance, open circuit or short circuit VSV 1 power supply open circuit VSV 1 failure
For VSV tests, <<310-03>>
P1237
Vacuum switching valve (VSV) 2 (atmosphere) circuit failure
P1238
Vacuum switching valve (VSV) 3 (release) circuit failure
P1240
Sensor reference voltage malfunction (throttle sensors, fuel tank pressure sensor) (ECM pins EM10-21; EM11-8)
ECM to sensors reference voltage short circuit to ground, short circuit to high voltage, open circuit, high resistance TP sensor, pedal position and mechanical guard sensor(s), fuel tank pressure sensor failure(s)
For sensor reference voltage circuit tests, Goto <<BL>> . For sensor reference voltage circuit tests, Goto <<BL>> .
P1241
Sensor reference voltage low (throttle sensors, fuel tank pressure sensor) (ECM pins EM10-21; EM11-8)
ECM to sensors reference voltage short circuit to ground TP sensor, APP and mechanical guard sensor(s), fuel tank pressure sensor failure(s)
2012-07-19
P1242
Sensor reference voltage high (throttle sensors, fuel tank pressure sensor) (ECM pins EM10-21; EM11-8)
ECM to sensors reference voltage circuit open circuit, high resistance, short circuit to high voltage TP sensor, APP and mechanical guard sensor(s), fuel tank pressure sensor failure(s)
For sensor reference voltage circuit tests, Goto <<BL>> . For sensor reference ground circuit tests, Goto <<BM>> . For engine crank circuit tests, Goto <<BN>> . For engine crank circuit tests, Goto <<BN>> . Install a new throttle body, <<303-04>> For TP sensor circuit tests, Goto <<AS>> , and Goto <<AZ>> . For throttle motor circuit tests, Goto <<BI>> . For throttle body information, <<303-04>>
P1243
Sensor reference ground malfunction (throttle sensors, fuel tank pressure sensor, ECT sensor, IAT sensor, IAT sensor 2) (ECM pins EM10-20; EM11-12)
ECM to sensors reference ground circuit open circuit, high resistance Throttle sensors, fuel tank pressure sensor, ECT sensor, IAT sensor, IAT sensor 2 failures
P1245
Engine crank signal low voltage
Starter relay coil to ECM/BPM circuit open circuit
P1246
P1250 P1251
Engine load malfunction Throttle position malfunction (engine off)
Throttle valve spring failure TP sensor to ECM wiring open circuit or high resistance TP sensor to ECM sensing circuits ('1' or '2') short circuit to high voltage TP sensor failure Throttle motor disconnected Throttle motor to ECM drive circuits short circuit or open circuit Throttle motor failure Throttle assembly failure
P1252
Mechanical guard position malfunction (cruise control)
VSV 1, 2, 3 vacuum and/or electrical circuit fault(s) open circuit, short circuit or high resistance Mechanical guard sensor to ECM sense circuit Mechanical guard sensor failure Mechanical guard actuator siezed/spring broken Throttle vacuum actuator fault
See pinpoint tests for components listed.
www.JagDocs.com
P1253
Mechanical guard position malfunction (engine off)
VSV 1, 2, 3 vacuum and/or electrical circuit fault(s) Mechanical guard sensor to ECM sense circuit Mechanical guard sensor failure Mechanical guard actuator siezed/spring broken Throttle vacuum actuator fault
See pinpoint tests for components listed.
P1260 P1313 ' ' P1336
Security input malfunction Misfire rate catalyst damage, Right-hand. NOTE. This DTC will flag only when accompanied by a random or individual cylinder misfire DTC; P0300, P0301 to P0304 ' ' Crankshaft position (CKP) sensor / camshaft position (CMP) sensor synchronization malfunction
KTM to ECM circuit short circuit, high resistance or open circuit KTM failure Refer to possible causes for P0300-P0308 P1314 P1316 CKP sensor/CMP sensor disconnected CKP sensor/CMP sensor gap incorrect/foreign matter on sensor face CKP sensor/CMP sensor sensing circuit open circuit, short circuit to ground, short circuit to high voltage CKP sensor/CMP sensor failure
For KTM circuit tests, Goto <<BO>> Refer to actions for P0300-P0308 Misfire rate catalyst damage, Left-Hand. NOTE. This DTC will flag only when accompanied by a random or individual cylinder misfire DTC; P0300 to P0308 Misfire excess emission. NOTE. This DTC will flag only when accompanied by an individual cylinder misfire DTC; P0300 to P0308 For CKP sensor circuit tests, Goto <<BC>> . For CMP sensor circuit tests, Goto <<BD>>
P1367
Ignition monitor (ignition module 1)
Ignition module 1 disconnected Ignition module 1 to ECM circuits open circuit, short circuit to ground or short circuit to B+ voltage Ignition module 1 ground circuit fault Ignition coil relay failure Ignition coil open/short circuit Ignition module 1 failure
P1368
Ignition monitor (ignition module 2)
Ignition module 2 disconnected Ignition module 2 to ECM circuits open circuit, short circuit to ground or short circuit to B+ voltage Ignition module 2 ground circuit fault Ignition coil relay failure Ignition coil open/short circuit Ignition module 2 failure
2012-07-19
P1474
Intercooler coolant pump relay malfunction
Intercooler pump relay failure Intercooler pump relay to ECM drive circuit fault Intercooler pump relay coil ground circuit fault ECM power supply fault
For intercooler pump relay circuit tests, Goto <<BP>>
P1475
Radiator fans slow (series) circuit malfunction
Radiator fan control relay module to ECM 'series' drive circuit (relay pin 9) fault Relay coil ignition power supply open circuit ECM ground circuit fault (relay coil drive) ECT sensor circuit malfunction (refer to P0116)
For radiator fan series circuit tests, Goto <<BQ>>
P1476
Radiator fans fast (parallel) circuit malfunction
Radiator fan control relay module to ECM 'parallel' drive circuit (relay pin 7) fault Relay coil ignition power supply open circuit ECM ground circuit fault (relay coil drive) ECT sensor circuit malfunction (refer to P0116)
For radiator fan parallel circuit tests, Goto <<BR>>
P1516
Gear change PARK/NEUTRAL driving malfunction
Transmission range (TR) sensor to ECM circuit open circuit or high resistance TR sensor failure D-4 switch to TCM circuit open circuit or high resistance D-4 switch fault
For PARK/NEUTRAL tests, Goto <<BS>>
P1517
Engine PARK/NEUTRAL cranking malfunction
Transmission range (TR) sensor to ECM circuit open circuit or high resistance TR sensor failure Brake switch to ECM circuit open circuit, short circuit to ground, high resistance Brake switch ignition switched ground circuit open circuit Brake switch failure Brake cancel switch to ECM circuit open circuit, short circuit to ground, high resistance Brake cancel switch to cruise control switch circuit open circuit, short circuit to ground, high resistance Brake cancel switch ignition switched power supply open circuit Brake cancel switch failure Cruise control switch failure
For PARK/NEUTRAL tests, Goto <<BS>> For cruise control circuit tests, <<310-03>>
P1571
P1606
Engine management system (EMS) control relay malfunction
ECM control relay failure ECM control relay to ECM circuit fault ECM control relay coil power supply open circuit ECM ground circuit fault (relay coil drive)
For ECM relay circuit tests, Goto <<BT>>
P1609 P1611
ECM microprocessor-to-microprocessor communication failure Throttle angle malfunction
ECM failure TP sensor circuit fault (refer to P0121) APP sensor circuit fault (refer to P0121) Throttle assembly failure ECM failure
Contact dealer technical support for advice on possible ECM failure. See pinpoint tests for components listed. For throttle body information, <<303-04>> Contact dealer technical support for advice on possible ECM failure.
P1612
Throttle offset malfunction
TP sensor circuit fault (refer to P0121) APP sensor circuit fault (refer to P0121) Throttle assembly failure ECM failure
See pinpoint tests for components listed. For throttle body information, <<303-04>> Contact dealer technical support for advice on possible ECM failure.
P1637
CAN ABS/TCCM token missing
CAN open circuit fault - ABS/TCCM to ECM CAN short circuit fault ABS/TCCM failure ECM failure
P1638
CAN INST token missing
CAN open circuit fault - INST to ECM CAN short circuit fault INST failure ECM failure
2012-07-19
P1642
P1643
CAN open circuit fault - TCM to ECM CAN short circuit fault TCM failure ECM failure
P1646
Fuel pump 2 relay malfunction. NOTE. This DTC applies only to the S/C fuel pump 2
Fuel pump 2 relay failure Fuel pump 2 relay to ECM circuit fault Fuel pump 2 relay coil power supply open circuit ECM ground circuit fault (relay coil drive)
For fuel pump 2 relay circuit tests, Goto <<BU>>
Pinpoint Tests AP : DTC P0101, P0102, P0103; MASS AIR FLOW (MAF) SENSOR RANGE/PERFORMANCE, HIGH/LOW VOLTAGE
NOTE: Before commencing this test, check the air filter for blockage, the engine air intake and breather systems for leaks, and the TPS for additional DTCs.
www.JagDocs.com
AP1 : CHECK THE MAF SENSOR SENSE CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM12. 3. Disconnect the MAF sensor electrical connector, PI35. 4. Measure the resistance between EM12, pin 13 (GY) and PI35, pin 02 (GY). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
2012-07-19
-> No Goto <<AP2>>
AP2 : CHECK THE MAF SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between the MAF sensor electrical connector, PI35, pin 02 (GY) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AP3>>
AP3 : CHECK THE MAF SENSOR SENSE CIRCUIT FOR SHORT TO GROUND
NOTE: The short to GROUND may be intermittent. Move the wiring to attempt to reproduce the conditions under which the DTC was logged, and visually inspect the harness for any signs of chafing, see 'visual inspection chart'. 1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI35, pin 02 (GY) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation -> No Goto <<AP4>>
AP4 : CHECK THE MAF SENSOR SUPPLY CIRCUIT VOLTAGE

1. Reconnect the ECM electrical connector, EM12. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between the MAF sensor electrical connector, PI35, pin 01 (WU) and GROUND. Is the voltage greater than 10 volts? -> Yes Goto <<AP5>> -> No REPAIR the circuit between the MAF sensor electrical connector, PI35, pin 01 (WU) and BATTERY. This circuit includes the EMS control relay, fuse 12 of the EMS fuse board, and splices in the harness. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
AP5 : CHECK THE MAF SENSOR SUPPLY CIRCUIT FOR HIGH RESISTANCE
37
2012-07-19
1. Disconnect the battery negative terminal. 2. Disconnect the EMS fuse board electrical connector, EM20. 3. Measure the resistance between EM20, pin 10 (WU) and PI35, pin 01 (WU). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new MAF sensor. CLEAR the DTC. TEST the system for normal operation.
AQ : DTC P0111, P0112, P0113; INTAKE AIR TEMPERATURE (IAT) SENSOR RANGE/PERFORMANCE, HIGH/LOW VOLTAGE
NOTE: Before commencing this test, check the air filter for blockage and the engine air intake and breather systems for leaks.
www.JagDocs.com
AQ1 : CHECK THE IAT SENSOR SENSE CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM12. 3. Disconnect the MAF sensor electrical connector, PI35. 4. Measure the resistance between EM12, pin 12 (UP) and PI35, pin 03 (UP). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AQ2>>
AQ2 : CHECK THE IAT SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between PI35, pin 03 (UP) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AQ3>>
AQ3 : CHECK THE IAT SENSOR SENSE CIRCUIT FOR SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI35, pin 03 (UP) and GROUND.
38
2012-07-19
Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new MAF sensor. CLEAR the DTC. TEST the system for normal operation.
AR : DTC P0116, P0117, P0118; ENGINE COOLANT TEMPERATURE (ECT) SENSOR RANGE/PERFORMANCE, HIGH/LOW VOLTAGE
NOTE: Before commencing this test, check the coolant level and condition, check the operation of the thermostat, rectify as necessary.
AR1 : CHECK THE ECT SENSOR SENSE CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM11. 3. Disconnect the ECT sensor electrical connector, PI04. 4. Measure the resistance between EM11. pin 09 (UY) and PI04, pin 02 (UY). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AR2>>
AR2 : CHECK THE ECT SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between PI04, pin 02 (UY) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AR3>>
AR3 : CHECK THE ECT SENSOR SENSE CIRCUIT FOR SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI04, pin 02 (UY) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
39 2012-07-19
-> No INSTALL a new ECT sensor. <<303-03A>><<303-03B>> CLEAR the DTC. TEST the system for normal operation.
AS : DTC P0121, P0122, P0123; THROTTLE POSITION (TP) SENSOR RANGE/PERFORMANCE, HIGH/LOW VOLTAGE AS1 : CHECK THE TP SENSOR SENSE CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM11. 3. Disconnect the TP sensor electrical connector, PI06. 4. Measure the resistance between EM11, pin 11 (U) and PI06, pin 03 (U). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AS2>>
www.JagDocs.com
AS2 : CHECK THE TP SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between PI06, pin 03 (U) and GROUND. Is the voltage greater than 5 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AS3>>
AS3 : CHECK THE TP SENSOR SENSE CIRCUIT FOR SHORT TO GROUND

1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI06, pin 03 (U) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new TP sensor. CLEAR the DTC. TEST the system for normal operation.
AT : DTC P0131, P0132, P0133; RIGHT-HAND H02S LOW/HIGH VOLTAGE, SLOW RESPONSE
40
2012-07-19
AT1 : CHECK THE H02S SENSE CIRCUIT FOR HIGH RESISTANCE

1. Disconnect the battery negative terminal. 2. Disconnect the H02S electrical connector, EM21. 3. Disconnect the ECM electrical connector, EM12. 4. Measure the resistance between EM21, pin 03 (R) and EM12, pin 15 (R). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AT2>>
AT2 : CHECK THE H02S SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between EM12, pin 15 (R) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AT3>>
AT3 : CHECK THE H02S SENSE CIRCUIT FOR SHORT TO GROUND

1. Turn the ignition switch to the OFF position. 2. Measure the resistance between EM12, pin 15 (R) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AT4>>
AT4 : CHECK THE H02S GROUND CIRCUIT FOR OPEN CIRCUIT

1. Reconnect the ECM electrical connector, EM12. 2. Measure the resistance between EM21, pin 04 (BRD) and GROUND. Is the resistance greater than 5 ohms?
41
2012-07-19
-> Yes REPAIR the circuit. (This is a braided lead which would require different repair techniques to standard wiring). For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new H02S. CLEAR the DTC. TEST the system for normal operation.
AU : DTC P0133, P0135; RIGHT-HAND H02S HEATER CIRCUIT MALFUNCTION AU1 : CHECK THE H02S HEATER POWER SUPPLY CIRCUIT
1. Disconnect the H02S electrical connector, EM21. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between EM21, pin 02 (WP) and GROUND. Is the voltage greater than 10 volts? -> Yes Goto <<AU2>> -> No REPAIR the circuit. This circuit includes the EMS control relay and fuse 14 of the EMS fuse board. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
www.JagDocs.com
AU2 : CHECK THE H02S HEATER CONTROL CIRCUIT FROM ECM FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM15. 3. Measure the resistance between EM15, pin 02 (PU) and EM21, pin 01 (PU). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AU3>>
AU3 : CHECK THE H02S HEATER CONTROL CIRCUIT FROM ECM FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between EM21, pin 01 (PU) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AU4>>
42
2012-07-19
AU4 : CHECK THE H02S HEATER CONTROL CIRCUIT FROM ECM FOR SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between EM21, pin 01 (PU) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new H02S. CLEAR the DTC. TEST the system for normal operation.
AV : DTC P0137, P0138; RIGHT-HAND CATALYST MONITOR SENSOR LOW/HIGH VOLTAGE, NO ACTIVITY AV1 : CHECK THE CATALYST MONITOR SENSOR SENSE CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the catalyst monitor sensor electrical connector, EM22. 3. Disconnect the ECM electrical connector, EM12. 4. Measure the resistance between EM22, pin 02 (U) and EM12, pin 17 (U). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AV2>>
AV2 : CHECK THE CATALYST MONITOR SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between EM12, pin 17 (U) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AV3>>
AV3 : CHECK THE CATALYST MONITOR SENSOR SENSE CIRCUIT FOR SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between EM12, pin 17 (U) and GROUND.
43
2012-07-19
Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AV4>>
AV4 : CHECK THE CATALYST MONITOR SENSOR GROUND CIRCUIT FOR OPEN CIRCUIT
www.JagDocs.com
AW : DTC P0151, P0152, P0153; LEFT-HAND H02S LOW/HIGH VOLTAGE, SLOW RESPONSE
AW1 : CHECK THE H02S SENSE CIRCUIT FOR HIGH RESISTANCE

1. Disconnect the battery negative terminal. 2. Disconnect the H02S electrical connector, EM23. 3. Disconnect the ECM electrical connector, EM12. 4. Measure the resistance between EM23, pin 03 (G) and EM12, pin 14 (G). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AW2>>
AW2 : CHECK THE H02S SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between EM12, pin 14 (G) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
44
2012-07-19
-> No Goto <<AW3>>
AW3 : CHECK THE H02S SENSE CIRCUIT FOR SHORT TO GROUND

1. Turn the ignition switch to the OFF position. 2. Measure the resistance between EM12, pin 14 (G) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AW4>>
AW4 : CHECK THE H02S GROUND CIRCUIT FOR OPEN CIRCUIT

1. Reconnect the ECM electrical connector, EM12. 2. Measure the resistance between EM23, pin 04 (BRD) and GROUND. Is the resistance greater than 5 ohms? -> Yes REPAIR the circuit. (This is a braided lead which would require different repair techniques to standard wiring). For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new H02S. CLEAR the DTC. TEST the system for normal operation.
AX : DTC P0153, P0155; LEFT-HAND H02S HEATER CIRCUIT MALFUNCTION AX1 : CHECK H02S HEATER POWER SUPPLY CIRCUIT
1. Disconnect the H02S electrical connector, EM23. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between EM23, pin 02 (WP) and GROUND. Is the voltage greater than 10 volts? -> Yes Goto <<AX2>> -> No REPAIR the power supply circuit to the H02S heater. This circuit includes the EMS control relay and fuse 14 of the EMS fuse board. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
AX2 : CHECK H02S HEATER CONTROL CIRCUIT FROM ECM FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM15.
45
2012-07-19
3. Measure the resistance between EM15, pin 01 (PS) and EM23, pin 01 (PS). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AX3>>
AX3 : CHECK H02S HEATER CONTROL CIRCUIT FROM ECM FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between EM23, pin 01 (PS) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AX4>>
www.JagDocs.com
AX4 : CHECK H02S HEATER CONTROL CIRCUIT FROM ECM FOR SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between EM23, pin 01 (PS) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new H02S. CLEAR the DTC. TEST the system for normal operation.
AY : DTC P0157, P0158; LEFT-HAND CATALYST MONITOR SENSOR LOW/HIGH VOLTAGE, NO ACTIVITY AY1 : CHECK THE CATALYST MONITOR SENSOR SENSE CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the catalyst monitor sensor electrical connector, EM24. 3. Disconnect the ECM electrical connector, EM12. 4. Measure the resistance between EM24, pin 02 (N) and EM12, pin 16 (N). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AY2>>
46 2012-07-19
AY2 : CHECK THE CATALYST MONITOR SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between EM12, pin 16 (N) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AY3>>
AY3 : CHECK THE CATALYST MONITOR SENSOR SENSE CIRCUIT FOR SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between EM12, pin 16 (N) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AY4>>
AY4 : CHECK THE CATALYST MONITOR SENSOR GROUND CIRCUIT FOR OPEN CIRCUIT
AZ : DTC P0222, P0223; THROTTLE POSITION (TP) SENSOR CIRCUIT 2 LOW VOLTAGE AZ1 : CHECK TP SENSOR 2 SENSE CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the TP sensor electrical connector, PI06. 3. Disconnect the ECM electrical connector, EM11. 4. Measure the resistance between PI06, pin 02 (G) and EM11, pin 10 (G).
47
2012-07-19
Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<AZ2>>
AZ2 : CHECK TP SENSOR 2 SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE

1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between PI06, pin 02 (G) and GROUND. Is the voltage greater than 5 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new TP sensor. CLEAR the DTC. TEST the system for normal operation.
www.JagDocs.com
BA : DTC P0327, P0328; RIGHT-HAND KNOCK SENSOR (KS) CIRCUIT OUT OF RANGE (LOW VOLTAGE)
BA1 : CHECK THE KS SENSE CIRCUIT FOR HIGH RESISTANCE

1. Disconnect the battery negative terminal. 2. Disconnect the KS electrical connector, PI26. 3. Disconnect the ECM electrical connector, EM13. 4. Measure the resistance between PI26, pin 01 (S) and EM13, pin 18 (S). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BA2>>
BA2 : CHECK THE KS SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE

1. Turn the ignition switch to the ON position. 2. Reconnect the battery negative terminal. 3. Measure the voltage between PI26, pin 01 (S) and GROUND. Is the voltage greater than 3 volts? -> Yes
48
2012-07-19
REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BA3>>
BA3 : CHECK THE KS SENSE CIRCUIT FOR SHORT TO GROUND

1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI26, pin 01 (S) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new KS. CLEAR the DTC. TEST the system for normal operation.
BB : DTC P0332, P0333; LEFT-HAND KNOCK SENSOR (KS) CIRCUIT OUT OF RANGE (LOW VOLTAGE)
BB1 : CHECK THE KS SENSE CIRCUIT FOR HIGH RESISTANCE

1. Disconnect the battery negative terminal. 2. Disconnect the KS electrical connector, PI27. 3. Disconnect the ECM electrical connector, EM13. 4. Measure the resistance between PI27, pin 01 (N) and EM13, pin 17 (N). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BB2>>
BB2 : CHECK THE KS SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE

1. Turn the ignition switch to the ON position. 2. Reconnect the battery negative terminal. 3. Measure the voltage between PI27, pin 01 (N) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BB3>>
49
2012-07-19
BB3 : CHECK THE KS SENSE CIRCUIT FOR SHORT TO GROUND

1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI27, pin 01 (N) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new KS. CLEAR the DTC. TEST the system for normal operation.
BC : DTC P0335; CRANKSHAFT POSITION (CKP) SENSOR CIRCUIT MALFUNCTION BC1 : CHECK THE CKP SENSOR FOR CORRECT INSTALLATION
1. Turn the ignition switch to the OFF position. 2. Check the CKP sensor for correct installation. Is the CKP sensor correctly installed? -> Yes Goto <<BC2>> -> No INSTALL the CKP sensor correctly. Reconnect the sensor. CLEAR the DTCs. TEST the system for normal operation.
www.JagDocs.com
BC2 : CHECK THE CKP SENSOR FOR DEBRIS

1. Remove the CKP sensor and inspect for debris. Is the CKP sensor free of debris? -> Yes Goto <<BC3>> -> No CLEAN the sensor and wheel. INSTALL the sensor. Reconnect the sensor. CLEAR the DTCs. TEST the system for normal operation.
BC3 : CHECK THE CKP SENSOR SENSE CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM13. 3. Measure the resistance between EM13, pin 19 (Y) and PI17, pin 01 (Y). 4. Measure the resistance between EM13, pin 28 (P) and PI17, pin 02 (P). Is either resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
50
2012-07-19
-> No Goto <<BC4>>
BC4 : CHECK THE CKP SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between PI17, pin 19 (Y) and GROUND. 4. Measure the voltage between PI17, pin 28 (P) and GROUND. Is either voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BC5>>
BC5 : CHECK THE CKP SENSOR SENSE CIRCUIT FOR SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between EM13, pin 19 (Y) and GROUND. 3. Measure the resistance between EM13, pin 28 (P) and GROUND. Is either resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new CKP sensor. CLEAR the DTC. TEST the system for normal operation.
BD : DTC P0340; CAMSHAFT POSITION (CMP) SENSOR CIRCUIT MALFUNCTION BD1 : CHECK THE CMP SENSOR FOR CORRECT INSTALLATION
1. Turn the ignition switch to the OFF position. 2. Check the CMP sensor for correct installation. Is the CMP sensor correctly installed? -> Yes Goto <<BD2>> -> No INSTALL the CMP sensor correctly. CLEAR the DTCs. TEST the system for normal operation.
BD2 : CHECK THE CMP SENSOR FOR FOREIGN DEBRIS

1. Remove the CMP sensor and inspect for foreign debris. Is the CMP sensor free of foreign debris?
51
2012-07-19
-> Yes Goto <<BC3>> -> No CLEAN the sensor and wheel. INSTALL the sensor. CLEAR the DTCs. TEST the system for normal operation.
BD3 : CHECK THE CMP SENSOR SENSE CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM13. 3. Measure the resistance between EM13, pin 20 (B) and PI15, pin 01 (B). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BD3>>
www.JagDocs.com
BD4 : CHECK THE CMP SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between EM13, pin 20 (B) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BD5>>
BD5 : CHECK THE CMP SENSOR SENSE CIRCUIT FOR SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI15, pin 01 (B) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new CMP sensor. CLEAR the DTC. TEST the system for normal operation.
BE : DTC P0560; VEHICLE VOLTAGE MALFUNCTION

NOTE: When checking the EMS switched supplies to the ECM in test P3, the EMS relay must be energised when testing EM10, pin 01 and EM14, pin 03.
52
2012-07-19
BE1 : CHECK THE BATTERY POWER SUPPLY TO THE ECM

1. Disconnect the ECM electrical connector, EM10. 2. Measure the voltage between EM10, pin 09 (NO) and GROUND. Is the voltage greater than 10 volts? -> Yes Goto <<BE2>> -> No REPAIR the battery power supply circuit. This circuit includes fuse 4 of the EMS fuse board. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
BE2 : CHECK THE IGNITION SWITCHED POWER SUPPLY TO THE ECM

1. Turn the ignition switch to the ON position. 2. Measure the voltage between EM10, pin 05 (WK) and GROUND. Is the voltage greater than 10 volts? -> Yes Goto <<BE3>> -> No REPAIR the ignition switched power supply circuit. This circuit includes fuse 9 of the Right-hand heelboard fuse box. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
BE3 : CHECK THE EMS SWITCHED POWER SUPPLIES TO THE ECM

1. Disconnect the ECM electrical connector, EM14. 2. Make sure the EMS relay is energised. 3. Measure the voltage between EM10, pin 01 (WR) and GROUND. 4. Measure the voltage between EM14, pin 03 (WR) and GROUND. Are both voltages greater than 10 volts? -> Yes Contact Dealer technical support for advice on possible ECM failure. -> No REPAIR the EMS switched power supply circuits. The supply circuit to EM10, pin 01 includes fuse 18 of the Right-hand heelboard fuse box, the supply circuit to EM14, pin 03 includes fuse 01 of the trunk fuse box. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
BF : DTC P1112, P1113; INTAKE AIR TEMPERATURE (IAT) SENSOR #2 SENSE CIRCUIT HIGH/LOW VOLTAGE BF1 : CHECK IAT SENSOR 2 SENSE CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the IAT sensor 2 electrical connector, PI03.
53 2012-07-19
3. Disconnect the ECM electrical connector, EM12. 4. Measure the resistance between PI03, pin 02 (UP) and EM12, pin 07 (UP). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BF2>>
BF2 : CHECK IAT SENSOR 2 SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between PI03, pin 02 (UP) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BF3>>
www.JagDocs.com
BF3 : CHECK IAT SENSOR 2 SENSE CIRCUIT FOR SHORT TO GROUND

1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI03, pin 02 (UP) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new IAT sensor 2. CLEAR the DTC. TEST the system for normal operation.
BG : DTC P1121, P1122, P1123; ACCELERATOR PEDAL POSITION (APP) SENSOR CIRCUIT 'A' RANGE/PERFORMANCE, HIGH/LOW VOLTAGE BG1 : CHECK THE APP SENSOR SENSE CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM11. 3. Disconnect the APP sensor electrical connector, PI42. 4. Measure the resistance between EM11, pin 16 (K) and PI42, pin 05 (K). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
54
2012-07-19
-> No Goto <<BG2>>
BG2 : CHECK THE APP SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between PI42, pin 05 (K) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BG3>>
BG3 : CHECK THE APP SENSOR SENSE CIRCUIT FOR SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI42, pin 05 (K) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BG4>>
BG4 : CHECK THE APP SENSOR COMMON REFERENCE VOLTAGE AT THE SENSOR
1. Reconnect the ECM electrical connector, EM11. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between PI42, pin 04 (UW) and GROUND. Is the voltage less than 4 volts? -> Yes Goto <<BG5>> -> No Goto <<BG6>>
BG5 : CHECK THE APP SENSOR COMMON REFERENCE VOLTAGE CIRCUIT

1. Turn the ignition switch to the OFF position. 2. Disconnect the ECM electrical connector, EM11. 3. Measure the resistance between EM11, pin 08 (UW) and PI42, pin 04 (UW). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the
55 2012-07-19
DTC. TEST the system for normal operation. -> No Check the ECM power supplies.
BG6 : CHECK THE APP SENSOR COMMON REFERENCE GROUND

1. Measure the resistance between PI42, pin 02 (BG) and GROUND. Is the resistance greater than 5 ohms? -> Yes Goto <<BG7>> -> No INSTALL a new APP sensor. CLEAR the DTC. TEST the system for normal operation.
BG7 : CHECK THE APP SENSOR COMMON REFERENCE GROUND CIRCUIT

1. Disconnect the ECM electrical connectors, EM10 and EM11. 2. Measure the resistance between EM10, pin 20 (BG) and PI42, pin 02 (BG). 3. Measure the resistance between EM11, pin 12 (BG) and PI42, pin 02 (BG). Is either resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Check the ECM GROUND circuits. If the GROUND circuits are sound, contact dealer technical support for advice on possible ECM failure.
www.JagDocs.com
BH : DTC P1221, P1222, P1223; ACCELERATOR PEDAL POSITION (APP) SENSOR CIRCUIT 'B' RANGE/PERFORMANCE, HIGH/LOW VOLTAGE BH1 : CHECK THE APP SENSOR SENSE CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM11. 3. Disconnect the APP sensor electrical connector, PI42. 4. Measure the resistance between EM11, pin 15 (R) and PI42, pin 03 (R). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BH2>>
BH2 : CHECK THE APP SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal.
56
2012-07-19
2. Turn the ignition switch to the ON position. 3. Measure the voltage between PI42, pin 03 (R) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BH3>>
BH3 : CHECK THE APP SENSOR SENSE CIRCUIT FOR SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI42, pin 03 (R) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BH4>>
BH4 : CHECK THE APP SENSOR COMMON REFERENCE VOLTAGE AT THE SENSOR
1. Reconnect the ECM electrical connector, EM11. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between PI42, pin 04 (UW) and GROUND. Is the voltage less than 4 volts? -> Yes Goto <<BH5>> -> No Goto <<BH6>>
BH5 : CHECK THE APP SENSOR COMMON REFERENCE VOLTAGE CIRCUIT

BH6 : CHECK THE APP SENSOR COMMON REFERENCE GROUND
57
2012-07-19
1. Measure the resistance between PI42, pin 02 (BG) and GROUND. Is the resistance greater than 5 ohms? -> Yes Goto <<BH7>> -> No INSTALL a new APP sensor. CLEAR the DTC. TEST the system for normal operation.
BH7 : CHECK THE APP SENSOR COMMON REFERENCE GROUND CIRCUIT

1. Disconnect the ECM electrical connectors, EM10 and EM11. 2. Measure the resistance between EM10, pin 20 (BG) and PI42, pin 02 (BG). 3. Measure the resistance between EM11, pin 12 (BG) and PI42, pin 02 (BG). Is either resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Check the ECM GROUND circuits. If the GROUND circuits are sound, contact dealer technical support for advice on possible ECM failure.
www.JagDocs.com
BI : DTC P1224, P1229; THROTTLE CONTROL POSITION SENSOR ERROR/THROTTLE MOTOR CONTROL CIRCUIT MALFUNCTION
NOTE: Before commencing this test, check the TP sensor connections, perform the throttle adaptions procedure.
BI1 : CHECK THE TP SENSOR TO ECM SENSE CIRCUIT 1 FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the TP sensor electrical connector, PI06. 3. Disconnect the ECM electrical connector, EM11. 4. Measure the resistance between PI06, pin 02 (G) and EM11, pin 10 (G). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BI2>>
BI2 : CHECK THROTTLE MOTOR RELAY CONSTANT SUPPLY

1. Reconnect the battery negative terminal. 2. Remove the throttle motor relay. 3. Measure the voltage between the throttle motor relay base, pin 3 and GROUND. Is the voltage greater than 10 volts?
58
2012-07-19
-> Yes Goto <<BI3>> -> No REPAIR the circuit. This circuit includes the EMS fuse box, fuse 09. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
BI3 : CHECK THROTTLE MOTOR RELAY EMS SWITCHED SUPPLY

1. Turn the ignition switch to the ON position. 2. Measure the voltage between the throttle motor relay base, pin 1 and GROUND. Is the voltage greater than 10 volts? -> Yes Goto <<BI4>> -> No REPAIR the circuit between the throttle motor relay base, pin 1 and the battery. This circuit includes the EMS fuse box, fuse 14, and the EMS control relay. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
BI4 : CHECK THROTTLE MOTOR RELAY TO ECM CIRCUIT FOR HIGH RESISTANCE
1. Turn the ignition switch to the OFF position. 2. Disconnect the battery negative terminal. 3. Disconnect the ECM electrical connector, EM13. 4. Measure the resistance between EM13, pin 14 (GR) and throttle motor relay base, pin 2. Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BI5>>
BI5 : CHECK THROTTLE MOTOR RELAY OUTPUT TO ECM

1. Reconnect the ECM electrical connector, EM13. 2. Disconnect the ECM electrical connector, EM14. 3. INSTALL the throttle motor relay. 4. Reconnect the battery negative terminal. 5. Turn the ignition switch to the ON position. 6. Measure the voltage between EM14, pins 01 and 02, (GY) and GROUND. Is the voltage greater than 10 volts? -> Yes Goto <<BI6>> -> No INSTALL a new throttle motor relay. For additional information, refer to the electrical guide. CLEAR the DTC. TEST the system for normal operation.
59
2012-07-19
BI6 : CHECK THROTTLE MOTOR TO ECM DRIVE SUPPLY CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the throttle motor electrical connector, PI33. 2. Measure the resistance between PI33, pin 01 (R) and EM14, pins 05 and 06 (R). Is either resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BI7>>
BI7 : CHECK THROTTLE MOTOR TO ECM DRIVE GROUND CIRCUIT FOR HIGH RESISTANCE
1. Measure the resistance between PI33, pin 02 (G) and EM14, pins 11 and 12 (G). Is either resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BI8>>
www.JagDocs.com
BI8 : CHECK THROTTLE MOTOR TO ECM DRIVE SUPPLY CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the ECM electrical connector, EM14. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between PI33, pin 01 (R) and GROUND. Is the voltage greater than 10 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BI9>>
BI9 : CHECK THROTTLE MOTOR TO ECM DRIVE SUPPLY CIRCUIT FOR SHORT TO GROUND
1. Disconnect the ECM electrical connector, EM14. 2. Turn the ignition switch to the OFF position. 3. Measure the resistance between PI33, pin 01 (R) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No
60
2012-07-19
INSTALL a new throttle motor. <<303-04>> CLEAR the DTC. TEST the system for normal operation.
BJ : DTC P1226; MECHANICAL GUARD SENSOR RANGE/PERFORMANCE, HIGH /LOW VOLTAGE BJ1 : CHECK THE MECHANICAL GUARD SENSE CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the mechanical guard sensor electrical connector, PI42. 3. Disconnect the ECM electrical connector, EM11. 4. Measure the resistance between PI42, pin 01 (BY) and EM11, pin 13 (BY). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BJ2>>
BJ2 : CHECK THE MECHANICAL GUARD SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between PI42, pin 01 (BY) and GROUND. Is the voltage greater than 10 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BJ3>>
BJ3 : CHECK THE MECHANICAL GUARD SENSE CIRCUIT FOR SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI42, pin 01 (BY) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BJ4>>
BJ4 : CHECK THE MECHANICAL GUARD SENSOR POWER SUPPLY CIRCUIT

1. Reconnect the ECM electrical connector, EM11. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between PI42, pin 04 (UW)and GROUND.
61 2012-07-19
Is the voltage less than 5 volts? -> Yes REPAIR the power supply circuit. This circuit includes the ECM. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new mechanical guard sensor. CLEAR the DTC. TEST the system for normal operation.
BK : DTC P1230; FUEL PUMP RELAY MALFUNCTION BK1 : CHECK THE FUEL PUMP RELAY TO ECM CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Remove the fuel pump relay. 3. Disconnect the ECM electrical connector, EM13. 4. Measure the resistance between EM13, pin 01 (KN) and the relay base, pin 02. Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BK2>>
www.JagDocs.com
BK2 : CHECK THE FUEL PUMP RELAY TO ECM CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between EM13, pin 01 (KN) and GROUND. Is the voltage greater than 10 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BK3>>
BK3 : CHECK THE FUEL PUMP RELAY TO ECM CIRCUIT FOR SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between EM13, pin 01 (KN) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BK4>>
62
2012-07-19
BK4 : CHECK THE FUEL PUMP RELAY CONSTANT POWER SUPPLY

1. Reconnect the ECM electrical connector, EM13. 2. Measure the voltage between the relay base, pin 03 and GROUND. Is the voltage less than 10 volts? -> Yes REPAIR the circuit between the relay base, pin 03 and the battery power bus. This circuit includes the trunk fuse box and the high power protection module. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BK5>>
BK5 : CHECK THE FUEL PUMP RELAY IGNITION SWITCHED POWER SUPPLY
1. Turn the ignition switch to the ON position. 2. Measure the voltage between the relay base, pin 01 and GROUND. Is the voltage less than 10 volts? -> Yes REPAIR the circuit between the relay base, pin 01 and battery. This circuit includes the trunk fuse box, fuse 16 of the Left-Hand fuse box, the ignition positive relay and the high power protection module. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BK6>>
BK6 : CHECK THE FUEL PUMP RELAY ECM SWITCHED GROUND SUPPLY
1. Turn the ignition switch to the ON position. 2. Make sure the ignition positive relay is engaged. 3. Check the resistance between the fuel pump relay base, pin 02 and GROUND. Is the resistance greater than 5 ohms? -> Yes Contact dealer technical support for advice on possible ECM failure. -> No INSTALL a new fuel pump relay. For additional information, refer to the electrical guide. CLEAR the DTC. TEST the system for normal operation.
BL : DTC P1240, P1241, P1242; SENSOR REFERENCE VOLTAGE MALFUNCTION, HIGH/LOW VOLTAGE (THROTTLE SENSORS, FUEL TANK PRESSURE SENSOR) BL1 : CHECK THE REFERENCE VOLTAGE AT THE APP SENSOR/MECHANICAL GUARD SENSOR
1. Disconnect the APP sensor electrical connector, PI42. 2. Turn the ignition switch to the ON position.
63 2012-07-19
3. Measure the voltage between PI42, pin 04 (UW) and GROUND. Is the voltage less than 5 volts? -> Yes Goto <<BL2>> -> No Goto <<BL3>>
BL2 : CHECK THE APP SENSOR/MECHANICAL GUARD SENSOR REFERENCE VOLTAGE CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connectors, EM10 and EM11. 3. Measure the resistance between PI42, pin 04 (UW) and EM10, pin 21 (UW). 4. Measure the resistance between PI42, pin 04 (UW) and EM11, pin 08 (UW). Is either resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BL3>>
www.JagDocs.com
BL3 : CHECK THE APP SENSOR/MECHANICAL GUARD SENSOR REFERENCE VOLTAGE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between PI42, pin 04 (UW) and GROUND. Is the voltage greater than 6 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BL4>>
BL4 : CHECK THE APP SENSOR/MECHANICAL GUARD SENSOR REFERENCE VOLTAGE CIRCUIT FOR SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI42, pin 04 (UW) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BL5>>
64
2012-07-19
BL5 : CHECK THE REFERENCE VOLTAGE AT THE THROTTLE POSITION SENSOR

1. Disconnect the TP sensor electrical connector, PI06. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between PI06, pin 04 (UW) and GROUND. Is the voltage less than 5 volts? -> Yes Goto <<BL6>> -> No Goto <<BL7>>
BL6 : CHECK THE THROTTLE POSITION SENSOR REFERENCE VOLTAGE CIRCUIT FOR HIGH RESISTANCE
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI06, pin 04 (UW) and EM10, pin 21 (UW). 3. Measure the resistance between PI06, pin 04 (UW) and EM11, pin 08 (UW). Is either resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BL7>>
BL7 : CHECK THE THROTTLE POSITION SENSOR REFERENCE VOLTAGE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Turn the ignition switch to the ON position. 2. Measure the voltage between PI06, pin 04 (UW) and GROUND. Is the voltage greater than 6 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BL8>>
BL8 : CHECK THE THROTTLE POSITION SENSOR REFERENCE VOLTAGE CIRCUIT FOR SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI06, pin 04 (UW) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST
65
2012-07-19
the system for normal operation. -> No Goto <<BL9>>
BL9 : CHECK THE REFERENCE VOLTAGE AT THE FUEL TANK PRESSURE SENSOR
1. Disconnect the FTP sensor electrical connector, FP01. 2. Reconnect the ECM electrical connectors, EM10 and EM11. 3. Turn the ignition switch to the ON position. 4. Measure the voltage between FP01, pin 03 (UW) and GROUND. Is the voltage less than 5 volts? -> Yes Goto <<BL10>> -> No CHECK for DTCs associated with TP sensor, APP/mechanical guard sensor, or FTP sensor. INSTALL a new sensor as indicated by the DTC. CLEAR the DTC. TEST the system for normal operation.
www.JagDocs.com
BL10 : CHECK THE FUEL TANK PRESSURE SENSOR REFERENCE VOLTAGE CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connectors, EM10 and EM11. 3. Measure the resistance between FP01, pin 03 (UW) and EM10, pin 21 (UW). 4. Measure the resistance between FP01, pin 03 (UW) and EM11, pin 08 (UW). Is either resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BL11>>
BL11 : CHECK THE FUEL TANK PRESSURE SENSOR REFERENCE VOLTAGE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between FP01, pin 03 (UW) and GROUND. Is the voltage greater than 6 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BL12>>
BL12 : CHECK THE FUEL TANK PRESSURE SENSOR REFERENCE VOLTAGE CIRCUIT FOR
66 2012-07-19
SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between FP01, pin 03 (UW) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No CHECK for DTCs associated with TP sensor,APP/mechanical guard sensor, or FTP sensor. INSTALL a new sensor as indicated by the DTC. CLEAR the DTC. TEST the system for normal operation.
BM : DTC P1243; SENSOR REFERENCE GROUND MALFUNCTION (THROTTLE SENSORS, FUEL TANK PRESSURE SENSOR, ECT, IAT, IAT 2 SENSORS) BM1 : CHECK THE SENSOR REFERENCE GROUND AT THE THROTTLE SENSORS
1. Disconnect the TP sensor electrical connector, PI06. 2. Measure the resistance between PI06, pin 01 (BG) and GROUND. Is the resistance greater than 5 ohms? -> Yes Goto <<BM2>> -> No Goto <<BM3>>
BM2 : CHECK THE THROTTLE SENSOR REFERENCE GROUND CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the ECM electrical connectors, EM10 and EM11. 2. Measure the resistance between PI06, pin 01 (BG) and EM10, pin 20 (BG). 3. Measure the resistance between PI06, pin 01 (BG) and EM11, pin 12 (BG). Is either resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BM3>>
BM3 : CHECK THE SENSOR REFERENCE GROUND AT THE APP SENSOR/MECHANICAL GUARD SENSOR
1. Disconnect the APP sensor/mechanical guard sensor electrical connector, PI42. 2. Reconnect the ECM electrical connectors, EM10 and EM11. 3. Measure the resistance between PI42, pin 02 (BG) and GROUND. Is the resistance greater than 5 ohms? -> Yes
67
2012-07-19
Goto <<BM4>> -> No Goto <<BM5>>
BM4 : CHECK THE APP SENSOR/MECHANICAL GUARD SENSOR REFERENCE GROUND CIRCUIT FOR HIGH RESISTANCE
www.JagDocs.com
BM5 : CHECK THE SENSOR REFERENCE GROUND AT THE FUEL TANK PRESSURE SENSOR
1. Disconnect the FTP sensor electrical connector, FP01. 2. Reconnect the ECM electrical connectors, EM10 and EM11. 3. Measure the resistance between FP01, pin 01 (BG) and GROUND. Is the resistance greater than 5 ohms? -> Yes Goto <<BM6>> -> No Goto <<BM7>>
BM6 : CHECK THE FUEL TANK PRESSURE SENSOR REFERENCE GROUND CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the ECM electrical connectors, EM10 and EM11. 2. Measure the resistance between FP01, pin 01 (BG) and EM10, pin 20 (BG). 3. Measure the resistance between FP01, pin 01 (BG) and EM11, pin 12 (BG). Is either resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BM7>>
BM7 : CHECK THE SENSOR REFERENCE GROUND AT THE ECT SENSOR

1. Reconnect the ECM electrical connectors, EM10 and EM11. 2. Disconnect the ECT sensor electrical connector, PI04.
68
2012-07-19
3. Measure the resistance between PI04, pin 01 (BG) and GROUND. Is the resistance greater than 5 ohms? -> Yes Goto <<BM8>> -> No Goto <<BM9>>
BM8 : CHECK THE ECT SENSOR REFERENCE GROUND CIRCUIT FOR HIGH RESISTANCE
BM9 : CHECK THE SENSOR REFERENCE GROUND AT THE IAT SENSOR (MAF)
1. Reconnect the ECM electrical connectors, EM10 and EM11. 2. Disconnect the IAT sensor (MAF) electrical connector, PI35. 3. Measure the resistance between PI35, pin 04 (BG) and GROUND. Is the resistance greater than 5 ohms? -> Yes Goto <<BM10>> -> No Goto <<BM11>>
BM10 : CHECK THE IAT SENSOR REFERENCE GROUND CIRCUIT FOR HIGH RESISTANCE
BM11 : CHECK THE SENSOR REFERENCE GROUND AT THE IAT SENSOR #2

1. Reconnect the ECM electrical connectors, EM10 and EM11.
69 2012-07-19
2. Disconnect the IAT sensor 2 electrical connector, PI03. 3. Measure the resistance between PI03, pin 01 (BG) and GROUND. Is the resistance greater than 5 ohms? -> Yes Goto <<BM12>> -> No CHECK for DTCs associated with TP sensor, APP/mechanical guard sensor, FTP sensor, ECT sensor, IAT sensor, or IAT sensor 2. INSTALL a new sensor as indicated by the DTC. CLEAR the DTC. TEST the system for normal operation.
BM12 : CHECK THE IAT SENSOR #2 REFERENCE GROUND CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the ECM electrical connectors, EM10 and EM11. 2. Measure the resistance between PI03, pin 01 (BG) and EM10, pin 20 (BG). 3. Measure the resistance between PI03, pin 01 (BG) and EM11, pin 12 (BG). Is either resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No CHECK for DTCs associated with TPS, APP/mechanical guard sensor, FTP sensor, ECT sensor, IAT sensor, or IAT sensor #2. INSTALL a new sensor as indicated by the DTC. CLEAR the DTC. TEST the system for normal operation.
www.JagDocs.com
BN : DTC P1245, P1246; ENGINE CRANK SIGNAL LOW/HIGH VOLTAGE BN1 : CHECK THE STARTER RELAY SIGNAL CIRCUIT FROM ECM AND BPM FOR SHORT TO B+
1. Measure the voltage between the relay base, pin 02 and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BN2>>
BN2 : CHECK THE STARTER RELAY SIGNAL CIRCUIT FROM ECM AND BPM FOR HIGH RESISTANCE
1. Remove the starter relay. 2. Disconnect the ECM electrical connector, EM11. 3. Disconnect the BPM electrical connector, FC15. 4. Measure the resistance between EM11, pin 06 (GO) and the starter relay base, pin 02. 5. Measure the resistance between FC15, pin 73 (GO) and the starter relay base, pin 02. Is either resistance greater than 5 ohms? -> Yes
70 2012-07-19
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new BPM. CLEAR the DTC. TEST the system for normal operation.
BO : DTC P1260; SECURITY INPUT MALFUNCTION BO1 : CHECK THE KTM TO ECM CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the ECM electrical connector, EM10. 2. Disconnect the KTM electrical connector, FC22. 3. Measure the resistance between EM10, pin 06 (O) and FC22, pin 16 (O). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new KTM. CLEAR the DTC. TEST the system for normal operation.
BP : DTC P1474; INTERCOOLER COOLANT PUMP RELAY MALFUNCTION

NOTE: Early production vehicles have connector pin numbers that differ from the volume production pin numbers shown. Use the wire color code for pin identification on early production vehicles.
BP1 : CHECK THE INTERCOOLER PUMP RELAY TO ECM DRIVE CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Remove the intercooler pump relay. 3. Disconnect the ECM electrical connector, EM13. 4. Measure the resistance between the relay base, pin 01 and EM13, pin 10 (RY). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BP2>>
BP2 : CHECK THE INTERCOOLER PUMP RELAY TO ECM DRIVE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between the relay base, pin 01 and GROUND. Is the voltage greater than 3 volts?
71
2012-07-19
-> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BP3>>
BP3 : CHECK THE INTERCOOLER PUMP RELAY TO ECM DRIVE CIRCUIT FOR SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between the relay base, pin 01 and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BP4>>
www.JagDocs.com
BP4 : CHECK THE INTERCOOLER PUMP RELAY GROUND CIRCUIT

1. Measure the resistance between the relay base, pin 02 and GROUND. Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Check the ECM power supplies. Goto <<BE>>
BQ : DTC P1475; RADIATOR FANS SLOW (SERIES) CIRCUIT MALFUNCTION BQ1 : CHECK THE RADIATOR FAN MODULE TO ECM 'SERIES' DRIVE CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM13. 3. Disconnect the fan module electrical connector, LS31. 4. Measure the resistance between EM13, pin 15 (W) and LS31, pin 09 (W). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BQ2>>
72
2012-07-19
BQ2 : CHECK THE RADIATOR FAN MODULE TO ECM 'SERIES' DRIVE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between EM13, pin 15 (W) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BQ3>>
BQ3 : CHECK THE RADIATOR FAN MODULE TO ECM 'SERIES' DRIVE CIRCUIT FOR SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between EM13, pin 15 (W) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BQ4>>
BQ4 : CHECK THE RADIATOR FAN MODULE IGNITION SUPPLY

1. Reconnect the ECM electrical connector, EM13. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between LS31, pin 08 (WP) and GROUND. Is the voltage greater than 10 volts? -> Yes INSTALL a new radiator fan module. <<303-03A>><<303-03B>> CLEAR the DTC. TEST the system for normal operation. -> No REPAIR the circuit. This circuit includes the EMS fuse box, (fuse 14), the EMS relay, etc. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
BR : DTC P1476; RADIATOR FANS FAST (PARALLEL) CIRCUIT MALFUNCTION BR1 : CHECK THE RADIATOR FAN MODULE TO ECM 'PARALLEL' DRIVE CIRCUIT FOR HIGH RESISTANCE
73
2012-07-19
2. Disconnect the ECM electrical connector, EM13. 3. Disconnect the fan module electrical connector, LS31. 4. Measure the resistance between EM13, pin 16 (WU) and LS31, pin 07 (WU). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BQ2>>
BR2 : CHECK THE RADIATOR FAN MODULE TO ECM 'PARALLEL' DRIVE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between EM13, pin 16 (WU) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BR3>>
www.JagDocs.com
BR3 : CHECK THE RADIATOR FAN MODULE TO ECM 'PARALLEL' DRIVE CIRCUIT FOR SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between EM13, pin 16 (WU) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BQ4>>
BR4 : CHECK THE RADIATOR FAN MODULE IGNITION SUPPLY

1. Reconnect the ECM electrical connector, EM13. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between LS31, pin 08 (WP) and GROUND. Is the voltage greater than 10 volts? -> Yes INSTALL a new radiator fan module. <<303-03A>><<303-03B>> CLEAR the DTC. TEST the system for normal operation. -> No REPAIR the circuit between LS31, pin 08 (WP) and battery. This circuit includes the EMS fuse box, (fuse
74
2012-07-19
14), the EMS relay, etc. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
BS : DTC P1516, P1517; GEAR CHANGE PARK/NEUTRAL DRIVING MALFUNCTION BS1 : CHECK THE TRANSMISSION RANGE (TR) SENSOR TO ECM CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the TR sensor electrical connector, EM47. 3. Disconnect the ECM electrical connector, EM10. 4. Measure the resistance between EM47, pin K (RU) and EM10, pin 15 (RU). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<BS2>>
BS2 : CHECK THE TRANSMISSION RANGE (TR) SENSOR PARK/NEUTRAL SWITCHING ACTION
1. Measure the resistance between pins J and K of the TR sensor. 2. Move the selector lever from PARK to NEUTRAL and back. Does the resistance switch between open circuit and continuity as the lever moves? -> Yes Goto <<BS3>> -> No INSTALL a new transmission range sensor. CLEAR the DTC. TEST the system for normal operation.
BS3 : CHECK THE D-4 SWITCH TO TCM CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the D-4 switch electrical connector, CC07. 2. Disconnect the TCM electrical connector, EM07. 3. Measure the resistance between CC07, pin 01 (US) and EM07, pin 13 (US). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new transmission range sensor. CLEAR the DTC. TEST the system for normal operation.
BT : DTC P1606; EMS CONTROL RELAY MALFUNCTION BT1 : CHECK THE EMS RELAY PERMANENT B+SUPPLY
75
2012-07-19
1. Remove the EMS relay. 2. Measure the voltage between the relay base, pins 02 and 03 and GROUND. Are both voltages greater than 10 volts? -> Yes Goto <<BT2>> -> No REPAIR the circuit between the relay base and battery. This circuit includes the high power protection module. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
BT2 : CHECK THE EMS RELAY TO ECM CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM10. 3. Measure the resistance between the relay base, pin 01 and EM10, pin 16 (PK). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new EMS relay. CLEAR the DTC. TEST the system for normal operation.
www.JagDocs.com
BU : DTC P1646; FUEL PUMP 2 (SC) RELAY MALFUNCTION

NOTE: This DTC applies only to the supercharged system fuel pump 2.
BU1 : CHECK THE FUEL PUMP 2 RELAY POWER SUPPLY

1. Remove the fuel pump 2 relay. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between the relay base, pin 01 and GROUND. Is the voltage greater than 10 volts? -> Yes Goto <<BU2>> -> No REPAIR the circuit. This circuit includes the trunk fuse box, the Left-hand heelboard fuse box (fuse 16) the ignition positive relay, and the high power protection module. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
BU2 : CHECK THE FUEL PUMP 2 RELAY TO ECM CIRCUIT

1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM13. 3. Measure the resistance between the relay base, pin 02 and EM13, pin 09 (KB). Is the resistance greater than 5 ohms?
76
2012-07-19
-> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new fuel pump 2 relay. CLEAR the DTC. TEST the system for normal operation.
BV : CHECK ROCHESTER VALVE FUNCTION BV1 : CHECK VACUUM INTEGRITY OF ROCHESTER VALVE
1. Disconnect hoses from rochester valve. 2. Blank off outlet side of valve. 3. Connect a hand-held vacuum pump to the vacuum inlet of the valve. 4. Apply a vacuum to the valve and monitor the reading for 2 minutes. Does the valve hold vacuum? -> Yes Inspect the pipes at either side of the valve for leaks/damage. Rectify as necessary. -> No INSTALL a new rochester valve. TEST the system for normal operation.
77
2012-07-19
Camshaft Position (CMP) Sensor LH Vehicles Without: Supercharger 18.31.12

www.JagDocs.com
Removal WARNING: PLACE THE VEHICLE IN A QUARANTINED AREA AND ARRANGE 'NO SMOKING/PETROL FUMES' SIGNS ABOUT THE VEHICLE. WARNING: BEFORE ANY WORK IS CARRIED OUT ON THE FUEL SYSTEM, GROUND THE VEHICLE TO EARTH AND MAINTAIN THE GROUND CONNECTION UNTIL THE WORK IS COMPLETE. WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE VAPORS ARE ALWAYS PRESENT AND MAY IGNITE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WARNING: THE FUEL SYSTEM REMAINS PRESSURIZED FOR A LONG TIME AFTER THE IGNITION IS SWITCHED OFF. THE FUEL PRESSURE MUST BE RELEASED BEFORE ATTEMPTING ANY REPAIRS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WARNING: AFTER CARRYING OUT REPAIRS, THE FUEL SYSTEM MUST BE CHECKED VISUALLY FOR LEAKS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WARNING: THIS PROCEDURE INVOLVES FUEL HANDLING. BE PREPARED FOR FUEL SPILLAGE AT ALL TIMES AND ALWAYS OBSERVE FUEL HANDLING PRECAUTIONS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WARNING: IF FUEL IS TAKEN INTERNALLY DO NOT INDUCE VOMITING, SEEK IMMEDIATE MEDICAL ATTENTION. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WARNING: IF FUEL CONTACTS THE EYES, FLUSH THE EYES WITH COLD WATER OR EYEWASH SOLUTION AND SEEK MEDICAL ATTENTION.
2012-07-19
WARNING: WASH HANDS THOROUGHLY AFTER HANDLING, AS PROLONGED CONTACT MAY CAUSE IRRITATION. SHOULD IRRITATION DEVELOP, SEEK MEDICAL ATTENTION. WARNING: DO NOT CARRY OR OPERATE CELLULAR PHONES WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE VAPORS ARE ALWAYS PRESENT AND MAY IGNITE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
3. NOTE: Place an absorbent cloth under the fuel connection to absorb any spillages.
2012-07-19
NOTE: Cap the fuel line and fuel injection supply manifold to prevent contamination. Disconnect the fuel feed hose. 1. Disconnect the fuel feed hose at the Quick Fit connector, using special tool 310 - 044.
www.JagDocs.com
4. Disconnect the left-hand fuel injectors electrical connectors.
5. Detach the fuel injector supply manifold from the retaining clip.
2012-07-19
6. Detach the fuel injector supply manifold from the intake manifold.
7. NOTE: Cap the intake manifold injector ports. Reposition the fuel injector supply manifold. Remove and discard the fuel injector O-ring seals.
2012-07-19
www.JagDocs.com
8. Detach the camshaft position (CMP) sensor wiring harness from the throttle body elbow.
9. Disconnect the CMP sensor electrical connector.
2012-07-19
10. Remove the CMP sensor.
Installation
1. Install the CMP sensor. Tighten to 7 Nm.
2012-07-19
www.JagDocs.com
2. Connect the CMP sensor electrical connector.
3. Attach the CMP sensor wiring harness to the throttle body elbow.
2012-07-19
4.
CAUTION: Make sure the fuel injectors are correctly installed to the intake manifold. Failure to follow these instructions may result in damage to the vehicle. NOTE: Install new fuel injector O-ring seals.
Install the fuel injection supply manifold. Tighten to 12 Nm.
5. Attach the fuel injector supply manifold to the retaining clip.
2012-07-19
www.JagDocs.com
6. Connect the left-hand fuel injectors electrical connectors.
7. NOTE: Uncap the fuel line and fuel injection supply manifold. NOTE: Remove and dispose of absorbent cloth whilst complying to local health and safety standards. Connect the fuel feed hose. 1. Connect the fuel feed hose at the Quick Fit connector. Ensure that the hose is fully seated to the feed pipe. 8. Carry out the battery reconnection procedure. <<414-01>>
2012-07-19
Camshaft Position (CMP) Sensor LH Vehicles With: Supercharger 18.31.12

Removal WARNING: PLACE THE VEHICLE IN A QUARANTINED AREA AND ARRANGE 'NO SMOKING/PETROL FUMES' SIGNS ABOUT THE VEHICLE. WARNING: BEFORE ANY WORK IS CARRIED OUT ON THE FUEL SYSTEM, GROUND THE VEHICLE TO EARTH AND MAINTAIN THE GROUND CONNECTION UNTIL THE WORK IS COMPLETE. WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE VAPORS ARE ALWAYS PRESENT AND MAY IGNITE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WARNING: THE FUEL SYSTEM REMAINS PRESSURIZED FOR A LONG TIME AFTER THE IGNITION IS SWITCHED OFF. THE FUEL PRESSURE MUST BE RELEASED BEFORE ATTEMPTING ANY REPAIRS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WARNING: AFTER CARRYING OUT REPAIRS, THE FUEL SYSTEM MUST BE CHECKED VISUALLY FOR LEAKS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WARNING: THIS PROCEDURE INVOLVES FUEL HANDLING. BE PREPARED FOR FUEL SPILLAGE AT ALL TIMES AND ALWAYS OBSERVE FUEL HANDLING PRECAUTIONS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WARNING: IF FUEL IS TAKEN INTERNALLY DO NOT INDUCE VOMITING, SEEK IMMEDIATE MEDICAL ATTENTION. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WARNING: IF FUEL CONTACTS THE EYES, FLUSH THE EYES WITH COLD WATER OR EYEWASH SOLUTION AND SEEK MEDICAL ATTENTION. WARNING: WASH HANDS THOROUGHLY AFTER HANDLING, AS PROLONGED CONTACT MAY CAUSE IRRITATION. SHOULD IRRITATION DEVELOP, SEEK MEDICAL ATTENTION. WARNING: DO NOT CARRY OR OPERATE CELLULAR PHONES WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE VAPORS ARE ALWAYS PRESENT AND MAY IGNITE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Release the fuel system pressure. <<310-00>> 2. Remove the left-hand charge air cooler. <<303-12>>
2012-07-19
www.JagDocs.com
3. Detach the fuel injector wiring harness.
4. Detach the fuel injection supply manifold. Remove and discard the injector O-ring seals.
2012-07-19
5. Disconnect the camshaft position (CMP) sensor elecrical connector.
2012-07-19

Installation
www.JagDocs.com
1. Install the CMP sensor. 1. Tighten to 7 Nm.
2. Connect the CMP sensor elecrical connector.
2012-07-19
3.
CAUTION: Make sure the fuel injectors are correctly installed to the lower intake manifold. Failure to follow these instructions may result in damage to the vehicle. NOTE: Install new injector O-ring seals.
Attach the fuel injection supply manifold. Tighten to 21 Nm.
4. Attach the fuel injector wiring harness. Tighten to 5 Nm. 5. Install the left-hand charge air cooler. <<303-12>>
2012-07-19
Camshaft Position (CMP) Sensor RH Vehicles Without: Supercharger 18.31.11

Removal
www.JagDocs.com
2012-07-19
3. Detach the camshaft position (CMP) sensor wiring harness from the throttle body elbow.
4. Disconnect the CMP sensor electrical connector.
2012-07-19
www.JagDocs.com
Installation
1. Install the CMP sensor. Tighten to 7 Nm.
2012-07-19
2. Connect the CMP sensor electrical connector.
3. Attach the CMP sensor wiring harness to the throttle body elbow.
2012-07-19
www.JagDocs.com
4. Install the engine right-hand cover. 5. Carry out the battery reconnection procedure. <<414-01>>
2012-07-19
Camshaft Position (CMP) Sensor RH Vehicles With: Supercharger 18.31.11

Removal WARNING: PLACE THE VEHICLE IN A QUARANTINED AREA AND ARRANGE 'NO SMOKING/PETROL FUMES' SIGNS ABOUT THE VEHICLE. WARNING: BEFORE ANY WORK IS CARRIED OUT ON THE FUEL SYSTEM, GROUND THE VEHICLE TO EARTH AND MAINTAIN THE GROUND CONNECTION UNTIL THE WORK IS COMPLETE. WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE VAPORS ARE ALWAYS PRESENT AND MAY IGNITE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WARNING: THE FUEL SYSTEM REMAINS PRESSURIZED FOR A LONG TIME AFTER THE IGNITION IS SWITCHED OFF. THE FUEL PRESSURE MUST BE RELEASED BEFORE ATTEMPTING ANY REPAIRS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WARNING: AFTER CARRYING OUT REPAIRS, THE FUEL SYSTEM MUST BE CHECKED VISUALLY FOR LEAKS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WARNING: THIS PROCEDURE INVOLVES FUEL HANDLING. BE PREPARED FOR FUEL SPILLAGE AT ALL TIMES AND ALWAYS OBSERVE FUEL HANDLING PRECAUTIONS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WARNING: IF FUEL IS TAKEN INTERNALLY DO NOT INDUCE VOMITING, SEEK IMMEDIATE MEDICAL ATTENTION. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WARNING: IF FUEL CONTACTS THE EYES, FLUSH THE EYES WITH COLD WATER OR EYEWASH SOLUTION AND SEEK MEDICAL ATTENTION. WARNING: WASH HANDS THOROUGHLY AFTER HANDLING, AS PROLONGED CONTACT MAY CAUSE IRRITATION. SHOULD IRRITATION DEVELOP, SEEK MEDICAL ATTENTION. WARNING: DO NOT CARRY OR OPERATE CELLULAR PHONES WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE VAPORS ARE ALWAYS PRESENT AND MAY IGNITE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Release the fuel system pressure. <<310-00>> 2. Remove the right-hand charge air cooler. <<303-12>>
2012-07-19
www.JagDocs.com
2012-07-19
5. Detach the fuel injection supply manifold. Remove and discard the injector O-ring seals.
6. Disconnect the camshaft position (CMP) sensor elecrical connector.
2012-07-19
www.JagDocs.com
Installation
1. Install the CMP sensor. 1. Tighten to 7 Nm.
2012-07-19
2. Connect the CMP sensor elecrical connector.
3.
CAUTION: Make sure the fuel injectors are correctly installed to the lower intake manifold. Failure to follow these instructions may result in damage to the vehicle. NOTE: Install new injector O-ring seals.
Attach the fuel injection supply manifold. Tighten to 21 Nm.
2012-07-19
www.JagDocs.com
4. Attach the fuel injector wiring harness. Tighten to 5 Nm.
5. Attach the fuel injector wiring harness. 6. Install the left-hand charge air cooler. <<303-12>>
2012-07-19
Catalyst Monitor Sensor LH 18.30.81

Snap-on tool S6176
2. Release the catalyst monitor sensor electrical connector from the mounting bracket and disconnect. 3. Raise and support the vehicle. <<100-02>>
2012-07-19
www.JagDocs.com
4.
WARNING: MAKE SURE THE COMPONENTS ARE COOL BEFORE REMOVING THE CATALYST MONITOR SENSOR. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN PERSONAL INJURY. CAUTION: Make sure the wiring harness is not twisted or damaged on removal. Failure to follow this instruction may result in damage to the vehicle.
Using the Snap-on tool S6176, remove the catalyst monitor sensor. Installation
1.
CAUTION: Make sure the wiring harness is not twisted or damaged on installation. Failure to follow this instruction may result in damage to the vehicle. To install, reverse the removal procedure. Tighten to 45 Nm.
2 2012-07-19
Catalyst Monitor Sensor RH 18.30.80

Snap-on tool S6176 Removal
2. NOTE: Left-hand shown, right-hand similar. Release the catalyst monitor sensor electrical connector from the mounting bracket and disconnect.
2012-07-19
www.JagDocs.com
3.
WARNING: MAKE SURE THE COMPONENTS ARE COOL BEFORE REMOVING THE CATALYST MONITOR SENSOR. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN PERSONAL INJURY. CAUTION: Make sure the wiring harness is not twisted or damaged on removal. Failure to follow this instruction may result in damage to the vehicle. NOTE: Left-hand shown, right-hand similar.
Using the Snap-on tool S6176, remove the catalyst monitor sensor.
Installation
2012-07-19
1.
CAUTION: Make sure the wiring harness is not twisted or damaged on installation. Failure to follow this instruction may result in damage to the vehicle. NOTE: Left-hand shown, right-hand similar.
To install, reverse the removal procedure. Tighten to 45 Nm.
2012-07-19
Crankshaft Position (CKP) Sensor 18.30.12

Removal 1. Disconnect the battery ground cable. <<414-01>> 2. Raise and support the vehicle. <<100-02>>
www.JagDocs.com
3. Remove the crankshaft position (CKP) sensor. 1. Disconnect the CKP sensor electrical connector. 2. Remove the CKP sensor.
Installation
1. To install, reverse the removal procedure. Tighten to 7 Nm.
2012-07-19
Engine Control Module (ECM) 18.30.01

2. Remove ECM housing cover. 3. RHD only: Remove security bracket securing screws. Remove bracket. 4. Disconnect electrical connectors.
5. Lift ECM from housing.
2012-07-19
6. RHD only: Remove security bracket securing screws. Remove brackets.
Installation 1. NOTE: A replacement ECM may only be obtained from an authorised Jaguar dealer and MUST be ordered against the VIN. NOTE: Check condition of housing seals and replace as necessary. Installation is a reversal of the removal procedure. 2. Synchronize ECM, KTM and BPM using PDU. 3. Complete engine set-up using JDS/PDU.
www.JagDocs.com
2012-07-19
Engine Coolant Temperature (ECT) Sensor 18.30.10

Removal 1. Open the engine compartment and fit paintwork protection sheets.
2.
WARNING: ENSURE THAT THE ENGINE IS COLD BEFORE COMMENCING WORK.
Slacken the coolant reservoir cap to relieve coolant pressure and re-tighten.
3. Remove the engine coolant temperature sensor. 1. Disconnect the harness plug from the sensor. 2. Remove the sensor and sealing washer.
2012-07-19
Installation
www.JagDocs.com
1. Fitting is the reverse of the removal procedure, noting that a new sealing washer should be used and tighten the sensor as specified. 1. Fit the sensor and new sealing washer. 2. Connect the harness plug to the sensor. 2. Check and adjust the coolant level as required.
2012-07-19
Heated Oxygen Sensor (HO2S) LH 18.30.79

Snap-on tool S6176 Removal 1. WARNING: ENSURE THAT THE EXHAUST AND CATALYST ARE COLD BEFORE COMMENCING WORK
Disconnect the battery ground lead.
2.
CAUTION: Make sure the wiring harness is not twisted or damaged on removal. Failure to follow this instruction may result in damage to the vehicle.
From inside the engine compartment, release the relevant sensor(s) multiplug from its mounting bracket and disconnect the plug. 3. To gain access to the sensor(s) the front muffler assembly must be displaced for clearance; refer to <<30.10.18>>.
2012-07-19
4.
www.JagDocs.com
CAUTION: Make sure the wiring harness is not twisted or damaged on removal. Failure to follow this instruction may result in damage to the vehicle. NOTE: Right-hand shown, left-hand similar.
Using the Snap-on tool S6176, remove the sensor.
Installation 1. Fitting is the reverse of the removal procedure, noting that a new sealing washer should be used.
2.
CAUTION: Make sure the wiring harness is not twisted or damaged on installation. Failure to follow this instruction may result in damage to the vehicle.
2012-07-19
NOTE: Right-hand shown, left-hand similar. Tighten the sensor to specification. 3. Make good the exhaust seals.
2012-07-19
Heated Oxygen Sensor (HO2S) RH 18.30.78

Snap-on tool S6176 Removal 1. WARNING: ENSURE THAT THE EXHAUST AND CATALYST ARE COLD BEFORE COMMENCING WORK
Disconnect the battery ground lead.
www.JagDocs.com
2.
CAUTION: Make sure the wiring harness is not twisted or damaged on removal. Failure to follow this instruction may result in damage to the vehicle. NOTE: Left-hand shown, right-hand similar.
From inside the engine compartment, release the relevant sensor(s) multiplug from its mounting bracket and disconnect the plug. 3. To gain access to the sensor(s) the front muffler assembly must be displaced for clearance; refer to <<30.10.18>>.
2012-07-19
4.
CAUTION: Make sure the wiring harness is not twisted or damaged on removal. Failure to follow this instruction may result in damage to the vehicle.
Using the Snap-on tool S6176, remove the sensor.
Installation 1. Fitting is the reverse of the removal procedure, noting that a new sealing washer should be used.
2.
CAUTION: Make sure the wiring harness is not twisted or damaged on installation. Failure to follow this instruction may result in damage to the vehicle.
Tighten the sensor to specification. 3. Make good the exhaust seals.

2 2012-07-19
Intake Air Temperature (IAT) Sensor 18.30.52

Removal
www.JagDocs.com
1. Disconnect sensor connector at rear of bank 1 charge air cooler.
2012-07-19
2. Remove sensor. Remove sensor using a deep socket. Discard sealing washer.
2012-07-19
Knock Sensor (KS) LH Vehicles Without: Supercharger 18.30.92

Removal
www.JagDocs.com
1. Detach the coolant hose.
2012-07-19
3. Disconnect the knock sensor (KS) electrical connector.
4. Detach the KS electrical connector.
2012-07-19
www.JagDocs.com
5.
CAUTION: Make sure the KS is detached from the retaining stud before removal. Failure to follow this instruction may result in damage to the vehicle.
Remove the KS through the front aperture of the intake manifold. Carefully remove the KS retaining nut through the front aperture of the intake manifold.
Installation
2012-07-19
Knock Sensor (KS) LH Vehicles With: Supercharger 18.30.92

Removal 1. Remove supercharger; refer to <<18.50.15>>. 2. Remove knock sensor from engine. Detach connector and disconnect. Remove knock sensor.
Installation 1. Installation is a reversal of the removal procedure. 2. Tighten sensor to 31 - 41 Nm.
2012-07-19
Knock Sensor (KS) RH Vehicles Without: Supercharger 18.30.93

Removal
www.JagDocs.com
2. Disconnect the knock sensor (KS) electrical connector.
2012-07-19
3. Detach the KS electrical connector.
4.
CAUTION: Make sure the KS is detached from the retaining stud before removal. Failure to follow this instruction may result in damage to the vehicle.
Remove the KS through the front aperture of the intake manifold. Carefully remove the KS retaining nut through the front aperture of the intake manifold aperture.
2012-07-19

Installation
www.JagDocs.com
2012-07-19
Knock Sensor (KS) RH Vehicles With: Supercharger 18.30.93

Removal 1. Remove supercharger; refer to <<18.50.15>>. 2. Remove knock sensor from engine. Detach connector and disconnect. Remove knock sensor.
Installation 1. Installation is a reversal of the removal procedure. 2. Tighten sensor to 31 - 41 Nm.
2012-07-19
Mass Air Flow (MAF) Sensor 18.30.15

Removal
www.JagDocs.com
1. Remove the mass air flow (MAF) sensor. 1. Disconnect the MAF sensor electrical connector. 2. Remove the MAF sensor.
Installation
2012-07-19
Variable Camshaft Timing (VCT) Oil Control Solenoid 18.30.90

Removal 1. Remove the valve cover. <<303-01>>
2. Remove the variable camshaft timing oil control solenoid
Installation
2012-07-19
1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles Without: Supercharger
Lubricants, Fluids, Sealants and Adhesives - ZF Automatic Transmission (Normally Aspirated Vehicles) Unit Transmission fluid Torque converter spigot Specification Esso ATF LT 71141 Molycote or equivalent
Capacities - ZF Automatic Transmission (Normally Aspirated Vehicles) Unit Transmission fluid (with torque converter) Liters 10,0
Torques - ZF Automatic Transmission (Normally Aspirated Vehicles) Component Locking ferrule - Shift knob Plug - Drain fluid pan Plug - Level / fill (transmission case M18 x 1.5) Tube nut - Cooler pipe to transmission unit Bolt - Drive plate to torque converter Bolt - Driveshaft coupling to transmission Bolt - Fluid filter to valve block Bolt - Fluid pan to transmission case Bolt - Rear extension housing to transmission case Bolt - Rear engine (isolation) mounting to mounting bracket Bolt - Rear engine mounting bracket to body Bolt - Rear engine mounting bracket to transmission rear extension Bolt - Selector cable bracket to transmission case Bolt - Transmission unit to engine Nut - Transmission drive flange Nut - Selector cable inner to shift lever Nut - Selector cable inner to selector lever Nut - Selector cable outer to bracket Nut - Selector lever pivot shaft Nut - Shift interlock solenoid to housing Nut - Shift interlock solenoid actuating lever Screw - Input sensor bracket to transmission case (M5) Screw - Output sensor bracket to transmission case (M6) Screw - Solenoid / regulator plate to valve body Screw - Valve block to transmission case Nm 7 - 10 27 - 33 32 - 38 17 - 23 43 - 57 75 - 88 4,5 - 5,5 9 - 11 21 - 25 22 - 28 22 - 28 30 - 40 7 - 10 43 - 57 108 - 132 1,5 - 2,5 7 - 10 22 - 28 7 - 10 5-7 11 - 13 4,5 - 5,5 7,5 - 8,5 4,5 - 5,5 7,5 - 8,5
www.JagDocs.com
2012-07-19

Internal Gear Ratios - ZF Automatic Transmission (Normally Aspirated Vehicles) Gear 1st 2nd 3rd 4th 5th Reverse Ratio 3,571:1 2,2:1 1,508:1 1,00:1 0,803:1 4,063:1
2012-07-19
Transmission Fluid Drain and Refill

Syringe
www.JagDocs.com
Removal
1. Raise the vehicle for access.
2. NOTE: This procedure will not remove residual fluid from the torque converter. Drain the transmission fluid. WARNING: TRANSMISSION FLUID MAY CAUSE SEVERE BURNS, ENSURE THAT ALL SAFETY PROCEDURES ARE OBSERVED AND THAT THE RECEPTACLE FOR WASTE HAS SUFFICIENT CAPACITY. Carefully remove the drain plug and drain the transmission fluid.
2012-07-19
3. Refit the drain plug and tighten to the specified torque figure. Use a new O-ring.
Installation
1. Remove the fluid level / filler plug.
2.
CAUTION: It is essential that only the specified fluid is used.
Using a syringe dedicated to transmission fluid only (not used for any other type of oil or fluids), inject transmission fluid until it overflows from the plug orifice. Wait until the flow of fluid has reduced to a trickle.
2012-07-19
3. Fit, but do not tighten the plug. 4. Prepare PDU (at the base station). 1. Install the appropriate disk and switch ON. 2. Select the vehicle specification - ENTER. 3. From Engineering Tools select Toolbox - ENTER. 4. From Toolbox select Powertrain - ENTER. 5. Connect MPA and download cable to PDU and base station. 6. Select Datalogger - ENTER. 7. Select Transmission - ENTER. 8. Disconnect download cable. 9. Connect MPA to PDU. 5. Connect PDU (at the vehicle). 1. Connect MPA cable to the vehicle diagnostic socket - ENTER. 2. Energize the vehicle ignition - ENTER. 3. From the menu select Transmission oil temperature (TOT) - ENTER. 4. Check that the fluid temperature is <30C. 6. From above.
www.JagDocs.com
7. NOTE: Ensure that the TCM is connected and functioning correctly.
2012-07-19
Select Park and start the engine.
8. Cycle the gear selector. From P to D. From D to R. From R to P. 9. From below.
2012-07-19
www.JagDocs.com
10. Adjust the transmission fluid level. 1. Remove the filler / level plug. CAUTION: The fluid temperature MUST NOT exceed 50C. 2. Inject fluid until it overflows from the plug orifice. Wait for the flow of fluid to reduce to a trickle (for at least 1 minute).
2012-07-19
11. Refit the filler / level plug and tighten to the specified torque figure. 12. Check for leaks and remove spilt fluid. 13. Shut down and disconnect PDU.
2012-07-19
Transmission Description
Transmission Assembly
Introduction
www.JagDocs.com
Item 1 2 3 4 5 6 7
Description Torque converter housing Transmission casing Fluid pan Transmission breather Rear extension housing 16-way connector Gear selector shaft
Component Descriptions
The torque converter: Acts as a fluid coupling between the engine and transmission geartrain. Provides multiplication of engine torque. Consists of an impeller, turbine and stator, housed within a converter cover. Has a lock-up clutch with variable slip control. The transmission casing:
2012-07-19
Houses the geartrain and electro-hydraulic control unit. Contains the input speed sensor which measures turbine speed. Contains the output speed sensor which measures the transmission output speed. Contains the hydraulic system pump. Contains the fluid temperature sensor. The epicyclic geartrain: Provides five forward gears and Reverse. Has hydraulically actuated, multi-disk clutches, to select the required gear ratios. Features clutch-to-clutch operation to permit gear shifts for uninterrupted power flow. The electro-hydraulic control unit: Is located in the lower part of the unit, within the fluid pan. Is controlled by the TCM (transmission control module), and the manual selector valve which is cable operated. Regulates the flow of fluid to the geartrain clutches via three solenoid-operated valves and the manual selector valve. Has five pressure regulators for controlling fluid pressures within the system. Is connected to the TCM via a 16-way connector mounted on the left-hand side of the transmission casing. Refer to Connector Pins Identification, Section <<307-01A>>. The hydraulic system pump: Is located at the front of the transmission casing. Is driven from the impeller hub, pressurising the fluid whenever the engine is running. Supplies fluid under pressure to the torque converter, geartrain, electro-hydraulic control unit and the lubrication circuit. Draws fluid from the fluid pan below the transmission casing, through a filter. The rear extension housing: Is bolted to the rear of the transmission casing. Provides the rear engine / transmission mounting point; refer to Section <<303-01>>. Carries the transmission output shaft oil seal.
Filled-for-life Fluid System

The transmission is 'filled for life' and does not require fluid changes, except where extreme driving conditions prevail. Routine level checking is not required and a dipstick is not provided. A level / filler plug is fitted for level checking and replenishment, following service actions; see <<303-01>> General Procedures.
2012-07-19

Transmission Torque Converter
www.JagDocs.com
Operation
The Transmission Control Module (TCM) is able to monitor the state of the torque converter clutch at all times. There are three operating modes for the converter 1. Fully open - Torque converter 'unlocked' 2. Fully closed - Torque converter 'locked' 3. Slip control - The TCM monitors slip and may apply sufficient pressure to allow a small degree of slip. This mode maximises economy by reducing slip to a minimum whilst providing isolation from drive-line shunt and vibration. The TCM constantly measures the slip within the torque converter by comparing engine speed (via CAN) and input (turbine speed). Differences in these speeds indicate the amount of slip.
Clutch Hydraulic Pressure Regulation

The TCM supplies an internally switched +12V supply to the #4 pressure regulator. The regulator is operated by switching the other side of the operating winding to ground. Hydraulic pressure is controlled by 'pulse width modulation' (PWM) of the ground switching signal i.e. the duty cycle; the time that the pressure regulator is switched on.
2012-07-19

Hydraulic Control - Transmission Pressure Regulators and Shift Solenoids
Item 1 2 3 4 5 6 7 8
Description Shift Solenoid #3 Shift Solenoid #2 Shift Solenoid #1 Pressure Regulator #5 Pressure Regulator #4 Pressure Regulator #3 Pressure Regulator #2 Pressure Regulator #1
Operation
Fluid flow within the transmission assembly is controlled by three solenoid valves and five pressure regulators. The TCM supplies an internally switched +12V supply to each shift solenoid and pressure regulator. Hydraulic pressure from the pressure regulators is controlled by 'pulse width modulation' (PWM) of the ground switching signal i.e. the duty cycle; the time that the pressure regulator is switched on. Control of the solenoids is effected by switching one side to ground through the TCM. During normal operation the TCM monitors 'Switch On' of the solenoids, the regulators and the TCM output stages, but does not check the output stage 'Switch Off'.
2012-07-19
Voltage is monitored at the regulators and solenoids for continuity and shorts. For example, when a solenoid is ON the voltage on the TCM side should be ground, when OFF the voltage should be +12.
Shift Solenoid
www.JagDocs.com
The function of the three solenoid valves is to control the flow of transmission oil to the various transmission components. Three solenoid valves are located within the transmission assembly, and are closed when not energized.
Pressure Regulator
The function of the five pressure regulators is to modulate the oil pressure to the various transmission components. The regulators are pulse width modulated by the TCM, switching to ground potential. The other side of the regulators being connected, via an internal TCM relay, to battery voltage. The regulator is closed when not
2012-07-19
energized by the TCM.
Transmission Fluid Temperature Sensor
Operation
The transmission fluid temperature sensor is integrated into the internal harness within the fluid pan. It should be noted that this component is not serviceable, necessitating the renewal of the internal harness should a fault occur. Following engine start-up, if the fluid temperature is < 20C and does not increase by 10C after 180 seconds, a failure judgement is made. A similar judgement is made should the temperature change by more than 5C in <100 milliseconds. The MIL is illuminated if the failure judgement is made on two successive trips. Sensor output is continuously monitored for out of range values. If a sustained high, or low input is sensed, indicating a harness or connector fault, a failure judgement is made.
2012-07-19

Location of Sensor Within The Harness
Temperature / Resistance Relationship Chart

Temperature (C) -20 0 20 40 60 80 100 Nominal Resistance (kOHM) 685 812 953 1107 1276 1458 1653
www.JagDocs.com
2012-07-19

Transmission Speed Sensors (Gear Shift Control)
Operation
There are two speed sensors within the transmission assembly; one on the input shaft or convertor turbine and the other on the output shaft. Both sensors are of the inductive type and sense toothed wheels; the input wheel having 30 teeth and the output 36 teeth.
2012-07-19
www.JagDocs.com
Input speed is monitored by the TCM with a rationality check being made against output speed. A fault will be flagged if the indicated input speed exceeds 7400 rpm. Additionally, a failure judgement will be made if the indicated input speed is <160 rpm with engine speed >608 rpm and output speed >224 rpm The procedure is similar for the output speed diagnostic. A fault (non OBDII) will be flagged if the indicated input speed exceeds 6712 rpm. Additionally a failure judgement will be made if the indicated output speed is <160 rpm and the average road wheel speed exceeds 100 rpm. Under normal circumstances after the output speed diagnostic fault code has been set, the TCM uses rear wheel speed information to compute its calculations, this has no effect on transmission operation. However, should a second fault occur, in the ABS system, thus making rear wheel speed information unavailable, an additional fault code will be logged.
Control Systems Introduction

Gear selection is achieved by controlling the flow of transmission fluid to internal multi-disc clutches. The three solenoid valves direct the transmission fluid flow to the selected clutches and the pressure regulators control the fluid pressure to each component. One pressure regulator serves as a master pressure control for the entire system and a second is used exclusively for torque converter clutch lock-up operation. The TCM controls the internal components thus determining gear selection and shift pattern. In the event of an electronic system fault the basic functions Park, Reverse Neutral and Drive Fourth are retained by the hydraulic system.
2012-07-19

Transmission Control Module (TCM)
The TCM is located in the same housing as the ECM and is accessed in the same manner. The TCM performs several 'self check' procedures to ensure correct operation. It is possible due to the nature of these faults that the module will fail to communicate with other nodes. However, condemnation of the TCM should not take place until any CAN or power supply related problems have been resolved. There are three self check procedures for the TCM. 1. Check on ROM by calculating a checksum and comparing this with a known stored value. 2. Check on non-volatile diagnostic memory by writing a test pattern and then reading it back. 3. Internal 'watchdog' hardware to check whether the TCM has crashed.
Transmission Control Module Supply Voltage

The TCM monitors battery and ignition switched supply voltages. A permanent supply is used to maintain a battery backed 'memory'. Should this supply be cut, due to battery disconnection perhaps, the 'adaptive shift' values will be lost. This will result in a small reduction in shift quality for a period until the adaptions are 're-learned' The TCM will adopt 'limp home' mode as a result of the supply voltage being >16V or <7V with an engine speed >1600 rpm. Should the ignition supply be >7V but <9V the TCM will hold the gear that it has currently selected. If after 2.5 seconds, with the engine speed >1600 rpm, the voltage remains at this level, 'limp home' mode will be adopted. The 2.5 second delay is built in to prevent reaction to a momentary voltage fluctuation.
Operation
CAUTION: Disconnection of the TCM and / or the vehicle battery will cause system adaptions to be lost; this may be apparent by shift quality degradation. Following reconnection, a period of 'varied' driving will reinstate adaptions and thus normal operation. Please ensure that the customer is made aware that the adaption period is variable and may occur after handover, as the transmission re-learns the prevailing driving style. NOTE:
10
2012-07-19
Should the TCM fail, please ensure that the control housing cooling fan is operating correctly. Failure of the cooling fan MUST be rectified before renewing the TCM and details of a fan failure should accompany the returned TCM. The TCM processes information received in both analogue and digital form, such as: Transmission input speed Transmission output speed Throttle position Pedal demand Gear selector position Engine torque Engine speed Transmission oil temperature Mode switch This information is then used by the TCM to control shift energy management and decide which shift program to implement and which gear to select. The TCM uses the various sensors and inputs to monitor the correct operation of the system and is programmed to take default action and inform the operator when a fault occurs.
www.JagDocs.com
Safety Functions
The safety functions are designed to safeguard against inappropriate actions by the operator as well as against system malfunctions. The system prevents reverse gear from being engaged at high forward speeds and prevents manual downshifting at excessive engine speeds; these functions are not operational in mechanical limp-home mode. The TCM constantly monitors the transmission for faults. In the event of a problem the TCM will adopt a 'limp home' mode in which only P R N D - (selector in D but only fourth gear is enabled) are available. The operator will be made aware of certain faults by an instrument panel warning. The electrical and diagnostic system has been designed such that system integrity is protected at all times, the safety concept being based on the following three points: 1. The hydraulic system has 'fail-safe' characteristics regarding its electrical operation, such that should the power supply be lost to the electro-hydraulic actuators the transmission will initiate a limp-home mode. 2. Recognition of critical shift operation by monitoring the last element in the signal path, ie the solenoid valve, and checking by means of redundant measured variables, ie engine speed, input speed and output speed. 3. Each time the vehicle is started there is a check on the entire safety hardware and the associated program parts and signal paths. A malfunction in this part of the system, or triggering of the safety circuit, is communicated to the operator through the illumination of the transmission warning lamp.
TCM Inputs Input Speed Sensor (Torque Converter Turbine)

The input speed sensor provides the TCM with transmission input shaft speed information. This signal is produced from an inductive pick-up, generating 30 pulses per revolution.
11
2012-07-19

Transmission Output Speed Sensor
The output speed sensor provides the TCM with transmission output shaft speed information. This signal is produced from an inductive pick-up, generating 36 pulses per revolution.
Transmission Oil Temperature Sensor

A thermistor which provides an electrical indication of the oil temperature to the TCM. The signal is measured as a voltage with reference to analogue ground in the TCM.
Kickdown Switch (where fitted)

Kickdown is intended to provide maximum vehicle acceleration, via the appropriate downshift(s), when the operator uses full throttle. A kickdown switch provides an electrical signal to the TCM when the accelerator pedal is fully pressed. The switch is normally open, connected to vehicle ground. Should the switch fail the TCM will detect kickdown using the accelerator pedal position.
Throttle Pedal Stop (where fitted)

This component, used where the kickdown switch is not fitted, limits throttle pedal travel .in the same way. The kickdown feature is retained, but is controlled by throttle position only. The pedal stop must be set, using the PDU, in the same way as the kickdown switch to optimize performance.
Mode Selection Switch

The mode selection switch is a two position switch indicating to the TCM the current performance mode selected by the driver. The switch generates a two-bit digital input to the TCM.
Rotary Position Switch

The rotary position switch detects the position of the transmission selector shaft. The switch is supplied as part of a new transmission assembly, mounted on the transmission body. The switch is used to indicate to the TCM the six positions of the shaft: Park, Reverse, Neutral, Drive, Third and Second. The switch provides a four-bit input to the TCM.
Drive to Fourth Switch

Detects the movement of the selector lever from Drive to Fourth position. The selector cable, and therefore the transmission selector shaft, does not move as the lever is operated between these two positions. The switch is located within the 'J-gate' assembly, producing a digital output to indicate to the TCM that the lever has moved from D to 4 ..
Serial Communications Interfaces Controller Area Network (CAN)

The TCM is an integral part of the CAN system which facilitates the interchange of real-time data between control modules and sensors. Please see section <<303-14>> for a full description of CAN.
OBDII Interface
Data concerning OBDII related transmission failures is stored in the ECM for access via the J1962 socket.
12
2012-07-19

System Functions Range Selection
The selector lever is connected to the transmission via a bowden cable, which operates the transmission selector shaft between all positions except Drive to 4 . The TCM detects the gear selected by means of a rotary position switch fitted to the transmission selector shaft. A separate Drive to 4 switch is located within the 'J' gate' assembly. Movement of the selector lever between Park, Reverse, Neutral and Drive manually directs the flow of transmission oil; the TCM having control of the forward gears selected while the lever is in the Drive position.
Shift Point Selection

The gearshift points are selected, by the TCM, as a function of the output speed, engine load, selector position and shift program selected. The operator has control over the shift points via the selector lever, throttle pedal movement, kickdown function and mode switch.
'J' Gate Layout
www.JagDocs.com
Mode Switch
This switch allows the driver to select one of two base shift maps; Normal and Sport modes, the switch being illuminated when Sport is selected.
Special Shift Programs

These specific condition shift maps are available to enhance the operation of the vehicle under specific driving conditions. and are listed below in order of priority / title and operating condition. 1. Traction: When traction intervention is active 2. Hot mode: Extreme engine / transmission temperatures 3. Gradient: Under specific speeds and loads
13
2012-07-19
4. Cruise: During cruise control 5. Manual: Shift map when the LH side of the 'J gate' is used Three specific condition shift maps have a higher priority than the two base shift maps and will intervene when appropriate conditions prevail for traction, gradient or cruise. When traction control (engine or brake system derived) is operational the TCM will implement the traction map to maximise control of wheel slip. The gradient maps are intended to enhance vehicle drivability when towing or climbing a gradient. The TCM will implement the maps when increased driving resistance is detected and enhanced drivability, cooling and increased performance is appropriate. The cruise map is intended to minimize unwanted gearshifts and 'hunting' and is activated when cruising near to the set speed, or resuming.
Connector Pins Identification
Connector Pin Identity Chart for EM007
14
2012-07-19
Pin Number 001 002 003 004 005 006 007 008 009 010 to 011 012 013 014 015 016 017 018 019 to 020 021 022 023 024 to 025 026 027 028 029 030 031 032 033 034 035 036 037 038 to 041 042 043 044 045 046 to 050 051 052
Circuit
Circuit Function Pressure regulator 2 Mode switch status Not used Pressure regulator #4 Pressure regulator #1 Power ground Not used Rotary switch L2 Rotary switch L4 Not used Mode switch Pin B (Sport) D to 4 switch Input speed sensor (-) Output speed sensor (screen) Output speed sensor (+) Not used Kickdown switch (where used) Not used Analogue ground Fluid temperature sensor Input speed sensor (screen) Not used B+ Not used Digital ground Pressure regulator #3 Shift solenoid valve #1 Not used Shift solenoid valve #3 Shift solenoid valve #2 Power ground Not used Rotary switch L1 Rotary switch L3 Not used Input speed sensor (+) Not used Output speed sensor (-) Mode switch Pin A (Normal) Not used Pressure regulator #5 Solenoid valve (+)
www.JagDocs.com
15
2012-07-19
053 054 055 056 to 081 082 083 084 085 086 087 to 088
Pressure regulator (+) Fused ignition (+) Fused ignition (+) Not used CAN link In (-) CAN link In (+) Not used CAN link Out (-) CAN link Out (+) Not used
Connector Pin Identity Chart for FC088
Pin Number 1 2 3 4 5 6 7 8 9 10 11 12
Circuit
Circuit Function Gate illumination (ground) Security LED (power) CAN link In (-) CAN link In (+) Not used Dimmer (power) Gate illumination (power) Security LED (ground) CAN link Out (-) CAN link Out (+) Not used Dimmer (ground)
16
2012-07-19
www.JagDocs.com
Pin Number 00A 00B 00C 00D 00E 00F 00G 00H 00J 00K
Circuit
Circuit Function Position L1 Position L2 Position L3 Position L4 Digital ground Not used Not used Not used B+ Park and neutral switch
17
2012-07-19

Pin Number 001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016
Circuit
Circuit Function Output speed sensor (+) Pressure regulator #1 Pressure regulator #2 Shift solenoid valve #3 Input speed sensor (+) Input speed sensor (-) Pressure regulator #3 Shift solenoid valve #1 Shift solenoid valve #2 Output speed sensor (-) Pressure regulator #4 Shift solenoid valves (+) Analogue ground Fluid temperature sensor Pressure regulator #5 Pressure regulators (+)
18
2012-07-19
Diagnostic Strategy
Quick Reference Fault Chart
Condition(s): Normal transmission operation but fault codes stored Possible Source(s): NOTE: If P0706 is logged ignore P0742 Output speed sensor circuit fault TCM faulty ABS system fault (this code may log erroneously following an ABS problem) Position switch and D to 4 switch circuit fault P R 4 circuit fault Action(s) to take: GO to P0721 GO to P1603 GO to P0742
www.JagDocs.com
Sport mode will not select Possible Source(s): Mode switch circuit fault Action(s) to take: GO to P0790 Mode switch state lamp not working Possible Source(s): Mode switch supply Mode switch circuit fault Action(s) to take: GO to P0790 Poor, or reduced shift quality Possible Source(s): Presence of EMS faults (may affect the accuracy of the torque signal) Action(s) to take: GO to EMS Possible Source(s): Transmission temperature sensor circuit Action(s) to take: GO to P0710
2012-07-19
Out of sequence shift Possible Source(s): Output / input speed sensor circuit fault Mechanical fault (check all other operations) Action(s) to take: GO to P1731 No torque converter lock-up Possible Source(s): P R 4 circuit fault Action(s) to take: GO to P0743 Possible Source(s): Mechanical fault, should P R 4 be OK Action(s) to take: GO to P0741 Harsh shifts, engine stalling (torque converter stuck on) Possible Source(s): P R 4 circuit fault Mechanical fault, should P R 4 be OK Action(s) to take: GO to P0742 Default to 4th gear Possible Source(s): Solenoid / pressure regulator supply from TCM Action(s) to take: GO to P0702 Possible Source(s): NOTE: If the code logs when 3rd is selected, then the D to 4 switch is the most probable cause If the code logs when D is selected from the LH side of the gate, then check selector cable adjustment `J gate' or selector cable out of adjustment D to 4th switch Rotary position switch circuit Action(s) to take: GO to P0706 Possible Source(s): Input speed sensor circuit fault Input speed sensor faulty Action(s) to take: GO to P0715
2 2012-07-19
Possible Source(s): Solenoid #1 circuit fault Action(s) to take: GO to P0753 Possible Source(s): Solenoid #2 circuit fault Action(s) to take: GO to P0758 Possible Source(s): Solenoid #3 circuit fault Action(s) to take: GO to P0763 Possible Source(s): TCM faulty Action(s) to take: GO to P1605 and P1608 Possible Source(s): ABS fault CAN circuit fault between ABS/TCCM and TCM Output speed sensor circuit fault Action(s) to take: GO to P1720 Possible Source(s): Mechanical fault (check all other operations) Action(s) to take: GO to P1726 Possible Source(s): Pressure regulator, solenoid or speed sensor circuit fault Mechanical fault - transmission defaulted to 5th? Action(s) to take: GO to P1734 Possible Source(s): Pressure regulator #1 circuit fault Action(s) to take: GO to P1745 Possible Source(s): Pressure regulator #2 circuit fault Action(s) to take: GO to P1746 Possible Source(s): Pressure regulator #3 circuit fault
www.JagDocs.com
2012-07-19
Action(s) to take: GO to P1747 Possible Source(s): Pressure regulator #4 circuit fault Action(s) to take: GO to P0743 Possible Source(s): Pressure regulator #5 circuit fault Action(s) to take: GO to P1748 Possible Source(s): Mechanical fault - transmission defaulted during 2nd to 3rd or 3rd to 4th shift? Action(s) to take: GO to P1779 Possible Source(s): Power (ignition) supply fault to TCM Vehicle battery charging system fault Action(s) to take: GO to P1789 and P1793 Possible Source(s): Incompatible ECM, ABS/TCCM, TCM or INST - check part number Action(s) to take: GO to P1795 Possible Source(s): CAN circuit fault Check fault code(s) in ECM, ABS/TCCM or INST and rectify as required Action(s) to take: GO to P1796 Possible Source(s): Faulty ECM CAN circuit fault between ECM and TCM Action(s) to take: GO to P1797 Default to 5th gear Possible Source(s): Output speed sensor circuit fault Mechanical fault (check pulling away from standstill performance) Action(s) to take: GO to P1722 Possible Source(s): Output / input speed sensor circuit fault
2012-07-19
Mechanical fault (check operation of transmission in 2nd, 3rd and 4th gears) Action(s) to take: GO to P1730
www.JagDocs.com
2012-07-19
Transmission - Removal 44.20.01

Engine support 303-021
Engine lifting brackets 303-536 Removal 1. Select N gear position. 2. Open the engine compartment and fit paintwork protection sheets. 3. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors remain open until after the battery has been disconnected.
2012-07-19
www.JagDocs.com
4. Disconnect battery ground cable. Remove the battery cover. 5. Remove the engine covers (12.30.06). 6. Remove the air intake tube, MAFM and air cleaner cover assy, (19.10.30).
7. Install engine lifting bracket 303 - 536 at the rear RH.
2012-07-19
8. Reposition the coolant header tank for access. 1. Remove the securing bolt. 2. Reposition the tank.
9. Install engine lifting bracket 303 - 536 at the rear LH.
2012-07-19
www.JagDocs.com
10. Support the engine using 303 - 021. 1. Adjust and locate the stands in the LH and RH fender channels and tighten the beam fixings. 2. Engage the support hooks in the lifting brackets. 3. Tighten the support hook adjusters and take the weight of the engine. 11. Raise the vehicle for access. 12. Remove the LH downpipe catalytic converter (17.50.09). 13. Remove the front muffler (<<30.10.18>>). 14. Remove the RH downpipe catalytic converter (17.50.09 and 17.50.10). 15. Drain the transmission fluid, (<<44.24.02>>).
2012-07-19
16. Locate a transmission jack, Epco V - 100 or similar, under the transmission unit. Adjust the angle of the jack to suit the transmission. Secure the side clamps. Pass the safety chain over the transmission unit and secure.
17. Remove the engine rear mounting bracket. 1. Remove the engine rear mounting to bracket bolt. 2. Remove the mounting bracket to body bolts.
2012-07-19
www.JagDocs.com
18. Detach the driveshaft from the transmission drive flange. If the transmission is to be refitted, mark the position of the coupling to drive flange. CAUTION: Under no circumstances remove the driveshaft to flexible coupling fixings. 1. Remove the transmission drive flange to flexible coupling three fixings.
19. Lower the transmission unit by carefully releasing the engine support beam and by lowering the transmission jack.
2012-07-19
20. Detach the gear selector cable from the transmission unit. 1. Remove the selector cable ball pin to selector lever nut. 2. Remove the selector cable to transmission casing bolts.
21. Disconnect the transmission harness multiplug. 1. Rotate the locking lever to release. 2. Disconnect the multiplug.
2012-07-19
www.JagDocs.com
22. Detach the rotary switch. 1. Remove the switch fixings. 2. Displace the switch harness from the clips.
23. Disconnect the fluid cooler pipes. Unscrew the cooler pipe tube nuts, one at each side of the transmission casing. Discard the 'O' rings. Plug the pipes and transmission.
2012-07-19
24. Remove the three bolts which secure the torque converter to the drive plate. 1. Remove the access cover. 2. Rotate the crankshaft and hold to prevent movement, and remove the bolts.
25. Remove the LH and RH catalyst mounting brackets from the transmission case. Remove the bolts.
2012-07-19
www.JagDocs.com
26. Remove the bolts which secure the engine harness connector mounting bracket and move the bracket aside for access. 27. On the RH side, clear the cooler pipe for access.
28. NOTE: Viewed from the rear of the vehicle. Remove the four upper transmission to engine bolts.
10
2012-07-19
29. NOTE: Viewed from the rear of the vehicle. Remove the ground lead bolt. 30. On the LH side.
31. NOTE: Viewed from the rear of the vehicle. Remove the upper cooler pipe clip to transmission case bolt.
11
2012-07-19
32. NOTE: Viewed from the rear of the vehicle. Remove the six remaining transmission case to cylinder block bolts.
www.JagDocs.com
33. NOTE: Do not allow the converter to detach from the transmission. Remove the transmission / converter assembly from the vehicle. Lower the transmission jack and remove the transmission, ensuring that the torque converter spigot disengages cleanly from the engine. 34. If appropriate, fit retaining straps to the converter / transmission assembly.
12
2012-07-19
Transmission - Installation 44.20.01

Engine lifting brackets 303-536
Installation 1. Clean all mating faces and relevant parts.
2012-07-19
2. Apply lubricant, Molycote or equivalent, to the spigot of the torque converter.
www.JagDocs.com
3. Align the engine drive plate. 1. Rotate the crankshaft to position the ORANGE dot within the indicated sector. NOTE: Viewed from the rear of the vehicle. 2. Keeping the dot within the sector, align the nearest converter fixing hole to the access aperture.
2012-07-19
4. Align the torque converter 1. Rotate the converter to position the BLUE dot within the indicated sector. 2. Keeping the dot within the sector, align the nearest fixing boss as indicated, so that when the two units are mated, the converter need only be moved the minimum amount.
5. Fit the transmission to the engine. Loosely assemble - Cooler pipe clip. Loosely assemble - Ground lead. Loosely assemble - Catalyst brackets. 1. Tighten in sequence 1, 2, 3, 4 as shown on the illustration, then the others in any order.
2012-07-19
6. Reposition the mounting bracket for the engine harness connector and fit the securing bolts.
www.JagDocs.com
7. Connect the drive shaft, aligning any marks made when removing - if applicable. Tighten the bolts to the specified torque figure.
2012-07-19
8. Fit the engine rear mounting and tighten the centre bolt and outer bolts to the specified torque figures. Check that the hooks of the engine support beam are not trapped, before tightening the rear mounting. Check that the safety chain on the transmission jack will not be trapped when the mounting is fitted.
9. Remove the transmission jack.
2012-07-19
www.JagDocs.com
10. Fit the three bolts which secure the torque converter to the drive plate. 1. Loosely assemble all three drive plate to torque converter bolts. Whilst preventing crankshaft rotation, tighten the three converter bolts to the specified torque figure. 2. Fit the blanking plug.
11. Connect the transmission harness multiplug. 1. Engage the multiplug. 2. Rotate the locking lever to secure.
2012-07-19
12. Connect the selector cable to the selector lever and fit the abutment bracket to the transmission casing. Tighten the nut and two bolts to the specified torque figure.
13. Refit the rotary switch and tighten the two screws to the specified torque figure. Locate the switch harness into the clips.
2012-07-19
www.JagDocs.com
14. Connect the fluid cooler pipes to the transmission. Remove the blanking plugs. Fit new O-ring seals. Tighten the union nuts to the specified torque figure.
15. Remove the engine support beam. Remove both engine lifting brackets 303 - 536. 16. Refit the RH downpipe catalytic converter. Refer to Operation 17.50.09 and 17.50.10 17. Refit the front muffler. Refer to Operation <<30.10.18>>. 18. Refit the LH downpipe catalytic converter. Refer to Operation 17.50.09 19. Lower the vehicle on the ramp.
8 2012-07-19
20. Reposition the coolant header tank and tighten the securing bolt to the specified torque figure. 21. Refit the air intake tube, MAFM and air cleaner cover assembly. Refer to Operation 19.10.30. 22. Refit the engine covers. refer to operation 12.30.06. 23. Perform the Battery Reconnection Procedure described in Operation <<86.15.15>>. 24. Refill the transmission with new fluid. Refer to Operation <<44.24.02>>. 25. Remove the protection sheets and close the engine compartment.
2012-07-19
Electronic Pressure Control (EPC) Solenoid 44.15.51

www.JagDocs.com
2. Disconnect battery ground cable. Remove the battery cover.
3.
WARNING: TRANSMISSION FLUID MAY CAUSE SEVERE BURNS, ENSURE THAT ALL SAFETY PROCEDURES ARE OBSERVED.
Raise the vehicle on a suitable lift. Carefully remove the drain plug and drain the transmission fluid.
2012-07-19
4. Remove the twenty-two fixings which secure the fluid pan . Remove the fluid pan and all traces of gasket material.
5. Disconnect regulator / solenoid connectors.
2012-07-19
6. Remove RH rear valve body securing screws.
www.JagDocs.com
7. Remove the nine screws from the pressure regulator / solenoid retaining plate.
2012-07-19
8. Remove the relevant pressure regulator.
Installation
1. Installation is the reverse of the removal procedure, noting that a new pressure regulator 'O' ring MUST be used. Fit the nine screws securing the pressure regulator / solenoid retaining plate and tighten to the specified torque figure.
2012-07-19
2. Refit the RH rear valve body securing screws and tighten to the specified torque figure.
www.JagDocs.com
3. NOTE: Ensure extreme cleanliness and never reuse transmission fluid. Using a new gasket, install the fluid pan and tighten the fixings to the specified torque figure. 4. Perform the Battery Reconnection Procedure described in Operation <<86.15.15>>. 5. Refer to (<<44.24.02>>) for fluid fill procedure.
2012-07-19
Extension Housing Seal 44.20.18

Drive shaft flange wrench 205-053
Coupling nut socket 307-356
Oil seal replacer 307-358 Removal
2012-07-19
1. Remove the rear extension housing, <<44.20.19>>.
www.JagDocs.com
2. Fit tool 205 - 053 to the transmission drive coupling. Install two bolts to attach the coupling to the tool. 3. Locate the tool 205 - 053 / housing assembly in a vice.
4. Using a punch, knock back the two staked areas of the coupling nut.
2012-07-19
5. Use tool 307 - 356 to remove the coupling nut. 6. Remove tool 205 - 053 from the coupling.
7. Remove the drive coupling from the housing. Hold the housing assembly in a vice with soft jaws fitted and pull the coupling free.
2012-07-19
www.JagDocs.com
8. Remove the housing oil seal. Use a suitable seal puller. 9. Clean the oil seal mating faces.
Installation
1. Install a new housing oil seal. 1. Lubricate the oil seal prior to fitting. 2. Using tool 307 - 358, fit the oil seal.
2012-07-19
2. Fit the drive coupling to the housing. Hold the housing assembly in a vice with soft jaws fitted and carefully insert the coupling. Fit tool 205 - 053 to the coupling.
3. Use tool 307 - 356 to tighten the coupling nut to the specified torque figure.
2012-07-19
4. Stake the coupling nut at two positions. 5. Refit the rear extension housing. Refer to Operation <<44.20.19>>. 6. Check the transmission fluid level. Refer to Operation <<44.24.02>>.
www.JagDocs.com
2012-07-19
Extension Housing O-Ring Seal 44.20.19

Removal 1. Select N position. 2. Raise the vehicle for access. 3. Remove the front muffler, <<30.10.18>>.
4. Locate a transmission jack, Epco V - 100 or similar, under the transmission unit. Adjust the angle of the jack to suit the transmission. Secure the side clamps. Pass the safety chain over the transmission unit and secure. Take the weight of the transmission and engine.
2012-07-19
www.JagDocs.com
5. Remove the engine rear mounting bracket. 1. Remove the engine rear mounting to bracket bolt. 2. Remove the mounting bracket to body bolts. 6. Gently lower the transmission jack.
7.
CAUTION: Under no circumstances remove the driveshaft to flexible coupling fixings.
Detach the driveshaft from the transmission unit. Mark the position of the coupling to drive flange. 1. Remove the three bolts which secure the transmission drive flange to the flexible coupling .
2012-07-19
8. Remove the rear extension housing assembly. 1. Remove the ten bolts, noting their location for installation. 2. Remove and discard the O-ring. 9. Clean the mating faces.
Installation
1. Installation is the reverse of the removal procedure noting that; 1. Install a new O-ring seal. 2. Tighten the ten bolts to the specified torque figure.
2012-07-19
www.JagDocs.com
2. Align the driveshaft with the transmission drive flange using the marks made on removal. Tighten the three bolts to the specified torque figure. 3. Raise the transmission carefully to position, using the transmission jack
4. Fit the engine rear mounting and tighten the centre bolt and outer bolts to the specified torque figures. Check that the safety chain on the transmission jack will not be trapped when the mounting is fitted.
2012-07-19
5. Remove the transmission jack. 6. Check the transmission fluid level. Refer to Operation <<44.24.02>>.
2012-07-19
Main Control Valve Body 44.40.01

www.JagDocs.com
3.
Raise the vehicle for access. Carefully remove the drain plug and drain the transmission fluid.
2012-07-19
4. Remove the twenty-two bolts which secure the fluid pan. Remove the fluid pan and all traces of gasket material. 5. Remove the fluid filter, (<<44.24.07>>).
6. Remove the input speed sensor. NOTE: M5 fixing. 1. Remove the screw from the input speed sensor securing bracket and pull the sensor clear. Disconnect the harness multiplug.
2012-07-19
www.JagDocs.com
7. Remove the output speed sensor. NOTE: M6 fixing. 1. Remove the screw from the output speed sensor securing bracket and pull the sensor clear. Disconnect the harness multiplug.
8. Disconnect the five pressure regulator connectors and three solenoid connectors.
2012-07-19
9. Reposition the internal harness for access. Release the internal harness from the retaining clips.
10. Drain the valve body. 1. Position a suitable drain tin below the valve body. 2. Slacken (do not remove) the twenty-two screws, valve body to transmission case. Allow the fluid to drain.
2012-07-19
www.JagDocs.com
11. Remove the valve body. Remove five M6 X 30 screws, valve body to transmission case. Remove seventeen M6 X 60 screws, valve body to transmission case.
Installation 1. Installation is the reverse of the removal procedure, noting the following steps.
2012-07-19
2. Fit the valve body retaining screws. Note the location of the five screws M6 X 30. Fit and tighten to the specified torque figure. Note the location of the seventeen screws M6 X 60. Fit and tighten to the specified torque figure.
3. NOTE: M6 fixing. Fit the output speed sensor and tighten the retaining screw to the specified torque figure..
2012-07-19
www.JagDocs.com
4. NOTE: M5 fixing. Fit the input speed sensor and tighten the retaining screw to the specified torque figure..
5. Reposition the internal harness for. Release the internal harness from the retaining clips.
2012-07-19
6. Connect the five pressure regulator connectors and three solenoid connectors.
7. NOTE: Ensure extreme cleanliness and never reuse transmission fluid. Using a new gasket, install the fluid pan and tighten the twenty-two fixings to the specified. torque figure 8. Perform the Battery Reconnection Procedure described in Operation <<86.15.15>>. 9. Refer to (<<44.24.02>>) for fluid fill procedure. 10. Check for leaks and remove spilt fluid.
2012-07-19
Output Shaft Speed (OSS) Sensor 44.15.41

www.JagDocs.com
3.
Raise the vehicle on a lift. Carefully remove the drain plug and drain the transmission fluid.
2012-07-19
4. Remove the twenty-two bolts which secure the fluid pan. Remove the fluid pan and all traces of gasket material.
5. Remove the output speed sensor. NOTE: M6 fixing. 1. Release the screw which secures the output speed sensor bracket and pull the sensor clear.
2012-07-19
6. Disconnect the multiplug from the speed sensor.
www.JagDocs.com
Installation
1. NOTE: M6 fixing. Connect the multiplug, install the output speed sensor and securing bracket. Tighten the screw to the specified torque figure.
2012-07-19
2. NOTE: Ensure extreme cleanliness and never reuse transmission fluid. Using a new gasket, install the fluid pan and tighten the twenty-two fixings to the specified. torque figure. 3. Perform the Battery Reconnection Procedure described in Operation <<86.15.15>>. 4. Refer to (<<44.24.02>>) for fluid fill procedure.
2012-07-19
Shift Solenoids (SS) 44.15.50

www.JagDocs.com
3.
2012-07-19
5. Disconnect the eight solenoid / regulator connectors.
2012-07-19
6. Remove the RH rear valve body securing screws.
www.JagDocs.com
7. Remove the nine screws which secure the solenoid / pressure regulator retaining plate.
2012-07-19
8. Remove the relevant solenoid.
Installation
1. Installation is the reverse of the removal procedure, noting the specific tightening of fixings and related procedures. Fit the nine screws securing the pressure regulator / solenoid retaining plate and tighten to the specified torque figure.
2012-07-19
2. Refit the RH rear valve body securing screws and tighten to the specified torque figure.
www.JagDocs.com
3. NOTE: Ensure extreme cleanliness and never reuse transmission fluid. Using a new gasket, install the fluid pan and tighten the twenty-two fixings to the specified torque figure. 4. Perform the Battery Reconnection Procedure described in Operation <<86.15.15>>. 5. Refer to (<<44.24.02>>) for fluid fill procedure.
2012-07-19
Transmission Control Module (TCM) 44.15.32

3. Release the fixings and remove the cover from the ECM / TCM housing.
2012-07-19
4. Disconnect the TCM harness multiplug EM007. 5. Lift the TCM from its housing.
www.JagDocs.com
Installation 1. NOTE: A replacement TCM may only be obtained from an authorized Jaguar dealer and MUST be ordered against the VIN. Fitting a new TCM is the reverse of the removal procedure. At this point ensure that the ECM is correctly located and pushed fully rearward against the housing. 2. Perform the Battery Reconnection Procedure described in Operation <<86.15.15>>.
2012-07-19
Transmission Fluid Filter 44.24.07

Removal 1. Raise the vehicle for access. 2. Remove the fluid pan, <<44.24.04>>.
3. Remove and discard the fluid filter. Remove the two bolts which secure the filter. Discard the 'O' ring. Clean the fluid filter mating face.
Installation 1. Installation is the reverse of the removal procedure. 2. Renew the 'O' ring.
2012-07-19
3. Tighten the two bolts to the specified torque figure, to secure the filter . 4. Refill the transmission with fluid. Refer to Operation <<44.24.02>>.
www.JagDocs.com
2012-07-19
Transmission Fluid Pan 44.24.04

Removal 1. Raise the vehicle for access and drain the transmission fluid.
2. Remove the fluid pan. Remove the twenty-two bolts. 3. Discard the fluid pan gasket and clean the mating faces.
4. Remove the magnets from the fluid pan. Clean the magnets and refit them to the fluid pan.
2012-07-19

Installation 1. Installation is the reverse of the removal procedure:
www.JagDocs.com
2. Tighten the fluid pan bolts to the specified torque figure. 3. Refill the transmission fluid. Refer to Operation <<44.24.02>>.
2012-07-19
Transmission Fluid Pan Gasket 44.24.05

Removal 1. Raise the vehicle for access and drain the transmission fluid.
2. Remove the fluid pan. Remove the twenty-two bolts. 3. Discard the fluid pan gasket and clean the mating faces.
4. Remove the magnets from the fluid pan. Clean the magnets and refit them to the fluid pan.
2012-07-19

Installation 1. Installation is the reverse of the removal procedure:
www.JagDocs.com
2. Tighten the fluid pan bolts to the specified torque figure. 3. Refill the transmission fluid. Refer to Operation <<44.24.02>>.
2012-07-19
Transmission Internal Wiring Harness 44.15.35

RemovalNOTE: The temperature sensor is integral with the internal harness. 1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors remain open until after the battery has been disconnected.
3.
2012-07-19
www.JagDocs.com
5. Remove the input speed sensor. NOTE: M5 fixing. 1. Release the screw which secures the input speed sensor bracket and pull the sensor clear. Disconnect harness multiplug.
2012-07-19
6. Remove the output speed sensor. NOTE: M6 fixing. 1. Release the screw which secures the output speed sensor bracket and pull the sensor clear. Disconnect harness multiplug.
7. Remove the selector cable abutment bracket fixings and reposition the bracket for access to the multiplug.
2012-07-19
www.JagDocs.com
8. Disconnect the transmission harness multiplug. 1. Release the harness locking lever. 2. Disconnect the harness multiplug.
9. Remove harness multiplug retaining clip. Push the multiplug into the transmission casing to release. Discard the two 'O' rings.
2012-07-19
10. Disconnect the eight solenoid / regulator connectors.
11. Release the internal harness from the retaining clips and remove the harness.
2012-07-19

Installation
1. Position the internal harness and fit it to the retaining clips.
www.JagDocs.com
2. Connect the eight solenoid / regulator harness connectors. 3. Lubricate the harness connector 'O' rings with transmission fluid prior to fitting. Fit the new 'O' rings, the harness connector and the retaining clip
2012-07-19
4. Tighten selector cable abutment fixings.
5. NOTE: M5 fixing. Refit the input speed sensor and tighten the retaining screw to the specified torque figure.
2012-07-19
www.JagDocs.com
6. NOTE: M6 fixing. Refit the output speed sensor and tighten the retaining screw to the specified torque figure.
7. NOTE: Ensure extreme cleanliness and never reuse transmission fluid. Using a new gasket, install the fluid pan and tighten the twenty-two bolts to the specified torque figure. 8. Perform the Battery Reconnection Procedure described in Operation <<86.15.15>>. 9. Refer to (<<44.24.02>>) for fluid fill procedure.
2012-07-19
Transmission Internal Wiring Harness Electrical Connector O-Ring Seals 44.24.20

2. Disconnect battery ground cable. Remove the battery cover. 3. Raise the vehicle for access. 4. Remove the fluid pan; refer to <<44.24.04>>.
5. Remove selector cable abutment bracket fixings (2) and reposition the bracket for access to the multiplug.
2012-07-19
www.JagDocs.com
6. Disconnect the transmission harness multiplug. 1. Release the harness locking lever. 2. Disconnect the harness multiplug.
7. Remove harness multiplug retaining clip. Push the multiplug into the transmission casing to release. Discard the two 'O' rings.
Installation 1. Installation is the reverse of the removal procedure noting that: 2. Lubricate the new 'O' rings prior to fitting.
2012-07-19
3. Tighten the securing bolts, selector cable bracket to transmission casing, to the specified torque figure. 4. Perform the Battery Reconnection Procedure described in Operation <<86.15.15>>. 5. Refer to (<<44.24.02>>) for fluid fill procedure.
2012-07-19
Transmission Range (TR) Sensor

www.JagDocs.com
3. From above, disconnect the rotary switch harness multiplug.
2012-07-19
4. From below, release the harness from the retaining clips.
5. Remove the rotary switch retaining fixings.
2012-07-19

Installation
1. Fitting a new rotary switch is the reverse of the removal procedure noting that the fixings must be tightened to the specified torque figure. 2. Perform the Battery Reconnection Procedure described in Operation <<86.15.15>>.
www.JagDocs.com
2012-07-19
Turbine Shaft Speed (TSS) Sensor 44.15.40

3.
2012-07-19
www.JagDocs.com
5. Remove the input speed sensor. NOTE: M5 fixing. 1. Release the screw which secures the input speed sensor bracket and pull the sensor clear.
2012-07-19
6. Disconnect the multiplug from the speed sensor.
Installation
1. NOTE: M5 fixing. Connect the multiplug, install the input speed sensor and securing bracket. Tighten the screw to the specified torque figure.
2012-07-19
www.JagDocs.com
2. NOTE: Ensure extreme cleanliness and never reuse transmission fluid. Using a new gasket, install the fluid pan and tighten the twenty-two fixings to the specified. torque figure. 3. Perform the Battery Reconnection Procedure described in Operation <<86.15.15>>. 4. Refer to (<<44.24.02>>) for fluid fill procedure.
2012-07-19
Input Shaft Seal 44.32.07

Oil seal replacer 307-357
1. Remove the transmission unit, <<44.20.01>>. 2. Remove the torque converter from the transmission unit, <<44.17.07>>.
3. Remove the front pump seal. Remove and discard the seal retaining snap-ring. Using a 'Snap-on' oil seal puller, remove and discard the seal. 4. Clean the seal housing. 5. Installation is the reverse of the removal procedure.
2012-07-19
www.JagDocs.com
6. Use tool 307 - 357 to install the seal. Lubricate the seal prior to fitting.
2012-07-19
Torque Converter 44.17.07

Lifting handle 307-139
1. Remove the transmission unit from the vehicle; <<44.20.01>>.
2. Remove the torque converter from the transmission unit. Install lifting handles 307 - 139. 3. Remove lifting handles 307 - 139 from the torque converter. 4. Clean the torque converter and mating faces.
2012-07-19
www.JagDocs.com
5.
CAUTION: Use extreme care NOT to damage the oil seal with the converter spigot.
CAUTION: Ensure that the converter is fully located. Install the torque converter. 1. Install lifting handles 307 - 139. 2. Lubricate the front pump seal. To facilitate location, rotate the converter as it is being fitted and note the engagement of splines and oil pump drive. 6. Check that the three converter fixing boss faces are approximately 8,0 mm proud of the transmission mounting face. 7. Remove lifting handles 307 - 139 from the torque converter. 8. Install the transmission unit; refer to Operation <<44.20.01>>, noting especially the alignment instructions.
2012-07-19
1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
Lubricants, Fluids, Sealants and Adhesives - Automatic Transmission (Supercharged Vehicles) Unit Transmission fluid Specification Shell ATF 3403 - M115
Capacities - Automatic Transmission (Supercharged Vehicles) Unit Transmission assembly (with torque converter) Liters 9,5
Torques - Automatic Transmission (Supercharged Vehicles) Component Bolt - EMS bracket to cylinder head Bolt - Driveshaft coupling to transmission Bolt - Fluid pan (clamp) to transmission case Bolt - Harness heatshield to case and fluid pan clamp Bolt - Muffler bracket to transmission case Bolt - Rear engine (isolation) mounting to mounting bracket Bolt - Rear engine mounting bracket to adapter (transmission case) Bolt - Rear engine mounting bracket to body Bolt - Torque converter to drive plate Bolt - Transmission unit to engine Bolt - Valve body to transmission case Bolt - 'W' clip (fluid cooler pipe) to cylinder block Banjo bolt - Cooler pipe to transmission unit Nut - Coolant header tank to bracket Nut - Selector cable abutment to transmission case Nut - Selector cable ball end to selector lever Nut - Transmission output shaft flange Plug - Fluid pan drain Screw - Coolant header tank to bracket Screw - Filler tube to transmission case Nm 43 - 53 75 - 88 8 - 10 9 - 11 43 - 57 22 - 28 39 - 51 22 - 28 43 - 57 43 - 57 7-9 7-9 30 - 40 4-5 7 - 10 7 - 10 200 20 - 24 4-5 14 - 18
Internal Rear Ratios - Automatic Transmission (Supercharged Vehicles) Gear 1st 2nd 3rd 4th 5th Reverse Reverse Ratio 3,59:1 2,19:1 1,41:1 1,00:1 0,83:1 -1,93 (Normal mode) -3,165 (Sport mode)
2012-07-19
Transmission Fluid Drain and Refill

Dipstick 307-379
1. Disconnect the battery ground lead. 2. Raise the vehicle for access.
www.JagDocs.com
3. NOTE: This procedure will not remove residual fluid from the torque converter. Drain the transmission fluid. WARNING: TRANSMISSION FLUID MAY CAUSE SEVERE BURNS, ENSURE THAT ALL SAFETY PROCEDURES ARE OBSERVED AND THAT THE RECEPTACLE FOR WASTE HAS SUFFICIENT CAPACITY. Carefully remove the drain plug and discard the sealing washer.
2012-07-19
4. Refit the drain plug and tighten to the specified torque figure. Use a new sealing washer. 5. Connect the PDU to monitor the fluid temperature.
2012-07-19
www.JagDocs.com
6. Access the dipstick tube. 1. Break off the dipstick tube plug locking plate. 2. Push the locking pin downward, into the plug. 3. Remove the dipstick tube plug. Push the locking pin through the tube plug and discard the pin.
2012-07-19
7.
CAUTION: It is essential that only the specified fluid is used.
Pour approximately 4,0 liters of fluid into the transmission.
8. Select P and start the engine.
2012-07-19
9. Pour approximately 3,0 liters of fluid into the transmission.
www.JagDocs.com
10. Cycle the gear selector: From P to D. From D to R. From R to P.
2012-07-19
11. NOTE: Temperature will ONLY be displayed in D or R. Check the transmission fluid temperature to select the appropriate dipstick calibration. 1. MAX and MIN marks at 25C fluid temperature. 2. MAX and MIN marks at 80C fluid temperature.
12. Check the transmission fluid level. Insert the dipstick (special tool 307 - 379) until it stops (tip contact with the fluid pan). Remove the dipstick and check the level. NOTE: Only use a lint free cloth to wipe the dipstick. Repeat this operation. 13. Correct the fluid level as required, noting that excess fluid MUST be removed. 14. STOP the engine and remove the dipstick.
6 2012-07-19
www.JagDocs.com
15. Seal the dipstick tube. 1. Seat the tube plug. 2. Engage and fully seat the new locking pin. 16. Check for leaks and remove spilt fluid.
2012-07-19
Transmission - Removal 44.20.01

Engine lifting brackets 303-536 Removal 1. Select N gear position. 2. Disconnect the battery ground lead. 3. Remove the engine covers. Refer to Operation 12.30.06. 4. Remove the air intake tube, MAFM and air cleaner cover assembly. Refer to Operation 19.10.30.
2012-07-19
www.JagDocs.com
5. Disconnect the transmission link lead connector. 1. Release the connector from its mounting bracket. 2. Disconnect the multiplug.
6. Remove the EMS harness mounting bracket. Release the bolt, bracket to cylinder head.
2012-07-19
7. Fit engine lifting bracket 303 - 536 at the rear RH.
8. Remove the centre trim panel from the engine compartment. 1. Remove the left hand side enclosure panel. 2. Remove the centre trim panel.
2012-07-19
www.JagDocs.com
9. Move the coolant header tank for access. 1. Disconnect the bleed pipe, header tank to radiator . 2. Remove the header tank fixings.
10. Fit engine lifting bracket 303 - 536 at the rear LH.
2012-07-19
11. Support the engine using 303 - 021. 1. Adjust and locate the side support brackets to fit into the LH and RH body channels and tighten the beam fixings. 2. Engage the support hooks into the engine rear lifting brackets. 3. Tighten the support hook adjusters to take the weight of the engine. 12. Raise the vehicle for access. 13. Remove the LH downpipe catalytic converter. Refer to Operation 17.50.09. 14. Remove the front muffler. Refer to Operation <<30.10.18>>. 15. Remove the RH downpipe catalytic converter. Refer to Operation 17.50.09 and 17.50.10. 16. Drain the transmission fluid. Refer to Operation <<44.24.02>>.
2012-07-19
www.JagDocs.com
17. Locate an Epco V-100, or similar lift, under the transmission unit. Adjust the angle of the lift to suit the transmission. Secure the side clamps. Pass the safety chain over the transmission unit and tighten the clamp to secure the assembly.
18. Remove the rear engine mounting bracket. 1. Remove the centre bolt from the engine/transmission mounting. 2. Remove the four bolts which secure the mounting bracket to the body.
2012-07-19
19. Detach the driveshaft (prop-shaft) from the transmission drive flange. If the transmission is to be refitted, mark the position of the coupling relative to the drive flange. CAUTION: Under no circumstances remove the driveshaft to flexible coupling fixings. 1. Remove the transmission drive flange to flexible coupling fixings.
20. Lower the transmission unit.
2012-07-19
www.JagDocs.com
21. Detach the gear selector cable from the transmission unit. 1. Remove the selector cable ball pin to selector lever nut. 2. Lower the transmission lift for access. 3. Remove the selector cable to transmission casing bolts.
22. Release the transmission harness multiplug bracket. 1. Remove the two bolts which secure the bracket to the transmission case, noting that one bolt also retains the dipstick tube.
2012-07-19
23. Disconnect the fluid cooler upper pipe. Remove the bolt which secures the pipe to the cylinder block and remove the bracket. Remove the 'banjo' bolt. Discard the Dowty seals. Fit blanking plugs to the pipe and transmission.
24. Disconnect the fluid cooler lower pipe. Remove the 'banjo' bolt. Discard the Dowty seals. Fit blanking plugs to the pipe and transmission.
2012-07-19
www.JagDocs.com
25. Remove the three bolts which secure the torque converter to the drive plate. 1. Remove the access cover. 2. Rotate the crankshaft for access to each bolt and hold to prevent movement. Remove each bolt.
26. Remove the LH and RH catalyst mounting brackets from the transmission case. Remove the two bolts from each side. 27. On the RH side, clear the cooler pipe for access.
10
2012-07-19
28. NOTE: Viewed from the rear of the vehicle. Remove the two upper bolts, as indicated, transmission to engine.
29. NOTE: Viewed from the rear of the vehicle. Remove the two bolts which secure the starter motor power cable clip.
11
2012-07-19
www.JagDocs.com
30. NOTE: Viewed from the rear of the vehicle. Remove the ground lead bolt. 31. On the LH side.
32. NOTE: Viewed from the rear of the vehicle. Remove the bolt which secures the cooler upper pipe clip to the transmission case.
12
2012-07-19
33. NOTE: Viewed from the rear of the vehicle. Remove the six remaining bolts from the transmission case to cylinder block.
34. NOTE: Do not allow the converter to detach from the transmission. Remove the transmission / converter assembly from the vehicle. Lower the lift and remove the transmission, ensuring that the torque converter spigot disengages cleanly.
13
2012-07-19
35. Remove the side clamps and chain for access.
www.JagDocs.com
36. Remove the front muffler mounting bracket. Remove the two bolts which secure the bracket to the transmission case.
14
2012-07-19
37. Remove the transmission dipstick tube. 1. Remove the fixing which secures the tube to the case. Discard the filler tube 'O' ring. 2. Fit a blanking plug to the transmission casing orifice.
38. Remove the harness link lead. 1. If required, slacken the harness heatshield spring clamp bolt. 2. Remove the heatshield lower bolt. 3. Release the harness multi-lock lever, disconnect and remove the harness. 39. If appropriate, fit retaining straps to the converter / transmission assembly.
15
2012-07-19
Transmission - Installation 44.20.01

www.JagDocs.com
Engine lifting brackets 303-536
Installation 1. CAUTION: A new transmission requires a NEW torque converter.
Installation is the reverse of the removal procedure, noting the following: 2. Clean all mating faces and relevant parts.
2012-07-19
3. Apply lubricant, MOLYCOTE or equivalent to the torque converter spigot.
4. Fit the screw (lower) securing the harness link lead heatshield. Tighten to the specified torque figure.
2012-07-19
www.JagDocs.com
5. Fit the dipstick lower tube. Remove the blanking plug and fit a new O-ring seal. Tighten the bolt to the specified torque figure.
6. Fit the mounting bracket for the front muffler. Tighten the two bolts to the specified torque figure.
2012-07-19
7. Secure the transmission to the engine. Loosely assemble - Cooler pipe clip bolt. Loosely assemble - Ground lead bolt. Loosely assemble - Starter cable clips, two bolts. Loosely assemble - Catalyst bracket bolts, two each side. Loosely assemble - Remaining eight bolts. Refer to the illustration - tighten in sequence 1,2,3,4 then in any order.
8. Secure the torque converter to the engine. 1. Fit, but do not tighten, the three bolts which secure the torque converter to the drive plate. Prevent crankshaft rotation and tighten ALL converter bolts to the specified torque figure. 2. Fit the blanking plug to the cylinder block access aperture.
2012-07-19
www.JagDocs.com
9. Secure the oil cooler pipes. Fit new Dowty washers to each union. Connect the upper and lower cooler pipes. Tighten to the specified torque figure.
10. Refit the harness connector support bracket and tighten the two bolts to the specified torque figure, noting that one fixing also retains the dipstick upper tube.
2012-07-19
11. Connect the selector cable. Tighten the bolts and one nut to the specified torque figure.
12. Connect the driveshaft (prop-shaft) aligning the marks made when it was removed. Tighten the bolts to the specified torque figure.
2012-07-19
13. Fit the rear crossmember. Tighten the bolts to the specified torque figure.
www.JagDocs.com
14. Refit the coolant header tank. Tighten to the specified torque figure.
2012-07-19
15. Fit the harness and clip (transmission link harness) to the rear of the cylinder head. Tighten to the specified torque figure. 16. Refer to Operation <<44.24.02>> for fluid fill procedure.
2012-07-19
Extension Housing Seal 44.20.18

www.JagDocs.com
Driveshaft wrench 205-053 Removal 1. Disconnect the battery ground lead. 2. Select N and choc the road wheels. 3. Remove the front muffler, refer to Operation <<30.10.18>>.
2012-07-19
4. Remove the engine rear mounting bracket. 1. Support the transmission. 2. Remove the bolt, engine rear mounting to transmission. 3. Remove the four bolts which secure the mounting cross member to the body.
5. Detach the driveshaft from the transmission drive flange. 1. If the transmission is to be refitted, mark the position of the coupling relative to the drive flange. CAUTION: Under no circumstances remove the driveshaft to flexible coupling fixings. 2. Remove the three bolts, transmission drive flange to flexible coupling.
2012-07-19
6. Secure the driveshaft wrench 205 - 053 to the output shaft flange.
www.JagDocs.com
7. Remove the output shaft flange. 1. Using a suitable tool, relieve the 'staked' portion from the output shaft keyway. 2. Remove and discard the flange nut using a suitable socket and resisting rotation with special tool 205 - 053. Check the flange seal diameter for damage and renew if necessary.
2012-07-19
8. Remove and discard the oil seal. Use a proprietary seal removing tool, taking care NOT to damage either the shaft or the housing.
Installation 1. Installation is the reverse of the removal procedure noting the following:
2. Fit the oil seal. 1. Lubricate the housing seal bore. 2. Lubricate the outside diameter of the seal. 3. Using seal replacer 307-378 drive the seal squarely into position.
2012-07-19
www.JagDocs.com
3. Refit the drive flange. 1. Use a new nut. Tighten the flange nut to the specified torque figure. 2. Stake the nut to the output shaft.
4. Refit the bolts securing the driveshaft and tighten to the specified torque figure.
2012-07-19
5. Refit the the rear mounting crossmember and tighten the securing bolts to the specified torque figures. 6. Refer to Operation <<44.24.02>> for fluid fill procedure. 7. Check for leaks and remove spilt fluid.
2012-07-19
Main Control Valve Body 44.40.01

RemovalNOTE: This procedure will not remove residual fluid from the torque converter. 1. Disconnect the battery ground lead. 2. Raise the vehicle for access. 3. Remove the RH catalytic converter; refer to Operation 17.50.10.
www.JagDocs.com
4. Remove the harness heatshield lower fixing. Remove the screw heatshield / fluid pan clamp.
2012-07-19
5. Remove the harness heatshield. Pull the heatshield from under the clip.
6. Disconnect the transmission link harness connector. 1. Release the locking lever.
7. Release the (transmission case mounted) female connector. Remove the (center) retaining bolt.
2012-07-19
8. Drain the transmission fluid. WARNING: TRANSMISSION FLUID MAY CAUSE SEVERE BURNS, ENSURE THAT ALL SAFETY PROCEDURES ARE OBSERVED AND THAT THE RECEPTACLE FOR WASTE HAS SUFFICIENT CAPACITY. Carefully remove the drain plug and discard the sealing washer. 9. Remove the fluid pan; refer to Operation <<44.24.05>>,
www.JagDocs.com
10. Remove the fluid filter. Pull the filter squarely to disengage the pick-up 'O' ring and location tang - there is NO mechanical retention.
2012-07-19
11. Remove the selector detent leaf spring. Remove the screw.
12. Remove the dowel - leaf spring to valve body.
2012-07-19
www.JagDocs.com
13. Remove the valve body assembly. Remove the nine bolts which retain the valve body to the transmission case.
Installation 1. Installation is the reverse of the removal procedure, noting the following: 2. Clean all mating faces and relevant parts.
3. Tighten the nine bolts securing the valve body, to the specified torque figure.
2012-07-19
4. Refit the dowel (leaf spring to valve body) and the leaf spring. Fit and tighten the securing bolt to the specified torque figure.
5. Tighten the centre retaining bolt of the electrical connector to the specified torque figure. 6. Refer to Operation <<44.24.02>> for fluid fill procedure. 7. Check for leaks and remove spilt fluid.
2012-07-19
Transmission Fluid Filter 44.24.07

Removal 1. Disconnect the battery ground lead. 2. Raise the vehicle for access. 3. Remove the fluid pan, refer to Operation <<44.24.04>>.
www.JagDocs.com
4. Remove the fluid filter. Pull the filter squarely to disengage the pick-up 'O' ring and location tang - there is NO mechanical retention.
Installation 1. Installation is the reverse of the removal procedure noting that: 2. Renew the 'O' ring. 3. Refer to Operation <<44.24.02>> for fluid fill procedure. 4. Check for leaks and remove spilt fluid.
2012-07-19
Transmission Fluid Pan Gasket 44.24.05

RemovalNOTE: This procedure will not remove residual fluid from the torque converter. 1. Disconnect the battery ground lead. 2. Raise the vehicle for access.
3. Drain the transmission fluid. WARNING: TRANSMISSION FLUID MAY CAUSE SEVERE BURNS, ENSURE THAT ALL SAFETY PROCEDURES ARE OBSERVED AND THAT THE RECEPTACLE FOR WASTE HAS SUFFICIENT CAPACITY. Carefully remove the drain plug and discard the sealing washer.
2012-07-19
www.JagDocs.com
4. Remove the fluid pan. NOTE: The harness heatshield upper edge is retained by a clip. Remove the six bolts and clamps which secure the fluid pan to the transmission.
Installation
1. Installation is the reverse of the removal procedure. Tighten the fluid pan retaining bolts to the specified torque figure.
2012-07-19
2. Refit and tighten the drain plug to the specified torque figure. Use a new sealing washer. 3. Refer to Operation <<44.24.02>> for fluid fill procedure. 4. Check for leaks and remove spilt fluid.
2012-07-19
Transmission Internal Wiring Harness Electrical Connector O-Ring Seals 44.24.20

Removal 1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors remain open until after the battery has been disconnected. 2. Disconnect the battery ground cable. 3. Open the engine compartment and fit paint protection sheets. 4. Raise the vehicle for access.
www.JagDocs.com
5.
WARNING: TRANSMISSION FLUID MAY CAUSE SEVERE BURNS, ENSURE THAT ALL SAFETY PROCEDURES ARE OBSERVED AND THAT THE RECEPTACLE FOR WASTE HAS SUFFICIENT CAPACITY.
Drain the transmission fluid. Carefully remove the drain plug and discard the sealing washer.
2012-07-19
6. Remove the harness heatshield lower fixing. Remove the screw heatshield / fluid pan clamp.
7. Remove the harness heatshield. Pull the heatshield from under the clip.
2012-07-19
www.JagDocs.com
8. Disconnect the transmission link harness connector. 1. Release the locking lever on the guide bush and disconnect the harness connector.
9. Release the connector guide bush from the transmission case. Release the (center) retaining bolt; remains captive in the guide bush.
2012-07-19
10. Remove the guide bush from the transmission casing. Very carefully, pry the guide bush from the transmission casing using a screwdriver against the cast lug on the casing.
11. Remove and discard the sealing rings. Note the position and size of each ring.
Installation 1. Installation is the reverse of the removal procedure, noting the following: 2. Clean all mating faces and relevant parts. 3. Lubricate the new sealing rings using clean transmission fluid.
2012-07-19
4. Tighten the centre retaining bolt of the electrical connector guide bush to 2.25 to 2.75 Nm. 5. Perform the Battery Reconnection Procedure described in Operation <<86.15.15>>. 6. Refer to Operation <<44.24.02>> for fluid fill procedure. 7. Check for leaks and remove spilt fluid.
www.JagDocs.com
2012-07-19
Input Shaft Seal 44.32.07

1. Disconnect the battery ground lead. 2. Remove the air intake / MAFM assembly, refer to Operation 19.10.30. 3. Raise the vehicle for access. 4. Remove the front muffler, <<30.10.18>> 5. Remove the RH and LH catalytic converters, refer to Operation 17.50.09 and 17.50.10. 6. Drain the transmission fluid, refer to Operation <<44.24.02>>. 7. Remove the transmission unit, refer to Operation <<44.20.01>>. 8. Remove the torque converter from the transmission unit, refer to Operation <<44.17.07>>.
2012-07-19
www.JagDocs.com
9. Remove the front oil seal. Using a proprietary tool remove the seal, taking care not to damage the shaft or bore diameters. 10. Installation is the reverse of the removal procedure noting that:
11. Fit the oil seal. 1. Lubricate the housing seal bore. 2. Lubricate the outside diameter of the seal. 3. Using seal replacer 307 - 378, drive the seal squarely into place.
2012-07-19
Torque Converter 44.17.07

Torque converter lifting handles 307-139
CAUTION: If the transmission is to be renewed, renew the torque converter also.
1. Remove the transmission unit from the vehicle; refer to Operation <<44.20.01>>.
2. Remove the torque converter from the transmission unit. Fit lifting handles 307 - 139 ( JD-105). 3. Remove lifting handles 307 - 139 (JD-105) from the torque converter. 4. Clean the torque converter and mating faces.
2012-07-19
www.JagDocs.com
5.
CAUTION: Use extreme care NOT to damage the oil seal with the converter spigot.
CAUTION: Ensure that the converter is fully located. Fit the torque converter. 1. Fit lifting handles 307 - 139 (JD-105). 2. Lubricate the front pump seal. To facilitate location, rotate the converter as it is being fitted and feel for the engagement of the splines and of the oil pump drive. 6. Check that the converter fixing boss faces are approximately 8,0 mm proud of the transmission mounting face. 7. Remove the lifting handles from the torque converter. 8. Install the transmission unit; refer to Operation <<44.20.01>>.
2012-07-19
1999 XK RANGE - Transmission/Transaxle Cooling - Vehicles Without: Supercharger - 307
Transmission Cooling
The transmission fluid cooling system maintains fluid temperature within specified limits.
Parts List Item 1 2 Description Fluid pipe, oil FROM cooler Fluid pipe, oil TO cooler
Component Descriptions
The transmission fluid pipes: Transfer fluid from the transmission to the cooler under the action of the hydraulic system pump. Return the cooled fluid from the cooler to the transmission. The transmission fluid cooler: Is a plate type made from aluminium. Is mounted in the engine cooling radiator right-hand end tank.
Overheating Protection
If the engine coolant or transmission fluid temperatures exceed their predefined limits, the transmission control module locks the torque converter clutch. By reducing slip, this minimises the amount of heat transferred to the engine cooling system from the transmission fluid.
2012-07-20
1999 XK RANGE - Transmission/Transaxle Cooling - Vehicles With: Supercharger - 307-02
Transmission Cooling
The transmission fluid cooling system maintains the fluid temperature within specified limits. The cooling element is located in the engine cooling radiator LH end tank. Fluid is circulated, under pressure, by the transmission pump to the cooler.
General Layout
www.JagDocs.com
Overheating Protection
If the engine coolant or transmission fluid temperatures exceed their predefined limits, the transmission control module locks the torque converter clutch. By reducing slip, this minimises the amount of heat transferred to the engine cooling system from the transmission fluid.
2012-07-20
1999 XK RANGE - Automatic Transmission/Transaxle External Controls - Vehicles Without: Supercharger

Brake Shift Interlock Actuator Adjustment
2. Disconnect battery ground cable. Remove the battery cover. 3. Remove the J-gate surround, Section <<501-05>>. 4. Remove the console finisher veneer panel, Section <<501-12>>.
5. Remove the interlock solenoid actuating lever cover.
2012-07-20
6. Move the shift lever to N. Operate the gearshift interlock latch manually to release the selector lever from P .
www.JagDocs.com
7. NOTE: Assistance from another person is required. Adjust the gearshift interlock solenoid. 1. Slacken the solenoid fixings. 2. Hold the selector lever midway between P and R . 3. Move the solenoid rearwards, against spring pressure, to take up the free play. 4. Tighten the solenoid securing nuts. 5. Ensure that the interlock actuating lever has no free play with the selector lever midway between P and R . 8. Further installation is the reverse of the removal procedure. 9. Perform the Battery Reconnection Procedure described in Operation <<86.15.15>>.
2012-07-20

Brake Shift Interlock Actuator Manual Override
1. To override the gearshift interlock: 1. Unscrew the release catch blanking plug. 2. Insert the ignition key into the aperture, depress the release catch and simultaneously move the gear selector lever from the Park position. The lever will only move approximately 25 mm with the key inserted. 3. Remove the ignition key and replace the blanking plug.
2012-07-20

Kickdown Switch Adjustment
1. Ensure that the throttle cable is correctly adjusted, see <<19.20.06>>. 2. See the PDU User Guide for relevant software - 1040. 3. With PDU connected, running and the message 'EXISTING COMPONENTS TO BE TESTED YES / NO' displayed; 1. Select YES. 2. Select ENTER. 3. Follow the messages given on the screen. 4. Press ENTER on the PDU screen.
www.JagDocs.com
5. Following the PDU instruction; 1. Push the throttle pedal until light contact is made with the kickdown switch and hold. 2. Press ENTER on the display. 3. Note the percentage throttle open data (displayed as a bar graph). NOTE: Ensure that contact with the switch does not result in switch movement. 4. Release the throttle pedal. 6. If the target 90 % throttle open specification is NOT achieved the switch must be adjusted as follows:
2012-07-20
7. Disconnect the kickdown switch multiplug. Move the carpet for access.
8. Adjust the kickdown switch to the value as defined in step #6. Rotate the switch in the required direction. 9. Verify the setting. 10. With the PDU instructions completed, connect the Kickdown switch multiplug.
2012-07-20

Selector Lever Cable Adjustment
www.JagDocs.com
2. Disconnect battery ground cable. Remove the battery cover. 3. Position the shift to N. 4. Remove the J-gate surround, Section <<501-05>>. 5. Remove the console finisher veneer panel, Section <<501-12>>. 6. Remove the center console assembly, Section <<501-12>>.
2012-07-20
7. Slacken the selector cable locking nuts away from the abutment. 8. Raise the vehicle for access.
9. Verify the transmission selector position ( N ) 1. At the transmission, detach the inner cable from the selector lever. 2. With the lever moved fully rearward, push the lever forward two detents to achieve N. 3. Reconnect the inner cable. 10. From inside the vehicle.
2012-07-20
www.JagDocs.com
11. NOTE: When setting the selector cable, ensure that the transmission selector does not move from the N position. Adjust the selector cable. 1. Position the shift in the N detent 2. Adjust the nuts to lock against the bracket without moving the set position of either the shift lever or the selector lever. 3. Tighten the locknuts to the specified torque figure 4. Verify the N setting. 12. Further installation is the reverse of the removal procedure. 13. Perform the Battery Reconnection Procedure described in Operation <<86.15.15>>.
2012-07-20

External Controls
Introduction
Driver gearshift control is effected by: The gear shift lever. The accelerator pedal position. The kickdown switch (where fitted). The performance mode pushbutton.
Driver's Selector Module ('J' Gate)
Parts List Item 1 2 3 4 5 6 7 Description Gear selector lever Drive-to-fourth switch connector Neutral position switch connector Park position switch connector Gear selector illumination module Gear selector interlock solenoid Security system Active LED
2012-07-20
The gear selector lever: Has seven positions: Park, Reverse, Neutral, Drive, Fourth, Third and Second. Operates the transmission selector shaft and rotary switch, in all positions (except Drive-to-fourth) by means of a Bowden cable. Passes driver gearshift requests to the transmission control module via the rotary switch. The Drive-to-fourth switch: Detects when the gear selector lever is moved from Drive to Fourth. Is hard-wired to the transmission control module. The Neutral position switch: Is hard-wired to the body processor module. Detects when the gear selector lever is moved to the Neutral position. The Park position switch: Is hard-wired to the body processor module. Detects when the gear selector lever is moved to the Park position. The gear selector module: Provides illumination of the gear selector surround, which is dimmable via a CAN signal from the instrument cluster. Provides red illumination, on the gear selector surround, of the gear selected, by CAN signals from the instrument cluster. Illuminates the security system Active LED on the gear selector surround, in response to an input from the body processor module. Is connected to the fascia harness via a 12-way connector. Refer to Connector Pins Identification, 307-00A. The gear selector interlock solenoid: Prevents the gear selector lever from being moved from the Park position, unless the ignition switch is in position II, and the brake pedal is depressed. Is controlled by an input from the body processor module. The seven gear selector positions are: P : The transmission is mechanically locked (starting available). R : Reverse gear. N : No power to the rear wheels (starting available). D : All 5 forward gears available. 4 : Upshift to 4th gear only. 3 : Upshift to 3rd gear only. 2 : Upshift to 2nd gear only.
www.JagDocs.com
2012-07-20
The performance mode pushbutton: Is mounted on the gear selector surround. Selects Normal or Sport mode when pressed by the driver. Is illuminated when Sport mode is selected. Is hard-wired to the transmission control module.
Kickdown Switch (where fitted)
The kickdown switch: Is floor mounted under the accelerator pedal. Is operated by pressing the pedal to the full throttle position.
2012-07-20

Provides maximum acceleration on driver demand, by signalling the transmission control module to select the lowest gear to give maximum wheel torque.
Transmission Unit Gear Selector
www.JagDocs.com
The gear selector at the transmission unit: Is connected to the driver's selector module by a Bowden cable. Operates the manual selector valve, which is part of the electro-hydraulic control unit. Operates the rotary switch, which is connected to the transmission control module.
2012-07-20

Transmission Switches Location, Rotary Switch
2012-07-20

Location, Drive to 4th Switch
www.JagDocs.com
Operation
NOTE: The rotary position switch is NOT adjustable. The position of the gear selector lever is detected by the range sensor; a system which consists of two sensors (switch systems). 1. The rotary position switch, which is located on the RH side of the transmission case and is coaxial with the selector shaft. 2. The D to 4 (micro) switch, which is mounted in the 'J gate' assembly. When the selector is moved across the gate to engage 4, or back from that side towards D the selector cable does not move. In order that this change of state be registered by the TCM the D to 4 switch is incorporated. The rotary switch in isolation provides a 4-bit code, which, when added to the D to 4 switch becomes a 5-bit code. The TCM will make a failure judgement if it detects an 'illegal' code.
2012-07-20

Circuit Diagram, Rotary and Drive to 4th Switches / TCM
Item 1 2 3 4 5
Description Drive to 4th switch Switch L1 Switch L2 Switch L3 Switch L4
2012-07-20

External Controls
Digital multimeter
www.JagDocs.com
Generic scantool
Symptom Chart
Condition(s): DTC P0706 Transmission range sensor circuit range / performance Possible Source(s): Selector cable maladjusted Rotary switch fault D to 4 switch fault Rotary position switch fault Harness fault Connector pins(s) bent, loose or corroded Action(s) to take: GO to <<Pinpoint Test A>>
Pinpoint test A: P0706
2012-07-20
A : P0706 A1 : RETRIEVE DTCS

NOTE: Battery and or ECM disconnection prior to scanning will erase all data, ensure that the correct DTC is present 1.
2. Connect the scan tool Have the DTC(s) and freeze frame data been recorded? -> Yes GO to A2
A2 : STATUS / RELATIONSHIP CHECK

1.
2012-07-20
2. Move the selector lever slowly from P to 2 and back, noting the illumination / position relationship as follows: Does state illumination match the lever position in each direction of travel? -> Yes GO to A4 -> No GO to A3 With lever at D (when moving from 2 to P ) is 3 or 4 illuminated? -> Yes GO to A3 -> No GO to A5 With lever moved from P , to position 4, is D illuminated? -> Yes GO to A4 -> No GO to A5
www.JagDocs.com
A3 : CHECK SELECTOR CABLE ADJUSTMENT

1. Verify and correct as required the selector cable adjustment OK? -> Yes GO to A4 -> No Correct adjustment error, see Workshop Manual 307.05 and test the system for normal operation
A4 : CHECK HARNESS SIGNAL CONTINUITY - D TO 4 SWITCH

1.
2012-07-20
2. With EM007 and FC083 disconnected, measure the resistance between FC083/003 and EM007/028 3. Repeat for FC083/001 and EM007/013 Is the resistance < 0.5 OHM? -> Yes GO to A5 -> No Inspect EM007 and FC083 EM001 for corrosion, bent / pushed back pins or locate and repair the harness / splice EMS25 and FCS62. - test the system for normal operation
A5 : CHECK D TO 4 SWITCH
NOTE: Engage position 2 firmly
4 2012-07-20

1.
www.JagDocs.com
2. With FC083 disconnected, measure the resistance between switch pins 001 and 003 With the selector lever at 4, 3, 2 is the resistance < 0.5 OHM? With the selector lever at P, R, N, D is the resistance < >50 KOHM? -> Yes GO to A6 -> No Renew D to 4 switch and test the system for normal operation
A6 : CHECK HARNESS DIGITAL GROUND CONTINUITY

1.
2012-07-20
2. With EM007, EM047, Fc083 and AC027 (kickdown switch) disconnected, measure the resistance between EM007/028 to EM047/00E Is the resistance < 0.5 OHM? -> Yes GO to A7 -> No Inspect EM007, EM047, Fc083 and AC027 for corrosion, bent / pushed back pins or locate and repair the harness / splice EMS25 - test the system for normal operation
A7 : CHECK SWITCH L1
1.
2012-07-20
www.JagDocs.com
2. With EM007 disconnected, measure the resistance between EM007/028 and EM007/036 With the selector lever at P, N, D, 4 is the resistance < 0.5 OHM? With the selector lever at R, 3, 2 is the resistance >50 KOHM? -> Yes GO to A8 -> No Inspect EM007 and EM047 for corrosion, bent / pushed back pins or locate and repair the harness EM007/036 to EM047/00A OK, but fault still present? -> Yes Renew rotary position switch and test the system for normal operation
2012-07-20
1.
2. With EM007 disconnected, measure the resistance between EM007/028 and EM007/008 With the selector lever at R, N, 3 is the resistance < 0.5 OHM? With the selector lever at P, D, 4, 2 is the resistance >50 KOHM? -> Yes GO to A9 -> No Inspect EM007 and EM047 for corrosion, bent / pushed back pins or locate and repair the harness EM007/008 to EM047/00B - test the system for normal operation
2012-07-20

OK, but fault still present? -> Yes Renew rotary position switch and test the system for normal operation
1.
www.JagDocs.com
2. With EM007 disconnected, measure the resistance between EM007/028 and EM007/037 With the selector lever at N, D, 4, 3 is the resistance < 0.5 OHM? With the selector lever at P, R, 2 is the resistance >50 KOHM? -> Yes GO to A10
2012-07-20

-> No Inspect EM007 and EM047 for corrosion, bent / pushed back pins or locate and repair the harness EM007/037 to EM047/00C - test the system for normal operation OK, but fault still present? -> Yes Renew rotary position switch and test the system for normal operation

1.
2. With EM007 disconnected, measure the resistance between EM007/028 and EM007/009 With the selector lever at D, 4, 3, 2 is the resistance < 0.5 OHM?
10
2012-07-20

With the selector lever at P, R, N is the resistance >50 KOHM? -> Yes GO to A11 -> No Inspect EM007 and EM047 for corrosion, bent / pushed back pins or locate and repair the harness EM007/009 to EM047/00D - test the system for normal operation OK, but fault still present? -> Yes Renew rotary position switch and test the system for normal operation
A11 : END
1. Perform appropriate service drive cycle and check for the presence of DTC Has the fault code cleared? -> Yes STOP -> No Contact Jaguar Service
www.JagDocs.com
11
2012-07-20
Brake Shift Interlock Actuator 44.15.48

2. Disconnect battery ground cable. Remove the battery cover. 3. Remove the J-gate surround, Section <<501-05>>. 4. Remove the console finisher veneer panel, Section <<501-12>>.
5. Remove the interlock solenoid lever cover.
2012-07-20
www.JagDocs.com
6. Remove the gearshift interlock solenoid. 1. Remove the solenoid nuts. 2. Detach the solenoid from the latch pin. 3. Disconnect the solenoid multiplug.
2. Fit the gearshift interlock solenoid. 1. Connect the solenoid multiplug. 2. Locate the solenoid on the latch pin. 3. Fit the solenoid securing nuts. 3. Perform the Battery Reconnection Procedure described in Operation <<86.15.15>>.
2012-07-20
Kickdown Switch 44.15.23

Removal
2. Remove the kickdown switch. Rotate counter-clockwise.
Installation 1. Installation is the reverse of the removal procedure. 2. The kickdown switch MUST be adjusted in accordance with (<<44.15.38>>).
2012-07-20
Selector Lever Cable and Bracket 44.15.08

Removal 1. Position the selector to N. 2. Remove the J-gate surround, Section <<501-05>>. 3. Remove the console finisher veneer panel, Section <<501-12>>. 4. Remove the center console assembly, Section <<501-12>>. 5. Raise the vehicle for access.
www.JagDocs.com
6. Detach the selector cable from the transmission unit. 1. Remove the cable inner to selector lever nut. 2. Remove the cable to transmission casing fixings.
2012-07-20
7. Reposition the selector cable. 8. Remove the LH front seat, Section <<501-10>>. 9. Reposition the LH floor carpet for access.
10. Remove the selector cable to tunnel clip tie strap.
2012-07-20
www.JagDocs.com
11. Detach the selector cable from the gear shift assembly. 1. Remove the inner cable to shift lever nut. 2. Slacken the outer cable locknuts.
12. Push the outer cable grommet through the transmission tunnel aperture.
2012-07-20
13. Remove the selector cable assembly from the vehicle.
Installation
1. Assemble the cable to the gear shift assembly. 1. Locate the outer cable. 2. Fit and tighten the cable securing nut to the specified torque figure.
2012-07-20
www.JagDocs.com
2. Connect the selector cable to the transmission. 1. Fit the bolts which secure the cable to the transmission casing and tighten to the specified torque figure. 2. Fit and tighten the inner cable securing nut to the specified torque figure.
3. Secure the outer cable. 4. Adjust the selector cable in accordance with <<44.15.07>>. 5. Further installation is the reverse of the removal procedure.
2012-07-20
Selector Lever Gate Finish Panel 76.25.24

Removal 1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
2. Apply protective tape to veneer panel along each side of surround.
3. Using a thin plastic lever and exercising care to avoid damaging veneer surface, release the four surround tangs from the 'J' gate.
2012-07-20
www.JagDocs.com
4. Disconnect multiplugs from Sport mode and Cruise Control on/off switches.
5. Noting orientation of switches, depress tangs and remove switches from surround.
Installation 1. Ensuring correct orientation, fit and fully seat Sport mode and Cruise Control on/off switches in surround. 2. Position surround for access and connect switch harness multiplugs. 3. Position surround over 'J' gate and press firmly to fully seat tangs. 4. Remove protective tape from veneer panel.
2012-07-20
Selector Lever Indicator Assembly 44.15.14

2. Disconnect battery ground cable. Remove the battery cover. 3. Remove the selector lever knob, <<44.15.06>>. 4. Remove the J-gate surround, Section <<501-05>>. 5. Remove the console finisher veneer panel, Section <<501-12>>.
2012-07-20
6. Remove the selector indicator module screws.
www.JagDocs.com
7. Remove the selector indicator module. 1. Free the D to 4 switch harness multiplug from the mounting bracket and disconnect the multiplug. 2. Displace the P switch multiplug from the mounting bracket. 3. Route the D to 4 harness from under the P switch harness.
Installation 1. Installation is the reverse of the removal procedure 2. Perform the Battery Reconnection Procedure described in Operation <<86.15.15>>.
2012-07-20
Selector Lever Indicator Disc 44.15.15

2. Disconnect battery ground cable. Remove the battery cover. 3. Remove the selector indicator module; <<44.15.14>>.
4. Remove the selector indicator module disc. Remove the disc retaining screw.
2012-07-20
Installation 1. Installation is the reverse of the removal procedure. 2. Perform the Battery Reconnection Procedure described in Operation <<86.15.15>>.
www.JagDocs.com
2012-07-20
Selector Lever Switch 44.15.52

2. Disconnect battery ground cable. Remove the battery cover. 3. Remove the gear shift knob, (<<44.15.06>>). 4. Remove the console finisher veneer panel, (<<76.47.26>>). 5. Remove the 'J Gate' surround for access, (<<76.25.24>>).
2012-07-20
www.JagDocs.com
6. Remove the D to 4 switch. Press the retaining tangs to release.
Installation 1. Fitting a new D to 4 switch is the reverse of the removal procedure. 2. Perform the Battery Reconnection Procedure described in Operation <<86.15.15>>.
2012-07-20
Transmission Selector Lever Knob 44.15.06

Removal
1. Remove the selector lever knob. 1. Slacken the ferrule, rotate clock-wise. 2. Rotate the knob counter-clockwise to remove.
Installation
1. Refer to the illustration 1. Fit the knob. 2. Tighten the ferrule to the specified torque figure.
2012-07-20
Selector Lever 44.15.05

www.JagDocs.com
2. Disconnect battery ground cable. Remove the battery cover. 3. Remove the shift lever knob, <<44.15.06>>. 4. Remove the J-gate surround, Section <<501-05>>. 5. Remove the console finisher veneer panel, Section <<501-12>>. 6. Remove the center console assembly, Section <<501-12>>. 7. Remove the indicator module, <<44.15.14>>.
2012-07-20
8. Detach the selector cable from the gear shift assembly. 1. Remove the inner cable to selector lever nut. 2. Slacken one outer cable locknut, keeping one positioned for reference on reassembly.
9. Remove the gear shift assembly. Remove the four fixings.
2012-07-20
www.JagDocs.com
10. Remove the slide plate. Remove the four screws.
11. Remove the slide block/shaft assembly.
2012-07-20
12. Remove the gearshift interlock solenoid actuating lever. 1. Remove the actuating lever cover. 2. Remove the actuating lever securing nut.
13. Remove the shift lever assembly from the housing. Remove the washer from the pivot shaft.
2012-07-20
www.JagDocs.com
14. Disassemble the shift mechanism. 1. Remove the return spring. 2. Remove the pivot shaft nut, washer and pivot shaft. 3. Remove the pivot bracket, detent plate and washer. 4. Remove the ball and spring. 15. Clean all components.
16. Reassemble the shift mechanism. 1. Apply grease and install the detent ball and spring. 2. Apply grease to the pivot bracket and install the bracket, detent plate and washer. 3. Install the pivot shaft, washer and nut. 4. Apply grease and locate the return spring.
2012-07-20
17. Fit the shift lever assembly to the housing. Apply grease to the lever pivot and install the pivot washer.
18. Install the gearshift interlock solenoid actuating lever. 1. Secure the actuating lever nut. 2. Fit the actuating lever cover.
2012-07-20
www.JagDocs.com
19. Install the slide block / shaft assembly. Clean the slide block and shaft. Apply grease to the shaft.
20. Install the slide plate. Install the four slide plate screws.
2012-07-20
21. Fit the gear shift assembly. Install the four nuts.
22. Assemble the cable to the gear shift assembly. 1. Locate the outer cable. 2. Fit and tighten the cable securing nut to the specified torque figure. 23. Adjust, or verify, the cable in accordance with <<44.15.07>>. 24. Further installation is the reverse of the removal procedure. 25. Perform the Battery Reconnection Procedure described in Operation <<86.15.15>>.
2012-07-20
1999 XK RANGE - Automatic Transmission/Transaxle External Controls - Vehicles With: Supercharger

Brake Shift Interlock Actuator Manual Override
www.JagDocs.com
1. To override the gearshift interlock: 1. Unscrew the release catch blanking plug. 2. Insert the ignition key into the aperture, depress the release catch and simultaneously move the gear selector lever from the Park position. The lever will only move approximately 25 mm with the key inserted. 3. Remove the ignition key and replace the blanking plug.
2012-07-20

Kickdown Switch Adjustment
1. Ensure that the throttle cable is correctly adjusted; refer to Operation <<19.20.06>>. 2. Refer to the PDU User Guide for relevant software - 1040. 3. With PDU connected, running and the message 'EXISTING COMPONENTS TO BE TESTED YES / NO' displayed: Select YES. Select ENTER. Follow the messages given on the screen. 4. Press ENTER on the PDU screen.
5. Following the PDU instructions: Push the throttle pedal until light contact is made with the kickdown switch and hold in this position. Press ENTER on the display. Note the percentage throttle open data (displayed as a bar graph). NOTE: Ensure that contact with the switch does not result in movement of the switch. Release the throttle pedal. 6. If the target 90% throttle open specification is NOT achieved the switch must be adjusted as follows.
2012-07-20
www.JagDocs.com
8. Adjust the kickdown switch to the value as defined in step 6. Rotate the switch in the required direction. 9. Verify the setting. 10. With the PDU instructions completed, connect the kickdown switch multiplug.
2012-07-20

Selector Lever Cable Adjustment
1. Disconnect the vehicle battery ground lead. 2. Position the gear selector lever to N. 3. Remove the J-gate surround, Section <<501-05>>. 4. Remove the console finisher veneer panel, Section <<501-12>>. 5. Remove the center console assembly, Section <<501-12>>.
6. Slacken the selector cable locking nuts and screw them away from the abutment. 7. Raise the vehicle for access.
2012-07-20
www.JagDocs.com
8. Verify that the transmission selector lever is at position ( N ). At the transmission, detach the inner cable from the selector lever. With the lever moved fully rearward, push the lever forward two detents to achieve N. 1. Reconnect the inner cable.
9. NOTE: When setting the selector cable, ensure that the transmission selector does not move from the (N) position. Adjust the selector cable from inside the vehicle. 1. Position the gear selector lever to the N detent. 2. Adjust the nuts to lock against the bracket without moving the set position of either the gear selector lever or the selector lever on the transmission case. 3. Tighten to specification. 4. Verify the ( N ) setting. 10. Further installation is the reverse of the removal procedure.
2012-07-20

External Controls
Introduction
Operator gearshift control is effected by: The selector lever Accelerator pedal position Kickdown The mode switch
2012-07-20

Operator's Selector Module ('J' Gate)
www.JagDocs.com
2012-07-20

Parts List Item 1 2 3 4 5 6 7 8 9 Description Gear selector lever Access blank - Gear-shift interlock solenoid Dual Linear Switch (DLS) Connector - DLS Connector - Park position switch Connector - Illumination module Connector - Climate control Solenoid - Gear selector Security system Active LED
Selector lever:
Gear selector positions are: P Transmission mechanically locked, starting available * R Reverse gear N No power to the rear wheels (starting available) D All 5 forward gears available (see Performance Mode Pushbutton) 4 Upshift to 4th gear only 3 Upshift to 3rd gear only 2 Upshift to 2nd gear only
Gearshift Interlock Manual Override*

The interlock system which locks the selector in P and prevents the ignition key from being removed, may be manually overridden in the event of an emergency. 1. With the parking brake applied 2. Remove the access blank using a suitable Torx bit 3. Insert a small screwdriver into the vacated hole 4. Push the screwdriver downwards, gently, and hold whilst simultaneously moving the selector from P towards R , but do not engage R until the tool has been removed 5. An audible warning may be heard when operation 4 is carried out 6. With the selector in N and the access blank replaced,,the vehicle may be started
Range Selection
The selector lever transmits operator demand to the transmission and TCM by means of a cable and Dual-Linear Switch (DLS). The lever operates the transmission assembly selector shaft, only for P R N D , by means of a cable. Movement of the lever across the gate to 4, 3 and 2 positions disengages the cable from the selector lever and engages the DLS which controls gear selection electronically.
Gear selector module

Provides illumination of the decal relevant to the gear selected. This information is provided by CAN from the TCM, thus obviating the need for a dedicated illumination switch. Illuminates the security system Active LED on the gear selector surround, in response to an output from the BPM.
3 2012-07-20

Transmission Switches
Performance Mode Pushbutton
www.JagDocs.com
The performance mode pushbutton: Is mounted on the 'J' gate surround. This 'push-on push-off' switch selects Normal or Sport mode ( push-on for Sport) Is illuminated when Sport mode is selected. Is hard-wired to the transmission control module. With 'Normal' selected the transmission will start off in 2 nd gear with kickdown to 1 st being available. 'Sport' mode allows 1 st gear engagement from rest and modifies values in the TCM shift point calculations to provide higher upshift speeds and enhanced availability of downshifts.
2012-07-20
Kickdown Switch
The kickdown switch: Is floor mounted under the accelerator pedal. Is operated by pressing the pedal beyond the full throttle position. Provides maximum acceleration on driver demand, by signalling the TCM to select the lowest gear to give maximum wheel torque.
Gear selector interlock solenoid

Prevents the gear selector lever from being moved from P , unless the ignition switch is in position II, and the brake pedal is depressed. Is controlled by an input from the BPM
Park position switch

Is hard-wired to the BPM Detects when the gear selector lever is moved to the Park position
Dual-Linear Switch (DLS)

The TCM detects gear selection by means of a switch fitted to the 'J' gate; the DLS contains two multi-track slider switches, of which the upper controls P R N D and the lower 4 3 2 . Output from the DLS is changed as the selector lever is moved, thus indicating selected gear position. The parallel signal is input to the TCM by 4 discrete logic wires W0, W1, W2 and W3. The particular sequence, or grey code, will indicate which shift position is selected, as shown in the following table where 0 = low and 1 = high:
2012-07-20
Grey code
Selector Position P R N D 4 3 2 W3 0 1 1 0 1 0 0 W2 1 1 1 1 0 0 0 W1 1 1 0 0 0 1 0 W0 1 0 1 0 0 0 1
Transmission Unit Gear Selector
www.JagDocs.com
The gear selector at the transmission unit: Is connected to the operator's selector module by cable Operates the selector valve, at the electro-hydraulic control unit
2012-07-20

External Controls
Quick Reference Fault Chart
Condition(s): Shift stuck in P Possible Source(s): Selector cable seized Action(s) to take: GO to <<44.15.08>> Possible Source(s): Interlock solenoid not operating Action(s) to take: GO to PDU Possible Source(s): Interlock latch seized Transmission faulty Action(s) to take: Mechanical check Possible Source(s): Operator sequence error Action(s) to take: Correct the sequence Vehicle rolls on P Possible Source(s): Incorrect cable adjustment Action(s) to take: GO to <<44.15.07>> Possible Source(s): Faulty parking pawl (transmission internal) Action(s) to take: Mechanical check R does not engage Possible Source(s): Incorrect cable adjustment Action(s) to take: GO to <<44.15.07>> Possible Source(s): Transmission fluid level incorrect Action(s) to take:
1 2012-07-20

N not achieved Possible Source(s): Incorrect cable adjustment Transmission faulty Action(s) to take: GO to <<44.15.07>> D does not engage Possible Source(s): Incorrect cable adjustment Action(s) to take: GO to <<44.15.07>> Possible Source(s): Transmission fluid level incorrect Action(s) to take: GO to <<44.24.02>> Possible Source(s): Transmission faulty Action(s) to take: Mechanical check Lower ratios will not hold Possible Source(s): Excessive engine temperature DLS fault Action(s) to take: GO to PDU Shift lever position not visually correct Possible Source(s): Incorrect cable adjustment Action(s) to take: GO to <<44.15.07>> Shift lever has no effect upon the transmission and resistance cannot be felt Possible Source(s): Cable disconnected or broken Transmission selector problem Shift lever drive pin adrift Action(s) to take: Mechanical check GO to <<44.24.02>>
www.JagDocs.com
2012-07-20
Shift lever position not align correctly following manual selection of lower ratios Possible Source(s): Sliding block drive pin displaced - following road debris contact Action(s) to take: Mechanical check. Renew the selector if damaged, or re-align the drive pin and sliding block Shift lever detent indistinct in 3 causing poor location Possible Source(s): DLS detent fault Action(s) to take: GO to Renew the DLS Shift may be moved from P without brake pedal operation Possible Source(s): Interlock latch fault Action(s) to take: Mechanical check Possible Source(s): Solenoid permanently activated Action(s) to take: GO to PDU Engine may be started in positions other than P or N Possible Source(s): Incorrect cable adjustment DLS fault Action(s) to take: GO to <<44.15.07>> Shift lever vibration Possible Source(s): Loose selector assembly Cable isolation fault Action(s) to take: Mechanical check Noise / rattle from 'J' gate Possible Source(s): Debris in the mechanism Action(s) to take: Clean Possible Source(s):
2012-07-20

Worn 'J' gate track gasket allowing lever and moulding to contact Loose selector disc seal Action(s) to take: GO to <<44.15.05>>
www.JagDocs.com
2012-07-20
Brake Shift Interlock Actuator 44.15.48

Removal 1. Disconnect the vehicle battery ground lead. 2. Remove the J-gate surround, Section <<501-05>>. 3. Remove the console finisher veneer panel, Section <<501-12>>.
4. Remove the interlock solenoid lever cover.
5. Remove the gearshift interlock solenoid. 1. Remove the (2) solenoid nuts. 2. Detach the solenoid from the latch pin.
2012-07-20

3. Disconnect the solenoid multiplug.
www.JagDocs.com
2. Refer to the illustration.
2012-07-20
Kickdown Switch 44.15.23

Removal
2. Remove the kickdown switch. Rotate counter-clockwise.
Installation 1. Installation is the reverse of the removal procedure. 2. The kickdown switch MUST be adjusted in accordance with (<<44.15.38>>).
2012-07-20
Selector Lever Cable and Bracket 44.15.08

Removal 1. Disconnect the vehicle battery ground lead. 2. Position the selector to N. 3. Remove the J-gate surround, Section <<501-05>>. 4. Remove the console finisher veneer panel, Section <<501-12>>. 5. Remove the center console assembly, Section <<501-12>>. 6. Raise the vehicle for access.
www.JagDocs.com
7. Detach the gear selector cable from the transmission unit. 1. Remove the nut which secures the selector cable ball pin to the selector lever. 2. Lower the transmission lift for access. 3. Remove the bolts which secure the selector cable to the transmission casing.
2012-07-20
8. Reposition the selector cable. 9. Remove the LH front seat, Section <<501-10>>. 10. Reposition the LH floor carpet for access.
11. Remove the selector cable to tunnel clip tie strap.
2012-07-20
www.JagDocs.com
12. Detach the selector cable from the gear shift assembly. 1. Remove the inner cable to shift lever nut. 2. Slacken the outer cable locknuts.
13. Push the outer cable grommet through the transmission tunnel aperture.
2012-07-20
14. Remove the selector cable assembly from the vehicle.
Installation
1. Assemble the cable to the gear shift assembly. 1. Locate the outer cable and fit the inner cable to the gear selector arm. Tighten to the specified torque figure. 2. Position the abutment nuts to the approximate position, but do not tighten.
2012-07-20
2. Fit the cable to the transmission and tighten the fixings to the specified torque figure.
www.JagDocs.com
3. Secure the outer cable. 4. Adjust the selector cable in accordance with Operation <<44.15.07>>. 5. Further installation is the reverse of the removal procedure.
2012-07-20
Selector Lever Gate Finish Panel 76.25.24

2. Apply protective tape to veneer panel along each side of surround.
3. Using a thin plastic lever and exercising care to avoid damaging veneer surface, release the four surround tangs from the 'J' gate.
2012-07-20
www.JagDocs.com
4. Disconnect multiplugs from Sport mode and Cruise Control on/off switches.
5. Noting orientation of switches, depress tangs and remove switches from surround.
Installation 1. Ensuring correct orientation, fit and fully seat Sport mode and Cruise Control on/off switches in surround. 2. Position surround for access and connect switch harness multiplugs. 3. Position surround over 'J' gate and press firmly to fully seat tangs. 4. Remove protective tape from veneer panel.
2012-07-20
Selector Lever Indicator Disc 44.15.15

Removal 1. Disconnect the vehicle battery ground lead. 2. Remove the selector indicator module; Operation <<44.15.14>>.
3. Remove the selector indicator module disc. Remove the disc retaining screw.
2012-07-20
Transmission Control Switch 44.15.12

Removal 1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors remain open until after the battery has been disconnected. 2. Position the selector to 'N' to provide clearance for removing the console. 3. Disconnect the vehicle battery ground lead. 4. Remove the J-gate surround, operation <<76.25.24>>. 5. Remove the console finisher veneer panel, operation <<76.47.26>>. 6. Remove the console assembly, operation <<76.25.01>>.
www.JagDocs.com
7. Detach the selector cable from the gear shift assembly. 1. Remove the nut which secures the inner cable to the shift lever. 2. Slacken the outer cable locknuts. Move the cable clear.
2012-07-20
8. Disconnect the electrical connector from the linear switch. 9. Position the selector to 'P' to align the mechanism for installing the new linear switch.
10. Remove the linear switch. Remove the four screws. Remove the linear switch from the mounting bracket.
2012-07-20
Installation
www.JagDocs.com
1. Install the linear switch. Position the linear switch to the mounting bracket. Align the drive peg and lower sliding block of the switch to the mating components of the selector mechanism.
2. Install the four screws, but do not fully tighten. Remove the Ty-Strap from the dual linear switch. Use the manual release and reposition the selector to 'N' for installation of the selector cable.
2012-07-20
3. Connect the electrical connector to the linear switch.
4. Assemble the cable to the gear shift assembly. 1. Locate the outer cable and fit the inner cable to the gear selector arm. Tighten to 22-28 Nm. 2. Position the abutment nuts to the approximate position, but do not tighten.
2012-07-20
www.JagDocs.com
5. NOTE: When setting the selector cable, ensure that the selector lever on the transmission casing is still in the 'N' position. Adjust the selector cable from inside the vehicle. 1. Confirm that the selector lever is in the 'N' position. 2. Adjust the nuts to lock against the bracket without moving the set position of either the gear selector lever or the selector lever on the transmission casing. 3. Tighten to 22-28 Nm. 4. Verify the 'N' setting. 6. Check that all released connectors are safely insulated and connect the vehicle battery. 7. Switch ON the ignition. 8. Adjust the position of the linear switch so that the selector 'N' position graphic illuminates. Tighten the four screws to 0,7-1 Nm. 9. Move the gear selector to 'R' to confirm that the 'R' position graphic illuminates. 10. Check that the engine will start when the gear selector is in the 'N' and 'P' positions, but not in any other position. 11. Move the gear selector to 'N'. 12. Switch OFF the ignition. 13. Disconnect the battery. 14. Install the console assembly, operation <<76.25.01>>. 15. Install the console finisher veneer panel, operation <<76.47.26>>.
5 2012-07-20
16. Install the J-gate surround, operation <<76.25.24>>. 17. Perform the Battery Reconnection Procedure described in Operation <<86.15.15>>.
2012-07-20
Transmission Selector Lever Knob 44.15.06

Removal 1. Disconnect the vehicle battery ground lead.
www.JagDocs.com
2. Remove the selector lever knob. 1. Slacken the ferrule, rotate clockwise. 2. Rotate the knob counter-clockwise to remove.
Installation
1. Refer to the illustration. 1. Fit the knob. 2. Refer to the illustration.
2012-07-20
1999 XK RANGE - Exhaust System - 309-00
Exhaust System Settings Description Intermediate muffler - Rear inside edge of muffler to rear suspension A-frame Tailpipe to bumper aperture - Vertical Tailpipe trim position - Vertical (permissible variation LH to RH) Tailpipe trim position - Horizontal (permissible variation LH to RH) Tailpipe trim surface to inside of bumper aperture mm 116 25 - 35 0-6 0-6 35 - 45
Torques Component Nut - Downpipe to exhaust manifold Bolt - Downpipe to bracket Torca clamp assembly Tie strap fixings Bolt - Grass shield fixings (Japanese market only) Bolt - Over-axle mounting cradle to rear suspension A-frame Bolt - Tailpipe mounting rubber upper support to body Oxygen sensor to downpipe Nm 14 - 18 39 - 51 60 - 80 22 - 28 8,5 - 11,5 22 - 28 17 - 23 40 - 50
2012-07-20
Exhaust System
Exhaust Components
www.JagDocs.com
Item 1 2 3 4 5 6
Description Downpipe catalytic converter assembly Front muffler Intermediate muffler Rear muffler Tie strap Grass shields (Japanese market only)
All vehicles are fitted with a five-muffler, stainless steel exhaust system which features: Low back-pressure gas flow. Catalytic converters for markets having unleaded fuel. Front muffler common to the left- and right-hand engine cylinder banks.
2012-07-20

Downpipe Assembly
Item 1 2 3 4 5
Description Downpipe catalytic converter Upstream heated oxygen sensor Downstream oxygen sensor (North American markets only) Temperature sensor (Japanese market only) Engine mounting bracket (LHS and RHS)
The left- and right-hand downpipe assemblies feature: Catalytic converter with palladium/rhodium coated elements. The elements are uncoated for markets with only leaded fuel. Exhaust manifold fixing by four threaded studs. Joint-to-joint sealing is with a gasket. Engine-mounted bracket providing downpipe mounting by two nuts to torque converter and two bolts to downpipe.
2012-07-20

Front Muffler Assembly
The front muffler assembly features: Twin-pipe absorption type muffler. Pipe-to-pipe pressure damping. Inlet and outlet pipes welded to the muffler. Inlet pipes joined together by a loose metal tie strap secured by two nuts and bolts.
www.JagDocs.com
Intermediate Muffler Assembly
2012-07-20

The left- and right-hand intermediate muffler assemblies comprise: Absorption type muffler. S Inlet and outlet pipes welded to the muffler. Over-axle mounting peg welded to the outlet pipe located into a bush in a D-shaped rubber block, which is bonded to a cradle bolted to the rear suspension crossmember.
Rear Muffler Assembly
The left- and right-hand rear muffler assemblies comprise: Absorption type muffler. Inlet pipe and tailpipe welded to the muffler. Arrow-headed mounting peg welded to the tailpipe, held in a rubber suspension ring from a body attachment point. Finisher integral with the tailpipe.
2012-07-20

Joints and Clamps
www.JagDocs.com
All pipe-to-pipe joints are slip joints and feature: Clamping by Torca strap clamp. Indicator rings providing Maximum, Minimum and Nominal engagement marks.
Catalyst Monitoring Monitoring Procedure

Primary detection is based upon; 1. Downstream O2 sensor high frequency amplitude. 2. The response delay time between upstream and downstream change. A calculation of the average value of the downstream O2 sensor high frequency amplitude is made; this is normal if the value falls below a given threshold. Should a failure judgement occur, the main feedback frequency will be adjusted and the response delay time from the upstream to downstream feedback signal monitored. If the response delay time is greater than the threshold then a normal judgement will be made, less will incur a failure judgement.
2012-07-20

Oxygen Sensor (O2 Location
Parts List Item 1 2 3 Description Heated oxygen sensor (upstream) Oxygen sensor (downstream) Catalytic converter
2012-07-20

Operation
www.JagDocs.com
The upstream heated oxygen sensor is located at the catalytic converter inlet and detects the concentration of oxygen in the raw exhaust gases; an internal heater reduces the warm up time of the sensor output. An oxygen sensor (without heater) is located at the converter outlet. The ECM receives input signals from the sensors and varies the fuel injector duration (mixture) to provide optimum gas emissions.
Monitoring Procedure
The sensor outputs are monitored during steady driving with a fully warm engine. If the downstream sensors indicate lean Air / Fuel Ratio (AFR) and the fuel system has judged that the fueling is rich, then the upstream sensor is judged to have failed high voltage.
2012-07-20
The upstream sensor is judged to have failed low voltage by comparison of its output with that of the downstream sensor. Upstream slow response judgements are made when any of the following switching rates remain above a threshold: low to high switch time from one mid point of the switching cycle to the next mid point. Downstream sensor slow, high and no activity judgements are similar to upstream but the mapped values are different. If no activity is seen the AFR is enriched to force a response, and a failure judgement is made should this be unsuccessful. Downstream high and low voltage judgements are made after the sensor has remained above or below predetermined thresholds for a long period. Heater circuit judgements are made by comparing the expected heater drive state with the actual state. If these states are different for too long then the heater circuits are judged to be faulty. For all the above diagnostics, the relevant DTC is stored if the failure judgement is made on two successive trips.
2012-07-20

Circuit Diagram, O2 Sensors / ECM
www.JagDocs.com
2012-07-20
Item 1
Description To Fuse F14 (10A)
Inspection and Verification Vehicle Harness Check

1. Check for open and short circuit in harness and connector faults between the O2 sensor and ECM. 2. Check for approximately 12V between heater harness
Heater Resistance Check

1. Verify that the resistance between the heater terminals is between 4OHM and 10OHM at -20C to 100C.
Performance Check
1. Run the engine at 2500 RPM for two minutes, to heat up the O2 sensor. 2. Check the voltage of the sensor output: Alternates between less than 0.4V at feed back engine conditions and in excess of 0.5V, see graph.
These voltages are for reference only. 3. Check that cycle of the upstream sensor output is in accordance with the appropriate pinpoint test. 4. Check that cycle of the downstream sensor output is in accordance with the appropriate pinpoint test.
10
2012-07-20
Exhaust System
Digital multimeter
www.JagDocs.com
Generic scantool
Catalyst Monitoring
Condition(s): DTC P0420 Catalyst system efficiency below threshold (Bank 1) Possible Source(s): Catalyst failure Upstream O2 sensor failure Downstream O2 sensor failure O2 sensor heater failure Associated harness / connector failure Action(s) to take: See DTC P0137, P0138 and P0140 DTC P0430 Catalyst system efficiency below threshold (Bank 2) Possible Source(s): Catalyst failure
2012-07-21

Upstream O2 sensor failure Downstream O2 sensor failure O2 sensor heater failure Associated harness / connector failure Action(s) to take: See DTC P0157, P0158 and P0160
Oxygen Sensors (O2) - Bank 1(A)
Condition(s): DTC P0131 O2 sensor circuit low voltage (Bank 1 sensor 1) Possible Source(s): O2 sensor failure Sensor ground fault Harness failure Connector pin(s) bent, loose or corroded Action(s) to take: GO to <<Pinpoint Test A>> DTC P0132 O2 sensor circuit high voltage (Bank 1 sensor 1) Possible Source(s): O2 sensor failure to B+ Sensor ground fault Harness failure Connector pin(s) bent or tracking between connections. O2 sensor failure Action(s) to take: GO to <<Pinpoint Test A>> DTC P0133 O2 sensor circuit slow response (Bank 1 sensor 1) Possible Source(s): O2 sensor heater failure / out of spec Sensor ground fault Harness failure Connector pin(s) bent or tracking between connections. Low exhaust temperature O2 sensor failure Action(s) to take: GO to <<Pinpoint Test B>> DTC P0135 O2 sensor heater circuit malfunction (Bank 1 sensor 1) Possible Source(s): O2 sensor failure
2 2012-07-21

Harness failure Connector pin(s) bent or tracking between connections. ECM failure Action(s) to take: GO to <<Pinpoint Test A>> DTC P0137 O2 sensor circuit low voltage (Bank 1 sensor 2) Possible Source(s): O2 sensor failure Sensor ground fault Harness failure Connector pin(s) bent, loose or corroded Action(s) to take: GO to <<Pinpoint Test C>> DTC P0138 O2 sensor circuit high voltage (Bank 1 sensor 2) Possible Source(s): O2 sensor failure to B+ Sensor ground fault Harness failure Connector pin(s) bent or tracking between connections. ECM failure Action(s) to take: GO to <<Pinpoint Test C>> DTC P0140 O2 sensor circuit no activity detected (Bank 1 sensor 2) Possible Source(s): O2 sensor failure / out of spec Sensor ground fault Harness failure Connector pin(s) bent or tracking between connections. Low exhaust temperature Action(s) to take: GO to <<Pinpoint Test D>>
www.JagDocs.com
Oxygen Sensors (O2) - Bank 2 (B)
Condition(s): DTC P0151 O2 sensor circuit low voltage (Bank 2 sensor 1) Possible Source(s): O2 sensor failure Sensor ground fault Harness failure
3 2012-07-21

Connector pin(s) bent, loose or corroded Action(s) to take: GO to <<Pinpoint Test E>> DTC P0152 O2 sensor circuit high voltage (Bank 2 sensor 1) Possible Source(s): O2 sensor failure to B+ Sensor ground fault Harness failure Connector pin(s) bent or tracking between connections. O2 sensor failure Action(s) to take: GO to <<Pinpoint Test E>> DTC P0153 O2 sensor circuit slow response (Bank 2 sensor 1) Possible Source(s): O2 sensor heater failure / out of spec Sensor ground fault Harness failure Connector pin(s) bent or tracking between connections. Low exhaust temperature O2 sensor failure Action(s) to take: GO to <<Pinpoint Test F>> DTC P0155 O2 sensor heater circuit malfunction (Bank 2 sensor 1) Possible Source(s): O2 sensor failure Harness failure Connector pin(s) bent or tracking between connections. ECM failure Action(s) to take: GO to <<Pinpoint Test E>> DTC P0157 O2 sensor circuit low voltage (Bank 2 sensor 2) Possible Source(s): O2 sensor failure Sensor ground fault Harness failure Connector pin(s) bent, loose or corroded Action(s) to take: GO to <<Pinpoint Test G>> DTC P0158 O2 sensor circuit high voltage (Bank 2 sensor 2)
2012-07-21

Possible Source(s): O2 sensor failure to B+ Sensor ground fault Harness failure Connector pin(s) bent or tracking between connections. ECM failure Action(s) to take: GO to <<Pinpoint Test G>> DTC P0160 O2 sensor circuit no activity detected (Bank 2 sensor 2) Possible Source(s): O2 sensor failure / out of spec Sensor ground fault Harness failure Connector pin(s) bent or tracking between connections. Low exhaust temperature Action(s) to take: GO to <<Pinpoint Test H>> DTC P0430 Catalyst system efficiency below threshold (bank 2) Possible Source(s): Downstream O2 sensor failure Catalyst failure Catalyst low temperature caused by water splash Action(s) to take: GO to <<Pinpoint Test G>> GO to <<Pinpoint Test H>>
www.JagDocs.com
Pinpoint test A: P0131, P0132, P0135 A : P0131, P0132, P0135 A1 : RETRIEVE DTCS
2012-07-21
2. Connect the scan tool Have the DTC(s) and freeze frame data been recorded? -> Yes GO to A2
A2 : CHECK O2 SENSOR HEATER CONTINUITY

1.
2012-07-21
www.JagDocs.com
2. With EM021 disconnected, measure the resistance between EM021/001 and EM021/002. Is the resistance between 4 and 10OHM? -> Yes GO to A3 -> No Renew O2 sensor; reconnect plug(s) GO to A6
A3 : CHECK FOR O2 SENSOR FAILURE

1.
2012-07-21
2. Run the engine for a period to warm the sensor and then maintain a steady speed of approximately 2500 rpm 3. With EM021 disconnected, measure the voltage between EM021/003 and EM021/004. Is the voltage between 600mV and 1.0 Volt? -> Yes GO to A4 -> No Renew O2 sensor; reconnect plug(s) GO to A6

1.
2012-07-21
www.JagDocs.com
2. With the conditions held as A3, suddenly decelerate to idle Has the voltage dropped to 400mV or less ? -> Yes GO to A5 -> No Renew O2 sensor; reconnect plug(s) GO to A6

1.
2012-07-21
2. With the conditions held as A4, suddenly accelerate to approximately 2500 rpm Has the voltage risen to between 600mV and 1 volt? -> Yes GO to A7 -> No Renew O2 sensor; reconnect plug(s) GO to A6
A6 : STOP
1. Perform appropriate service drive cycle and check for the presence of DTC Has the fault code cleared?
10
2012-07-21

-> Yes STOP -> No Contact Jaguar Service
A7 : HEATED O2 SENSOR SHORT CIRCUIT TO GROUND

1.
www.JagDocs.com
2. With EM021 disconnected measure the insulation resistance between sensor pin 001 and sensor body 3. Repeat for pin 003 and sensor body Is the resistance > 10 MOHM? -> Yes GO to A9
11
2012-07-21

-> No Renew the O2 sensor and reconnect plug(s) GO to A8
A8 : STOP
A9 : SIGNAL GROUND 1 CONTINUITY

1.
12
2012-07-21
www.JagDocs.com
2. With EM010 and EM014 disconnected, measure the resistance between EM010/023 and chassis ground EM1BR (EM2BR) Is the resistance < 0.5OHM? -> Yes GO to A10 -> No Inspect connector EM010 for corrosion, damage, or pushed back pin Inspect ground stud EM1BR (EM2BR) for corrosion Repair as required, harness, splice EMS38, connector or ground; reconnect plug(s) GO to A11
A10 : SIGNAL GROUND 2 CONTINUITY
13
2012-07-21
1.
2. With EM010 and EM014 disconnected, measure the resistance between EM014/004 and chassis ground EM1BR (EM2BR) Is the resistance < 0.5OHM? -> Yes GO to A12 -> No Inspect connector EM014 for corrosion, damage, or pushed back pin Inspect ground stud EM1BR (EM2BR) for corrosion Repair as required, harness, splice EMS38, connector or ground; reconnect plug(s) GO to A11
14
2012-07-21
A11 : STOP
A12 : CHECK FOR HEATED O2 SENSOR CONTINUITY

1.
www.JagDocs.com
15
2012-07-21
2. With EM012 and EM021 disconnected, measure the resistance between EM012/015 and EM021/003 Is the resistance < 0.5OHM? -> Yes GO to A13 -> No Inspect connectors EM012, and EM021 for corrosion, damaged / pushed back pins or repair the harness; reconnect plug(s). GO to A18
A13 : HEATED O2 SENSOR SCREEN GROUND CONTINUITY

1.
16
2012-07-21
www.JagDocs.com
2. With EM012 and EM021 disconnected, measure the resistance between EM012/022 and EM021/004 Is the resistance < 0.5OHM? -> Yes GO to A14 -> No Inspect connectors EM012, and EM021 for corrosion, damaged / pushed back pins or repair the harness; reconnect plug(s). GO to A18
A14 : CHECK FOR SHORT TO B+

1.
17
2012-07-21
2. With EM010 and EM012 disconnected, measure the voltage between EM010/023 and EM012/015 Is the voltage 0 (zero) V? -> Yes GO to A15 -> No Inspect connectors EM010, EM012, and EM021 for corrosion, damaged / pushed back pins or repair the harness; reconnect plug(s). GO to A18
A15 : CHECK FOR SHORT TO B+

1.
18
2012-07-21
www.JagDocs.com
2. With EM010 and EM012 disconnected, measure the voltage between EM010/023 and EM012/022 Is the voltage 0 (zero) V? -> Yes GO to A16 -> No Inspect connectors EM010, EM012, and EM021 for corrosion, damaged / pushed back pins or repair the harness; reconnect plug(s). GO to A18
A16 : CHECK FOR SHORT TO B+ AT O2 SENSOR HEATER

1.
19
2012-07-21
2. Remove EMS fuse F14 3. Disconnect EM010 and EM015 4. Using a link lead, bridge EM010/016 and EM010/022 5. Measure the voltage between EM010/023 and EM015/002 Is the voltage 0 (zero) V? -> Yes Replace EMS fuse F14 but retain link lead GO to A17 -> No Inspect connectors EM010, EM015, and EM021 for corrosion, damaged / pushed back pins or repair the harness; reconnect plug(s). GO to A18
20
2012-07-21
A17 : CHECK B+ AT O2 SENSOR HEATER CIRCUIT

1.
www.JagDocs.com
2. With EM010 and EM015 disconnected, measure the voltage between EM010/023 and EM015/002 Is the voltage B+? -> Yes Remove link lead and reconnect all connectors GO to A18 -> No Check EMS fuse F14 and that EMS control relay (relay 1) is energized and with all connections made GO to A18
21
2012-07-21
A18 : END
Pinpoint test B: P0133 B : P0133 B1 : RETRIEVE DTCS

2. Connect the scan tool Have the DTC(s) and freeze frame data been recorded? -> Yes GO to B2
B2 : CHECK FOR LOW EXHAUST TEMPERATURE

1. Check the engine and exhaust system for normal running temperature Is the engine and exhaust system up to normal running temperature? -> Yes GO to B3
22
2012-07-21

-> No Rectify possible leaking exhaust manifold / catalyst, general causes of an over rich mixture and engine cooling system operation. Test the system for correct operation GO to B8
B3 : CHECK FOR O2 SENSOR HEATER CONTINUITY

1.
www.JagDocs.com
2. With EM021 disconnected, measure the resistance between EM021/001 and EM021/002. Is the resistance between 4 and 10OHM? -> Yes GO to B4 -> No
23
2012-07-21

Renew O2 sensor, reconnect plug(s) GO to B8
B4 : CHECK FOR O2 SENSOR FAILURE

1.
2. Run the engine for a period to warm the sensor and then maintain a steady speed of approximately 2500 rpm 3. Measure the voltage between EM021/003 and EM021/004. Is the voltage between 600mV and 1.0 Volt? -> Yes GO to B5 -> No Renew O2 sensor, reconnect plug(s)
24
2012-07-21

GO to B8

1.
www.JagDocs.com
2. With the conditions held as B4, suddenly decelerate to idle Has the voltage dropped to 400mV or less ? -> Yes GO to B6 -> No Renew O2 sensor, reconnect plug(s) GO to B8
25
2012-07-21

1.
2. With the conditions held as B5, suddenly accelerate to approximately 2500 rpm Has the voltage risen to between 600mV and 1 volt? -> Yes GO to B7 -> No Renew O2 sensor, reconnect plug(s) GO to B8
26
2012-07-21

1.
www.JagDocs.com
2. With the conditions held as in B6, run the engine at 1500 rpm for approximately 2 minutes Does the displayed voltage drop below 400mV and rise above 500 mV, cycling approximately every 4 seconds? -> Yes GO to B9 -> No Renew O2 sensor, reconnect plug(s) GO to B8
27
2012-07-21
B8 : STOP
B9 : HEATED O2 SENSOR SHORT CIRCUIT TO GROUND

1.
28
2012-07-21
www.JagDocs.com
2. With EM021 disconnected measure the insulation resistance between sensor pin 001 and sensor body 3. Repeat for pin 003 and sensor body Is the resistance > 10 MOHM? -> Yes GO to B11 -> No Renew the O2 sensor and reconnect plug(s) GO to B10
B10 : STOP
1. Perform appropriate service drive cycle and check for the presence of DTC
29
2012-07-21

Has the fault code cleared? -> Yes STOP -> No Contact Jaguar Service
B11 : SIGNAL GROUND 1 CONTINUITY

1.
2. With EM010 and EM014 disconnected, measure the resistance between EM010/023 and chassis ground EM1BR (EM2BR) Is the resistance < 0.5OHM? -> Yes
30 2012-07-21

GO to B12 -> No Inspect connector EM010 for corrosion, damage, or pushed back pin Inspect earthing stud EM1BR (EM2BR) for corrosion Repair as required, harness, splice EMS38, connector or ground, reconnect plug(s) GO to B13
B12 : SIGNAL GROUND 2 CONTINUITY

1.
www.JagDocs.com
2. With EM010 and EM014 disconnected, measure the resistance between EM014/004 and chassis ground EM1BR (EM2BR) Is the resistance < 0.5OHM?
31
2012-07-21

-> Yes GO to B14 -> No Inspect connector EM014 for corrosion, damage, or pushed back pin Inspect earthing stud EM1BR (EM2BR) for corrosion Repair as required, harness, splice EMS38, connector or ground, reconnect plug(s) GO to B13
B13 : CHECK FOR HEATED O2 SENSOR CONTINUITY

1.
2. With EM012 and EM021 disconnected, measure the resistance between EM012/015 and EM021/003
32
2012-07-21

Is the resistance < 0.5OHM? -> Yes GO to B14 -> No Inspect connectors EM012, and EM021 for corrosion, damaged / pushed back pins or repair the harness, reconnect plug(s) GO to B19
B14 : HEATED O2 SENSOR SCREEN GROUND CONTINUITY

1.
www.JagDocs.com
2. With EM012 and EM021 disconnected, measure the resistance between EM012/022 and EM021/004 Is the resistance < 0.5OHM?
33
2012-07-21

-> Yes GO to B15 -> No Inspect connectors EM012, and EM021 for corrosion, damaged / pushed back pins or repair the harness, reconnect plug(s) GO to B19
B15 : CHECK FOR SHORT TO B+

1.
2. With EM010 and EM012 disconnected, measure the voltage between EM010/023 and EM012/015 Is the voltage 0 (zero) V? -> Yes
34
2012-07-21

GO to B16 -> No Inspect connectors EM010, EM012, and EM021 for corrosion, damaged / pushed back pins or repair the harness, reconnect plug(s) GO to B19
B16 : CHECK FOR SHORT TO B+

1.
www.JagDocs.com
2. With EM010 and EM012 disconnected, measure the voltage between EM010/023 and EM012/022 Is the voltatage 0 (zero) V? -> Yes GO to B17
35
2012-07-21

-> No Inspect connectors EM010, EM012, and EM021 for corrosion, damaged / pushed back pins or repair the harness, reconnect plug(s) GO to B19
B17 : CHECK FOR SHORT TO B+ AT O2 SENSOR HEATER

1.
2. Remove EMS fuse F14 3. Disconnect EM010 and EM015 4. Using a link lead, bridge EM010/016 and EM010/022 5. ,Measure the voltage between EM010/023 and EM015/002
36
2012-07-21

Is the voltage 0 (zero) V? -> Yes Replace EMS fuse F14 but retain link lead GO to B18 -> No Inspect connectors EM010, EM015, and EM021 for corrosion, damaged / pushed back pins or repair the harness; reconnect plug(s). GO to B19
B18 : CHECK B+ AT O2 SENSOR HEATER CIRCUIT

1.
www.JagDocs.com
2. With EM010 and EM015 disconnected, measure the voltage between EM010/023 and EM015/002
37
2012-07-21

Is the voltage B+? -> Yes Remove link lead and reconnect all connectors GO to B19 -> No Check EMS fuse F14 and that EMS control relay (relay 1) is energized and with all connections made GO to B19
B19 : END
Pinpoint test C: P0137, P0138 C : P0137, P0138 C1 : RETRIEVE DTCS

2. Connect the scan tool Have the DTC(s) and freeze frame data been recorded? -> Yes GO to C2
38
2012-07-21
C2 : CHECK FOR O2 SENSOR FAILURE

1.
www.JagDocs.com
2. Run the engine for a period to warm the sensor and then maintain a steady speed of approximately 2500 rpm 3. Measure the voltage between EM022/001 and EM022/002 Is the voltage between 600mV and 1.0 Volt? -> Yes GO to C3 -> No Renew O2 sensor and reconnect plug(s) GO to C6
39
2012-07-21

1.
2. With the conditions held as C2, suddenly decelerate to idle Has the voltage dropped to 400mV or less ? -> Yes GO to C4 -> No Renew O2 sensor and reconnect plug(s) GO to C6
40
2012-07-21

1.
www.JagDocs.com
2. With the conditions held as C3, suddenly accelerate to approximately 2500 rpm Has the voltage risen to between 600mV and 1 volt? -> Yes GO to C5 -> No Renew O2 sensor and reconnect plug(s) GO to C6
41
2012-07-21

1.
2. With the conditions held as in C4, run the engine at 1500 rpm for approximately 3 minutes Does the displayed voltage drop below 400mV and rise above 500 mV, cycling approximately every 180 seconds? -> Yes GO to C7 -> No Renew O2 sensor and reconnect plug(s) GO to C6
42
2012-07-21
C6 : STOP
C7 : CHECK FOR O2 SENSOR CONTINUITY

1.
www.JagDocs.com
43
2012-07-21
2. With EM012 and EM022 disconnected, measure the resistance between EM012/017 and EM022/002 Is the resistance < 0.5OHM? -> Yes GO to C8 -> No Inspect connectors EM012, and EM022 for corrosion, damaged / pushed back pins or repair the harness; reconnect plug(s) GO to C10
C8 : O2 SENSOR SCREEN GROUND CONTINUITY

1.
44
2012-07-21
www.JagDocs.com
C9 : O2 SENSOR SHORT CIRCUIT TO GROUND

1.
45
2012-07-21
2. With EM022 disconnected measure the insulation resistance between sensor pin 001 and sensor body 3. Repeat for pin 002 and sensor body Is the resistance > 10 MOHM? -> Yes GO to C11 -> No Renew the O2 sensor and reconnect all plugs GO to C10
C10 : STOP
46
2012-07-21

C11 : SIGNAL GROUND 1 CONTINUITY

1.
www.JagDocs.com
47 2012-07-21

GO to C12 -> No Inspect connector EM010 for corrosion, damage, or pushed back pin Inspect ground stud EM1BR (EM2BR) for corrosion Repair as required, harness, splice EMS38, connector or ground; reconnect plug(s) GO to C13
C12 : SIGNAL GROUND 2 CONTINUITY

1.
48
2012-07-21

-> Yes GO to C14 -> No Inspect connector EM014 for corrosion, damage, or pushed back pin Inspect ground stud EM1BR (EM2BR) for corrosion Repair as required, harness, splice EMS38, connector or ground; reconnect plug(s) GO to C13
C13 : STOP
www.JagDocs.com
C14 : CHECK FOR O2 SENSOR CONTINUITY

1.
49
2012-07-21
C15 : O2 SENSOR SCREEN GROUND CONTINUITY

1.
50
2012-07-21
www.JagDocs.com
C16 : CHECK FOR SHORT TO B+

1.
51
2012-07-21
2. With EM010 and EM012 disconnected, measure the voltage between EM010/023 and EM012/017 Is the voltage 0 (zero) V? -> Yes GO to C17 -> No Inspect connectors EM010, EM012, and EM022 for corrosion, damaged / pushed back pins or repair the harness; reconnect plug(s) GO to C20
C17 : CHECK FOR SHORT TO B+

1.
52
2012-07-21
www.JagDocs.com
2. With EM010 and EM012 disconnected, measure the voltage between EM010/023 and EM012/022 Is the voltage 0 (zero) V? -> Yes GO to C18 -> No Inspect connectors EM010, EM012, and EM022 for corrosion, damaged / pushed back pins or repair the harness; reconnect plug(s) GO to C20
C18 : CHECK HARNESS SHORT TO GROUND

1.
53
2012-07-21
2. Measure the insulation resistance between EM012/017 and ground EM010/023 Is the resistance > 10 MOHM? -> Yes GO to C19 -> No Inspect EM012, EM022 for corrosion, bent / pushed back pins or locate and repair the harness / connector fault; reconnect plug(s) GO to C20
C19 : CHECK HARNESS SHORT CORE TO CORE

1.
54
2012-07-21
www.JagDocs.com
2. Measure the insulation resistance between EM012/017 and EM015/002 Is the resistance > 10 MOHM? -> Yes Reconnect all plugs GO to C20 -> No Inspect EM012, EM015 and EM022 for corrosion, bent / pushed back pins or locate and repair the harness / connector fault GO to C20
C20 : END
55
2012-07-21

Pinpoint test D: P0140 D : P0140 D1 : RETRIEVE DTCS

2. Connect the scan tool Have the DTC(s) and freeze frame data been recorded? -> Yes GO to D2
D2 : CHECK FOR LOW EXHAUST TEMPERATURE

1. Check the engine and exhaust system for correct operation and normal running temperature Is the engine and exhaust system operating correctly and up to normal running temperature? -> Yes GO to D3 -> No Rectify leaking exhaust manifold / catalyst, general causes of an over rich mixture and engine cooling system operation and test the system for correct operation GO to D7
56
2012-07-21
D3 : CHECK FOR O2 SENSOR FAILURE

1.
www.JagDocs.com
2. Run the engine for a period to warm the sensor and then maintain a steady speed of approximately 2500 rpm 3. Measure the voltage between EM022/001 and EM022/002 Is the voltage between 600mV and 1.0 Volt? -> Yes GO to D4 -> No Renew O2 sensor; reconnect plug(s) GO to D7
57
2012-07-21

1.
2. With the conditions held as D3, suddenly decelerate to idle Has the voltage dropped to 400mV or less ? -> Yes Stop the engine GO to D5 -> No Renew O2 sensor; reconnect plug(s) GO to D7
58
2012-07-21

1.
www.JagDocs.com
2. With the conditions held as D4, suddenly accelerate to approximately 2500 rpm Has the voltage risen to between 600mV and 1 volt? -> Yes GO to D6 -> No Renew O2 sensor; reconnect plug(s) GO to D7
59
2012-07-21

1.
2. With the conditions held as in D5, run the engine at 1500 rpm for approximately 3 minutes Does the displayed voltage drop below 400mV and rise above 500 mV, cycling approximately every 180 seconds? -> Yes GO to D8 -> No Renew O2 sensor; reconnect plug(s) GO to D7
60
2012-07-21
D7 : STOP
D8 : CHECK FOR O2 SENSOR CONTINUITY

1.
www.JagDocs.com
61
2012-07-21
2. With EM012 and EM022 disconnected, measure the resistance between EM012/017 and EM022/002 Is the resistance < 0.5OHM -> Yes GO to D9 -> No Inspect connectors EM012, and EM022 for corrosion, damaged / pushed back pins or repair the harness; reconnect plug(s) GO to D11
D9 : O2 SENSOR SCREEN GROUND CONTINUITY

1.
62
2012-07-21
www.JagDocs.com
2. With EM012 and EM022 disconnected, measure the resistance between EM012/022 and EM022/001 Is the resistance < 0.5OHM? -> Yes GO to D10 -> No Inspect connectors EM012, and EM022 for corrosion, damaged / pushed back pins or repair the harness; reconnect plug(s) GO to D11
D10 : O2 SENSOR SHORT CIRCUIT TO GROUND

1.
63
2012-07-21
2. With EM022 disconnected measure the insulation resistance between sensor pin 001 and sensor body 3. Repeat for pin 002 and sensor body Is the resistance > 10 MOHM? -> Yes GO to D12 -> No Renew the O2 sensor and reconnect all plugs GO to D11
D11 : STOP
64
2012-07-21

D12 : SIGNAL GROUND 1 CONTINUITY

1.
www.JagDocs.com
65 2012-07-21

GO to D13 -> No Inspect connector EM010 for corrosion, damage, or pushed back pin Inspect ground stud EM1BR (EM2BR) for corrosion Repair as required, harness, splice EMS38, connector or ground; reconnect plug(s) GO to D14
D13 : SIGNAL GROUND 2 CONTINUITY

1.
66
2012-07-21

-> Yes GO to D15 -> No Inspect connector EM014 for corrosion, damage, or pushed back pin Inspect ground stud EM1BR (EM2BR) for corrosion Repair as required, harness, splice EMS38, connector or ground; reconnect plug(s) GO to D14
D14 : STOP
www.JagDocs.com
D15 : CHECK FOR O2 SENSOR CONTINUITY

1.
67
2012-07-21
D16 : O2 SENSOR SCREEN GROUND CONTINUITY

1.
68
2012-07-21
www.JagDocs.com
D17 : CHECK FOR SHORT TO B+

1.
69
2012-07-21
2. With EM010 and EM012 disconnected, measure the voltage between EM010/023 and EM012/015 Is the voltage 0V? -> Yes GO to D18 -> No Inspect connectors EM010, EM012, and EM022 for corrosion, damaged / pushed back pins or repair the harness; reconnect plug(s) GO to D21
D18 : CHECK FOR SHORT TO B+

1.
70
2012-07-21
www.JagDocs.com
2. With EM010 and EM012 disconnected, measure the voltage between EM010/023 and EM012/022 Is the voltage 0V? -> Yes GO to D19 -> No Inspect connectors EM010, EM012, and EM022 for corrosion, damaged / pushed back pins or repair the harness; reconnect plug(s) GO to D21
D19 : CHECK HARNESS SHORT TO GROUND

1.
71
2012-07-21
2. With EM010 and EM012 and EM022 disconnected, measure the insulation resistance between EM012/017 and ground EM010/023 Is the resistance > 10 MOHM? -> Yes GO to D20 -> No Inspect EM012, EM022 for corrosion, bent / pushed back pins or locate and repair the harness / connector fault; reconnect plug(s) GO to D21
D20 : CHECK HARNESS SHORT CORE TO CORE

1.
72
2012-07-21
www.JagDocs.com
2. Measure the insulation resistance between EM012/017 and EM012/022 Is the resistance > 10 MOHM? -> Yes Reconnect all plugs GO to D21 -> No Inspect EM012, EM015 and EM022 for corrosion, bent / pushed back pins or locate and repair the harness / connector fault, remake all connections GO to D21
D21 : END
73
2012-07-21

Pinpoint test E: P0151, P0152, P0155 E : P0151, P0152, P0155 E1 : RETRIEVE DTCS
2. Connect the scan tool Have the DTC(s) and freeze frame data been recorded? -> Yes GO to E2
E2 : CHECK O2 SENSOR HEATER CONTINUITY

1.
74
2012-07-21
www.JagDocs.com
2. With EM023 disconnected, measure the resistance between EM023/001 and EM023/002. Is the resistance between 4 and 10OHM? -> Yes GO to E3 -> No Renew O2 sensor; reconnect plug(s) GO to E7
E3 : CHECK FOR O2 SENSOR FAILURE

1.
75
2012-07-21
2. Run the engine for a period to warm the sensor and then maintain a steady speed of approximately 2500 rpm 3. With EM023 disconnected, measure the voltage between EM023/003 and EM023/004. Is the voltage between 600mV and 1.0 Volt? -> Yes GO to E4 -> No Renew O2 sensor; reconnect plug(s) GO to E7

1.
76
2012-07-21
www.JagDocs.com
2. . With the conditions held as E3, suddenly decelerate to idle Has the voltage dropped to 400mV or less ? -> Yes GO to E5 -> No Renew O2 sensor; reconnect plug(s) GO to E7

1.
77
2012-07-21
2. With the conditions held as E4, suddenly accelerate to approximately 2500 rpm Has the voltage risen to between 600mV and 1 volt? -> Yes GO to E5 -> No Renew O2 sensor; reconnect plug(s) GO to E6
E6 : STOP
78
2012-07-21

E7 : HEATED O2 SENSOR SHORT CIRCUIT TO GROUND

1.
www.JagDocs.com
2. With EM023 disconnected measure the insulation resistance between sensor pin 001 and sensor body 3. Repeat for pin 003 and sensor body Is the resistance > 10 MOHM? -> Yes GO to E9
79
2012-07-21

-> No Renew the O2 sensor and reconnect plug(s) GO to E8
E8 : STOP
E9 : SIGNAL GROUND 1 CONTINUITY

1.
80
2012-07-21
www.JagDocs.com
2. With EM010 and EM014 disconnected, measure the resistance between EM010/023 and chassis ground EM1BR (EM2BR) Is the resistance < 0.5OHM? -> Yes GO to E10 -> No Inspect connector EM010 for corrosion, damage, or pushed back pin Inspect ground stud EM1BR (EM2BR) for corrosion Repair as required, harness, splice EMS38, connector or ground; reconnect plug(s) GO to E11
E10 : SIGNAL GROUND 2 CONTINUITY
81
2012-07-21
1.
2. With EM010 and EM014 disconnected, measure the resistance between EM014/004 and chassis ground EM1BR (EM2BR) Is the resistance < 0.5OHM? -> Yes GO to E12 -> No Inspect connector EM014 for corrosion, damage, or pushed back pin Inspect ground stud EM1BR (EM2BR) for corrosion Repair as required, harness, splice EMS38, connector or ground; reconnect plug(s) GO to E11
82
2012-07-21
E11 : STOP
E12 : CHECK FOR HEATED O2 SENSOR CONTINUITY

1.
www.JagDocs.com
83
2012-07-21
2. With EM012 and EM023 disconnected, measure the resistance between EM012/014 and EM023/003 Is the resistance < 0.5OHM? -> Yes GO to E13 -> No Inspect connectors EM012, and EM023 for corrosion, damaged / pushed back pins or repair the harness; reconnect plug(s). GO to E18
E13 : HEATED O2 SENSOR SCREEN GROUND CONTINUITY

1.
84
2012-07-21
www.JagDocs.com
2. With EM012 and EM023 disconnected, measure the resistance between EM012/022 and EM023/004 Is the resistance < 0.5OHM? -> Yes GO to E14 -> No Inspect connectors EM012, and EM023 for corrosion, damaged / pushed back pins or repair the harness; reconnect plug(s). GO to E18
E14 : CHECK FOR SHORT TO B+

1.
85
2012-07-21
2. With EM010 and EM012 disconnected, measure the voltage between EM010/023 and EM012/014 Is the voltage 0 (zero) V? -> Yes GO to E15 -> No Inspect connectors EM010, EM012, and EM023 for corrosion, damaged / pushed back pins or repair the harness; reconnect plug(s). GO to E18
E15 : CHECK FOR SHORT TO B+

1.
86
2012-07-21
www.JagDocs.com
2. With EM010 and EM012 disconnected, measure the voltage between EM010/023 and EM012/022 Is the voltage 0 (zero) V? -> Yes GO to E16 -> No Inspect connectors EM010, EM012, and EM023 for corrosion, damaged / pushed back pins or repair the harness; reconnect plug(s). GO to E18
E16 : CHECK FOR SHORT TO B+ AT O2 SENSOR HEATER

1.
87
2012-07-21
2. Remove EMS fuse F14 3. Disconnect EM010 and EM015 4. Using a link lead, bridge EM010/016 and EM010/022 5. Measure the voltage between EM010/023 and EM015/001 Is the voltage 0 (zero) V? -> Yes Replace EMS fuse F14 but retain link lead GO to E17 -> No Inspect connectors EM010, EM015, and EM023 for corrosion, damaged / pushed back pins or repair the harness; reconnect plug(s). GO to E18
88
2012-07-21
E17 : CHECK B+ AT O2 SENSOR HEATER CIRCUIT

1.
www.JagDocs.com
2. With EM010 and EM015 disconnected, measure the voltage between EM010/023 and EM015/001 Is the voltage B+? -> Yes Remove link lead and reconnect all connectors GO to E18 -> No Check EMS fuse F14 and that EMS control relay (relay 1) is energized and with all connections made GO to E18
89
2012-07-21
E18 : END
Pinpoint test F: P0153 F : P0153 F1 : RETRIEVE DTCS

2. Connect the scan tool Have the DTC(s) and freeze frame data been recorded? -> Yes GO to F2
F2 : CHECK FOR LOW EXHAUST TEMPERATURE

1. Check the engine and exhaust system for normal running temperature Is the engine and exhaust system up to normal running temperature? -> Yes GO to F3
90
2012-07-21

-> No Rectify possible leaking exhaust manifold / catalyst, general causes of an over rich mixture and engine cooling system operation. Test the system for correct operation GO to F8
F3 : CHECK FOR O2 SENSOR HEATER CONTINUITY

1.
www.JagDocs.com
2. With EM023 disconnected, measure the resistance between EM023/001 and EM023/002. Is the resistance between 4 and 10OHM? -> Yes GO to F4 -> No
91
2012-07-21

Renew O2 sensor, reconnect plug(s) GO to F8
F4 : CHECK FOR O2 SENSOR FAILURE

1.
2. Run the engine for a period to warm the sensor and then maintain a steady speed of approximately 2500 rpm 3. Measure the voltage between EM023/003 and EM023/004. Is the voltage between 600mV and 1.0 Volt? -> Yes GO to F5 -> No Renew O2 sensor, reconnect plug(s)
92
2012-07-21

GO to F8

1.
www.JagDocs.com
2. With the conditions held as F4, suddenly decelerate to idle Has the voltage dropped to 400mV or less ? -> Yes GO to F6 -> No Renew O2 sensor, reconnect plug(s) GO to F8
93
2012-07-21

1.
2. With the conditions held as F5, suddenly accelerate to approximately 2500 rpm Has the voltage risen to between 600mV and 1 volt? -> Yes GO to F7 -> No Renew O2 sensor, reconnect plug(s) GO to F8
94
2012-07-21

1.
www.JagDocs.com
2. With the conditions held as in F6, run the engine at 1500 rpm for approximately 2 minutes Does the displayed voltage drop below 400mV and rise above 500 mV, cycling approximately every 4 seconds? -> Yes GO to F9 -> No Renew O2 sensor, reconnect plug(s) GO to F8
95
2012-07-21
F8 : STOP
F9 : HEATED O2 SENSOR SHORT CIRCUIT TO GROUND

1.
96
2012-07-21
www.JagDocs.com
2. With EM023 disconnected measure the insulation resistance between sensor pin 001 and sensor body 3. Repeat for pin 003 and sensor body Is the resistance > 10 MOHM? -> Yes GO to F11 -> No Renew the O2 sensor and reconnect plug(s) GO to F10
F10 : STOP
97
2012-07-21

F11 : SIGNAL GROUND 1 CONTINUITY

1.
98 2012-07-21

GO to F12 -> No Inspect connector EM010 for corrosion, damage, or pushed back pin Inspect earthing stud EM1BR (EM2BR) for corrosion Repair as required, harness, splice EMS38, connector or ground, reconnect plug(s) GO to F13
F12 : SIGNAL GROUND 2 CONTINUITY

1.
www.JagDocs.com
2. With EM010 and EM014 disconnected, measure the resistance between EM014/004 and chassis ground EM1BR (EM2BR) Is the resistance < 0.5OHM? -> Yes GO to F14 -> No Inspect connector EM014 for corrosion, damage, or pushed back pin Inspect earthing stud EM1BR (EM2BR) for corrosion Repair as required, harness, splice EMS38, connector or ground, reconnect plug(s)
99
2012-07-21

GO to F13
F13 : CHECK FOR HEATED O2 SENSOR CONTINUITY

1.
2. With EM012 and EM023 disconnected, measure the resistance between EM012/014 and EM023/003 Is the resistance < 0.5OHM? -> Yes GO to F14 -> No Inspect connectors EM012, and EM023 for corrosion, damaged / pushed back pins or repair the harness, reconnect plug(s) GO to F19
F14 : HEATED O2 SENSOR SCREEN GROUND CONTINUITY

1.
100
2012-07-21
www.JagDocs.com
2. With EM012 and EM023 disconnected, measure the resistance between EM012/022 and EM023/004 Is the resistance < 0.5OHM? -> Yes GO to F15 -> No Inspect connectors EM012, and EM023 for corrosion, damaged / pushed back pins or repair the harness, reconnect plug(s) GO to F19
F15 : CHECK FOR SHORT TO B+

1.
101
2012-07-21
2. With EM010 and EM012 disconnected, measure the voltage between EM010/023 and EM012/014 Is the voltage 0 (zero) V? -> Yes GO to F16 -> No Inspect connectors EM010, EM012, and EM023 for corrosion, damaged / pushed back pins or repair the harness, reconnect plug(s) GO to F19
F16 : CHECK FOR SHORT TO B+

1.
102
2012-07-21
www.JagDocs.com
2. With EM010 and EM012 disconnected, measure the voltage between EM010/023 and EM012/022 Is the voltatage 0 (zero) V? -> Yes GO to F17 -> No Inspect connectors EM010, EM012, and EM023 for corrosion, damaged / pushed back pins or repair the harness, reconnect plug(s) GO to F19
F17 : CHECK FOR SHORT TO B+ AT O2 SENSOR HEATER

1.
103
2012-07-21
2. Remove EMS fuse F14 3. Disconnect EM010 and EM015 4. Using a link lead, bridge EM010/016 and EM010/022 5. ,Measure the voltage between EM010/023 and EM015/001 Is the voltage 0 (zero) V? -> Yes Replace EMS fuse F14 but retain link lead GO to F18 -> No Inspect connectors EM010, EM015, and EM023 for corrosion, damaged / pushed back pins or repair the harness; reconnect plug(s). GO to F19
104
2012-07-21
F18 : CHECK B+ AT O2 SENSOR HEATER CIRCUIT

1.
www.JagDocs.com
2. With EM010 and EM015 disconnected, measure the voltage between EM010/023 and EM015/002 Is the voltage B+? -> Yes Remove link lead and reconnect all connectors GO to F19 -> No Check EMS fuse F14 and that EMS control relay (relay 1) is energized and with all connections made GO to F19
105
2012-07-21
F19 : END
Pinpoint test G: P0157, P0158 G : P0157, P0158 G1 : RETRIEVE DTCS

2. Connect the scan tool Have the DTC(s) and freeze frame data been recorded? -> Yes GO to G2
G2 : CHECK FOR O2 SENSOR FAILURE

1.
106
2012-07-21
www.JagDocs.com
2. Run the engine for a period to warm the sensor and then maintain a steady speed of approximately 2500 rpm 3. Measure the voltage between EM024/001 and EM024/002 Is the voltage between 600mV and 1.0 Volt? -> Yes GO to G3 -> No Renew O2 sensor and reconnect plug(s) GO to G6

1.
107
2012-07-21
2. With the conditions held as G2, suddenly decelerate to idle Has the voltage dropped to 400mV or less ? -> Yes GO to G4 -> No Renew O2 sensor and reconnect plug(s) GO to G6

1.
108
2012-07-21
www.JagDocs.com
2. With the conditions held as G3, suddenly accelerate to approximately 2500 rpm Has the voltage risen to between 600mV and 1 volt? -> Yes GO to G5 -> No Renew O2 sensor and reconnect plug(s) GO to G6

1.
109
2012-07-21
2. With the conditions held as in G4, run the engine at 1500 rpm for approximately 3 minutes Does the displayed voltage drop below 400mV and rise above 500 mV, cycling approximately every 180 seconds? -> Yes GO to G7 -> No Renew O2 sensor and reconnect plug(s) GO to G6
G6 : STOP
110 2012-07-21

G7 : CHECK FOR O2 SENSOR CONTINUITY

1.
www.JagDocs.com
2. With EM012 and EM024 disconnected, measure the resistance between EM012/016 and EM024/002 Is the resistance < 0.5OHM? -> Yes GO to G8 -> No
111 2012-07-21

Inspect connectors EM012, and EM024 for corrosion, damaged / pushed back pins or repair the harness; reconnect plug(s) GO to G10
G8 : O2 SENSOR SCREEN GROUND CONTINUITY

1.
2. With EM012 and EM024 disconnected, measure the resistance between EM012/022 and EM024/001 Is the resistance < 0.5OHM? -> Yes GO to G9 -> No Inspect connectors EM012, and EM024 for corrosion, damaged / pushed back pins or repair the harness;
112
2012-07-21

reconnect plug(s) GO to G10
G9 : O2 SENSOR SHORT CIRCUIT TO GROUND

1.
www.JagDocs.com
2. With EM024 disconnected measure the insulation resistance between sensor pin 001 and sensor body 3. Repeat for pin 002 and sensor body Is the resistance > 10 MOHM? -> Yes GO to G11 -> No Renew the O2 sensor and reconnect all plugs
113 2012-07-21

GO to G10
G10 : STOP
G11 : SIGNAL GROUND 1 CONTINUITY

1.
114
2012-07-21
www.JagDocs.com
2. With EM010 and EM014 disconnected, measure the resistance between EM010/023 and chassis ground EM1BR (EM2BR) Is the resistance < 0.5OHM? -> Yes GO to G12 -> No Inspect connector EM010 for corrosion, damage, or pushed back pin Inspect ground stud EM1BR (EM2BR) for corrosion Repair as required, harness, splice EMS38, connector or ground; reconnect plug(s) GO to G13
G12 : SIGNAL GROUND 2 CONTINUITY
115
2012-07-21
1.
2. With EM010 and EM014 disconnected, measure the resistance between EM014/004 and chassis ground EM1BR (EM2BR) Is the resistance < 0.5OHM? -> Yes GO to G14 -> No Inspect connector EM014 for corrosion, damage, or pushed back pin Inspect ground stud EM1BR (EM2BR) for corrosion Repair as required, harness, splice EMS38, connector or ground; reconnect plug(s) GO to G13
116
2012-07-21
G13 : STOP
G14 : CHECK FOR O2 SENSOR CONTINUITY

1.
www.JagDocs.com
117
2012-07-21
2. With EM012 and EM024 disconnected, measure the resistance between EM012/016 and EM024/002 Is the resistance < 0.5OHM? -> Yes GO to G15 -> No Inspect connectors EM012, and EM024 for corrosion, damaged / pushed back pins or repair the harness; reconnect plug(s) GO to G20
G15 : O2 SENSOR SCREEN GROUND CONTINUITY

1.
118
2012-07-21
www.JagDocs.com
2. With EM012 and EM024 disconnected, measure the resistance between EM012/022 and EM024/001 Is the resistance < 0.5OHM? -> Yes GO to G16 -> No Inspect connectors EM012, and EM024 for corrosion, damaged / pushed back pins or repair the harness; reconnect plug(s) GO to G20
G16 : CHECK FOR SHORT TO B+

1.
119
2012-07-21
2. With EM010 and EM012 disconnected, measure the voltage between EM010/023 and EM012/016 Is the voltage 0 (zero) V? -> Yes GO to G17 -> No Inspect connectors EM010, EM012, and EM024 for corrosion, damaged / pushed back pins or repair the harness; reconnect plug(s) GO to G20
G17 : CHECK FOR SHORT TO B+

1.
120
2012-07-21
www.JagDocs.com
2. With EM010 and EM012 disconnected, measure the voltage between EM010/023 and EM012/022 Is the voltage 0 (zero) V? -> Yes GO to G18 -> No Inspect connectors EM010, EM012, and EM024 for corrosion, damaged / pushed back pins or repair the harness; reconnect plug(s) GO to G20
G18 : CHECK HARNESS SHORT TO GROUND

1.
121
2012-07-21
2. Measure the insulation resistance between EM012/016 and ground EM010/023 Is the resistance > 10 MOHM? -> Yes GO to G19 -> No Inspect EM012, EM024 for corrosion, bent / pushed back pins or locate and repair the harness / connector fault; reconnect plug(s) GO to G20
G19 : CHECK HARNESS SHORT CORE TO CORE

1.
122
2012-07-21
www.JagDocs.com
2. Measure the insulation resistance between EM012/016 and EM015/001 Is the resistance > 10 MOHM? -> Yes Reconnect all plugs GO to G20 -> No Inspect EM012, EM015 and EM024 for corrosion, bent / pushed back pins or locate and repair the harness / connector fault GO to G20
G20 : END
123 2012-07-21

Pinpoint test H: P0160 H : P0160 H1 : RETRIEVE DTCS

2. Connect the scan tool Have the DTC(s) and freeze frame data been recorded? -> Yes GO to H2
H2 : CHECK FOR LOW EXHAUST TEMPERATURE

1. Check the engine and exhaust system for correct operation and normal running temperature Is the engine and exhaust system operating correctly and up to normal running temperature? -> Yes GO to H3 -> No Rectify leaking exhaust manifold / catalyst, general causes of an over rich mixture and engine cooling system operation and test the system for correct operation GO to H7
124
2012-07-21
H3 : CHECK FOR O2 SENSOR FAILURE

1.
www.JagDocs.com
2. Run the engine for a period to warm the sensor and then maintain a steady speed of approximately 2500 rpm 3. With EM024 disconnected. measure the voltage between EM024/001 and EM024/002 Is the voltage between 600mV and 1.0 Volt? -> Yes GO to H4 -> No Renew O2 sensor; reconnect plug(s) GO to H7
125
2012-07-21

1.
2. With the conditions held as H3, suddenly decelerate to idle Has the voltage dropped to 400mV or less ? -> Yes Stop the engine GO to H5 -> No Renew O2 sensor; reconnect plug(s) GO to H7
126
2012-07-21

1.
www.JagDocs.com
2. With the conditions held as H4, suddenly accelerate to approximately 2500 rpm Has the voltage risen to between 600mV and 1 volt? -> Yes GO to H6 -> No Renew O2 sensor; reconnect plug(s) GO to H7
127
2012-07-21

1.
2. With the conditions held as in H5, run the engine at 1500 rpm for approximately 3 minutes Does the displayed voltage drop below 400mV and rise above 500 mV, cycling approximately every 180 seconds? -> Yes GO to H8 -> No Renew O2 sensor; reconnect plug(s) GO to H7
128
2012-07-21
H7 : STOP
H8 : CHECK FOR O2 SENSOR CONTINUITY

1.
www.JagDocs.com
129
2012-07-21
2. With EM012 and EM024 disconnected, measure the resistance between EM012/016 and EM024/002 Is the resistance < 0.5OHM -> Yes GO to H9 -> No Inspect connectors EM012, and EM024 for corrosion, damaged / pushed back pins or repair the harness; reconnect plug(s) GO to H11
H9 : O2 SENSOR SCREEN GROUND CONTINUITY

1.
130
2012-07-21
www.JagDocs.com
2. With EM012 and EM024 disconnected, measure the resistance between EM012/022 and EM024/001 Is the resistance < 0.5OHM? -> Yes GO to H10 -> No Inspect connectors EM012, and EM024 for corrosion, damaged / pushed back pins or repair the harness; reconnect plug(s) GO to H11
H10 : O2 SENSOR SHORT CIRCUIT TO GROUND

1.
131
2012-07-21
2. With EM024 disconnected measure the insulation resistance between sensor pin 001 and sensor body 3. Repeat for pin 002 and sensor body Is the resistance > 10 MOHM? -> Yes GO to H12 -> No Renew the O2 sensor and reconnect all plugs GO to H11
H11 : STOP
132
2012-07-21

H12 : SIGNAL GROUND 1 CONTINUITY

1.
www.JagDocs.com
133 2012-07-21

GO to H13 -> No Inspect connector EM010 for corrosion, damage, or pushed back pin Inspect ground stud EM1BR (EM2BR) for corrosion Repair as required, harness, splice EMS38, connector or ground; reconnect plug(s) GO to H14
H13 : SIGNAL GROUND 2 CONTINUITY

1.
134 2012-07-21

-> Yes GO to H15 -> No Inspect connector EM014 for corrosion, damage, or pushed back pin Inspect ground stud EM1BR (EM2BR) for corrosion Repair as required, harness, splice EMS38, connector or ground; reconnect plug(s) GO to H14
H14 : STOP
www.JagDocs.com
H15 : CHECK FOR O2 SENSOR CONTINUITY

1.
135
2012-07-21
H16 : O2 SENSOR SCREEN GROUND CONTINUITY

1.
136
2012-07-21
www.JagDocs.com
H17 : CHECK FOR SHORT TO B+

1.
137
2012-07-21
2. With EM010 and EM012 disconnected, measure the voltage between EM010/023 and EM012/016 Is the voltage 0V? -> Yes GO to H18 -> No Inspect connectors EM010, EM012, and EM024 for corrosion, damaged / pushed back pins or repair the harness; reconnect plug(s) GO to H21
H18 : CHECK FOR SHORT TO B+

1.
138
2012-07-21
www.JagDocs.com
2. With EM010 and EM012 disconnected, measure the voltage between EM010/023 and EM012/022 Is the voltage 0V? -> Yes GO to H19 -> No Inspect connectors EM010, EM012, and EM024 for corrosion, damaged / pushed back pins or repair the harness; reconnect plug(s) GO to H21
H19 : CHECK HARNESS SHORT TO GROUND

1.
139
2012-07-21
2. With EM010 and EM012 and EM024 disconnected, measure the insulation resistance between EM012/016 and ground EM010/023 Is the resistance > 10 MOHM? -> Yes GO to H20 -> No Inspect EM012, EM024 for corrosion, bent / pushed back pins or locate and repair the harness / connector fault; reconnect plug(s) GO to H21
H20 : CHECK HARNESS SHORT CORE TO CORE

1.
140
2012-07-21
www.JagDocs.com
2. Measure the insulation resistance between EM012/016 and EM012/022 Is the resistance > 10 MOHM? -> Yes Reconnect all plugs GO to H21 -> No Inspect EM012, EM015 and EM024 for corrosion, bent / pushed back pins or locate and repair the harness / connector fault, remake all connections GO to H21
H21 : END
141 2012-07-21

142
2012-07-21
Catalytic Converter LH Vehicles Without: Supercharger 17.50.15

Removal 1. Remove the front muffler; refer to the procedure in this section.
www.JagDocs.com
2. Remove the coolant header tank (left-hand only). 1. Remove the securing bolt. 2. Detach the header tank dowels from the mounting grommets.
3.
CAUTION: Note the position of the upstream and downstream oxygen sensor multiplugs for reassembly.
Disconnect the oxygen sensor multiplugs. Displace the multiplugs from the engine mounting bracket.
1 2012-07-20
4. Remove the downpipe catalytic converter to exhaust manifold securing nuts. 5. Raise the vehicle on a four-post ramp.
6. Remove the downpipe catalytic converter. Remove the mounting bracket securing bolts.
2012-07-20
www.JagDocs.com
7. Remove the oxygen sensor(s). Downstream sensor - north American markets only. 8. Clean the exhaust joints.
Installation
1. Install the oxygen sensor(s). Downstream sensor - north American markets only.
2012-07-20
2. Install the downpipe catalytic converter. Install, but do not tighten, the mounting bracket securing bolts. (Leave loose until the nuts securing the downpipe to the exhaust manifold are fitted and tightened.)
3. Install the downpipe catalytic converter to exhaust manifold securing nuts.
2012-07-20
www.JagDocs.com
4. Tighten the mounting bracket securing bolts. 5. Lower the four-post ramp.
6. Connect the oxygen sensor multiplugs. Correctly position the multiplugs on the engine mounting bracket.
2012-07-20
7. Install the coolant header tank (left-hand only). 1. Position the header tank dowels on the mounting grommets. 2. Install the securing bolt. 8. Install the front muffler; refer to the procedure in this section.
2012-07-20
Catalytic Converter LH Vehicles With: Supercharger 17.50.15

1. Information not available at this time
www.JagDocs.com
2012-07-20
Catalytic Converter RH Vehicles Without: Supercharger 17.50.16

Removal 1. Remove the front muffler; refer to the procedure in this section.
2. Remove the coolant header tank (left-hand only). 1. Remove the securing bolt. 2. Detach the header tank dowels from the mounting grommets.
3.
CAUTION: Note the position of the upstream and downstream oxygen sensor multiplugs for reassembly.
Disconnect the oxygen sensor multiplugs. Displace the multiplugs from the engine mounting bracket.
1 2012-07-20
4. Remove the downpipe catalytic converter to exhaust manifold securing nuts. 5. Raise the vehicle on a four-post ramp.
www.JagDocs.com
6. Remove the downpipe catalytic converter. Remove the mounting bracket securing bolts.
2012-07-20
7. Remove the oxygen sensor(s). Downstream sensor - north American markets only. 8. Clean the exhaust joints.
Installation
1. Install the oxygen sensor(s). Downstream sensor - north American markets only.
2012-07-20
www.JagDocs.com
2. Install the downpipe catalytic converter. Install, but do not tighten, the mounting bracket securing bolts. (Leave loose until the nuts securing the downpipe to the exhaust manifold are fitted and tightened.)
3. Install the downpipe catalytic converter to exhaust manifold securing nuts.
2012-07-20
4. Tighten the mounting bracket securing bolts. 5. Lower the four-post ramp.
6. Connect the oxygen sensor multiplugs. Correctly position the multiplugs on the engine mounting bracket.
2012-07-20
www.JagDocs.com
7. Install the coolant header tank (left-hand only). 1. Position the header tank dowels on the mounting grommets. 2. Install the securing bolt. 8. Install the front muffler; refer to the procedure in this section.
2012-07-20
Catalytic Converter RH Vehicles With: Supercharger 17.50.16

2012-07-20
Catalytic Converter Gasket LH Vehicles Without: Supercharger 17.50.06

www.JagDocs.com
2012-07-20
Catalytic Converter Gasket LH Vehicles With: Supercharger 17.50.06

2012-07-20
Catalytic Converter Gasket RH Vehicles Without: Supercharger 17.50.07

www.JagDocs.com
2012-07-20
Catalytic Converter Gasket RH Vehicles With: Supercharger 17.50.07

2012-07-20
Front Muffler Vehicles Without: Supercharger 30.10.18

Removal 1. Raise the vehicle on a four-post ramp.
www.JagDocs.com
2. Move the front muffler forward to allow the intermediate mufflers to be displaced. Slacken the muffler to catalytic converter securing clamps (left- and right-hand sides).
3. Slacken the front to intermediate muffler securing clamps (left - and right-hand sides). 4. Remove the front muffler. Disconnect the front muffler from the intermediate mufflers and then from the downpipe catalytic converters.
2012-07-20
Installation 1. Install the front muffler. Connect the front muffler to the downpipe catalytic converters and then to the intermediate mufflers.
2. Tighten the front to intermediate muffler securing clamps (left - and right-hand sides). Correctly position the muffler joints.
3. Correctly position the front muffler rearward. Tighten the muffler to catalytic converter securing clamps (left- and right-hand sides). 4. Lower the ramp.
2012-07-20
Front Muffler Vehicles With: Supercharger 30.10.18

www.JagDocs.com
2012-07-20
Intermediate Muffler LH 30.10.15

Removal 1. Position the vehicle on a four-post ramp. 2. Raise the rear of the vehicle and support on two suitable vehicle stands. 3. Raise the vehicle on the ramp. 4. Remove the rear muffler/tailpipe assembly; refer to the procedure in this section.
5. Remove the front grass shields (Japanese market only). Remove the grass shield securing bolts.
2012-07-20
6. Move the front muffler forward to allow the intermediate muffler to be removed. Slacken the front muffler to downpipe catalytic converter securing clamps (left- and right-hand sides).
www.JagDocs.com
7. Remove the intermediate muffler assembly. 1. Slacken the intermediate to front muffler securing clamp and disconnect the intermediate muffler from the front muffler. 2. Disengage the peg from the mounting rubber. 8. Clean the exhaust joints.
Installation
1. Install the intermediate muffler assembly. 1. Engage the peg with the mounting rubber. 2. Tighten the intermediate to front muffler securing clamp.
2012-07-20
2. Correctly position the front muffler rearward. Tighten the muffler to downpipe catalytic converter securing clamps (left- and right-hand sides).
3. Install the front grass shields (Japanese market only). Install the grass shield securing bolts.
2012-07-20
www.JagDocs.com
4. NOTE: If necessary, rotate the intermediate muffler at the front to intermediate muffler joint to achieve the tailpipe trim settings; refer to Specifications in this section. Correctly position the rear muffler/tailpipe assembly. Connect the rear muffler to the intermediate muffler and insert to the Nominal indicator ring, rotating back and forth to aid engagement. Engage the peg with the mounting rubber. Check that the tailpipe position is within the specified settings, adjusting engagement within the Maximum and Minimum indicator rings if necessary; refer to Specifications in this section.
5. Tighten the intermediate to rear muffler securing clamp. 6. Lower the ramp and remove the stands.
2012-07-20
Intermediate Muffler RH 30.10.16

Removal 1. Position the vehicle on a four-post ramp. 2. Raise the rear of the vehicle and support on two suitable vehicle stands. 3. Raise the vehicle on the ramp. 4. Remove the rear muffler/tailpipe assembly; refer to the procedure in this section.
5. Remove the front grass shields (Japanese market only). Remove the grass shield securing bolts.
2012-07-20
6. Move the front muffler forward to allow the intermediate muffler to be removed. Slacken the front muffler to downpipe catalytic converter securing clamps (left- and right-hand sides).
www.JagDocs.com
7. Remove the intermediate muffler assembly. 1. Slacken the intermediate to front muffler securing clamp and disconnect the intermediate muffler from the front muffler. 2. Disengage the peg from the mounting rubber. 8. Clean the exhaust joints.
Installation
1. Install the intermediate muffler assembly. 1. Engage the peg with the mounting rubber. 2. Tighten the intermediate to front muffler securing clamp.
2012-07-20
2. Correctly position the front muffler rearward. Tighten the muffler to downpipe catalytic converter securing clamps (left- and right-hand sides).
3. Install the front grass shields (Japanese market only). Install the grass shield securing bolts.
2012-07-20
www.JagDocs.com
4. NOTE: If necessary, rotate the intermediate muffler at the front to intermediate muffler joint to achieve the tailpipe trim settings; refer to Specifications in this section. Correctly position the rear muffler/tailpipe assembly. Connect the rear muffler to the intermediate muffler and insert to the Nominal indicator ring, rotating back and forth to aid engagement. Engage the peg with the mounting rubber. Check that the tailpipe position is within the specified settings, adjusting engagement within the Maximum and Minimum indicator rings if necessary; refer to Specifications in this section.
5. Tighten the intermediate to rear muffler securing clamp. 6. Lower the ramp and remove the stands.
2012-07-20
Muffler and Tailpipe LH 30.10.22

2. Slacken the rear to intermediate muffler securing clamp.
3. Remove the rear muffler and tailpipe assembly. Disengage the peg from the mounting rubber. Rotate the assembly back and forth to aid removal. 4. Clean the exhaust joints.
2012-07-20

Installation
www.JagDocs.com
1. Install the rear muffler and tailpipe assembly. Connect the rear muffler to the intermediate muffler and insert to the Nominal indicator ring. Engage the peg with the mounting rubber. Check that the tailpipe position is within the specified settings, adjusting engagement within the Maximum and Minimum indicator rings if necessary; refer to Specifications in this section.
2. Tighten the rear to intermediate muffler securing clamp. 3. Lower the ramp.
2012-07-20
Muffler and Tailpipe RH 30.10.52

2. Slacken the rear to intermediate muffler securing clamp.
3. Remove the rear muffler and tailpipe assembly. Disengage the peg from the mounting rubber. Rotate the assembly back and forth to aid removal. 4. Clean the exhaust joints.
2012-07-20

Installation
www.JagDocs.com
1. Install the rear muffler and tailpipe assembly. Connect the rear muffler to the intermediate muffler and insert to the Nominal indicator ring. Engage the peg with the mounting rubber. Check that the tailpipe position is within the specified settings, adjusting engagement within the Maximum and Minimum indicator rings if necessary; refer to Specifications in this section.
2. Tighten the rear to intermediate muffler securing clamp. 3. Lower the ramp.
2012-07-20
1999 XK RANGE - Fuel System - General Information - 310-00
Fuel System Pressure Check

WARNING: WORKING ON THE FUEL SYSTEM RESULTS IN FUEL AND FUEL VAPOR BEING PRESENT IN THE ATMOSPHERE. FUEL VAPOR 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 WORK AREA DISCONNECT THE BATTERY BEFORE WORKING ON THE FUEL SYSTEM AVOID SPARKS MAKE SURE SUITABLE FIRE EXTINGUISHERS ARE AT HAND MAKE SURE ABSORBENT MATERIAL IS AT HAND TO SOAK UP ANY SPILLAGE MAKE SURE THE WORK AREA IS WELL VENTILATED MAKE SURE THAT THE GAUGE IS CORRECTLY CONNECTED, AND THAT ALL CONNECTIONS ARE SECURE BEFORE STARTING THE ENGINE DO NOT DISCONNECT THE GAUGE FROM THE SCHRADER VALVE WHILE THE ENGINE IS RUNNING MAKE SURE THE SCHRADER VALVE RESEALS ONCE THE GAUGE IS DISCONNECTED 1. Make sure the vehicle is in Park for vehicles with automatic transmission, Neutral for vehicles with manual transmission. 2. Apply the parking brake. 3. Place suitable absorbent material around the schrader valve to absorb any spillage when connecting the gauge set. 4. Remove the protective cap from the schrader valve. NOTE: Depending on the design of the gauge set, there may be a drain valve and tube. Make sure this valve is closed, and the drain tube placed in a suitable container BEFORE connecting the gauge to the schrader valve. 5. Connect the gauge, using adaptors if required. 6. Remove the absorbent material and dispose of safely. 7. Disconnect and plug the vacuum hose from the pressure regulator. 8. Start the engine and record the fuel pressure reading. As a guide, the fuel pressure should be approximately 3.0 bar (44.1 psi) with the regulator disconnected. 9. With the engine still running, reconnect the vacuum hose to the pressure regulator and record the reading. The pressure should drop to approximately 2.6 bar (38 psi) when the vacuum hose is reconnected. 10. Switch off the engine.
2012-07-20
11. Place more absorbent material around the schrader valve. 12. Where fitted, open the drain valve and allow the fuel from the gauge and line to flow into the container to depressurize the system. 13. Disconnect and remove the gauge set and any adaptors. 14. Clean up any fuel which may have been spilt and remove the absorbent material. Dispose of safely. 15. Refit and secure the protective cap to the schrader valve. 16. Reconnect the fuel pressure regulator vacuum hose. 17. Start the engine and make sure there are no leaks.
www.JagDocs.com
2012-07-20
Fuel System Pressure Release

Fuel Pressure Gauge 310-012 (JD209)
WARNING: PLACE THE VEHICLE IN A QUARANTINED AREA AND ARRANGE 'NO SMOKING/PETROL FUMES' SIGNS ABOUT THE VEHICLE. WARNING: BEFORE ANY WORK IS CARRIED OUT ON THE FUEL SYSTEM, GROUND THE VEHICLE TO EARTH AND MAINTAIN THE GROUND CONNECTION UNTIL THE WORK IS COMPLETE. WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE VAPORS ARE ALWAYS PRESENT AND MAY IGNITE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WARNING: THE FUEL SYSTEM REMAINS PRESSURIZED FOR A LONG TIME AFTER THE IGNITION IS SWITCHED OFF. THE FUEL PRESSURE MUST BE RELIEVED BEFORE ATTEMPTING ANY REPAIRS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WARNING: AFTER CARRYING OUT REPAIRS, THE FUEL SYSTEM MUST BE CHECKED VISUALLY FOR LEAKS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WARNING: THIS PROCEDURE INVOLVES FUEL HANDLING. BE PREPARED FOR FUEL SPILLAGE AT ALL TIMES AND ALWAYS OBSERVE FUEL HANDLING PRECAUTIONS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WARNING: IF TAKEN INTERNALLY DO NOT INDUCE VOMITING, SEEK IMMEDIATE MEDICAL ATTENTION. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WARNING: IF FUEL CONTACTS THE EYES, FLUSH THE EYES WITH COLD WATER OR EYEWASH SOLUTION AND SEEK MEDICAL ATTENTION. WARNING: WASH HANDS THOROUGHLY AFTER HANDLING, AS PROLONGED CONTACT MAY CAUSE
2012-07-20
IRRITATION. SHOULD IRRITATION DEVELOP, SEEK MEDICAL ATTENTION. WARNING: DO NOT CARRY OR OPERATE CELLULAR PHONES WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE VAPORS ARE ALWAYS PRESENT AND MAY IGNITE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
All vehicles
1. Disconnect the battery ground cable. <<414-01>>
www.JagDocs.com
2. Remove the fuel system pressure release valve cap.
2012-07-20

4. Remove the fuel system pressure release valve cap.
All vehicles
2012-07-20
www.JagDocs.com
5.
WARNING: MAKE SURE THE TAP OF THE SPECIAL TOOL IS ROTATED FULLY CLOCKWISE BEFORE INSTALLING THE SPECIAL TOOL TO THE FUEL SYSTEM PRESSURE RELEASE VALVE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
Install the special tool to the fuel system pressure relief valve.
6. NOTE: When relieving the fuel system pressure, catch any displaced fuel in a suitable container. Relieve the fuel system pressure. Rotate the tap of the special tool fully counterclockwise.
2012-07-20
7. Remove the special tool from the fuel system pressure relief valve.
8. Install the fuel system pressure relief valve cap.
2012-07-20
www.JagDocs.com
10. Install the fuel system pressure relief valve cap.
All vehicles
11. Connect the battery ground cable. <<414-01>>
2012-07-20
Fuel System
Fuel System
Fuel is stored in the fuel tank mounted across the vehicle behind the passenger compartment bulkhead. Fuel is drawn by the fuel pump from the tank and then supplied to the rail via a filter. Fuel injectors, controlled by the ECM are installed in the fuel rail on each side of the intake manifold. The amount of fuel injected into the engine is controlled by the ECM. A cross-over pipe connects the the fuel rail together at the front of the manifold. A test valve in the rail allows the fuel rail to be pressurized and de-pressurized during the servicing and troubleshooting procedures. A pressure regulator on the rear of the fuel rail controls the pressure in the fuel rail. A return line directs excess fuel from the pressure regulator back to the fuel tank.
2012-07-20
1999 XK RANGE - Fuel Tank and Lines - 310-01
Fuel Tank and Lines
Fuel Tank
www.JagDocs.com
The steel fuel tank is located inside the trunk and mounted across the vehicle behind the passenger compartment bulkhead. On the coupe model the tank is held in position by locating pins at at the front and retaining straps fitted to body-mounted brackets; on the convertible model it is held in position by the closing panel and locating pins at the front of the tank. A closing panel is fitted behind the tank on the convertible version. The fuel tank has an integral non-adjustable filler pipe and breather. Fuel is drawn by the fuel pump from the fuel tank and supplied via the fuel lines and 70 micron filter to the fuel rails. The fuel lines run from front-to-rear down the vehicle's left-hand-side and consist of two assembly clusters, front and rear, jointed near the fuel-filter position. The fuel pumps run constantly and excess fuel is returned to the fuel tank. The amount of fuel being injected into the engine is controlled by the engine management system.
Filler Cap and Pipe

The fuel filler cap with bayonet-type fixing is located beneath a remote-release spring-latched lid on the side of the rear panel tonneau on the left-hand-side of the vehicle. This is attached to a non-adjustable fuel pipe and breather integral with the fuel tank.
Check Valve
On vehicles with on-board refueling vapor recovery (ORVR) a check valve is located inside the fuel tank.
2012-07-20

Purge Valve
The purge valve is mounted in the left-hand front wheel arch and is controlled by the engine control module (ECM). It is linked to the evaporative emission canister system located in the left-hand front wheel arch.
Fuel Lines
The fuel lines run from front-to-rear down the vehicle's left side and consist of two assembly clusters front and rear, which are jointed near the fuel filter position. All fuel lines are serviceable; the removal of the front cluster requires no major disassembly but rear cluster removal requires the lowering of the rear suspension assembly. A variety of quick fit connectors are used throughout the fuel system, including the fuel tank to underfloor pipe connections above the rear axle.
Fuel Filter (In-line)
An in-line fuel filter is located under the rear seat pan.
2012-07-20

Fuel Pump
www.JagDocs.com
The fuel pump which is located inside the fuel tank, is energized by an ECM controlled relay. Fuel is drawn by this pump and supplied to the fuel injectors via the fuel line, filter and fuel rails. Servicing of the fuel pump requires fuel tank removal. Vehicles with supercharger are fitted with an additional fuel pump to compensate for the increase in fuel demand.
Fuel-Gauge Sender Unit
The sender unit for the fuel gauge is fitted into the back of the fuel tank and can be serviced without removing the tank. The fuel tank must be drained before removing the fuel gauge sender unit.
Fuel Valves
Any excess fuel flowing through the system is returned to the fuel tank via a diaphragm-operated fuel regulator
3 2012-07-20
valve which is mounted on the rear of the right fuel rail. Fuel-rail pressure is regulated at 3,0 bar above intake manifold pressure. Excess fuel is directed back to the fuel tank via a return line. A test valve is fitted to the fuel injection supply manifold. This valve allows the fuel rail to be pressurized and depressurized during servicing and troubleshooting.
Fuel Tank Supports
Two bracket-and-strap assemblies secure the tank in position on the coupe model only. A steel closing panel on the convertible version is fitted across the full width of the vehicle, bolted to the body behind the fuel tank with access to the fuel-gauge sender in the rear of the tank.
2012-07-20

Fuel Cut-Off Inertia Switch
www.JagDocs.com
The inertia switch, when operated, disables the ignition system and fuel pump, releases any locked doors and switches off unnecessary electrical systems. The inertia switch is located next to the fuse box at the left-hand end of the fascia. To reset the switch after it has been activated, the rubber cap on the top of the switch is pressed down.
Fuel Tank Earth Strap

On vehicles with a convertible top an earth strap is fitted from the left-hand rear flange of the fuel tank to the left-hand wheelarch.
2012-07-20

Fuel Pump Relay Location
Fuel Pump Relay
Operation
The fuel pump relay, under control of the ECM, switches power to the fuel pump motor.
2012-07-20
Monitoring Procedure
With the ignition on, the drive to the main fuel pump relay is examined. If the state of the drive is not as expected, then a main fuel relay failure judgement is made. The DTC is stored if failure is detected on two successive ignition cycles.
Access to Luggage Compartment Components

There are no mechanical fixings or retainers to be dealt with to gain access to the battery, fuse / relay center and fuel tank. However, the compartment floor should be removed to release the fuel tank liner.
www.JagDocs.com
2012-07-20
Fuel Filter 19.25.02

Removal 1. WARNING: BEFORE PROCEEDING, IT IS ESSENTIAL THAT THE WARNING NOTES GIVEN IN SECTION <<100-00>> (UNDER THE HEADING 'SAFETY PRECAUTIONS') ARE READ AND UNDERSTOOD.
Depressurize the fuel system, refer to <<19.50.02>>. 2. Drain the fuel tank using a suitable manually operated (NOT electrically operated) suction pump / tanker. 3. Raise the vehicle on a ramp.
4. Release the filter clamp from the vehicle body. Remove the bolt. Reposition the clamp clear of the filter.
2012-07-20
www.JagDocs.com
5.
CAUTION: Use two spanners to make sure no strain is placed on the pipes. NOTE: Position a suitable container below the filter to collect the fuel.
Remove the filter from the fuel pipes. Release the union nut and detach the pipe; fuel tank pipe to filter. Allow residual fuel to drain.
6. Remove the filter from the fuel pipes. 1. Release the union nut and detach the under floor pipe from the filter. 2. Remove the filter. Remove and discard the seals from the pipes. 7. Install blanking plugs to the pipes.
2012-07-20
Installation 1. Installation is the reverse of the removal procedure. Install new seals to the under floor pipe and to the fuel tank pipe. Tighten the bolt, filter bracket to body, to 5-7 Nm. Tighten the fuel pipe union nuts to 26-34 Nm.
2012-07-20
Fuel Level Sensor 88.25.32

Wrench - Fuel Level Sensor 310-001 (18G 1001) Removal 1. WARNING: BEFORE PROCEEDING, IT IS ESSENTIAL THAT THE WARNING NOTES GIVEN IN SECTION <<100-00>> (UNDER THE HEADING 'SAFETY PRECAUTIONS') ARE READ AND UNDERSTOOD.
www.JagDocs.com
Remove battery. Refer to operation <<86.15.01>>. 2. NOTE: If On-board Refueling Vapor Recovery (ORVR) system is fitted, refer to General Procedures Section <<310-00>>. Drain fuel tank using a suitable suction pump / tanker. 3. Remove trunk carpet for access. 4. Remove trunk front liner for access. Refer to operation <<76.19.31>>.
2012-07-20
5. Disconnect harness connections to the sensor.
6. Using special tool 18G 1001, remove sensor retaining ring.
2012-07-20
7. Remove sensor assembly and discard seal.
www.JagDocs.com
Installation 1. NOTE: Install new seal. Installation is a reversal of the removal procedure.
2012-07-20
Fuel Pump 19.45.08

Removal WARNING: PLACE THE VEHICLE IN A QUARANTINED AREA AND ARRANGE 'NO SMOKING/PETROL FUMES' SIGNS ABOUT THE VEHICLE. WARNING: BEFORE ANY WORK IS CARRIED OUT ON THE FUEL SYSTEM, GROUND THE VEHICLE TO EARTH AND MAINTAIN THE GROUND CONNECTION UNTIL THE WORK IS COMPLETE. WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE VAPORS ARE ALWAYS PRESENT AND MAY IGNITE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WARNING: THE FUEL SYSTEM REMAINS PRESSURIZED FOR A LONG TIME AFTER THE IGNITION IS SWITCHED OFF. THE FUEL PRESSURE MUST BE RELIEVED BEFORE ATTEMPTING ANY REPAIRS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WARNING: AFTER CARRYING OUT REPAIRS, THE FUEL SYSTEM MUST BE CHECKED VISUALLY FOR LEAKS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WARNING: THIS PROCEDURE INVOLVES FUEL HANDLING. BE PREPARED FOR FUEL SPILLAGE AT ALL TIMES AND ALWAYS OBSERVE FUEL HANDLING PRECAUTIONS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WARNING: IF TAKEN INTERNALLY DO NOT INDUCE VOMITING, SEEK IMMEDIATE MEDICAL ATTENTION. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WARNING: IF FUEL CONTACTS THE EYES, FLUSH THE EYES WITH COLD WATER OR EYEWASH SOLUTION AND SEEK MEDICAL ATTENTION. WARNING: WASH HANDS THOROUGHLY AFTER HANDLING, AS PROLONGED CONTACT MAY CAUSE IRRITATION. SHOULD IRRITATION DEVELOP, SEEK MEDICAL ATTENTION. WARNING: DO NOT CARRY OR OPERATE CELLULAR PHONES WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE VAPORS ARE ALWAYS PRESENT AND MAY IGNITE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Remove the fuel vapor vent valve. <<303-13>>
2012-07-20
2. Detach the fuel pump and position through top of tank.
www.JagDocs.com
3. Disconnect fuel pump electrical connector.
2012-07-20
4. Remove the fuel pump. Disconnect the fuel hose Remove the fuel pump.
Installation
1. Connect the fuel hose.
2012-07-20
www.JagDocs.com
2. Connect fuel pump electrical connector.
3.
CAUTION: Make sure the fuel pump is correctly located before the retaining bolt is fully tightened. Failure to follow these instructions may result in damage to the vehicle.
Install the fuel pump. Tighten to 10 Nm. 4. Install the fuel vapor vent valve. <<303-13>>
2012-07-20
Fuel Pump Relay 19.22.39

Removal 1. Disconnect the battery ground lead
2. Remove the luggage compartment fuse box cover
3. Locate relay #4 and remove
Installation 1. Fitting a new relay is the reverse of the removal procedure.
2012-07-20
Fuel Tank 19.55.01

www.JagDocs.com
Fuel Tank Sender Unit Wrench 310-001 Removal 1. WARNING: BEFORE PROCEEDING, IT IS ESSENTIAL THAT THE WARNING NOTES GIVEN IN SECTION <<100-00>> (UNDER THE HEADING 'SAFETY PRECAUTIONS') ARE READ AND UNDERSTOOD.
Release the fuel filler flap from inside vehicle. 2. Open the engine compartment and install paintwork protection covers. 3. Open the luggage compartment. 4. Remove the battery. Refer to operation <<86.15.01>>. 5. Depressurise the fuel system. Refer to operation <<19.50.02>>.
2012-07-20
6. Remove the paintwork protection covers and close the engine compartment. 7. Drain the fuel tank using a suitably manually operated (NOT electrically operated) suction pump / tanker. 8. Remove the carpet from the luggage compartment floor. 9. Remove the front liner from the luggage compartment. Refer to operation <<76.19.31>>. 10. Remove the side liner, left hand. Refer to operation <<76.19.22>>. 11. Remove the side liner, right hand. Refer to operation 76.19.23.
12. Convertible / Soft Top vehicles only - remove the fuel tank closing panel. Remove the seven bolts; three from the top edge and two from each lower bracket to body. Remove the closing panel. 13. Remove the fuel gauge tank sender unit. Refer to operation <<88.25.32>>. 14. Drain the remaining fuel from the tank, through the sender aperture, using the equipment described previously. 15. Install the fuel gauge tank sender unit. Refer to operation <<88.25.32>>.
2012-07-20
www.JagDocs.com
16. Release the filler neck gaiter retaining plate. 1. Remove the bolts which secure the retaining plate. 2. Remove the retaining plate. Reposition the gaiter into the luggage compartment area.
17. Release the tank retaining straps (Coupe). 1. Remove the screw which secures each strap. 2. Tape or tie the two retaining straps to the top of the luggage compartment.
2012-07-20
18. Disconnect the drain hose from the filler neck body aperture. Release and reposition the securing clip. Disconnect the drain hose.
19. Disconnect the electrical connector from the fuel filler flap solenoid.
2012-07-20
www.JagDocs.com
20. Disconnect the harness from the fuel tank connections. Disconnect the harness from the evaporative loss flange. Release the harness securing clips from along the tank flange. Move the harness and clips clear of the tank.
21. Remove the straps which secure the harness to the filler neck breather pipe.
2012-07-20
22. Disconnect the ground lead from the fuel tank flange.
23. Disconnect the tank breather hose. Release and reposition the securing clip. Disconnect the hose from the tank pipe. 24. Raise the vehicle on a ramp.
2012-07-20
www.JagDocs.com
25. Disconnect the filler neck gaiter drain hose from below the luggage compartment floor. Release the hose from the clip on the luggage compartment floor. Reposition the hose through the grommet into the luggage compartment.
26. From under the vehicle, identify the fuel feed and return tank / pipe connections which are located above and slightly to the rear of the axle assembly. 1. Identify the fuel feed pipe. 2. Identify the fuel return pipe.
2012-07-20
27. Disconnect the fuel feed and return pipes from the fuel tank. Install special tool 310-054 around the pipe as shown. Press the tool in between the fuel pipe and tank connector to release the quick-fit tangs. While holding the tool firmly in place, pull out the fuel pipe. Repeat for the second pipe. Plug the tank outlet connectors and the fuel pipes. 28. Lower the vehicle.
29.
CAUTION: Whilst removing the fuel tank, take care not to damage the left side of the vehicle body with the filler neck.
Remove the fuel tank. Reposition the fuel tank rearwards into the luggage compartment area. Lift the tank and turn it through 90 so that the filler neck protrudes rearwards, out of the luggage compartment.
2012-07-20
Remove the tank from the vehicle.
www.JagDocs.com
30. If installing a new, complete tank assembly - remove the insulation padsfrom the top of the tank. Use a sharp knife to very carefully remove the pads.
31. If installing a new, complete tank assembly - remove the seal (fuel tank to body) from the fuel line stub pipes at the base of the tank.
Installation
2012-07-20
1. If removed previously, install the seal (fuel tank to body) to the fuel line stub pipes at the base of the tank. Apply adhesive to the tank face of the seal before installation to the stub pipes.
2. If removed previously, install the insulation pads to the top of the tank. Apply adhesive to the pads, carefully align and locate them onto the tank.
10
2012-07-20
www.JagDocs.com
3.
CAUTION: Whilst installing the fuel tank, take care not to damage the left side of the vehicle body with the filler neck.
Install the fuel tank. Place the tank into the luggage compartment so that the filler neck protrudes rearwards from the vehicle. Lift the tank and turn it through approximately 90 so that the filler neck is on the left side, and the tank positioned towards the front. Reposition the fuel tank forwards into the luggage compartment well.
4. Route the filler neck gaiter drain hose through the luggage compartment floor. Reposition the hose through the grommet aperture in the luggage compartment. Install the grommet. Reposition the hose retaining clip to the side of the luggage compartment.
11
2012-07-20
5. Connect the tank breather hose. Connect the hose to the tank pipe. Reposition the securing clip.
6. Connect the harness to the fuel tank connections. Position the harness and clips along the tank to the filler flap latch. Install the harness securing clips along the tank top flange. Connect the harness to the evaporative loss flange. Secure the harness to the filler neck breather pipe using tie straps.
12
2012-07-20
www.JagDocs.com
7. Connect the ground lead to the fuel tank flange. Tighten to 7-10 Nm.
8. Install new straps which secure the harness to the filler neck breather pipe.
13
2012-07-20
9. Connect the electrical connector to the fuel filler flap solenoid.
10. Connect the drain hose to the filler neck body aperture. Connect the drain hose. Reposition the securing clip.
14
2012-07-20
www.JagDocs.com
11. Install the tank retaining straps (Coupe). 1. Release the two retaining straps taped to the top of the luggage compartment. 2. Install the screw which secures each strap. Tighten to 4-5.5 Nm.
12. NOTE: Reposition the gaiter through the body aperture. Install the filler neck gaiter retaining plate. 1. Reposition the retaining plate to align with the securing holes. 2. Install the bolts which secure the retaining plate. Tighten to 2.5-3.5 Nm. 13. Raise the vehicle on a ramp.
15
2012-07-20
14. NOTE: Remove the blanking plugs from the tank outlet connectors and the fuel pipes. Connect the fuel feed and return pipes to the fuel tank. 1. Install the fuel feed pipe to the Quick Fit Connector. Ensure that the pipe is fully locked in place. 2. Repeat for the return pipe. Ensure that the pipe is fully locked in place. 15. Install the filler neck drain tube into the clip. 16. Lower the vehicle. 17. Refill the fuel tank. Install the fuel filler cap and close the flap. Check for fuel leaks.
18. Convertible / Soft Top vehicles only - install the fuel tank closing panel.
16
2012-07-20
Install the closing panel. Install the seven bolts; three to the top edge and two to each lower bracket. Tighten to 22-28 Nm. 19. Install the left hand side liner to the luggage compartment. Refer to operation <<76.19.22>>. 20. Install the right hand side liner. Refer to operation 76.19.23. 21. Install the front liner. Refer to operation <<76.19.31>>. 22. Install the battery and battery cover. Refer to operation <<86.15.01>>. 23. Refer to the Battery Reconnection Procedure <<86.15.15>>. 24. Install the floor carpet. Refer to 76.19.30. 25. Close the luggage compartment cover.
www.JagDocs.com
17
2012-07-20
Fuel Tank Access Panel 76.11.32.90

Removal 1. Remove trunk floor carpet. 2. Remove battery cover. 3. Disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 4. Remove trunk rear liner. Refer to <<76.19.44>>. 5. Remove trunk left hand liner. Refer to <<76.19.22>>. 6. Remove trunk right hand liner. Refer to <<76.19.22>>.
7. Slacken and remove fuel tank closing panel securing bolts and carefully withdraw panel from trunk.
Installation 1. Carefully position fuel tank closing panel in trunk. 2. Fit and tighten panel securing bolts. 3. Fit trunk right hand liner. Refer to <<76.19.22>>. 4. Fit trunk left hand liner. Refer to <<76.19.22>>. 5. Fit trunk rear liner. Refer to <<76.19.44>>.
2012-07-20
6. Connect ground cable to battery terminal. Refer to <<86.15.15>>. 7. Fit battery cover. 8. Fit trunk floor carpet.
www.JagDocs.com
2012-07-20
Inertia Fuel Shutoff (IFS) Switch 18.30.35

2. Remove left hand instrument panel end fuse box cover.
3. Remove inertia switch. Remove screws. Disconnect connector and remove switch.
2012-07-20
1999 XK RANGE - Acceleration Control - 310-02
Accelerator Cable Adjustment

1. Load the Approved Jaguar Diagnostic System with power train data logger. 2. Connect the Approved Jaguar Diagnostic System to the vehicle. 3. With 'Disable Network Integrity Test - YES/ NO' displayed on the screen select YES. 4. With new menu displayed on the screen, select ' Engine Management'. 5. Turn the ignition to ON. Remove any previously selected data logger parameters. 6. On data logger select PPS11 and PPS2 (Pedal demand sensors 1 and 2). 7. On Sedan models only, remove the bulkhead covers on both sides and the engine compartment rear cover. 8. Cut, remove and discard the ratchet strap which retains the throttle cable to the abutment bracket. 9. Ensure there is no tension on the throttle cable by releasing the throttle cable adjustment nut from the abutment bracket. 10. Record the voltages for both sensors, PPS11 and PPS2. 11. Partially insert the throttle cable adjustment nut into the abutment bracket. 12. Recheck the voltages for both sensors, PPS11 and PPS2. 13. Where the voltages at step 12 are higher than the voltages taken at step 10, continue to step 15 below. 14. Where the voltages at step 12 are the same as the voltages taken at step 10, continue to step 16 below. 15. Rotate the adjustment nut clockwise (as viewed from the front of the vehicle) until the same voltages are indicated as in step 10. Continue to turn through a part revolution until the sides of the nut are vertical. Turn through a further 90 degrees, then fully insert the nut into the abutment bracket. 16. Rotate the adjustment nut anti-clockwise (as viewed from the front of the vehicle) until the indicated voltage starts to increase. Then rotate the nut clockwise through a part revolution until the sides are vertical. Turn through a further 90 degrees, then fully insert the nut into the abutment bracket. 17. Fit a new ratchet strap to secure the throttle cable adjusting nut to the abutment bracket. 18. Operate the throttle pedal through 20 full cycles to settle the cable. Check the voltages now shown, remain the same as in steps 15 and 16.
www.JagDocs.com
2012-07-20
19. Check and where necessary adjust the kickdown switch. For additional information, refer to <<307-05A>><<307-05B>> . 20. On Sedan models only, refit the engine compartment rear cover and the bulkhead covers on both sides. 21. Switch the ignition OFF and disconnect the Approved Jaguar Diagnostic System.
2012-07-20
Accelerator Cable 19.20.06

Removal 1. Disconnect the battery ground cable. 2. Remove the windshield and wiper arm assembly. 3. Remove the plenum chamber finisher, refer to <<76.10.01>>.
www.JagDocs.com
4. Disconnect the throttle cable from the electronic throttle assembly quadrant. 1. Rotate the throttle quadrant to release the cable. 2. Disconnect the throttle cable from the electronic throttle assembly quadrant.
2012-07-20
5. Displace the outer cable from the abutment bracket. 1. Cut the retaining strap. 2. Displace the outer cable from the abutment bracket.
6. Release the grommet from the plenum chamber closing plate and route the cable/grommet through the aperture.
7. Remove the throttle cable from the bulkhead retaining clip.
2012-07-20
8. Route the throttle cable through the water deflector bracket. 9. Ensure the drivers seat is fully rearward. 10. Remove the A-Pillar lower trim pad.
www.JagDocs.com
11. Disconnect the throttle cable from the pedal. 1. Remove the throttle cable split pin. 2. Remove the throttle cable retaining sleeve. 3. Disconnect the throttle cable. 12. From under the hood, remove the cable from the vehicle.
Installation 1. Installation is the reverse of the removal procedure. Adjust the throttle cable, refer to 19.20.08.
3 2012-07-20
1999 XK RANGE - Speed Control - 310-03
Speed Control
The Vehicle Speed Control system offers the driver relaxed vehicle cruising by enabling a pre-set constant vehicle speed to be maintained without driver operation of the accelerator pedal.
Vehicle Speed Control is activated by an ON/OFF master switch adjacent to the 'Sport' mode switch in the 'J' gate surround. An integral red light illuminates when the system is activated.
A steering wheel mounted four button control pad provides for driver increase (+) or decrease (-) of set vehicle speed, suspension of system operation with set speed memorised (CANCEL) and resumption of operation at memorised vehicle speed (RESUME). The selected vehicle speed is displayed in the message centre. The vehicle speed control system will not operate below 26km/h (16mph). The set vehicle speed can be increased or decreased in 2km/h (1mph) increments by briefly pressing the (+) or (-) control button up to a maximum of five times. Alternatively, the (+) or (-) button can be pressed and held until the required vehicle speed is displayed in the message centre.
2012-07-20
Speed Control
Principles of operation
The speed control system is activated by an ON/OFF master switch in the J-gate surround, which has an integral LED to indicate status. The steering wheel switches allow the driver to set the speed, increase or decrease the selected speed, cancel and resume the facility without his/her hand ever leaving the steering wheel The vehicle speed can be increased and decreased in increments of 2 kmh (1 mph) by briefly pressing the + or -buttons up to a maximum of five times. Alternatively, the + or - button can be held until the desired speed is reached. The selected speed (by whichever method) will be displayed in the message center. The system will not function at speeds below 26 kmh (16 mph), and can be cancelled from the master switch, the steering wheel switches, and by depressing the brake pedal. The system can be overridden by accelerating as normal.
www.JagDocs.com

1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical or electrical damage. 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the cause is not visually evident, verify the symptom, check for DTCs and follow the routines in this section. Visual Inspection Chart Mechanical Throttle body mechanism Electrical Throttle body actuator Module Switch(es) Instrument cluster
2012-07-20

DTC P0566 Description Speed control CANCEL switch ON fault Possible Source Speed control switches internal steering wheel short circuit to ground Steering wheel cassette reel short circuit to ground Cassette reel to ECM circuit short circuit to ground CANCELswitch failure (stuck ON) P0567 Speed control RESUME switch ON fault Speed control switches internal steering wheel short circuit to ground Steering wheel cassette reel short circuit to ground Cassette reel to ECM circuit short circuit to ground RESUMEswitch failure (stuck ON) P0568 Speed control switch ground malfunction Speed control switches internal steering wheel open circuit Steering wheel cassette reel open circuit or high resistance Cassette reel to ECM circuit open circuit or high resistance ACCEL/DECELswitch failure P0569 Speed control DECEL/SET (SET-) switch ON fault Speed control switches internal steering wheel short circuit to ground Steering wheel cassette reel short circuit to ground Cassette reel to ECM circuit short circuit to ground DECEL/SET switch failure (stuck ON) P0570 Speed control ACCEL/SET (SET+) switch ON fault Speed control switches internal steering wheel short circuit to ground Steering wheel cassette reel short circuit to ground Cassette reel to ECM circuit short circuit to ground ACCEL/SET switch failure (stuck ON) For ACCEL/SET circuit tests, Goto <<E>> . For DECEL/SET (SET-) switch circuit tests, Goto <<D>> . For ACCEL/DECEL switch circuit tests, Goto <<C>> . For RESUME switch circuit tests, Goto <<B>> . Action For CANCEL switch circuit tests, Goto <<A>> .
2012-07-20
P1571
Brake switch to ECM circuit open circuit, short circuit to ground, high resistance Brake switch ignition switched ground circuit open circuit Brake switch failure Brake cancel switch to ECM circuit open circuit, short circuit to ground, high resistance Brake cancel switch to speed control switch circuit open circuit, short circuit to ground, high resistance Brake cancel switch ignition switched power supply open circuit Brake cancel switch failure Speed control switch failure
For brake switch circuit tests, Goto <<F>> .
Pinpoint tests A : DTC P0566; SPEED CONTROL CANCEL SWITCH ON FAULT

WARNING: WHERE TESTS INVOLVE THE REMOVAL OF THE STEERING WHEEL, AND/OR DISCONNECTION OF AIR BAG CONNECTORS, THE PROCEDURE FOR DISARMING AIR BAGS MUST BE FOLLOWED, <<501-20A>><<501-20B>>
www.JagDocs.com
A1 : CHECK THE SPEED CONTROL SWITCHPACK INTERNAL CIRCUITS FOR SHORT TO GROUND
1. Disconnect the battery negative terminal. 2. Disconnect the speed control switchpack electrical connector, SW02. 3. Reconnect the battery negative terminal. 4. Measure the resistance between SW02, pin 06 (BO) and GROUND. 5. Measure the resistance between SW02, pin 03 (SG) and GROUND. Is either resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<A2>>
A2 : CHECK THE SPEED CONTROL CASSETTE REEL FOR SHORT TO GROUND

1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM11. 3. Reconnect the battery negative terminal. 4. Measure the resistance between SW02, pin 06 (at the cassette reel side of the connector) and GROUND.
2012-07-20
5. Measure the resistance between SW02, pin 03 (at the cassette reel side of the connector) and GROUND. Is either resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<A3>>
A3 : CHECK THE SPEED CONTROL CANCEL SWITCH ACTION

1. Measure the resistance between SW02, pin 06 (BO) and SW02, pin 03 (SG). 2. Operate the speed control CANCEL switch. Does the resistance vary by 680 ohms? -> Yes Recheck DTCs. No short found. Possible intermittent fault. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new speed control switchpack. CLEAR the DTC. TEST the system for normal operation.
B : DTC P0567; SPEED CONTROL RESUME SWITCH ON FAULT

B1 : CHECK THE SPEED CONTROL SWITCHPACK INTERNAL CIRCUITS FOR SHORT TO GROUND
1. Disconnect the speed control switchpack electrical connector, SW02. 2. Measure the resistance between SW02, pin 06 (BO) and GROUND. 3. Measure the resistance between SW02, pin 03 (SG) and GROUND. Is either resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<B2>>
B2 : CHECK THE SPEED CONTROL CASSETTE REEL FOR SHORT TO GROUND

1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM11. 3. Reconnect the battery negative terminal. 4. Measure the resistance between SW02, pin 06 (at the cassette reel side of the connector) and GROUND. 5. Measure the resistance between SW02, pin 03 (at the cassette reel side of the connector) and GROUND.
2012-07-20
Is either resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<B3>>
B3 : CHECK THE SPEED CONTROL RESUME SWITCH ACTION

1. Measure the resistance between SW02, pin 06 (BO) and SW02, pin 03 (SG). 2. Operate the speed control RESUME switch. Does the resistance vary by 430 ohms? -> Yes Recheck DTCs. No short found. Possible intermittent fault. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new speed control switchpack. CLEAR the DTC. TEST the system for normal operation.
www.JagDocs.com
C : DTC P0568; SPEED CONTROL SWITCH GROUND MALFUNCTION

C1 : CHECK FOR CONTINUITY THROUGH STEERING WHEEL CANCEL AND RESUME SWITCHES (SWITCHES OPEN)
1. Disconnect the speed control switchpack electrical connector, SW02. 2. Check for continuity between SW02, pins 06 (BO) and 03 (SG) with the steering wheel switches inactive. Is the circuit continuous? -> Yes INSTALL a new speed control switchpack. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<C2>>
C2 : CHECK FOR CONTINUITY THROUGH STEERING WHEEL CANCEL SWITCH (SWITCH CLOSED)
1. Check for continuity between SW02, pins 06 (BO) and 03 (SG) with the steering wheel CANCEL switch operated. Is the circuit continuous? -> Yes Goto <<C3>> -> No INSTALL a new speed control switchpack. CLEAR the DTC. TEST the system for normal operation.
2012-07-20
C3 : CHECK FOR CONTINUITY THROUGH STEERING WHEEL RESUME SWITCH (SWITCH CLOSED)
1. Check for continuity between SW02, pins 06 (BO) and 03 (SG) with the steering wheel RESUME switch operated. Is the circuit continuous? -> Yes Goto <<C4>> -> No INSTALL a new speed control switchpack. CLEAR the DTC. TEST the system for normal operation.
C4 : CHECK FOR CONTINUITY THROUGH STEERING WHEEL + AND - SWITCHES (SWITCHES OPEN)
1. Check for continuity between SW02, pins 06 (BO) and 04 (SR) with the steering wheel switches inactive. Is the circuit continuous? -> Yes INSTALL a new speed control switchpack. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<C5>>
C5 : CHECK FOR CONTINUITY THROUGH STEERING WHEEL + SWITCH (SWITCH CLOSED)

1. Check for continuity between SW02, pins 06 (BO) and 04 (SR) with the steering wheel CANCEL switch operated. Is the circuit continuous? -> Yes Goto <<C6>> -> No INSTALL a new speed control switchpack. CLEAR the DTC. TEST the system for normal operation.
C6 : CHECK FOR CONTINUITY THROUGH STEERING WHEEL - SWITCH (SWITCH CLOSED)

1. Check for continuity between SW02, pins 06 (BO) and 04 (SR) with the steering wheel CANCEL switch operated. Is the circuit continuous? -> Yes Goto <<C7>> -> No INSTALL a new cruise control switchpack. CLEAR the DTC. TEST the system for normal operation.
C7 : CHECK THE STEERING WHEEL CASSETTE REEL FOR CONTINUITY (CIRCUIT #1)
1. Disconnect the steering wheel cassette electrical connector, SW01.
2012-07-20
2. Measure the resistance between SW01, pin 06 and SW02, pin 06 through the cassette reel. Is the cassette reel continuous? -> Yes Goto <<C8>> -> No INSTALL a new steering wheel cassette. CLEAR the DTC. TEST the system for normal operation.
C8 : CHECK THE STEERING WHEEL CASSETTE REEL FOR CONTINUITY (CIRCUIT 2)

1. Measure the resistance between SW01, pin 03 and SW02, pin 03 through the cassette reel. Is the cassette reel continuous? -> Yes Goto <<C9>> -> No INSTALL a new steering wheel cassette. CLEAR the DTC. TEST the system for normal operation.
www.JagDocs.com
C9 : CHECK THE ECM TO CASSETTE REEL CIRCUIT FOR CONTINUITY (CIRCUIT 1)

1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM11. 3. Reconnect the battery negative terminal. 4. Measure the resistance between EM11, pin 01 (SR) and SW01, pin 04 (SR). Is the resistance greater than 5 ohms? -> Yes REPAIR the circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<C10>>
C10 : CHECK THE ECM TO CASSETTE REEL CIRCUIT FOR CONTINUITY (CIRCUIT 2)
1. Measure the resistance between EM11, pin 05 (SG) and SW01, pin 03 (SG). Is the resistance greater than 5 ohms? -> Yes REPAIR the circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Contact dealer technical support for advice on possible ECM failure.
D : DTC P0569; SPEED CONTROL DECEL/SET- SWITCH ON FAULT

2012-07-20
D1 : CHECK THE SPEED CONTROL SWITCHPACK INTERNAL CIRCUITS FOR SHORT TO GROUND
1. Disconnect the speed control switchpack electrical connector, SW02. 2. Measure the resistance between SW02, pin 06 (BO) and GROUND. 3. Measure the resistance between SW02, pin 04 (SR) and GROUND. Is either resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<D2>>
D2 : CHECK THE SPEED CONTROL CASSETTE REEL FOR SHORT TO GROUND

1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM11. 3. Reconnect the battery negative terminal. 4. Measure the resistance between SW02, pin 06 (at the cassette reel side of the connector) and GROUND. 5. Measure the resistance between SW02, pin 04 (at the cassette reel side of the connector) and GROUND. Is either resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<D3>>
D3 : CHECK THE SPEED CONTROL DECEL/SET- SWITCH ACTION

1. Measure the resistance between SW02, pin 06 (BO) and SW02, pin 04 (SR). 2. Operate the speed control DECEL/SET- switch. Does the resistance vary by 680 ohms? -> Yes Recheck DTCs. No short found. Possible intermittent fault. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new speed control switchpack. CLEAR the DTC. TEST the system for normal operation.
E : DTC P0570; SPEED CONTROL 'ACCEL/SET+' SWITCH 'ON' FAULT

2012-07-20
E1 : CHECK THE SPEED CONTROL SWITCHPACK INTERNAL CIRCUITS FOR SHORT TO GROUND
1. Disconnect the speed control switchpack electrical connector, SW02. 2. Measure the resistance between SW02, pin 06 (BO) and GROUND. 3. Measure the resistance between SW02, pin 04 (SR) and GROUND. Is either resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<E2>>
E2 : CHECK THE SPEED CONTROL CASSETTE REEL FOR SHORT TO GROUND

1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, EM11. 3. Reconnect the battery negative terminal. 4. Measure the resistance between SW02, pin 06 (at the cassette reel side of the connector) and GROUND. 5. Measure the resistance between SW02, pin 04 (at the cassette reel side of the connector) and GROUND. Is either resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<E3>>
www.JagDocs.com
E3 : CHECK THE SPEED CONTROL ACCEL/SET+ SWITCH ACTION

1. Measure the resistance between SW02, pin 06 (BO) and SW02, pin 04 (SR). 2. Operate the cruise control ACCEL/SET+ switch. Does the resistance vary by 430 ohms? -> Yes Recheck DTCs. No short found. Possible intermittent fault. CLEAR the DTC. TEST the system for normal operation. -> No INSTALL a new speed control switchpack. CLEAR the DTC. TEST the system for normal operation.
F : DTC P1571; BRAKE SWITCH MALFUNCTION

2012-07-20
F1 : CHECK THE BRAKE SWITCH TO ECM CIRCUIT FOR HIGH RESISTANCE

1. Disconnect the battery negative terminal. 2. Disconnect the brake switch electrical connector, AC24. 3. Disconnect the ECM electrical connector, EM10. 4. Measure the resistance between AC24, pin 01 (US) and EM10, pin 10 (US). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<F2>>
F2 : CHECK THE BRAKE SWITCH TO ECM CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between AC24, pin 01 (US) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<F3>>
F3 : CHECK THE BRAKE SWITCH TO ECM CIRCUIT FOR SHORT TO GROUND

1. Turn the ignition switch to the OFF position. 2. Measure the resistance between AC24, pin 01 (US) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<F4>>
F4 : CHECK THE BRAKE SWITCH IGNITION SWITCHED GROUND CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the brake switch electrical connector, AC24. 3. Disconnect the ignition switch electrical connector, FC04. 4. Measure the resistance between AC24, pin 04 (WO) and FC04, pin 03 (WO). Is the resistance greater than 5 ohms? -> Yes
10
2012-07-20
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<F5>>
F5 : CHECK THE BRAKE SWITCH OPERATION

1. Measure the resistance between AC24, pins 01 and 04. 2. Operate the brake pedal up and down. Does the resistance switch between open circuit and continuity as the pedal is operated? -> Yes Goto <<F6>> -> No INSTALL a new brake switch. CLEAR the DTC. TEST the system for normal operation.
F6 : CHECK THE BRAKE CANCEL SWITCH TO ECM CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the brake switch electrical connector, AC24. 2. Disconnect the ECM electrical connector, EM10. 3. Measure the resistance between AC24, pin 02 (PG) and EM10, pin 11 (PG). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<F7>>
www.JagDocs.com
F7 : CHECK THE BRAKE CANCEL SWITCH TO ECM CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between AC24, pin 02 (PG) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<F8>>
F8 : CHECK THE BRAKE CANCEL SWITCH TO ECM CIRCUIT FOR SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between AC24, pin 02 (PG) and GROUND. Is the resistance less than 10,000 ohms? -> Yes
11
2012-07-20
REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<F9>>
F9 : CHECK THE BRAKE CANCEL SWITCH TO CRUISE CONTROL SWITCH TO ECM CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the brake switch electrical connector, AC24. 3. Disconnect the ECM electrical connector, EM11. 4. Disconnect the speed control switch electrical connector, FC63. 5. Measure the resistance between AC24, pin 03 (WU) and EM11, pin 04 (WU). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<F10>>
F10 : CHECK THE BRAKE CANCEL SWITCH TO CRUISE CONTROL SWITCH TO ECM CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between AC24, pin 03 (WU) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<F11>>
F11 : CHECK THE BRAKE CANCEL SWITCH TO CRUISE CONTROL SWITCH TO ECM CIRCUIT FOR SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between AC24, pin 03 (WU) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<F12>>
12
2012-07-20
F12 : CHECK THE BRAKE CANCEL SWITCH IGNITION SWITCHED POWER SUPPLY
1. Turn the ignition switch to the ON position. 2. Measure the voltage between AC24, pin 03 (WU) and GROUND. Is the voltage less than 10 volts? -> Yes REPAIR the circuit between the brake cancel switch and the ignition switch. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation. -> No Goto <<F13>>
F13 : CHECK THE BRAKE CANCEL SWITCH OPERATION

1. Measure the resistance between AC24, pins 02 and 03. 2. Operate the brake pedal up and down. Does the resistance switch between open circuit and continuity as the pedal is operated? -> Yes Recheck the DTCs. Failure of other cruise control circuits will set other DTCs, indicating the component at fault. -> No INSTALL a new brake cancel switch. CLEAR the DTC. TEST the system for normal operation.
www.JagDocs.com
13
2012-07-20
1999 XK RANGE - Climate Control System - General Information - 412-00
Specification for Recovery / Recycle / Recharge Equipment NOTE: ppm = parts per million Feature Recovery rate Cleaning capability Oil separator Moisture indicator Vacuum pump Filter Charge Hoses Charge pressure Requirement 0,014 - 0,062 m3 / min. (1,36 kg in 20 minutes) 15 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 Two-stage 0,07 - 0,127 m3 / min. Replaceable, with moisture indicator Selectable charge weight and automatic delivery Dedicated HFC 134A port connections Heating element to increase pressure
Lubricants, Fluids, Sealants and Adhesives Unit Refrigerant Compressor lubricant Specification HFC 134A Polyalkyleneglycol (PAG)
Capacities Unit Refrigerant charge weight Compressor lubricant capacity Specification 650 +/- 50 g 160 - 200 ml
2012-07-21
Air Conditioning (A/C) System Check - Retail Procedure
Evacuating the Manifold Gauge Set

1. Attach the center (service) hose to a vacuum pump and start the pump. Open fully both high and low valves and allow the vacuum to remove air and moisture from the manifold set for at least five minutes. CAUTION: It is imperative that the vacuum pump is not subjected to a positive pressure of any degree. Therefore the pump must be fitted with an isolation valve at the center (service hose) connection and this valve must be closed before the pump is switched off. This operation replaces the 'purge' procedure used on previous systems. Observe the manufacturer's recommendation with regard to vacuum pump oil changes. Turn the vacuum pump off and isolate it from the center service hose but do not open the hose to atmosphere.
Connecting the Manifold Gauge Set

CAUTION: Only use hoses with connectors which are dedicated to HFC 134A charge ports.
www.JagDocs.com
1. Attachment of the hose quick release connectors to the high and low side system ports is straightforward, provided that the high and low valves are closed and the system is NOT operational. 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. Assessment of system operating efficiency and fault classification may be achieved by using the facilities on your Recovery / Recharging / Recycling station, follow the manufacturer's instructions implicitly and observe all safety considerations.
Stabilizing the System

1. 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 recommended that a free standing air mover is placed in front of the vehicle to provide air flow through the condenser / cooling system. Start the engine, allow it to attain normal working temperature and set at fast idle (typically 1200 to 1500 rpm). Select full air conditioning performance. With all temperatures and pressures stable, or displaying symptoms of faults; begin relevant test procedures.
2012-07-21
Air Conditioning (A/C) System Recovery, Evacuation and Charging
Recover / Reclaim
1.
CAUTION: Read the procedures and instructions supplied by the manufacturer of the air conditioning service center before commencing any process requiring the handling of refrigerant. In addition to the manufacturer's information, observe all safety precautions and advice detailed in this section.
Disconnect battery ground lead; refer to <<86.15.19>>. 2. Remove passenger side firewall cover. 3. Remove driver side firewall cover. 4. Remove engine compartment rear cover.
5. Remove vehicle charge port protective caps and connect equipment pressure hoses to vehicle. 1. BLUE hose = low pressure. 2. RED hose = high pressure. 6. Complete procedure in accordance with equipment manufacturer's instructions.
Evacuation
1. Complete procedure in accordance with equipment manufacturer's instructions. This process will typically take 30 minutes, but will depend upon the equipment and the extent of repairs carried out to the system.
2012-07-21
Charging
1. Set the appropriate charge weight, see Specifications in this section. 2. Complete procedure in accordance with equipment manufacturer's instructions. 3. Disconnect hoses from vehicle and replace charge port protective caps. 4. Reconnect battery ground lead; refer to <<86.15.15>>. 5. Check system for correct operation.
www.JagDocs.com
2012-07-21
Manifold Gauge Set Connection

1. The 'manifold gauge set' is a most important tool for tracing faults and system efficiency assessment. The relationship between HIGH and LOW pressures and their correlation to AMBIENT and EVAPORATOR temperatures must be compared to determine system status (see Pressure / Temperature graphs).Because of the heavy reliance upon this piece of equipment for service diagnosis, ensure that the gauges are calibrated regularly and the equipment is treated with care.
2. Parts List Item 1 2 3 4 5 6 7 Description LOW side service hose - BLUE LOW side hand valve - BLUE LOW pressure compound gauge _ BLUE HIGH pressure gauge _ RED HIGH side hand valve - RED HIGH side service hose - RED System service hose - Neutral color, commonly YELLOW
Manifold.
1. The manifold is designed to control refrigerant flow. When connected into the system, pressure is registered
2012-07-21

on 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 center (service) hose.
Low Side Pressure Gauge.

1. This compound gauge, is designed to register positive and negative pressure and may be typically calibrated - Full Scale Deflection, 0 to 10 bar (0 to 150 lbf / in2) pressure in a clockwise direction; 0 to 1000 mbar (0 to 30 in Hg) FSD negative pressure in a counter clockwise direction.
High Side Pressure Gauge.

1. This pressure gauge may be typically calibrated from 0 to 30 bar (0 to 500 lbf / in2) FSD in a clockwise direction. Depending on the manufacturer, this gauge may also be of the compound type.
www.JagDocs.com
2012-07-21
Refrigerant Adding
CAUTION: If oil was drawn out during the recovery process, the correct amount may be added directly from the recovery, recycle and recharge station (if so equipped) prior to the charging process. It must be stressed that the need to protect compressor oil from moisture is vital, observe the procedures in HANDLING LUBRICATING OIL and those concerning excessive engine speed.
1. In order that the air conditioning system may operate efficiently it must contain a full refrigerant charge. The indications of some system defects, and the results of certain tests, will show that a low charge is the most probable cause of the fault. In such cases the charge should be recovered from the system, the weight noted, and the correct amount added.Should refrigerant be added in liquid form, the engine speed must not exceed 2000 rpm for a period of two minutes after first running the compressor. If the engine speed is excessive, compressor damage may occur due to the lubricating oil and the liquid refrigerant being initially forced around the system as a 'slug', thus taking oil away from the compressor. These marginal lubrication conditions in the compressor will cease as the refrigerant becomes gaseous.Never attempt to estimate the amount of refrigerant in a system. Always recover and recharge with the correct charge weight; this is the only accurate method.
2012-07-21
Refrigerant Oil Adding

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.
1. 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 30 to 40 ml.; this may vary, and the figure is given only for guidance.The oil separator vessel in the recovery equipment must be clean and empty at the start of the process, so that the quantity of oil which is drawn out may be accurately measured.NOTE: The equipment manufacturer's instructions must be followed when adding oil directly into an original, or new unit, owing to rectification work to the existing compressor, or the need to fit a new compressor. Oil may be added to the system either via the recovery, recycle and recharge station or by using a proprietary oil injector. Alternatively, if the compressor has been removed from the vehicle, the oil may be added directly to the compressor.
www.JagDocs.com
Original Compressor
1. From an existing compressor, drain the oil into a measuring cylinder and record the amount. Flush the unit out with fresh oil and drain thoroughly. Replenish the compressor with the same amount of oil that was originally drained out and immediately plug all orifices ready for refitting to the vehicle.
New Compressor
1. Drain and discard the transit lubricating oil from the new compressor before it is be fitted.To avoid over-filling the system, an allowance must be made for the quantity of oil found in the original compressor and the quantity deposited in the recovery equipment oil separator from the charge recovery operation.Typical example: Drained from original compressor - 50 ml. Recovered from oil separator - 40 ml. Quantity to be put in new compressor - 50 + 40 = 90 ml. 2. The difference between the combined total quantity of recovered and drained oil and the nominal capacity of the system (180 ml.), is due to the quantity of oil remaining in components such as the condenser, receiver drier or evaporator. This oil is not normally recoverable.The same procedure may be followed if a problem has occurred due to oil leakage, as the amount of oil lost is generally small. If the recovery process has not been necessary, because refrigerant has also been lost, then only the quantity drained from the original compressor needs to be replaced.
System Components
1. Should a major component such as condenser, receiver drier or evaporator be renewed, then an adjustment to the system oil content must be made. This may be carried out in the same way as the examples for the compressor, except for the fact that trapped oil within any of these components cannot normally be recovered. An extra quantity of oil should be added, in addition to that recovered from the recovery station separator, as follows: Condenser - Add 40 ml. Evaporator - Add 40 ml. Receiver drier - No addition.
1 2012-07-21
Refrigerant System Tests

WARNING: USE EXTREME CARE AND OBSERVE ALL SAFETY PRECAUTIONS RELATED TO THE USE OF REFRIGERANTS. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN PERSONAL INJURY. CAUTION: The A/C refrigerant analyzer must be used before the recovery of any vehicle's A/C refrigerant. Failure to do so puts workshop bulk refrigerant at risk of contamination. If the vehicle A/C refrigerant is contaminated, refer the customer to return to the repair facility that carried out the last A/C repair. If the customer wishes to pay the additional cost, use the A/C recovery equipment that is designated for recovering contaminated A/C refrigerant. All contaminated A/C refrigerant must be disposed of as hazardous waste. To prevent possible personal injury, for all equipment, follow the equipment manufacturer's procedures and instructions. NOTE: Jaguar Cars Ltd. supports the efficient usage, recovery and recycling of the refrigerant used in passenger car air conditioners. Jaguar Cars Ltd. recommends the use of UL-approved recovery/recycling equipment during any A/C system repair and recharge procedure which requires that the system be evacuated. 1. Use UL-approved recovery/recycling equipment to evacuate and recover the A/C system. Follow the equipment manufacturer's procedures and instructions for use of equipment.
2012-07-21
Climate Control System

CAUTION: Observe all relevant safety requirements. Wear suitable eye and skin protection Do not mix HFC 134A and CFC 12 refrigerants. Do not vent refrigerant directly to atmosphere and always use Jaguar approved recovery, recycle and recharge equipment. Note the amount of recovered refrigerant; it will indicate the state of the system.
Working Practices
Be aware of, and comply with all health and safety requirements, whether they be legislative or common sense. This applies to conditions set both for the operator and workshop. Before commencing any repair or service procedure, disconnect the vehicle battery ground lead and protect the vehicle, where appropriate, from dirt or damage. Work in a well ventilated, clean and tidy area. Keep all components and tools clean. Recovery, recycle and recharge equipment must meet, or exceed, the requirements detailed in the Specification sub-section.
www.JagDocs.com
Handling Refrigerant
Wear eye protection at all times. Use gloves and keep all skin covered that may come into contact with refrigerant. Should refrigerant come into contact with eyes or skin, wash the affected area with cool water and seek medical advice; do not attempt to treat the condition yourself. Avoid breathing refrigerant vapor; it may cause irritation to the respiratory system. CAUTION: Never use high pressure compressed air to flush out a system. Under certain circumstances a combination of HFC 134A refrigerant, compressed air and a source of combustion (welding and brazing operations in the vicinity), may result in an explosion and the release of potentially toxic compounds.
2012-07-21

HFC 134A and CFC 12 refrigerants must never come into contact with each other. They will form an inseparable mixture which can only be disposed of by incineration. Do not vent refrigerant directly to atmosphere; always use Jaguar approved recovery equipment. Never depress the charge or discharge port valves to check for the presence of refrigerant. HFC 134A refrigerant is fully recycleable and it may be 'cleaned' by the recovery equipment and therefore re-used following removal from a system. WARNING: NEVER USE A CFC 12 ANALYZER OR NAKED FLAME TYPE. Leak tests should be carried out with a UV spot lamp or an electronic analyzer which is dedicated to HFC 134A refrigerant.
Handling Lubricating Oil

Avoid breathing lubricant mist; it can cause irritation to the respiratory system. Always use fresh oil from a sealed container and do not leave oil exposed to the atmosphere for any reason other than to fill or empty a system. PAG oil is very hygroscopic (absorbs water) and will rapidly become contaminated by atmospheric moisture.
PAG oil is NOT compatible with previously used mineral based oils and must NEVER be mixed. Do not re-use oil when it has been separated from refrigerant, following a recovery cycle. Dispose of used oil safely.
System Maintenance
Plug pipes and units immediately after disconnection and do not remove the plugs until immediately before making the connection. Do not leave the system open to atmosphere. The receiver drier must be renewed if the compressor has failed or if it is suspected that debris may be present in the system. It is not always necessary to renew the receiver drier if the correct procedures have been followed. However, if a component or part of the system is left dismantled for more than five minutes, it may be advisable to renew the receiver drier. This guidance is based on UK average humidity levels; locations with lower humidity levels will be less critical to moisture contamination. It must be stressed however that there is not a safe period for work to be carried out in. Do not use any replacement parts supplied without transit plugs and seals - return them to the supplier.
2012-07-21
Diagnostic equipment for pressure, mass and volume should be calibrated regularly and certified by a third party organization. Use extreme care when handling and securing aluminum fittings; always use a backing spanner and take special care when handling the evaporator. Use only the correct or recommended tools for the job and apply the manufacturer's torque specifications.
Graph - High Side Pressure against Ambient Temperature
www.JagDocs.com
The 'Normal' condition is that which is relevant to the prevailing ambient temperature.
2012-07-21
Graph - Low Side Pressure against Evaporator Temperature
(To obtain lbf / in2 from bar, multiply the figure by 14.5) Probable causes of faults may be found by comparing actual system pressures, registered on your manifold gauge set or recovery / recharge / recycle station, and the relevant pressure to temperature relationship graph. The following chart shows the interpretation that may be made by this difference. NOTE: The A/CCM will disengage the compressor clutch should the evaporator temperature fall to 0C. NOTE: Graphs are typical for HFC 134A The 'Normal' condition is that which is relevant to the prevailing evaporator temperature.
System Pressure Fault Classification

NOTE: If erratic or unusual gauge movements occur, check the equipment against a known (calibrated) manifold gauge set. This table should be used in conjunction with the graphical representations of 'High side' pressure / ambient temperature and 'Low side' pressure / evaporator temperature.
2012-07-21

Low side gauge reading Normal Normal to low Low Low Low High side gauge reading Normal Normal Low Low Low Fault Cause
Discharge air initially cool then warms up As above Discharge air slightly cool Discharge air warm Discharge air slightly cool or frost build up at expansion valve Discharge air slightly cool, sweating or frost after point of restriction Compressor noisy Discharge air warm and high side pipes hot Discharge air warm / Sweating or frost at evaporator
Moisture in system As above Refrigerant charge low Refrigerant charge very low Expansion valve stuck closed
Low
Low
Restriction in High side of system
High High
Low High
Defective compressor reed valve Refrigerant charge high or inefficient condenser cooling due to air flow blockage or engine cooling fans not working Expansion valve stuck open
High
High
www.JagDocs.com
Leak Test
Faults associated with low refrigerant charge weight and low pressure may be caused by leakage. Leaks traced to mechanical connections may be caused by torque relaxation or joint face contamination. Evidence of oil around such areas is an indicator of leakage. Models that have fluorescent tracer dye incorporated into the refrigeration system can be checked for non-apparent leaks by scanning with a high intensity ultraviolet lamp. The location of leaks can be pinpointed by the bright yellow glow of the tracer dye. CAUTION: Observe ALL safety precautions associated with ultraviolet equipment. Should a leak be traced to a joint, check that the fixing is secured to the correct tightening torque before taking any other action. When examining the system for leaks, check the compressor shaft seal and evaporator.
Charge Recovery (system depressurization)

The process of charge recovery will depend on the basic characteristics of your chosen recovery / recycle / recharge equipment, therefore, follow the manufacturer's instructions carefully. Remember that compressor oil may be drawn out during this process, take note of the quantity recovered so that it may be replaced.
Evacuating the System

This process, the removal of unwanted air and moisture, is critical to the correct operation of the air conditioning system. Moisture in the system can be highly destructive and may cause internal blockages due to freezing; water suspended in the lubricating oil will damage the compressor. Once the system has been dismantled, or the refrigerant charge
2012-07-21

recovered, all traces of moisture must be removed before recharging. Specific procedures will vary depending on the individual characteristics of the recovery / recycle / recharge equipment, and must be carried out exactly in accordance with the manufacturer's instructions. However, it is recommended that initially only the high-side 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 and the evacuation process completed. If a vacuum is not registered on the low-side, it may indicate that the expansion valve is permanently closed or that the system is blocked. This simple check may save time and effort when the system is recharged.
2012-07-21
Climate Control System

Introduction
It is very important to positively identify the 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. See below for example:
Condition(s): No defrost Possible Source(s): No airflow to windshield Action(s) to take: Check blowers and flaps Possible Source(s): No function in defrost mode Action(s) to take: Check A/CCM Possible Source(s): Mode selection not available Action(s) to take: Check control panel communication Possible Source(s): Airflow OK but no heat Action(s) to take: Check water pump and valve Relevant criteria are: Weather conditions, ambient temperature, intermittent or continuous fault, airflow fault, temperature control fault, distribution fault and air inlet problem.
www.JagDocs.com
Functional Check
This simple 'first line check' will allow you to ascertain whether the system is operating within its design parameters, without recourse to PDU. 1. With the engine at normal running temperature. 2. Presss AUTO to display selected temperature and illuminate AUTO and A/C state lamps. 3. Rotate FAN to increase or decrease lower speed, verify bar graph representation. 4. Select A/C to toggle on or off. (The compressor may be inhibited by the ECM should either the engine temperature NOT be normal or the ambient be < 2 C). 5. Select RECIRC , state lamp should be lit and the recirculation flaps open. 6. Select distribution buttons in turn, verify correct air distribution and relevant state lamp. 7. Select DEFROST , check max fans and air to the windshield. 8. Cycle TEMPERATURE to ' HI ' and ' LO ' to verify demanded variations and display operation. Note that extremes will provide max heat or cold independent of in-car temperature.
1 2012-07-21
9. Select EXT to toggle between ambient and control temperatures. 10. Select F (where fitted) and R - noting exterior mirror; verify timer and operation (glass may be warm to the touch) 11. Initiate system 'Self Test' to display stored faults should any of the above not perform as stated.
System symptoms
There are five basic symptoms associated with air conditioning fault diagnosis. The following conditions are not in order of priority.
Symptom #1
Condition(s): No cooling Possible Source(s): Compressor seized Compressor seal failure Compressor valve or piston damage Action(s) to take: Renew compressor Possible Source(s): Compressor clutch / circuit faulty Action(s) to take: Refer to PDU Possible Source(s): Drive belt slack / broken Action(s) to take: Adjust or renew Possible Source(s): Blower motor / circuit faulty Pressure switch / circuit fault Action(s) to take: Refer to PDU Possible Source(s): Total loss of refrigerant caused by broken pipe or joint Action(s) to take: Repair / renew. Check code 23 Possible Source(s): Partial loss of refrigerant caused by leaking joint or pipe Action(s) to take: Repair / renew, check fault code #23 Possible Source(s):
2 2012-07-21

Condenser damage Action(s) to take: Renew, check fault code #23 Possible Source(s): Blocked receiver / drier filter Action(s) to take: Renew receiver / drier Possible Source(s): Evaporator sensor / circuit faulty Action(s) to take: Refer to PDU, check fault code #13 Possible Source(s): Blocked pollen filter (if fitted) Action(s) to take: Clean or renew
www.JagDocs.com
Symptom #2
Condition(s):NOTE: Should a leak 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. Insufficient cooling Possible Source(s): Compressor clutch slipping Action(s) to take: Renew clutch assembly Possible Source(s): Flaps or vents closed / seized Action(s) to take: Check fault codes #41 to 46 Possible Source(s): Blower circuit fault Action(s) to take: Refer to PDU Possible Source(s): Blocked condenser matrix / fins Action(s) to take: Check high / low side pressures / renew. Check / clean fins Possible Source(s): Blocked evaporator matrix Action(s) to take:
2012-07-21

Check high / low side pressures / renew
Possible Source(s): Blocked pollen filter (if fitted) Action(s) to take: Clean or renew Possible Source(s): Evaporator temperature sensor faulty Action(s) to take: Refer to PDU Possible Source(s): Partial loss of refrigerant caused by leaking joint or pipe Action(s) to take: Repair / renew Possible Source(s): Blocked expansion valve Action(s) to take: Check high / low side pressures / renew Possible Source(s): Expansion valve fault Action(s) to take: Check system pressure differential Possible Source(s): Collapsed air conditioning hose hose Action(s) to take: Check high / low side pressures / renew Possible Source(s): Moisture or air in the system Action(s) to take: Check system pressures Possible Source(s): Low refrigerant charge Action(s) to take: Initiate recovery procedure, check fault code #23 Possible Source(s): Coolant flow valve open Action(s) to take: Check operation
Symptom #3
Condition(s):
2012-07-21
Intermittent cooling Possible Source(s): Compressor clutch slipping Action(s) to take: Renew clutch assembly Possible Source(s): Compressor clutch circuit faulty Blower(s) circuit faulty Action(s) to take: Refer to PDU Possible Source(s): Motorized in-car aspirator faulty Action(s) to take: Refer to PDU, check fault code #11 Possible Source(s): Evaporator temperature sensor faulty Action(s) to take: Refer to PDU, check fault code #13 Possible Source(s): Blocked condenser matrix / fins Action(s) to take: Check high / low side pressures / renew. Check / clean fins Possible Source(s): Blocked evaporator matrix Action(s) to take: Check high / low side pressures / renew
www.JagDocs.com
Symptom #4
Condition(s): Noisy system Possible Source(s): Loose or damaged compressor drive belt Action(s) to take: Adjust or renew Possible Source(s): Loose compressor mountings Action(s) to take: Check for damage, tighten to specification if OK Possible Source(s): Compressor oil level low
2012-07-21
Action(s) to take: Look for evidence of leakage and rectify as required Possible Source(s): Compressor internal damage Action(s) to take: Check for debris, renew compressor and receiver drier Possible Source(s): Blower motor noise Action(s) to take: Renew motor (assuming no fan interference) Possible Source(s): Excessive refrigerant charge Action(s) to take: Check for vibration or 'thumping' in high pressure line; may be witnessed by high pressure on both HIGH and LOW sides. Recover / recharge Possible Source(s): Low refrigerant charge Action(s) to take: Check for 'hissing' at expansion valve; may be witnessed by low HIGH side pressure. Recover / recharge Possible Source(s): Moisture or air in the system Action(s) to take: Check system pressures Possible Source(s): Heater circuit air-lock Action(s) to take: Refer section 303-03 for fill / bleed procedure Possible Source(s): Suction pipe touching bank 1 (A) cylinder head (rubber isolator missing) Action(s) to take: Check the pipe cluster for correct fitting
Symptom #5
Condition(s):NOTE: Electrical faults may be more rapidly traced using PDU Insufficient heating Possible Source(s): Coolant flow valve stuck 'closed' Coolant flow valve stuck 'open' allowing recirculation of coolant at engine idle
2012-07-21
Action(s) to take: Renew valve Possible Source(s): Motorized in-car aspirator seized Action(s) to take: Renew aspirator Possible Source(s): Cool air bypass damper stuck open Action(s) to take: Renew, check fault code #43 Possible Source(s): Blocked air inlet / pollen filter Action(s) to take: Check / clean / renew Possible Source(s): Blower speed low Action(s) to take: Check performance range Possible Source(s): Low coolant level Action(s) to take: Adjust as required (verify and correct reason for loss) Possible Source(s): Engine thermostat faulty Action(s) to take: Check engine running temperature Possible Source(s): Heater water pump seized Action(s) to take: Check operation Possible Source(s): Heater matrix blocked Action(s) to take: Renew matrix Possible Source(s): Heater circuit air-lock Action(s) to take: Refer section 303-03 for fill / bleed procedure
www.JagDocs.com
2012-07-21
1999 XK RANGE - Air Distribution and Filtering - 412-01
Air Distribution and Filtering

Air Distribution
Outside air enters the plenum via two inlets in the lower finisher at the base of the windshield. If the air conditioning system is operating in FRESH mode (not recirculation mode), then air is drawn through an air particle filter (where fitted) and into the air conditioning unit via the blower interconnecting ducts in the LH and RH blower assemblies. Air is cooled and dehumidified as it passes through the evaporator and is then 'reheated' to the required temperature as it passes through the heater matrix. In RECIRCULATION mode, the air in the passenger compartment is drawn into the air conditioning unit via the recirculation air inlets on the blower assemblies. In FRESH mode, air flows from the cabin into the trunk via extraction slots in the rear parcel shelf at the base of the backlight on the Coupe and the hood containment panel on Convertible. The air is exhausted from the vehicle through extraction vent assemblies (incorporating one way flaps) whose outlets are above the rear mufflers.
Air Flow Path
2012-07-21
Air Distribution Modes

Bi-level mode. Minimum temperature differential.
www.JagDocs.com
Bi-level mode. Maximum temperature differential.
2012-07-21

Foot / defrost mode.
Face mode.
2012-07-21

Defrost mode.
Foot mode.(with automatic air bleed to the windshield)
www.JagDocs.com
2012-07-21

Air Particle Filter (Rain deflector removed for clarity)
The air particle filter system (where fitted) is located in the 'wet' plenum below the windshield finisher. The filter element is retained by clips which are moulded onto the filter housing. Please note that the filter must be fitted with the light, flocked surface, towards the engine.
LADD and Footwell Ducts
2012-07-21
Air Distribution Box (ADB)
www.JagDocs.com
Parts List Item 1 2 3 4 5 Description Air outlet - EOD vent Servomotor - center fascia vent Servomotor - windshield Air outlet - fascia center Air outlet - windshield
The upper air distribution box ADB, is fixed to the defrost duct and facia assembly, and seals by contact pressure to the outlet (top) of the air conditioning unit. The ADB incorporates two servo motor operated flaps which regulate airflow to: Windshield and door drop glass Fascia center and end of dash (EOD) vents Air is ducted from the ADB to the fascia air outlet vents. The center vent duct incorporates a baffle plate which balances the volume of airflow between the center and EOD vents.
2012-07-21

Internal Components and Air Flow
Parts List Item 1 2 3 4 5 6 7 8 Description Air inlet - from RH blower (LH opposite, not shown) Air outlet - fascia center vent Air outlet - defrost Air outlet - EOD 1LH and 1RH Air outlet - footwell Flap - cool air bypass Evaporator Matrix - heater
2012-07-21
Center Registers 82.20.38

Removal 1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 2. Using a thin plastic lever, carefully remove fascia centre veneer panel from fascia. Refer to <<76.47.06>> 3. Remove glove box. Refer to <<76.52.03>>.
www.JagDocs.com
4. Accessing through glove box aperture, disconnect fascia centre vent harness multiplug.
5. Exercising care to avoid damaging surfaces, use a thin plastic lever to release centre vent dowels from fascia. 6. Positioning vent for access, move vent lead and multiplug clear of fascia harness and remove vent from fascia.
2012-07-21
Installation 1. Position centre vent at fascia and route harness multiplug to fascia location. 2. Finally position vent and fully seat dowels in fascia. 3. Accessing through glovebox aperture, connect centre vent nultiplug to fascia harness. 4. Fit and fully seat centre vent veneer panel. Refer to <<76.47.06>>. 5. Fit glovebox. Refer to <<76.52.03>>. 6. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
2012-07-21
Driver Side Blower Motor 82.25.56

www.JagDocs.com
2012-07-21
Passenger Side Blower Motor 82.25.55

2012-07-21
Pollen Filter 76.10.09

Removal 1. Install covers on front fenders. 2. Remove windshield wiper arms and blades. Refer to 84.15.44.90. 3. Remove plenum cover for access. Refer to <<76.10.01>>.
www.JagDocs.com
4. Release two tangs securing the top of the filter element and tilt the top of the element forward.
5. Release the two lower securing tangs, lightly press the accelerator cable support clear and remove the filter element.
2012-07-21
Installation
1.
CAUTION: The air particle filter element must be installed with the white flock side facing forwards. If the element supplied will not fit in this position it must be changed for the correct part.
Positioning lower securing tangs and accelerator cable support to achieve clearance, install element lower edge in the housing
2. Lift the upper securing tangs, press the top of the filter element rearwards and fully seat it in the housing. 3. Install the plenum cover. Refer to <<76.10.01>>. 4. Install windshield wiper arms and blades. Refer to 84.15.44.90. 5. Remove covers from fenders.
2012-07-21
1999 XK RANGE - Heating and Ventilation - 412-02
Heating and Ventilation

Schematic Diagram
www.JagDocs.com
Parts List Item 1 2 3 4 5 6 7 8 Description Heater matrix Firewall Non return valve Water pump Water valve Return to engine Feed from engine Non return valve (heater bypass)
2012-07-21

Heater System Components
Parts List Item 1 2 3 4* 5 6* 7 Description Hose - heater (from engine) Assembly pump - water Assembly valve - water Hose - water valve to water pump Hose - water pump to heater (feed) Assembly hose - heater to water valve (return) Valve - non return
NOTE: * These hoses are flattened at the bends by design and NOT by incorrect installation. The heater circuit 'scavenges' coolant from the engine cooling system by means of an electric water pump. The water pump has a protection circuit to inhibit operation when the coolant temperature is <16C; this is to prevent possible damage to the impeller due to the presence of coolant borne ice particles. Coolant is drawn from the engine system through the water valve inlet port into the heater matrix. The coolant passes through the bottom section of the heater matrix from left to right filling the end tank of the matrix before returning through the top half of the matrix and through the outlet ports of the water valve and back into the engine cooling system. Non return valves are located in the heater bypass hose and the hose between heater outlet and water valve. These valves are required to prevent coolant flowing in the wrong direction at low engine speeds and restrict convected flow through the heater after the engine is switched off. When the exterior ambient temperature is > 3 C the refrigeration system automatically operates cooling and dehumidifying incoming air before it is re-heated by the heater matrix.
2012-07-21

Water Valve Assembly Location
The water valve assembly is located above the water pump, in the engine compartment and is secured to the firewall by a bracket. The valve operates by means of an electrical solenoid which oscillates the valve stem between the inlet and outlet ports. A heatshield protects the water valve from exhaust system radiated heat. When in automatic mode, the water valve is controlled by the following inputs to the A/CCM: Face outlet temperature, corrected for solar loading 'Air off' heater matrix temperature External ambient display temperature Coolant temperature Engine speed (valve closed with the engine not running) Demand (set) temperature Re-heating of the refrigerated air is controlled by the time that the water valve is open (i.e. not energised) over a six second interval. The duty cycle of the water valve, the time open / time closed, is controlled by the A/CCM. Maximum heating demand will cause the water valve to be fully open (not energised) to allow maximum coolant flow through the heater matrix. At Maximum cooling, the water valve will be fully closed (energised) to prevent hot (engine temperature) coolant entering the heater circuit; the pump however will continue to circulate coolant through both the heater matrix and water valve bypass. The water valve defaults open when the ignition is OFF. Under engine stall conditions, when ignition is ON, the water valve will be open.
www.JagDocs.com
Water Pump Assembly

Located in the same area as the water valve, the water pump continually circulates coolant through the heater matrix except when the conditions below apply: The engine coolant is below 16C. The ignition is OFF. Under engine stall conditions, when ignition is ON. Control panel OFF
Non return valves

The heater bypass hose has a non-return valve, located between the engine feed and return hoses. The valve prevents the water pump from recirculating coolant from the heater at low engine speeds. The flow indicator arrow embossed on the valve body MUST point towards the coolant header tank. CAUTION: Coolant flow will be compromised if either valve is fitted incorrectly. Observe the correct direction. A second non-return valve is located in the heater outlet to water valve hose. This valve prevents hot coolant from flowing into the heater with the engine switched off. The flow indicator arrow MUST point towards the water valve.
Heater feed and return hoses

The heater feed and return hoses are connected to the engine feed and return hoses by 'Quick-Fit' connection unions. The feed hose has a Norma R20 connector and the return hose a Norma push and seal connector. The coolant system bleed joints have Cobra clamps. All remaining hose connections have spring band hose clamps.
2012-07-21
The engine feed hose is connected to the engine bypass housing and the engine return hose is connected to the engine water pump.
Clamp Identification
Parts List Item 1 2 3 4 5 Description Cobra Spring band Quick-fit Norma push and seal 'R' type Norma push and seal 15
2012-07-21
Heating and Ventilation

Refer to Section <<412-00>>.
www.JagDocs.com
2012-07-21
Heater Core 80.20.29

Removal 1. Remove upper steering column; refer to <<57.40.02>>. 2. Drain radiator coolant only; refer to 26.10.01 or (SC)26 .10.01.
3. Remove footwell lamp mounting bracket. Remove bracket to fascia securing screws. Remove bracket. 4. Remove major gauge module; refer to 88.20.24. 5. Remove fascia support bracket to bulkhead securing bolts (from between air duct and fascia harness). 6. Disconnect cool air bypass servo motor connector and heater matrix pipes. Disconnect connector. Remove screws which secure retaining brackets. NOTE: Position suitable cloth to absorb coolant leakage before disconnecting pipes. Remove retaining brackets. Remove screws which secure matrix clamps. Remove clamps. NOTE: Remove and discard O-ring seals from pipes; fit suitable blanking plugs. Displace pipes from matrix. 7. Remove heater matrix from heater/cooler assembly. Remove screw which secures heater matrix retaining plate. Remove heater matrix retaining plate.
2012-07-21

Displace and reposition fascia support bracket to permit removal of heater matrix. Remove heater matrix.
Installation 1. NOTE: Fit new O-ring seals. Installation is the reverse of removal procedure.
www.JagDocs.com
2012-07-21
Heater Core and Evaporator Core Housing 82.25.21

Removal 1. Disconnect battery ground cable (IMPORTANT, see SRO <<86.15.19>> for further information). 2. Recover refrigerant from air conditioning system; refer to <<82.30.30>>. 3. Drain radiator coolant only; refer to 26.10.01 or (SC) 26.10.01. 4. Remove instrument panel; refer to 76.46.01.90.
5. From under the hood: Disconnect air conditioning pipes at the evaporator. 1. Remove bolts. 2. Discard O-rings. 3. Install suitable blanking plugs.
2012-07-21
www.JagDocs.com
6. Disconnect heater hoses from heater matrix pipes. 1. Release spring band clips and disconnect heater hoses. 2. Install suitable blanking plugs.
7. From inside the vehicle: remove brace. Remove steering column upper mounting bracket / brace to firewall securing bolt. Remove brace to firewall securing bolt (where fitted). Remove brace to transmission tunnel securing bolts. Remove brace.
2012-07-21
8. Remove LH fan motor duct. Remove screws. Remove duct.
9. Remove RH fan motor duct. Remove screws. Remove duct.
2012-07-21
10. Disconnect heater / cooler unit electrical connector.
www.JagDocs.com
11. Disconnect air conditioning control module electrical connectors.
2012-07-21
12. Disconnect condensate drain tubes from heater / cooler assembly.
13. Remove fixing securing evaporator pipe support bracket to firewall.
2012-07-21
www.JagDocs.com
14. Remove heater / cooler assembly fixings. 1. Remove lower fixing nut. 2. Remove upper fixing nuts.
15. Remove heater / cooler unit from vehicle. Manoeuvre matrix heater pipe stubs through firewall grommet into vehicle. Remove unit.
2012-07-21

Installation
1. Install heater / cooler unit into vehicle. Guide matrix heater pipe stubs through firewall grommet. Position heater / cooler unit against firewall.
2. Install heater / cooler assembly fixings. Install upper fixing nuts. Install lower fixing nut.
2012-07-21
3. Install fixing securing evaporator pipe support bracket to firewall.
www.JagDocs.com
4. Connect condensate drain tubes to heater / cooler unit.
2012-07-21
5. Reconnect air conditioning control module electrical connectors.
6. Connect heater / cooler unit electrical connector.
2012-07-21
www.JagDocs.com
7. Install LH fan motor duct. Reposition and install duct. Install screws.
8. Install RH fan motor duct. Reposition and install duct. Install screws.
10
2012-07-21
9. Install brace. Reposition and align brace to heater / cooler unit. Install brace to transmission tunnel securing bolts. Install brace to bulkhead securing bolt (where fitted). Install steering column upper mounting bracket / brace to firewall securing bolt. 10. Under hood: reconnect heater hoses to heater matrix pipes. Remove blanking plugs. Reconnect heater hoses and reposition spring band clips.
11. Reconnect air conditioning pipes at the evaporator. Remove blanking plugs. Install , fully seat and lubricate new O-rings. Install bolts. 12. Install instrument panel; refer to 76.46.01.90.
11
2012-07-21
13. Recharge air conditioning system; refer to <<82.30.30>>. 14. Re-fill cooling system, 26.10.01 15. Reconnect battery ground cable (IMPORTANT, see SRO <<86.15.15>> for further information).
www.JagDocs.com
12
2012-07-21
1999 XK RANGE - Air Conditioning - 412-03
Air Conditioning
Introduction
Component Location
Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Description Fascia panel with integral ducting Heater / cooler assembly A/CCM Blower LH and RH Plenum Control panel Solar sensor (LHD shown) Assembly valve - water Assembly pump - water Temperature sensor - external Compressor Pressure switch - 4 level Motorized in-car aspirator (LHD shown) Receiver drier Condenser
The climate control system features fully automatic control of temperature, blower speed (airflow) and air distribution to maintain optimum comfort under most driving conditions. Manual controls are provided to allow the operator to over-ride automatic operation.
2012-07-21
System Features
Twin blower assemblies Center mounted evaporator, heater and air distribution unit Electric solenoid water valve controlled heating Electric water pump assembly Servo motor driven air distribution flaps Temperature differential control between foot and face outlets Dedicated side glass defrost / demist vents External temperature sensor Motorised in-car aspirator Solar sensor
Electronic Control Panel

Liquid Crystal Display (LCD) Digital temperature display Manual fan speed level External temperature display Celsius / Fahrenheit selection Heated windshield switch (where fitted) Heated backlight switch Defrost switch Manual airflow distribution overrides (4) Access to self diagnostic system and error codes
www.JagDocs.com
Sensors
External ambient temperature sensor Motorized in-car aspirator Heater matrix temperature sensor Evaporator temperature sensor Solar sensor These sensors feedback information to the Air Conditioning Control Module (A/CCM) which automatically adjusts air temperature, airflow volume and distribution from the air conditioning unit to maintain a stable passenger compartment average temperature under changing weather conditions.
2012-07-21

Major Components
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Description Compressor assembly Condenser Evaporator and heater matrix (internal) Receiver drier 4-level pressure switch Expansion valve (internal) High-side charge port Low-side charge port Suction muffler Discharge hose Discharge pipe Suction hose Suction pipe Liquid line Jumper hose (condenser hose)
Compressor
Features Engine mounted, driven by the accessory drive belt. Fixed displacement type. High-pressure relief valve, to avoid system over-pressure. ECM controlled clutch energized via a relay.
Receiver drier
2012-07-21
Vertically mounted on the right-hand side of the engine compartment next to the engine coolant radiator. Fitted with the high-side charge port.
Condenser
Multi-pass fin-over-tube type, mounted in front of the engine cooling pack and directly to the radiator.
Pressure (Bitron) switch

Located in the discharge pipe. Provides a signal, via the A/CCM, to the ECM, to disengage the compressor clutch should the refrigerant pressure be < 2 bar or > 30 bar. Provides a hard-wired signal to the ECM, to switch the cooling fans to HIGH speed at 22 bar rising pressure and to LOW speed at 17,5 bar falling pressure. Provides a hard-wired signal to the ECM, to switch the radiator cooling fans to LOW speed at 12 bar rising pressure and to switch the fans OFF at 8 bar falling pressure.
Expansion Valve
www.JagDocs.com
Parts List Item 1 2 3 4 5 6 7 8 Description Valve body Pressure spring Diaphragm Capillary tube Temperature sensing bulb Valve inlet Valve outlet Equalizer pipe The expansion valve is located inside the heater / air conditioning unit and comprises of a diaphragm, connected by a capillary tube to a temperature sensing bulb, which regulates the valve according to temperature variations at the evaporator outlet pipe. This component is NOT serviceable. See 'Refrigeration Cycle'
2012-07-21
Air Conditioning (Heater / Cooler) Unit
Parts List Item 1 2 3 4 5 Description Air inlet - LH (RH opposite, not shown) Servomotor - cool air bypass Servomotor - footwell outlet Air outlet - footwell Air outlet - ADB (with foam seal)
The air conditioning unit houses the evaporator, heater matrix and their temperature sensors. The unit also incorporates two servo motor operated air distribution flaps which regulate airflow to the front footwells and the quantity of airflow through the cool air bypass (air which by-passes heater matrix) up to the upper air distribution box (ADB). When the front footwell flap is open, air is ducted to the footwell area via the lower air distribution duct (LADD) and front footwell duct. The LADD is clipped to the bottom of the air conditioning unit case and the front foot ducts clipped onto the outlets of the LADD. Condensate (water) which forms on the evaporator fins is drained out of the unit case through two drains, located either side of the unit underneath the evaporator. The liquid is routed to the vehicle exterior via flexible tubes which are located behind the firewall heatshield.
2012-07-21

Refrigeration Cycle
www.JagDocs.com
Item 1 2 3 4 5 6
Description Compressor Condenser Receiver drier Expansion valve Evaporator 4-level pressure switch
The Compressor draws low pressure, low temperature, refrigerant from the evaporator and, by compression, raises the refrigerant 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 in the condenser and it becomes a reduced temperature, high pressure, liquid. From the condenser, the liquid passes into the receiver drier which has three functions:
2012-07-21
Storage vessel for varying system refrigerant demand. Filter to remove system contaminants. Moisture removal via the dessicant. With the passage through the receiver drier completed, the liquid refrigerant, still at high pressure, enters the expansion valve where it is metered through a controlled orifice, which has the effect of reducing the pressure and temperature. The refrigerant, now in a cold atomized state, flows into the evaporator and cools the air passing through the matrix. As heat is absorbed by the refrigerant, it once again changes state, into a vapor, and returns to the compressor for the cycle to be repeated. An automatic safety valve is incorporated in the compressor, which will operate if the system pressure rises above 41 bar. The valve will reseat when the pressure drops below 27,6 bar. The terms 'high' and 'low' pressure (or side) refer to the pressure differential between the compressor and expansion valve ports. This differential is critical to system fault diagnosis and efficiency checks.
2012-07-21
Air Conditioning
Refer to section <<412-00>>.
www.JagDocs.com
2012-07-21
Air Conditioning (A/C) Compressor 82.10.20

Removal 1. Disconnect battery ground cable (IMPORTANT, see SRO <<86.15.19>> for further information). 2. Recover refrigerant from air conditioning system; refer to <<82.30.30>>. 3. Remove supercharger drive belt (where fitted); refer to <<18.50.08>>. 4. Remove front end accessory drive belt; refer to <<12.10.40>> or (SC) 12.10.40.
5. NOTE: A commercially available brake pipe clamp is recommended. Do not over tighten. Clamp power steering reservoir to pump feed hose. 6. Raise vehicle for access
2012-07-21
www.JagDocs.com
7. NOTE: Position drain tin to collect the fluid when union nut is released. Disconnect steering rack hose from pump. 1. Release union nut. 2. Discard O-ring. 3. Fit suitable blanking plugs.
8. Disconnect clutch harness connector from compressor. 1. Disconnect connector.
2012-07-21
9. Remove suction and discharge pipes from compressor. Discard O-rings. Fit suitable blanking plugs.
10. NOTE: Reposition compressor after releasing the fixings to allow removal. Remove compressor. Remove bolts. 11. NOTE: This step is not necessary in the case of refrigerant loss. Measure amount of oil held in compressor. Remove blanking plugs from the compressor. Pour oil from compressor into a suitable measuring container. Note amount and discard the oil. Fit blanking plugs to compressor.
2012-07-21
Installation 1. Fill new compressor with correct amount of oil. Remove blanking plugs from compressor. Pour oil from compressor into a suitable container. Fill compressor with the same amount of oil that was removed from original compressor, plus amount recovered from recovery equipment. Fit blanking plugs to compressor.
www.JagDocs.com
2. Install compressor. Tighten fixings.
3. Fit suction and discharge pipes. Fit new O-rings. Tighten fixings.
2012-07-21
4. Connect clutch harness connector to compressor. 1. Connect clutch connector.
5. Connect power steering hose to pump. 1. Remove blanking plugs. 2. Fit new O-ring to hose. 3. Tighten union nut. 6. Lower ramp.
2012-07-21
7. Unclamp power steering reservoir to pump feed hose. 8. Install front end accessory drive belt; refer to <<12.10.40>> or (SC) 12.10.40. 9. Install supercharger drive belt (where fitted); refer to <<18.50.08>>. 10. Reconnect battery ground cable (IMPORTANT, see SRO <<86.15.15>> for further information). 11. Recharge air conditioning system; refer to <<82.30.30>>. 12. Check / bleed / top up power steering fluid reservoir; refer to <<211-02>>.
www.JagDocs.com
2012-07-21
Condenser Core 82.15.07

Removal 1. NOTE: It is not necessary to remove the fan cowl in order to access the condenser. Remove radiator assembly; refer to <<26.40.01>> or (SC) 26.40.01.
2012-07-21
Evaporator Core 82.25.20

Removal 1. Remove heater / cooler unit; refer to <<82.25.21>>.
www.JagDocs.com
2. Remove air conditioning control module from heater / cooler unit. Slacken upper fixing. Remove lower fixings.
3. Remove evaporator pipe firewall seal plate. Remove screws. Remove plate.
2012-07-21
4. Disconnect heater matrix temperature sensor. Detach heater matrix temperature sensor connector from unit. Disconnect connector.
5. Remove footwell servo motor from heater / cooler unit. Disconnect connector. Remove screws. Remove motor complete with bracket.
2012-07-21
www.JagDocs.com
6. Disconnect evaporator sensor connector. Detach heater / cooler unit connector. Detach evaporator sensor connector. Disconnect connector.
7. Remove heater / cooler unit upper case from lower case. Remove screw. Remove 15 clips. Remove upper case from lower case.
2012-07-21
8. Remove evaporator from case. Remove sensor and clip. Remove evaporator.
Installation 1. Installation is the reverse of removal.
2012-07-21
Receiver Drier 82.17.01

Removal 1. Disconnect battery ground cable (IMPORTANT, see SRO <<86.15.19>> for further information). 2. Recover refrigerant from air conditioning system; refer to <<82.30.30>>.
www.JagDocs.com
3. Disconnect liquid line from drier bottle. 1. Remove bolt. 2. Disconnect hose and discard O-ring seal. 3. Fit suitable blanking plugs.
4. Disconnect condenser hose from drier bottle. 1. Remove bolt. 2. Disconnect hose, remove and discard O-ring. 3. Fit suitable blanking plugs.
2012-07-21
5. Remove drier bottle assembly. Remove bolt. Remove assembly.
6. Remove drier bottle bracket. Remove clamping bolt. Remove bracket.
Installation 1. NOTE: Install new O-rings and lubricate with clean compressor oil. Installation is a reversal of the removal procedure.
2012-07-21
2. Tighten fixings to specification (8-10 Nm).
www.JagDocs.com
3. Tighten fixings to specification (8-10 Nm). 4. Recharge air conditioning system; refer to <<82.30.30>>.
2012-07-21
1999 XK RANGE - Control Components - 412-04
Control Components
System Controls
The climate control system is controlled by : 1. Manual input from the operator, via the center console located control panel. 2. Automatically by means of the A/CCM. Output is based upon input from the following devices: Motorized In-car aspirator External air temperature sensor Coolant temperature sensor Heater 'air-off' (the temperature of the air leaving the matrix fins) temperature sensor Evaporator 'air-off' (the temperature of the air leaving the evaporator fins) temperature sensor Solar sensor Left hand blower recirculation / fresh air flap potentiometer Right hand blower recirculation / fresh air flap potentiometer Upper air distribution box (ADB) center and side face flap servomotor potentiometer ADB defrost flap servomotor potentiometer Air conditioning unit Foot flap servomotor potentiometer Air conditioning unit Cool Air Bypass flap servomotor potentiometer Center vent assembly temperature differential potentiometer Thumbwheel controls on the facia vent assemblies which provide manual adjustment of the airflow volume. Road and engine speed signals input to the A/CCM
Climate Control Panel

Communication between the control panel and the A/CCM is via a serial data communications link.
Switching the Climate Control system ON

The climate control system can be switched ON by pressing one of the following :
2012-07-21
Ref #1 On / Off (resumes the system on in the previous settings). Ref #10 A / C (resumes the system on in the previous settings). Ref #11 AUTO (resumes the system on at the previous temperature setting). Ref #12 DEF (resumes the system on at the previous temperature setting).
Button (switch) logic

All buttons with an integral LED state lamp conform to the following operating logic. When the state lamp is lit the relevant function is operational. From this condition, pressing the button will de-activate the function, confirmed by the LED being de-energized and the presence of a single audible 'beep'. A single 'beep' will accompany the state lamp to confirm function re-selection. 1. ON / OFF and manual fan speed. Pressing this knob activates the system ON at the last setting or switches the system OFF. Rotate the knob clockwise to increase and anti-clockwise to decrease fan speed and thus airflow. With the system OFF, ram air is available by the selected air distribution mode (indicated by state lamp). Air flow will NOT occur unless a manual air distribution mode is selected, this air being unconditioned and flow dependent upon vehicle speed. NOTE: The blowers are inhibited until the engine coolant temperature is > 35C, unless DEFROST is selected. 2. Manual Air Recirculation Closes the outside air intakes of the blower assemblies and recirculates air within the vehicle. Two options of control are available : Timed Recirculation. Pressing the button for less than 1.5 seconds lights up the LED (confirmed by a single bleep). This provides recirculation of interior air for a period of approximately 5 minutes. Pressing the button within five minutes returns the system to fresh air intake mode. Continuous Recirculation. Pressing and holding the button for more than 1.5 seconds lights up the LED (confirmed by two beeps). This provides continuous recirculation of interior air. Pressing the button returns the system to fresh air intake mode. NOTE: Avoid using manual air recirculation for prolonged periods in cold weather, this may result in interior misting of glass. 3. Temperature Scale Selection Press the appropriate button to display temperatures in degrees Celsius or Fahrenheit. 4. Manual Fan Speed Rotating the fan speed control knob (to vary fan speed) will display a proportional number of horizontal bars on the LCD. There are total of eleven manual fan speeds available. 5. Temperature Display Indicator of internal demand temperature or external ambient temperature. The external ambient is updated every 4 seconds when the road speed > 25 km / h. 6. Scale Selected temperature scale, Celsius or Fahrenheit. 7. External temperature
www.JagDocs.com
2012-07-21
Symbol indicates when this option is selected 8. Automatic Symbol indicates when the control of, temperature, fan speed and air distribution are all in Auto mode. 9. External There are two modes of external ambient temperature selection; Quick Display. Pressing the button for <1.5 seconds (confirmed by a single bleep) will display the external temperature for 4 seconds. Continuous Display. Pressing and holding the button for >1.5 seconds (confirmed by two beeps) displays the external ambient temperature continuously, the value of which will be updated every 4 seconds given that vehicle road speed is > 25 km/h. Pressing the button again for <1.5 seconds resets to the previous display. NOTE: Continuous external temperature display will be cancelled when the ignition is switched OFF but not during engine cranking. 10. A/C This push-on / push-off button will either select or deselect (as indicated by the state lamp) the refrigeration system. The refrigeration system is automatically engaged when the Auto button is pressed. NOTE: Interior misting of screens may be reduced by continuous operation of the refrigeration system. 11. Auto When selected and the state lamp lit, A/C mode will be operational and control of vent outlet temperature, fans speed and air distribution will be automatic. AUTO mode will disengage should manual air distribution or defrost buttons be operated or the manual fan speed knob be rotated. NOTE: Automatic temperature control is constantly maintained irrespective of selected manual overrides. 12. Defrost Push-on push-off button, which when engaged will direct all air to the front and side glass at maximum fan speed. The heated windshield (if fitted) will also be energized for a timed cycle of 6,5 minutes, but may be cancelled by pressing the HEATED WINDSHIELD (F) button. Pressing 'DEF' again will return to the last setting with automatic temperature control being maintained. Directing warm and humid air onto a cold screen can produce interior misting of screens. Operating the climate control system without the refrigeration system operating will exacerbate this problem. NOTE: Directing cold air onto the screen in warm humid conditions can produce external condensation. 13. Heated Windshield (F) Pressing the heated windshield button (where fitted) will energize the electrically heated windshield elements for a timed cycle of 6,5 minutes; pressing the button again will cancel the request. Should the engine stall or the ignition be turned OFF, the timer will be cleared and the function cancelled. NOTE: The heated windshield may be activated with the climate control system OFF but the engine must be running. In very cold ambient temperatures, icing of the interior of the glass is possible when the climate control system is operating in AUTO mode; to reduce this possibility the A/CCM provides automatic operation of the heated windshield.
2012-07-21
With the following conditions met, the heated windshield will automatically energize but the state lamp will NOT be lit. External temperature < 0 C Vehicle speed > 48 km / h The first two conditions exist > 2 minutes. Engine speed > 50 revs / min 14. Heated Backlight (R) Pressing the heated backlight button will simultaneously energize the heater elements for timed cycles of; 21 minutes backlight 11 minutes exterior mirrors Pressing the button again within the 21 minute timer will cancel the request. If the engine is stalled, or the ignition switched OFF, the backlight and door mirror timers will be cleared, resulting in both functions being switched off. NOTE: Both the backlight and door mirrors may be activated with the climate control system OFF, but the engine must be running. 15. Temperature Decrease Pressing this button (BLUE symbol) decreases the interior temperature setting in 1 increments. Should the button be pressed when the setting temperature is below the lower automatic control temperature limit, the display will indicate 'LO'. 16. Temperature Increase Pressing this button (RED symbol) will raise the temperature setting in 1 increments Should the button be pressed when the setting temperature is above the upper automatic control temperature limit, the display will indicate 'HI'. Automatic Temperature Control Range C LO 17 18 19 20 21 22 23 24 F LO 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76
www.JagDocs.com
2012-07-21

25 26 27 28 29 30 31 HI 77 78 79 80 81 82 83 84 85 86 87 88 89 90 HI
LO demands the maximum COOLING performance from the system with the blowers operating automatically at maximum speed. HI demands the maximum HEATING performance from the system with the blowers operating automatically at maximum speed. Pressing and holding either temperature selection button continuously changes the setting temperature by steps of 1, every 0.4 seconds. NOTE: The interior temperature does not change when the temperature scale is changed between Celsius and Fahrenheit, however the temperature display will change to the nearest equivalent number. Examples: 17C 61F 17C 66F 19C 66F NOTE: When operating in HI or LO mode and the AUTO button is pressed, the system will adopt the nearest automatic control temperature setting: LO AUTO DISPLAY INDICATES 17 C or 61 F HI AUTO DISPLAY INDICATES 31 C or 90 F NOTE: When switching the system on using the AUTO button, the system will display the previous temperature setting, except under the following conditions: LO, system OFF, auto display indicates 17 C or 61 F HI, system OFF, auto display indicates 31 C or 90 F 17. Face Pressing this button will direct all airflow to the center and side face vents only; pressing again will return the system to automatic control mode. NOTE: When in AUTO mode and in a hot climate, a bleed of cold air is delivered to foot level. This bleed automatically shuts off when the interior temperature has cooled sufficiently.
2012-07-21
18. Bi-Level This push-on / push-off button will direct air to the center and side face vents and the front footwells. Pressing the button (off) will return the system to automatic control mode. 19. Foot This push-on / push-off button will direct the majority of airflow to the front footwells with a small bleed of air to the front and side screens. Pressing the button (off) will return the system to automatic control mode. 20. Demist Pressing this button will direct air to the front and side screens and the front footwells. Pressing the button (off) will return the system to automatic control mode.
Fascia (Center) Air Outlets
www.JagDocs.com
Parts List Item 1 2 3 Description Temperature differential control Airflow control Air direction control The center vent assembly incorporates the Temperature Differential control thumbwheel. This control provides adjustment of the outlet air temperature from the center and end of dash vents (EOD), relative to the foot duct air temperature. The air temperature from the face vents air will increase when the thumbwheel is rotated upwards and decrease when rotated downwards. NOTE: The face level air temperature is always cooler than the foot air temperature and the temperature differential control ONLY operates when the system is in AUTO or manual Bi-Level mode. Only the center face air vent assembly incorporates the three listed controls; the EOD vents, not shown, only feature items 2 and 3.
2012-07-21
Automatic Operation Initial setting

Should a new A/CCM be fitted, it will 'power-up' in the OFF mode; switching ON will result in the following settings: Feature Setting temperature LH and RH blower assembly recirculation / fresh flap Control mode Blower Compressor output Heated windshield and mirrors Water valve Status 24C or 75F Fresh mode Automatic 'AUTO' displayed Auto A/C ON OFF Auto temperature control
After initial start up the system operating conditions will be stored in the A/CCM to the conditions which prevailed prior to ignition OFF.
Maximum Heating / Cooling Maximum Heating (temperature setting HI)

Item Water valve Blower Fresh / recirc Air distribution A/C system Cool air by-pass Control Fully open (not energised) Maximum Fresh Feet (state lamp OFF) OFF Fully closed Override Allowed Yes Yes Yes Yes -
Maximum Cooling (temperature setting LO)

Item Water valve Blower Fresh / recirc Air distribution A/C system Cool air by-pass Control Fully closed (energised) Maximum Recirculation Face (state lamp OFF) ON Fully open Override Allowed Yes Yes Yes Yes -
2012-07-21

Air Conditioning Control Module (A/CCM) Location
www.JagDocs.com
The A/CCM is located on the right hand side of the air conditioning unit and controls all system functions. The temperature within the passenger compartment is continually compared with the temperature selected on the control panel LCD. The A/CCM receives data input signals and compares these with signals from the system temperature sensors and feedback devices. Based on this information the A/CCM adjusts the air outlet temperature, airflow and distribution from the air conditioning system into the passenger compartment.
2012-07-21

Identification
Inputs / Outputs
1. Engine speed: Input to the A/CCM from the ECM. Heated windshield and backlight will be inhibited when engine speed < 50 RPM. 2. Vehicle speed: Input from the instrument cluster. Blower speed control to minimise the effects of ram air. Road speed compensation is inhibited when maximum cooling LO, or maximum heating HI, is selected; also inhibited in defrost mode with airflow set to maximum. Used to determine the frequency at which the exterior temperature display is updated. 3. Coolant temperature (signal derived from ECM via instrument cluster): Input from the heater matrix temperature sensor used to control water valve and thus vent temperatures. Used to monitor the temperature of coolant at the heater matrix to assist the control of air outlet temperature. Used to inhibit the blowers when heating is selected and the engine coolant temperature is below 30C. Is used to provide progressive increase in blower speed up to 60C. To inhibit the water valve and pump when the coolant temperature is = < 10C 4. Compressor ON signal: Input to the A/CCM from the compressor relay output.
2012-07-21

Used to determine compressor fault conditions.
Sensors and Controls
Solar Sensor
www.JagDocs.com
The solar sensor is mounted on the top surface of the fascia between the driver's defrost grille and speaker grille. The sensor is a photo-diode which is calibrated to measure direct sunlight. It provides an output signal to the A/CCM which automatically reduces air temperature and increases fan speed (airflow volume) to compensate for solar heating.
10
2012-07-21

Evaporator Sensor
This thermistor device changes electrical resistance as a result of temperature variations. The sensor is positioned next to the evaporator fins and measures air temperature after it has passed through the evaporator. The sensor inputs a signal to the A/CCM which controls the compressor (see table) when the refrigeration system is operating. The sensor's connector is located on the LH side of the air conditioning unit, in front of the main power connector. Evaporator Temperature Signal 3C 2C Compressor State ON - clutch engaged OFF - clutch disengaged
The A/CCM disengages the compressor clutch when the temperature of the air off the evaporator is 2 C or less. This is to prevent the moisture which may collect between the cooling fins of the evaporator from freezing and thus restricting airflow.
11
2012-07-21

Heater Matrix Temperature Sensor
www.JagDocs.com
The heater matrix temperature sensor is a thermistor which changes its electrical resistance in response to changes in air temperature converting a temperature rating to an electrical signal. The sensor connector is located on the RH SIDE of the air conditioning unit. The sensor bead is located inside the unit down-stream from the heater matrix and measures the 'post-heater' air temperature, before the air is distributed to the cabin The sensor provides a signal to the A/CCM which adjusts the duty ratio of the water valve to provide the required air temperature from the heater.
Ambient Temperature Sensor
The sensor is a thermistor which changes its electrical resistance in response to changes in air temperature, converting a temperature rating to an electrical signal. The ambient temperature sensor measures exterior air temperature and is mounted on the RH horn bracket which is located on the front bumper beam. The signal from the ambient sensor allows the A/CCM to compensate for the ambient conditions and to display the information on the control panel - updated every four (4) seconds.
12
2012-07-21
Sensor response is 'damped' by the A/CCM and therefore does not appear to react to temperature changes as quickly as the other sensors. This feature prevents the effects of sudden changes in air outlet temperatures due to factors such as: Recirculating air from the engine cooling pack at low vehicle speeds Sudden changes in ambient temperature The effects of water splash
Motorised In-car Aspirator.
Cabin air is drawn through a grille (located near the steering column on the knee bolster) over a thermistor. Remotely mounted from the thermistor is the motorised aspirator with a rubber hose which connects both components. The electrical resistance of the thermistor changes in response to variations in air temperature and converts this temperature rating into an electrical signal; the signal is used by the A/CCM to adjust the temperature, airflow and air distribution from the air conditioning unit.
Coolant Temperature Signal.

This signal is supplied to the A/CCM from the instrument cluster, the input being required to: Provide blower inhibit control , to avoid the system in heating mode delivering cold air when the coolant temperature is below 35C unless DEFROST is selected. To progressively increase the fan speed up to maximum blower speed during warm up control. To assist in the control of the outlet temperature. To avoid possible pump or valve damage caused by ice particles in the coolant.
Compressor ON Signal.
This signal monitors the compressor relay to confirm the compressor operating state and so provide relevant fault information.
Servo Motor Control.

Flap position, which directs the flow of air through the system, is controlled by servo motors; these may be driven in
13
2012-07-21

either a clockwise or anti-clockwise direction by signals from the A/CCM. Motor, thus flap position, is monitored via a feedback potentiometer which is situated within the motor housing. Servo motors control the following flaps: RH and LH Air Intake (Fresh / Recirc) Center Vent Defrost Foot Cool Air Bypass
Blower Motor Control.

The A/CCM controls the speed of two blower motors which deliver airflow to the air conditioning unit. The blower motors are regulated by power transistor modules which provide a linear variation of blower speed.
Relationship Manual Control Blower Speed / Voltage

NOTE: Blower motors are inhibited when the engine coolant temperature is below 35C and heating is demanded, unless DEFROST is selected. Blower Mode OFF Manual LO Manual M1 Manual M2 Display Output - No of Bars Nil 1 2 2 3 3 4 4 Manual M3 Manual M4 4 5 5 6 6 Manual M5 6 7 7 Manual M6 7 8 8 Manual M7 Manual M8 Manual M9 8 9 9 10 10 11 Manual HI and DEFROST 11 Blower Motor Voltage (V) 0.0 4.00 4.33 4.67 5.00 5.33 5.67 6.00 6.33 6.67 7.00 7.33 7.67 8.00 8.33 8.67 9.00 9.33 9.67 10.00 10.33 10.67 11.00 11.33 11.67 12.00
www.JagDocs.com
Control Components
Connector Pins Identification
Connector Pin Identity Chart for AC001
Pin Number 001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 017 018 019 020 021 022
Circuit
Circuit Function Compressor ON signal Coolant valve RH Blower motor relay Heated windshield relays (where fitted) Heated door mirror relay Defrost servomotor (positive) Center vent servomotor (positive) LH air intake servomotor fresh / recirculation (positive) RH air intake servomotor fresh / recirculation (positive) Not used Not used Foot servomotor (positive) Cool air bypass servomotor (positive) Not used Not used LH Blower motor relay Coolant pump motor relay Heated backlight relay Defrost servomotor (negative) Center vent servomotor (negative) LH air intake servomotor fresh / recirculation (negative) RH air intake servomotor fresh / recirculation (negative)
2012-07-21

023 024 025 026 Not used Not used Foot servomotor (negative) Cool air bypass servomotor (negative)
www.JagDocs.com
Pin Number 001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016
Circuit
Circuit Function Solar sensor Center vent servomotor feedback potentiometer RH air intake servomotor feedback potentiometer fresh / recirculation Not used Cool air bypass servomotor feedback potentiometer Coolant temperature signal RH blower motor voltage feedback RH blower motor drive signal Differential potentiometer Defrost servomotor feedback potentiometer LH air intake servomotor feedback potentiometer fresh / recirculation Not used Foot servomotor feedback potentiometer Not used LH blower motor voltage feedback LH blower motor drive signal
2012-07-21

Pin Number 001 002 003 004 005 006 007 008 009 010 011 012
Circuit
Circuit Function Screen request to ECM CLOCK signal to control panel DATA OUT signal to control panel Compressor lock signal Exterior air temperature sensor Heater matrix temperature sensor DATA IN signal from control panel START signal to control panel Not used Compressor lock select In-car temperature sensor Evaporator temperature sensor
2012-07-21

www.JagDocs.com
Pin Number 001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 017 018 019 020 021 022
Circuit
Circuit Function Ignition positive supply Battery isolate supply Auxiliary ground Auxiliary ground to control panel Battery supply Engine speed input Electrical load drive inhibit +5V sensors Clutch request to ECM Diagnostic L-line Not used Ignition (positive) to control panel System ground Ground to control panel Air conditioning isolation relay Vehicle speed Pressure switch Aspirator motor (In-car sensor) Sensor ground Logic ground for diagnostic lines Diagnostic K-line Not used
2012-07-21

Connector Pin Identity Chart for FC043
Pin Number 1 2 3 4 5 6 7 8 9 10 11 12
Circuit
Circuit Function Input CLOCK Input START Input DATA IN Output DATA OUT Input ignition (positive) Input auxiliary (negative) Ground Dimmer Dimmer override Not used Not used Not used
Control Panel Communication

The control panel provides operator interface with the climate control system. Control panel operation is described in detail in the D section.
2012-07-21

Control Panel Inputs / Outputs
Pin # 1 2 3 4 5 6 7 8 9 10 11 12 Description Output clock Output start Input data in Output data out Output ignition positive Output auxiliary positive Output ground Dimmer Dimmer override Not used Not used Not used Cable color Slate Slate / Red Slate / Yellow Slate / Green White / Red White / Blue Black Red Red / Green n/a n/a n/a
A/CCM Connections
www.JagDocs.com
2012-07-21

Pin # 1 (22-way) 2 (22-way) 3 (22-way) 4 (22-way) 5 (22-way) 6 (22-way) 7 (22-way) 8 (22-way) 9 (22-way) 10 (22-way) 11 (22-way) 12 (22-way) 13 (22-way) 14 (22-way) 15 (22-way) 16 (22-way) 17 (22-way) 18 (22-way) 19 (22-way) 20 (22-way) 21 (22-way) 22 (22-way) 23 (12-way) 24 (12-way) 25 (12-way) 26 (12-way) 27 (12-way) Output Output Output Output Output Input Input Output Output Input Input Output Input Input / Output Input Input Input Output Input Input Input Output Output Input n/a Output Function Ignition positive supply Battery isolate supply Auxiliary ground Auxiliary ground B+ Engine speed input Electrical load drive inhibit Sensor +5V Clutch request Diagnostic L line Not used Ignition (+VE) to control panel System ground Ground to control panel Isolation relay Vehicle speed input Pressure switch Aspirator motor (Motorized In-car Aspirator) Sensor ground Logic ground for diagnostic lines Diagnostic K line Water pump ground Screen request to ECM CLOCK signal to control panel DATA OUT signal to control panel Compressor lock signal Ambient air temperature sensor Voltage / temperature values Sensing cct current signal Open collector R = 57OHM, connected to IGN, activated low Open collector R = 1KOHM, connected to IGN, activated high Open collector R = 1KOHM, connected to IGN, activated high Ground for normal pressure. IGN+ for abnormal pressure 0.05A at 12V, activated high during ON mode only Activated when IGN ON and for 30 seconds after IGN OFF n/a Open collector R = 1KOHM, connected to IGN, activated high Open collector, 3 pulses per rev. Active low signal from EMS Specification With ign ON Activated when IGN ON and for 30 seconds after IGN OFF Auxiliary switch closed to ground Direct line to pin #3
2012-07-21

28 (12-way) 29 (12-way) 30 (12-way) 31 (12-way) 32 (12-way) 33 (12-way) 34 (12-way) 35 (16-way) 36 (16-way) 37 (16-way) 38 (16-way) 39 (16-way) 40 (16-way) 41 (16-way) 42 (16-way) 43 (16-way) 44 (16-way) 45 (16-way) 46 (16-way) 47 (16-way) 48 (16-way) 49 (16-way) 50 (16-way) Input Input Output Not used Input Input Input Input Input Input Not used Input Input Input Output Input Input Input Not used Input Not used Input Output LH blower motor voltage feedback LH blower motor drive signal 0V to 3V max. Foot servo motor feedback potentiometer Resistance 6KOHM +/-10%. 0% closed - 1V, 100% open - 4V Cool air bypass servo motor feedback potentiometer Coolant temperature signal RH blower motor voltage feedback RH blower motor drive signal Differential potentiometer Defrost servo motor feedback potentiometer LH air intake servo motor feedback potentiometer 0V to 3V max. Resistance 10KOHM +/-10%. Min. 1V, Max. 4V Resistance 6KOHM. +/-10%. 0% closed - 1V, 100% open - 4V Resistance 6KOHM +/-10%. 0% closed - 1V, 100% open - 4V Resistance 6KOHM +/-10% 0% closed - 1V, 100% open - 4V PWM signal Compressor lock select In-car temperature sensor (Motorized In-car Aspirator) Evaporator temperature sensor Solar sensor Centre vent servo motor feedback potentiometer RH air intake servo motor feedback potentiometer Ign. voltage Voltage / temperature values Voltage / temperature values Voltage / temperature values Resistance 6KOHM +/-10% 0% closed - 1V, 100% open - 4V Resistance 6KOHM +/-10% 0% closed - 1V, 100% open - 4V Heater matrix temperature sensor DATA IN signal from control panel START signal to control panel Open collector R = 1KOHM, connected to IGN, activated high Voltage / temperature values
www.JagDocs.com
2012-07-21

51 (26-way) 52 (26-way) 53 (26-way) 54 (26-way) 55 (26-way) 56 (26-way) 57 (26-way) 58 (26-way) 59 (26-way) 60 (26-way) 61 (26-way) 62 (26-way) 63 (26-way) 64 (26-way) 65 (26-way) 66 (26-way) 67 (26-way) 68 (26-way) 69 (26-way) 70 (26-way) 71 (26-way) 72 (26-way) 73 (26-way) 74 (26-way) Input Output Output Output Output Output Output Output Output Not used Not used Output Output Output Output Output Output Output Output Output Output Output Not used Not used Foot servo motor (+VE) Cool air bypass servo motor (+VE) RH High speed relay LH High speed relay LH Blower motor relay Water pump motor relay Heated backlight relay Defrost servo motor (-VE) Centre vent servo motor (-VE) LH air intake servo motor (-VE) RH air intake servo motor (-VE) B+ when operated B+ when operated Load 105OHM at 12V IGN, activated low Load 105OHM at 12V IGN, activated low Load 105OHM at 12V IGN, activated low Load 105OHM at 12V IGN, activated low Load 72OHM at 12V IGN, activated low B+ when operated B+ when operated B+ when operated B+ when operated Compressor ON signal Water valve RH Blower motor relay Heated windshield relays Heated door mirror relay Defrost servo motor (+VE) Centre vent servo motor (+VE) LH air intake servo motor (+VE) RH air intake servo motor (+VE) B+ @ compressor ON 1amp at 12 volts Load 105OHM at 12V IGN, activated low Load 36OHM at 12V IGN, activated low Load 105OHM at 12V IGN, activated low B+ when operated B+ when operated B+ when operated B+ when operated
2012-07-21

75 (26-way) 76 (26-way) Output Output Foot servo motor (-VE) Cool air bypass servo motor (-VE) B+ when operated B+ when operated
System Self-test Control Panel Interrogation Procedure

The control panel has a self-diagnosis feature, and is capable of displaying and clearing stored fault codes. Climate control is an integrated system, therefore it is recommended that the PDU is used for fault diagnosis. The fault codes displayed with the control panel self-diagnosis feature are not as comprehensive as those of the PDU. The PDU will display the relevant fault code, fault code description and information of the system peripherals at the time the fault occurred.
Fault Code Extraction and Deletion Procedure

Error information is stored in the A/CCM up to a maximum of 5 faults. Should a sensor fault occur there will be an audible beep and the message Er will be displayed on the control panel display for 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 following procedure This procedure must be completed through one complete cycle, 1 through 6 Step #1 Simultaneously hold AUTO and RECIRC Switch ignition to ON #2 Press AUTO #3 Press FACE #4 Simultaneously press FACE and R #5 Press RECIRC (Press FAN to skip actuator check) #6 Press FAN Result Display element check Display of stored fault (NUMERIC) code. If ZERO appears, there are no stored codes Scroll through stored faults (maximum of 5) Clear stored fault codes (may need to be repeated for each fault) Initiate actuator check (Actuator codes 20 through 27 * ) Exit error check mode
www.JagDocs.com
NOTE: * Actuator codes do NOT equate to system fault codes. NOTE: Only codes 11, 15 and 21 (see Fault Code Listing) will cause audible beep and 'Er' display. NOTE: If '0' is displayed, there are no stored fault codes, wait 30 seconds to allow system self-test. The control panel display will flash repeatedly indicating a list of two digit numbers (see table for code analysis). Should a code be displayed accompanied by an audible beep, the fault is current and therefore still present within the system. A code displayed without an accompanying 'beep' indicates a fault had previously occurred but is not present within the system. NOTE: It is advisable to check all areas indicated with cleared fault codes. Such faults may re-occur if intermittent
10
2012-07-21

problems are present in the system. To delete stored and cleared fault codes press 'R' and 'FACE' buttons simultaneously. After investigating and correcting all stored faults, press the 'Push Off' button to restore normal operation with default panel settings, ie AUTO at 24C.
Control Panel Fault Code Listing
Condition(s):NOTE: Reference fault code #23*: In ambient temperatures below 0C, this code may be logged because the low ambient causes a temporary low gas pressure. NOTE: Where the ambient temperature rises above 40C, with the engine close to overheating, electrical feed to the compressor clutch may be cut and code #23 registered. 0 Normal operation no fault codes present Possible Source(s): None Action(s) to take: Wait 30 seconds for system self-check. 11 Motorized in-car aspirator malfunction Possible Source(s): Harness / connector fault Sensor open / short circuit Action(s) to take: Panel fault codes are not stored for motorized in-car aspirator motor failure. 12 Ambient temperature sensor malfunction Possible Source(s): Harness / connector fault Sensor open / short circuit Action(s) to take: After rectification, disconnect the vehicle battery for 10 seconds to reset the system. 13 Evaporator temperature sensor malfunction Possible Source(s): Harness / connector fault Sensor open / short circuit Action(s) to take: Refer to PDU 14 Water temperature input malfunction Possible Source(s): Instrument cluster output Action(s) to take:
11
2012-07-21

Refer to PDU
15 Heater matrix temperature sensor malfunction Possible Source(s): Harness / connector fault Sensor open / short circuit Action(s) to take: Refer to PDU 21 Solar sensor Possible Source(s): Sensor open /short circuit Action(s) to take: Refer to PDU 22 Compressor lock signal fault Possible Source(s): Low refrigerant charge, low compressor oil level, loose drive belt Harness / connector fault Action(s) to take: Adjust items as required 23 Refrigerant pressure switch malfunction Possible Source(s): Harness / connector fault Switch open / short circuit Action(s) to take: Refer to PDU 23 Refrigerant pressure low refrigerant charge * Possible Source(s): Leak from damaged pipe or joint Action(s) to take: Rectify as required and recharge system 24 Face vent demand potentiometer fault Possible Source(s): Potentiometer open / short circuit Harness / connector fault Action(s) to take: Refer to PDU 31 LH fresh / recirc. potentiometer fault Possible Source(s): Harness / connector fault
www.JagDocs.com
12
2012-07-21

In certain circumstances the servo motor may over-travel and cause further logged faults. This may be cured, following fault rectification, by cycling the ignition ON-OFF-ON 3 times Action(s) to take: Refer to PDU 32 RH fresh / recirc. potentiometer fault Possible Source(s): Harness / connector fault In certain circumstances the servo motor may over-travel and cause further logged faults. This may be cured, following fault rectification, by cycling the ignition ON-OFF-ON 3 times Action(s) to take: Refer to PDU 33 Cool air by-pass potentiometer fault Possible Source(s): Harness / connector fault In certain circumstances the servo motor may over-travel and cause further logged faults. This may be cured, following fault rectification, by cycling the ignition ON-OFF-ON 3 times Action(s) to take: Refer to PDU 34 Defrost vent potentiometer fault Possible Source(s): Harness / connector fault In certain circumstances the servo motor may over-travel and cause further logged faults. This may be cured, following fault rectification, by cycling the ignition ON-OFF-ON 3 times Action(s) to take: Refer to PDU 35 Centre vent potentiometer fault Possible Source(s): Harness / connector fault In certain circumstances the servo motor may over-travel and cause further logged faults. This may be cured, following fault rectification, by cycling the ignition ON-OFF-ON 3 times Action(s) to take: Refer to PDU 36 Foot vent potentiometer fault Possible Source(s): Harness / connector fault In certain circumstances the servo motor may over-travel and cause further logged faults. This may be cured, following fault rectification, by cycling the ignition ON-OFF-ON 3 times Action(s) to take: Refer to PDU 41 LH fresh / recirc. motor fault
13
2012-07-21

Possible Source(s): Harness / connector fault Servo motor seized or sticking Flap seized or sticking Action(s) to take: Refer to PDU 42 RH fresh / recirc. motor fault Possible Source(s): Harness / connector fault Servo motor seized or sticking Flap seized or sticking Action(s) to take: Refer to PDU 43 Cool air by-pass motor fault Possible Source(s): Harness / connector fault Servo motor seized or sticking Flap seized or sticking Action(s) to take: Refer to PDU 43 Cool Air by-pass motor fault Possible Source(s): Harness / connector fault Servo motor seized or sticking Flap seized or sticking Action(s) to take: Refer to PDU 44 Defrost vent motor fault Possible Source(s): Harness / connector fault Servo motor seized or sticking Flap seized or sticking Action(s) to take: Refer to PDU 45 Centre vent motor fault Possible Source(s): Harness / connector fault Servo motor seized or sticking Flap seized or sticking
www.JagDocs.com
14
2012-07-21
Action(s) to take: Refer to PDU 46 Foot vent motor fault Possible Source(s): Harness / connector fault Servo motor seized or sticking Flap seized or sticking Action(s) to take: Refer to PDU
Associated Faults
Other conditions which may exist but will NOT log fault codes:
Condition(s): No heat Possible Source(s): Airlock in system. Action(s) to take: Refer section 303-03 for fill / bleed procedure Possible Source(s): Heater water pump inoperative Coolant flow valve stuck closed Action(s) to take: Check operation and circuit Possible Source(s): Faulty engine coolant thermostat Action(s) to take: Renew as required One vent failing to open / close Possible Source(s): Broken linkage. Action(s) to take: Renew as required Poor airflow Possible Source(s): Blower motors - incorrect operation Action(s) to take: Check operation and circuit
15
2012-07-21
Panel Communication Check

The panel communication check verifies the inputs and outputs from the control panel to the A/CCM. Step #1 Simultaneously hold FACE and FAN - Switch ignition to ON #2 Press ON Result Panel communication with FACE, Bi-LEVEL, FOOT, DEMIST, DEFROST and RECIRC lines checked - State lamps will illuminate if all is OK. Unlit state lamp indicates a continuity fault for that specific link Exit check mode
Item Ignition Auxiliary Clock Start input Data out Dimmer override
Check LED Defrost Face Feet / face Foot Screen / foot Recirc.
Condition IGN input at 12V, check LED is illuminated AUX input at 12V, check LED is illuminated Clock input normal, check LED is illuminated Start input normal, check LED is illuminated Data out input normal, check LED is illuminated Dimmer override input ON, check LED is illuminated
www.JagDocs.com
Actuator Check Procedure

The system self test procedure drives all the actuator motors, to check their operation. If an actuator is operating incorrectly or operating outside of its limits then a fault code will be present. Before commencing with the actuator check procedure, ensure the car is operating under normal conditions. 1. Switch ignition OFF. 2. Press and hold the RECIRC and AUTO buttons simultaneously, switch ignition ON and run the engine. 3. All the control panel LEDs and all LCD segments will flash on and off. Any function LED indicator which does not flash on / off suggests a fault condition within that area of the panel or, with the LED. Any LCD element which fails to flash on / off indicates a fault within the display element or panel. 4. Press AUTO 5. Press RECIRC button to instigate actuator check mode. 6. Press FACE to cycle through the actuator mode conditions 20 to 27. 7. Press the FAN button to restore normal operation with default panel settings, ie AUTO @ 24C.
Actuator Fault Codes

NOTE: * The water valve operates on a 6 second pulse, ie 3 seconds ON, 3 seconds OFF.
16
2012-07-21

Outlet Centre vent open open open bleed bleed closed closed closed
Code 20 21 22 23 24 25 26 27
Blower Level 0 1 10 17 17 23 23 31
Foot Defrost closed closed closed half open half open open half open closed closed closed closed closed closed bleed half open open
Cool air by-pass closed closed open half open closed closed closed closed
Fresh / Recirc. fresh fresh half open half open recirc. recirc. recirc. open
Compressor OFF OFF A/C ON A/C ON A/C ON A/C ON A/C ON A/C ON
Water valve closed closed closed 6s pulse * 6s pulse * open open open
17
2012-07-21
Air Discharge Temperature Sensor 82.20.64

Removal 1. Remove heater matrix for access; refer to 82.25.10.
www.JagDocs.com
2. Detach sensor connector from heater / cooler assembly. Disconnect connector.
3. Detach clip and sensor from evaporator. Remove clip.
2012-07-21
4. Remove sensor from heater / cooler assembly. Remove clip. Lever case apart sufficient enough to withdraw sensor through aperture.
2012-07-21
Climate Control Assembly 82.20.07

Removal 1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 2. Remove 'J'gate surround. Refer to <<76.25.24>>. 3. Remove centre console. Refer to <<76.25.01>>.
www.JagDocs.com
4. Remove radio console securing screws and position console for access.
5. Disconnect air conditioning control module harness multiplug and cut and remove securing tiestrap.
2012-07-21
6. Remove remaining switch control module central securing screw and withdraw module from vehicle.
Installation 1. Position air conditioning switch control module on radio console and install module securing screws. 2. Connect switch control module harness multiplug. 3. Install new harness securing tiestrap. 4. Position radio and install console securing screws. 5. Install centre console. Refer to <<76.25.01>>. 6. Install 'J' gate surround. Refer to <<76.25.24>>. 7. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
2012-07-21
Cold Air Bypass Blend Door Actuator 82.20.86

Removal 1. Remove instrument panel for access; refer to 76.46.01.90.
www.JagDocs.com
2. Remove motor from heater / cooler assembly. Remove connector. Remove screws. Remove motor.
2012-07-21
Defrost Vent/Register Blend Door Actuator 82.20.84

Removal 1. Remove air distribution box; refer to 82.20.87.
2. Remove motor from air distribution box. Remove connector. Remove screws. Remove motor.
2012-07-21
Footwell Vent/Duct Blend Door Actuator 82.20.85

Removal 1. Remove instrument panel for access; refer to 76.46.01.90.
www.JagDocs.com
2. Remove motor from heater / cooler assembly. Remove connector. Remove screws. Remove motor complete with bracket. Remove motor.
2012-07-21
Instrument Panel Blend Door Actuator 82.20.83

Removal 1. Remove air distribution box; refer to 82.20.87.
2. Remove motor from air distribution box. Remove connector. Remove screws. Remove motor.
2012-07-21
1999 XK RANGE - Instrument Cluster and Panel Illumination - 413-00
Instrument Cluster and Panel Illumination

Details on the Instrument Cluster and Panel Illumination can be found in sections <<413-01>>, <<413-06>>, <<413-07>> and <<413-08>>.
www.JagDocs.com
2012-07-21
High Beam Indicator Bulb 86.45.65

Removal 1. Remove major gauge module. Refer to 88.20.24.
2. Position housing for access, rotate bulb holder 1/4 turn counter-clockwise, withdraw holder and remove bulb.
Installation 1. Install bulb in holder. 2. Install bulb holder in housing and rotate 1/4 turn clockwise to fully engage. 3. Install major gauge module. Refer to 88.20.24.
2012-07-21
Instrument Cluster Bulb 86.46.22

Removal 1. Remove major gauge module. Refer to 88.20.24.
www.JagDocs.com
2. Position housing for access, rotate bulb holder 1/4 turn counter-clockwise, withdraw holder and remove bulb.
Installation 1. Install bulb in holder. 2. Install bulb holder in housing and rotate 1/4 turn clockwise to fully engage. 3. Install major gauge module. Refer to 88.20.24.
2012-07-21
Instrument Panel Console Instrument Cluster Bulb 86.46.21

Removal 1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 2. Remove fascia centre veneer panel. Refer to <<76.47.06>>. 3. Remove minor gauge module. Refer to <<88.20.29>>.
4. Rotate appropriate bulb holder 1/4 turn counter-clockwise, withdraw holder and remove bulb.
Installation 1. Install bulb in holder. 2. Install bulb and holder in module and rotate 1/4 turn clockwise to fully engage. 3. Install minor gauge module. Refer to <<88.20.29>>. 4. Install fascia centre veneer panel. Refer to <<76.47.06>>. 5. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
2012-07-21
1999 XK RANGE - Instrument Cluster - 413-01
Instrument Cluster
www.JagDocs.com
2012-07-21

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Description Variable Power Steering Coolant Level Fuel Level Oil Pressure Lamp Dimmer Driver's Switchpack (Trip Computer) Generator (Charge Warning Lamp) Catalyst Overheat Instrument Cluster Climate Control (Signal to Module) ICE Head Unit Airbag Circuit Integrity Adaptive Damping Body Processor Module
The Instrument Cluster comprises a Major Cluster and a Minor Cluster, as well as being a primary Electronic Control Module. The Minor Cluster indicates engine oil pressure and battery state of charge. The Major Cluster provides indications for the speedometer, tachometer, coolant temperature, fuel level, driver information (Message Centre) and warning lamps. The Major Instrument Cluster also: - provides input / output information signals for use by other modules. - acts as a protocol converter (software language translator - the languages used on each network are very similar, but neither can be directly interpreted by the opposite system) for communication between all modules on both the CAN and SCP multiplexed networks. The Instrument Cluster is the only module on the vehicle which communicates between the two networks.
2012-07-21

Major Cluster
www.JagDocs.com
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Description Low Fuel Level Exhaust System Temperature * Engine Coolant High Temperature Direction Indicator Right Hand Side / Parking Lamps Handbrake ON / Low Brake Fluid Level Main Beam Airbag / Airbag System Fault High Priority Text Message Displayed Message Centre (Text Messages) Low Priority Text Message Displayed Seat Belt Not Fastened (Driver's) ABS Integrity EMS Fault Direction Indicator Left Hand
*Not used on all markets. Refer to the Driver's Handbook. All gauges look like conventional analogue gauges, but each pointer is driven by a stepper motor to provide more accurate indication. The message centre is used to warn the driver, using text messages; for warnings not covered by conventional warning lamps, to indicate that the Automatic Stability Control is operating and for other shared warnings. Two warning lamps, Red and Amber, are located above the Message centre to attract the driver's attention when a text warning message has been displayed.
2012-07-21
Instrument Cluster
Tests Using the Portable Diagnostic Unit Refer to PDU User Guide
The complexity of the electronics involved with the Instrument Cluster and the two multiplexed communication networks which are connected to it, preclude the use of workshop general electrical test equipment. Therefore, reference should be made to the PDU User Guide for detailed instructions on testing the Instrument Cluster and associated circuits. The PDU systematically tests and analyses all functions of the Instrument Cluster, the various systems controlled by it and individual sensors which are attached to each separate system. Where a fault involving a remote sensor e.g. water temperature sensor, is indicated, some basic diagnostic methods may be necessary to confirm that connections are good and that wiring is not damaged, before replacing the component. Diagnostics using the PDU is via the CAN network, accessed at the diagnostic connector on the car.
Replaceable Parts
The only replaceable parts are, General Illumination Bulbs, Direction Indicator Warning Bulbs and Main Beam Warning Bulb, which are all of the conventional filament type. Other warning lamps are LEDs and are not replaceable.
2012-07-21
Instrument Cluster 88.20.01

Removal 1. Turn ignition key to position 'II', adjust steering column to lowest and fully extended position and turn ignition key to 'O'. 2. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 3. Remove driver airbag. Refer to <<76.73.39>>. 4. Remove steering wheel. Refer to <<57.60.01>>. 5. Remove driver side underscuttle. Refer to <<76.46.11>>.
www.JagDocs.com
6. Accessing through underscuttle aperture, disconnect gauge module harness connectors. 7. Using a thin plastic lever, remove major gauge module veneer panel.
2012-07-21
8. Remove gauge module screws and withdraw module from facia.
Installation 1. Position and fully seat gauge module in facia. 2. Install gauge module screws. 3. Connect gauge module harness connectors. 4. Install veneer panel, ensuring dowels are fully seated. 5. Install steering wheel. Refer to <<57.60.01>>. 6. Install driver side underscuttle. Refer to <<76.46.11>>. 7. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>. 8. Turn ignition key to position 'II', return steering column to original position and turn ignition key to 'O'.
2012-07-21
Instrument Cluster Lens 88.20.28

Removal 1. Turn ignition key to position 'II', adjust steering column to lowest and fully extended position and turn ignition key to 'O'. 2. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 3. Remove driver airbag. Refer to <<76.73.39>>. 4. Remove steering wheel. Refer to <<57.60.01>>. 5. Remove driver side underscuttle. Refer to <<76.46.11>>. 6. Remove major gauge module. Refer to 88.20.24.
www.JagDocs.com
7. Remove lens assembly screws and withdraw lens from module.
Installation 1. The installation procedure is the reverse of removal.
2012-07-21
Instrument Panel Console Instrument Cluster 88.20.29

2. Remove center veneer panel. Using a thin plastic lever at base of center veneer panel, release four dowels from facia. Lower panel to release upper locating tongues.
3. Remove the four gauge module screws.
2012-07-21
4. Position gauge module for access and disconnect harness connector.
www.JagDocs.com
Installation 1. Position gauge module at facia and connect harness connector. 2. Fully seat gauge module and install four screws. 3. Install center veneer panel, ensuring dowels are fully seated. 4. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
2012-07-21
Instrument Panel Console Instrument Cluster Lens 88.20.32

Removal
1. Remove center veneer panel. Using a thin plastic lever at base of center veneer panel, release four dowels from facia. Lower panel to release upper locating tongues.
2. Remove the four gauge module lens assembly screws.
2012-07-21
3. Withdraw lens assembly from gauge module and remove clock setting stalks.
www.JagDocs.com
Installation 1. Install clock setting stalks in lens assembly. 2. Position lens assembly on gauge module and install securing screws. 3. Install center veneer panel, ensuring dowels are fully seated.
2012-07-21
1999 XK RANGE - Horn - 413-06
Horn
The horns are operated by the Body Processor Module (BPM), as described below. The switch, located on the steering wheel pad, signals the BPM to sound the horn. The BPM horn-output connection responds by providing an earth path for the horn relay coil. The relay contacts are subsequently closed and the horns sound. The horn operating relay is located in the under bonnet fusebox at the left hand side of the engine compartment.
2012-07-21
1999 XK RANGE - Horn - 413-06
Horn
The complexity of the electronics involved with the various Electronic Control Modules and the two multiplexed communication networks, preclude the use of workshop general electrical test equipment. Therefore, reference should be made to the PDU User Guide for detailed instructions on testing the horn circuit. The PDU systematically tests and analyses all functions of the horn, the horn relay, the body processor module and the operating switch. Where a fault involving the horn, relay or switch is indicated by the PDU, some basic diagnostic methods may be necessary to confirm that connections are good and that wiring is not damaged, before replacing the component.
www.JagDocs.com
2012-07-21
1999 XK RANGE - Horn - 413-06
Horn 86.30.02
Removal 1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 2. Raise front of vehicle to working height and support on stands.
3. Disconnect harness spade connectors from horns.
4. RH horn only. Release ambient air temperature sensor from horn mounting bracket tang .
2012-07-21
1999 XK RANGE - Horn - 413-06
www.JagDocs.com
5. Remove horns and mounting brackets. Remove horn mounting bracket securing bolt and remove horn and bracket from beam. Remove horn securing nut and remove horn and spacer from mounting bracket.
Installation
1. Install horn and mounting bracket. Position horn mounting bracket on bumper beam ensuring that bracket lug locates in hole. Install bracket securing bolt. Position horn on mounting bracket and install securing nut. 2. RH horn only. Install ambient temperature sensor on horn mounting bracket tang. 3. Connect harness spade connectors to horn. 4. Raise front of vehicle, remove stands and lower vehicle onto wheels. 5. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
2 2012-07-21
1999 XK RANGE - Clock - 413-07
Clock
The analogue clock is in the center of three instruments, located on the minor instrument cluster.
2012-07-21
1999 XK RANGE - Clock - 413-07
Clock
The complexity of the electronics involved with the various Electronic Control Modules and the two multiplexed communication networks, preclude the use of workshop general electrical test equipment. Therefore, reference should be made to the PDU User Guide for detailed instructions on testing the clock circuit. The PDU systematically tests and analyses the clock and the electrucal connections to it. Where a fault involving the clock is indicated by the PDU, some basic diagnostic methods may be necessary to confirm that connections are good and that wiring is not damaged, before replacing the minor instrument cluster.
www.JagDocs.com
2012-07-21
1999 XK RANGE - Information and Message Center - 413-08
Information and Message Center
Item 1 2 3 4 5
Description Driver's Information / Message Center Amber Warning Lamp Red Warning Lamp Major Instrument Cluster Speedometer
The Driver's Information Center has a liquid crystal display and is located at the lower area of the Major Instrument Cluster. The message centre is used to warn the driver, using text messages, for warnings not covered by conventional warning lamps, to indicate that the Automatic Stability Control is operating and for other shared warnings. The amber and red warning lamps attract the driver's attention when a new message has been displayed. The importance of the message dictates which lamp is swithed on. The lamps are also used together for some warnings and for some non-text warnings - refer to the Driver's Handbook for variations in local markets. The odometer is incorporated into the Driver's Message Center.
2012-07-21
1999 XK RANGE - Information and Message Center - 413-08
Information and Message Center

The complexity of the electronics involved with the speedometer and instrument cluster, of which the Message Center is a part, and the two multiplexed communication networks which are connected to it preclude the use of workshop general electrical test equipment. Therefore, reference should be made to the PDU User Guide for detailed instructions on testing the speedometer and odometer. The PDU systematically tests and analyses all functions and the various systems affected by it. Where a fault is indicated, some basic diagnostic methods may be necessary to confirm that connections are good and that wiring is not damaged, before replacing a component.
www.JagDocs.com
2012-07-21
1999 XK RANGE - Charging System - General Information - 414-00
Charging System
Details of the Charging System can be found in sections <<414-01>> and <<414-02>>.
2012-07-21
1999 XK RANGE - Battery, Mounting and Cables - 414-01
Battery Connect
1. NOTE: Whether one, or both, cables are disconnected, a minimum of 30 seconds MUST elapse between disconnection of the FIRST cable and reconnection of the LAST cable. A clean final connection must be made; do not allow temporary contact. Connect the battery terminal(s). 2. Reset the clock. 3. Enter the radio security code. If necessary, refer to the Sound System Handbook. 4. Cycle (both) door drop glass up and down to establish the upper and lower datum points. Switch the ignition ON . Lower the glass to the stop and hold the switch in the DOWN position for a further five seconds. Raise the glass fully and hold the switch in the UP position for a further five seconds. 5. Switch the ignition OFF .
www.JagDocs.com
2012-07-21
Battery and Cables

The battery has been designed specifically for Jaguar. It provides the high output which is required for this vehicle, but with a substantial saving in weight. It is a low maintenance battery, located on the right hand side of the luggage compartment floor. The negative (Ground) lead is connected to the vehicle body. The positive lead is connected to a high power protection module; from here power is connected to the starter motor and distributed to other systems on the vehicle. The high power protection module comprises three fuses, each of 250A capacity. Two fuses are connected in parallel to provide protection for the starter circuit. The third one provides high level protection for fusebox supply circuits . PDU is unable to diagnose the overall condition of the battery - only that it is present and supplying battery voltage to the system. To test the battery, follow the test procedure described in Section <<414-02>> Generator and Regulator of this Manual. Although these tests will not actually test the battery, they will confirm that the generator, regulator and connecting cables are working correctly and that consequently, the battery may be at fault. Alternatively, the tests may indicate that the fault lies in the generator, regulator or wiring and not in the battery.
Battery
Item 1 2 3 4 5
Description Battery Positive Lead Battery Hold-Down Clamp Negative (Ground) Lead High Power Protection Module (Fuses)
2012-07-21
Battery 86.15.01
Removal 1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors remain open until after the battery has been disconnected. 2. Remove the luggage compartment floor panel (when standard size spare wheel is supplied) and the cover from the battery.
www.JagDocs.com
3. Disconnect the battery cables. Disconnect the ground cable. Disconnect the positive cable. 1. Disconnect the vent pipe.
4. Remove the battery.
2012-07-21

1. Remove the two bolts which secure the battery clamp. 2. Remove the clamp. 3. Remove the battery.
Installation 1. Installation is the reverse of removal. 2. Perform the Battery Reconnection Procedure described in this section.
2012-07-21
Battery Ground Cable 86.15.19

Removal 1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors remain open until after the battery has been disconnected. 2. Remove the luggage compartment floor panel (when standard size spare wheel is supplied) and the battery cover.
www.JagDocs.com
3. Remove the negative lead. Reposition the front edge of the side trim for access to the ground stud. 1. Slacken the clamp of the negative lead at the battery terminal. Disconnect the negative lead from the battery terminal. 2. Remove the nut from the ground stud. 3. Remove the negative lead.
2012-07-21
Battery Positive Cable 86.15.17

Removal 1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors remain open until after the battery has been disconnected. 2. Remove the luggage compartment floor panel (when standard size spare wheel is supplied) and the battery cover.
3. Disconnect the positive lead. 1. Slacken the clamp of the positive lead at the battery terminal. Disconnect the positive lead from the battery terminal. 2. Remove the cover from the high power protection module for access to the positive supply stud.
4. Remove the positive lead. 1. Remove the nut from the positive supply stud.
1 2012-07-21

2. Remove the positive lead.
www.JagDocs.com
2012-07-21
Battery Retaining Bracket 86.15.12

Removal 1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors remain open until after the battery has been disconnected. 2. Remove the luggage compartment floor panel (when standard size spare wheel is supplied) and the cover from the battery. 3. Disconnect the battery terminal ground cable.
4. Remove the battery hold-down clamp. 1. Remove the two bolts which secure the battery hold-down clamp. 2. Remove the hold-down clamp.
2012-07-21
1999 XK RANGE - Generator and Regulator - 414-02
Generator
Generator - General View
www.JagDocs.com
Item 1 2 3 4 5
Description Generator Bolt - Mounting Upper Bolt - Mounting Lower Voltage Regulator (Internal component) Drive Belt - Multi-Ribbed
Features
Manufacturer - Denso Type - L3B-HE Drive Ratio - 3.04:1 Output - 120amps @ 5000 rpm (generator speed) at 25 C The generator is fitted at the front right hand side of the engine, to a separate mounting bracket, which in turn is bolted to the cylinder block. Two bolts secure the generator to the mounting bracket; one is reached from above and one from below the vehicle. The voltage regulator is integral with the generator body. Battery charging capability has been optimised for charging a battery which is located remotely, in the luggage compartment. The design of the generator and regulator has been finely matched, to generate charging current with very low ripple. This provides the best electrical refinement to the system. The generator is driven by a single, multi-ribbed belt which also drives all other front-end accessories.
2012-07-21
No special service tools are required to remove the generator from the vehicle. Belt tension is achieved by an automatic tensioner; neither the belt nor the tensioner require service apart from checking the belt wear indicators at each normal service interval. The minimum service life of the drive belt is 100,000 miles. Never apply oil to the belt or to the belt tensioner.
Generator - Charging Circuit
Item 1 2 3 4 5 6 7
Description Generator Suppression Module Starter Motor Battery Power Cable to Rear Fuse Box High Power Protection Module Power Cable to Front Fuse Boxes
The main components of the charging system are shown above. The output from the generator 'B+' main terminal passes to the battery via the main terminal on the starter motor and then the power cable to the high power protection module located in the luggage compartment. From this module, a short main power cable supplies the battery positive terminal. The return circuit is through the vehicle body and supplementary ground cables. The high power protection module comprises four fuses, each rated at 250amps. Battery output uses the same power cable as the charging circuit, to the high power protection module and to the starter motor main terminal. Two similar cables, but not such a high rating, supply battery power from the high power protection module to the fuse box in the luggage compartment and to the fuse boxes at the front of the vehicle.
2 2012-07-21
The interference suppression module (where fitted) connects to the generator main terminal 'B+' and a ground stud on the rear face of the generator. A multi-plug (3 pin) is connected to the rear of the generator. Pin #1 not connected. Pin #2 ignition supply to the regulator. Pin #3 output to the charge warning lamp.
Generator - Internal Circuit Diagram
www.JagDocs.com
Item 1 2 3 4 5 6 7 8
Description Generator Assembly Voltage Regulator Main Terminal 'B+' Ignition Supply Terminal 'IG' to Rotor Output Terminal L to Charge Lamp Rotor Stator Rectifier Pack
As with most vehicle ac generators, there is only minimal residual magnetism in the field (rotor) windings. To compensate for this and to achieve high current output at low engine speed, the field is excited by battery voltage
2012-07-21

supplied to the generator at the 'IG' terminal. To control the level of field excitation and ultimately, generator output, the voltage supplied to the field (rotor) is controlled by the voltage regulator. The voltage regulator senses (at the 'B' terminal) battery terminal voltage, which within limits is proportional to the state of charge of the battery. The regulator then adjusts the supplied voltage between the 'IG' terminal and the regulator 'F' terminal (a continuously variable process) to maintain the 'B+' output at a constant level. If the field were not controlled, the 'B+' output would rise to a level which could damage bulbs and ECMs. The regulator compares the output voltage to an internal voltage reference circuit to achieve the controlled output of the generator.
Suppression Module
Although the output from the generator is finely controlled and relatively smooth, it is still a pulsed DC output at a varying frequency proportional to engine speed. The suppression module damps out any ripple which may be sensed on the main output of the generator. This prevents possible interference via the power supply, affecting the radio reception or, where fitted, the telephone. The module is located on the right hand side of the engine compartment adjacent to the generator. It is secured to a mounting bracket by three bolts. The mounting bracket is bolted to the inner panel, just above the chassis leg. The illustration shows the suppression module viewed from below the vehicle. A fuse is fitted internally to the suppression module to protect the generator output in the event of a short circuit within the suppression module.
2012-07-21

Drive Belt Automatic Tensioner
www.JagDocs.com
Item 1 2 3
Description New Belt - Minimum Length New Belt - Maximum Length Replace the Belt
Belt tension is achieved by an automatic tensioner; neither the belt nor the tensioner require service apart from checking the belt wear indicators at each normal service interval. The minimum service life of the drive belt is 100,000 miles. Never apply oil to the belt or to the belt tensioner.
2012-07-21
Generator
Refer to the PDU User Manual for detailed instructions on testing the charging circuit. When diagnosing the charging circuit, the PDU indicates only whether the generator is charging or not charging. The reason for this is that the PDU cannot handle the potential full charging current and that the voltage control circuits are located within the generator assembly, making them inaccessible by the PDU directly. It is possible that the battery has failed. In this case, the voltage output at the generator could be correct, but the voltage at the battery terminals, and therefore the rest of the vehicle system, will be adversely affected by the faulty battery. The same result is given by the PDU if the battery is faulty (generator not faulty), wiring fault (damaged or severe corrosion at the terminals) or if the generator is at fault.

The following manual tests help to pinpoint which component is at fault. Mechanical Visually check the condition of the drive belt Check that the belt wear indicator, located on the automatic belt tensioner, is within the limit marks Electrical Connections on the rear face of the generator are fully located?
Testing the Battery Circuit
Using the Vehicle Battery
Remove the battery cover.
2012-07-21
Ensure that all electrical loads are switched OFF and that the engine is cool. Start the engine and allow to IDLE. Whilst the engine is idling, disconnect the battery negative terminal and, using a digital multimeter (DMM), measure the voltage between the terminal on the battery negative cable and the battery positive terminal. If the generator is working, the measured voltage should be within the range 13V to 15V. This indicates the system voltage without the battery in circuit. If the generator is inoperative, the engine will stall when the ground lead is disconnected. Repeat the test, using the ground bolt, as indicated (shown dotted on the illustration). There should be hardly any detectable difference in the voltage reading (due to minimal current flow); if there is a detectable difference, clean the cable terminal and the adjacent area of the body. When the voltage has been measured, STOP THE ENGINE. Reconnect the battery or fit a new battery if it was established that the battery was at fault (Refer to <<414-01>>). If the cooling fans operate during the above test, the large demand of current will overload the generator and cause the engine to stall. If the battery is in a low state of charge the voltage will rise momentarily when the battery is disconnected. However, the maximum that the voltage can increase to with this new generator is 25V and then only for a maximum time of 200 mS.
www.JagDocs.com
Using a Substitute Battery

A substitute battery may be fitted for the tests. This battery must be a known good example and must have been off-charge for at least twelve hours, with a terminal voltage of approximately 12.8V. Ensure that all electrical loads are switched OFF and that the engine is cool. Start the engine and allow to IDLE. Measure the voltage across the battery terminals. It should have dropped a little due to the large start current and then risen to a value of between 13V and 15V. If the above test (whichever one used) indicates that the generator is not working then the connections on the rear face of the generator should be checked. If there is a faulty connection, then the generator will not perform correctly no matter how fast it is driven.
2012-07-21

Checking Generator Connections
Item 1 2 3 4
Description Multi-Plug Connector B+ Main Output Terminal Ground Stud for Suppression Module Heatsink for Voltage Regulator
CAUTION: The engine must not be running when multiplugs are connected or disconnected. Check that the main B+ terminal is clean and tight. Check that the IG terminal is clean and making good contact; if this connection is faulty, the generator will never function correctly. Disconnect the multi-plug at the rear of the generator With the engine not running and with the ignition switched on, use a DMM to check for battery voltage between the centre pin on the multi-plug connector and a good vehicle ground. If the measured voltage is correct, switch off the ignition and reconnect the multi-plug.
2012-07-21
Multiplug Connector
www.JagDocs.com
Item 1 2 3
Description Not Connected IG - Ignition Supply to Generator WL - Output to Charge Warning Lamp
If no voltage or low voltage is indicated, check for continuity of the harness between the multi-plug and Fuse 5 (10A) in the Engine Compartment Fusebox - Left Hand Side. Repair any damage to the harness if necessary. It should be noted that if Fuse 5 has blown, the starter motor will not operate and the Engine Control Module will not receive an ignition supply. Consequently, the engine will not start, even with a slave battery. Start the engine and test for correct charge or voltage level; check as described previously. If not charging and the generator is being driven ie. no belt slipping - renew the generator.
2012-07-21
Generator 86.10.02
2. Disconnect the battery ground cable. Remove the battery cover. 3. Remove the air cleaner assembly (including fit body paintwork protection sheets to the adjacent working area); refer to <<303-12>>. 4. Remove the fan and motor assembly from behind the radiator; refer to 303-03. Check that the belt wear indicator is within the limit marks. Raise the vehicle on a ramp; refer to <<100-02>>
2012-07-21
5. Remove the air intake ducting from the generator. The ducting comprises two sections; each is retained by two screws and a clip.
www.JagDocs.com
6. Remove the drive belt from the generator and accessory drive, 1. Use a spanner e.g. Churchill JD-230 or Snap On XDHM 1415, on the centre bolt of the belt tensioner idler pulley, to turn the adjuster assembly to the left against spring tension. 2. Whilst holding the tensioner against spring tension, remove the drive belt from the generator pulley. Release the tensioner slowly and remove the spanner. Disconnect the belt from the other pulleys, as necessary, to move it clear of the generator.
2012-07-21
7. Disconnect the generator harness. 1. Disconnect the harness multi-plug. 2. Remove the protective boot from the positive terminal, remove the terminal nut and disconnect the cable from the terminal. Disconnect the suppressor module positive cable from the positive terminal. 3. Remove the nut which secures the suppression module negative cable and disconnect the cable from the generator. Reposition the suppression module harness clear of the generator.
8. Remove the lower mounting bolt.
2012-07-21
9. Remove the upper securing bolt and withdraw the generator from the mounting bracket.
www.JagDocs.com
10. Carefully, manoeuvre the generator forward towards the radiator.
2012-07-21
11. Change the position of the generator and remove it upwards between the engine and the radiator.
Installation
1. Move the spacing bush rearwards slightly in the generator mounting bracket, to ease fitting the new generator. 1. Position a suitable length bolt through the bush, fit a tubular spacer or socket spanner, fit a nut and tighten the assembly to move the bush slightly. Remove the nut, bolt and spacer.
2012-07-21
www.JagDocs.com
2. Fit the generator to the engine. 1. From above, position the generator and fit the upper mounting bolt and nut, but do not fully tighten.
3. Fit the generator lower mounting. 1. From below, reposition and align the harness clip to the generator lower mounting. 2. Fit the lower mounting bolt and nut, tighten to 38-48 Nm.
2012-07-21
4. Connect the harness. 1. Reposition the suppression module harness and connect the negative cable to the generator negative terminal. Fit and tighten the terminal nut. 2. Secure the suppression module positive cable and main positive cable to the generator positive terminal. 3. Fit the boot to the terminal. 4. Reconnect the generator harness multi-plug. 5. Lower the vehicle on the ramp; refer to <<100-02>>. 6. Fully tighten the generator upper mounting bolt, to 18 -24 Nm.
7. Refit the drive belt to the generator. 1. Pass the drive belt around the idler pulley. 2. Using spanner )Churchill JD-230 or Snap On XDHM 1415) on the centre bolt of the belt tensioner idler pulley, rotate the adjuster against spring tension. 3. Whilst holding the tensioner against spring tension, pass the drive belt over the generator pulley and check that it is correctly located on the other pulleys. Release the tensioner slowly and remove the
2012-07-21

spanner. Check the alignment of the belt. 8. Refit the fan and motor assembly; refer to 303-03. 9. Refit the air cleaner assembly; refer to <<303-12>>. 10. Reconnect the battery in accordance with <<414-01>>.
www.JagDocs.com
2012-07-21
Voltage Regulator 86.10.28

2. Disconnect the battery ground cable. Remove the battery cover. 3. Remove the generator from the vehicle. Refer to Operation <<86.10.02>>.
4. Remove the nut from the main terminal and remove the insulator.
2012-07-21
www.JagDocs.com
5. Remove the ground tag. 1. Remove the nut which secures the ground tag. 2. Remove the screw which secures the ground tag and remove the tag.
6. Remove the two remaining nuts which secure the rear cover and remove the cover.
2012-07-21
7. Remove the rubber cover from the brush holder.
8. Remove the screws which secure the brush holder. Remove the brush holder, taking care not to damage the brushes.
2012-07-21
www.JagDocs.com
9. Remove the screws, two long and one short, from the regulator. Remove the regulator.
Installation
1. Check that the rubber gasket for the brush holder is correctly located.
2012-07-21
2. Check that the new regulator is of the same type and is not damaged.
3. Locate and align the new regulator. Install, but do not tighten the screws, two long and one short, to secure the regulator.
2012-07-21
www.JagDocs.com
4. Install the brush holder; do not damage the brushes. Hold the brushes fully into the brush holder using a plastic rod, and very carefully slide the holder into position.
5. Install the screws which secure the brush holder. 1. Tighten the screws which secure the brush holder. 2. Tighten the screws which secure the regulator.
2012-07-21
6. Install the rubber cover to the brush holder.
7. Install the rear cover and the ground tag.
2012-07-21
www.JagDocs.com
8. Install the screw to secure the ground tag and install the three nuts to secure the rear cover. Tighten the four fixings.
9. Install the insulator to the main terminal. 1. Slide the insulator onto the main terminal. 2. Note the locating flat on the insulator and in the rear cover. 3. Install the nut to the main terminal. 10. Install the generator to the vehicle. Refer to Operation <<86.10.02>>. 11. Connect the battery and install the battery cover. Reset the side glass memory. Refer to the Battery Reconnection Procedure <<86.15.15>>.
2012-07-21
1999 XK RANGE - Audio Unit - 415-01
Audio System
Base or premium specification audio systems are available and switches on the steering wheel provide for remote operation in each case. The radio and electrically operated aerial are also common to both systems An identical audio unit is installed in both systems. On initial installation this is matched to the appropriate system by selecting the STD or PRM switch position on the underside of the unit chassis. Telephone controls incorporated in the audio unit facilitate installation of a GSM hands-free telephone system available as an option.
Base Audio System

The base system audio unit incorporates integral message display and 'Phone Ready' controls for installation of a GSM hands-free telephone system. A CD autochanger is installed in the trunk and six speakers are located two at each side of the facia and one in each door and rear quarter.
Premium Audio System

As in the base system, the audio unit incorporates integral message display and 'Phone Ready' controls, and a CD autochanger is installed in the trunk. The premium audio system also includes an amplifier unit installed in the trunk a sub-woofer speaker on the rear parcel shelf (a sub-woofer in each rear quarter on convertible models), two mid-range speakers in each door, a mid-range speaker in each rear quarter and a tweeter at each side of the facia.
Navigation System Interface.

An optional integrated navigation system supplied with the vehicle, or as a service fit accessory, interfaces with either of the above systems to provide control of voice guidance volume. All other navigation system functions are controlled from a separate display/controls panel installed in the facia above the audio unit.
Audio System
The PDU is unable to diagnose radio head faults; there are no self-diagnostics associated with the radio. PDU is able to test the speakers and the antenna, along with associated wiring and connections, therefore by a process of elimination, the radio head can be diagnosed.
www.JagDocs.com
2012-07-21
Audio Unit 86.50.03

Removal 1. Remove battery cover and disconnect ground lead from terminal. Refer to <<86.15.19>>. 2. Remove 'J' gate surround. Refer to <<76.25.24>>. 3. Move gear selector to 'D'. 4. Remove center console assembly for access. Refer to <<76.25.01>>.
5. Remove the six radio console securing screws and partially withdraw the console for access.
2012-07-21
www.JagDocs.com
6. Disconnect radio assembly. Disconnect console harness multiplugs and aerial co-axial connector. Remove nut securing earth lead to radio and remove lead from stud. Disconnect radio harness multiplug and position harness clear of center console. Disconnect compact disc player 'Din' plug from radio.
7. Remove radio. 1. Release spring retaining clips, remove radio from console and remove radio from mounting panel.
Installation 1. Slide radio into mounting panel and position at console for access. 2. Connect aerial co-axial lead to radio and stow excess harness and lead lengths in radio mounting aperture. 3. Fully seat radio in console, ensuring that retaining clips are fully seated and harnesses and leads do not
2 2012-07-21

obstruct. 4. Install radio mounting panel on the console. 5. Holding radio console in position, route radio harness multiplugs into center console. 6. Connect radio harness and radio console harness multiplugs. 7. Route ground and aerial leads through radio console. 8. Finally position radio console and install the six securing screws. 9. Position ground lead on radio stud and install securing nut. 10. Connect aerial lead to radio. 11. Ensuring harness and leads do not obstruct, push radio fully home. 12. Install center console. Refer to <<76.25.01>>. 13. Return gear selector to 'P'. 14. Install 'J' gate surround. Refer to <<76.25.24>>. 15. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
2012-07-21
Audio Unit Amplifier 86.50.10

Removal 1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 2. Remove RH side liner from trunk. Refer to <<76.19.22>>.
www.JagDocs.com
3. Disconnect amplifier harness multiplugs.
4. Disconnect CD autochanger data cable.
2012-07-21
5. Remove upper bolts securing amplifier mounting bracket to outer mounting bracket.
6. Remove side bolts securing amplifier mounting bracket to outer mounting bracket.
2012-07-21
7. Withdraw amplifier/mounting bracket assembly from trunk and remove bolts securing amplifier to bracket.
www.JagDocs.com
Installation 1. Position amplifier on mounting bracket and install securing bolts. 2. Position amplifier/mounting bracket assembly in trunk. 3. Install upper bolts securing amplifier mounting bracket to outer mounting bracket. 4. Install side bolts securing amplifier mounting bracket to outer mounting bracket. 5. Connect amplifier harness multiplugs. 6. Connect CD autochanger data cable. 7. Install trunk RH liner . 8. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
2012-07-21
Capacitor 86.10.33
2. Disconnect the battery ground cable. Remove the battery cover. 3. Raise the vehicle on a ramp.
4. Disconnect the multi-plug from the mounting bracket clip. 1. Disconnect the multi-plug. 2. Remove the three bolts which secure the suppression module to the mounting bracket. 3. Remove the suppression module.
2012-07-21
Installation 1. Connect the battery ground cable. Refit the battery cover. 2. Reconnect the battery in accordance with <<414-01>>.
www.JagDocs.com
2012-07-21
Compact Disc (CD) Changer 86.50.06

Removal 1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 2. Remove RH side liner from trunk. Refer to <<76.19.22>>.
3. Premium ICE only: Disconnect amplifier harness multiplugs.
4. Disconnect CD autochanger data cable.
2012-07-21
5. Remove upper bolts securing autochanger mounting bracket to outer mounting bracket.
www.JagDocs.com
6. Remove side bolts securing autochanger mounting bracket to outer mounting bracket
2012-07-21
7. Withdraw autochanger/mounting bracket assembly from trunk and remove four bolts securing autochanger to bracket.
Installation 1. Position autochanger on mounting bracket and fit and install securing bolts. 2. Position autochanger/mounting bracket assembly in trunk. 3. Install upper bolts securing autochanger mounting bracket to outer mounting bracket. 4. Install side bolts securing autochanger mounting bracket to outer mounting bracket. 5. Connect amplifier harness multiplugs. 6. Connect CD autochanger data cable 7. Install trunk RH liner . 8. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
2012-07-21
1999 XK RANGE - Antenna - 415-02
Antenna
The electrically operated antenna operates automatically when the Ignition switch is set to position 1 or 2, and the radio is switched on.
www.JagDocs.com
2012-07-21
Antenna
The PDU tests whether or not the antenna raises and lowers correctly. Although it is obvious if the antenna is not operating, the PDU analyses why it is not operating and indicates problems such as a faulty radio head signal output, faulty wiring, loss of power due to a blown fuse - two fuses in the fascia end fusebox left side and one in the luggage compartment fusebox.
2012-07-21
Antenna
Removal
www.JagDocs.com
1. Loosen the mast retaining nut. 2. Remove the mast. Switch ON the ignition and the radio. Allow the antenna to fully extend. Remove the mast, noting the position of the teeth on the cable - towards the side of the vehicle. Switch OFF the ignition.
2012-07-21
Antenna Motor 86.50.21

Removal
1. Remove the carpet and trim panels from the luggage compartment. For detailed information see <<501-05>>. 1. Remove the carpet. 2. Remove the front liner. 3. Remove the liner from the right hand side.
2. Disconnect the electrical connections from the antenna. 1. Remove the bolt which secures the ground lead to the vehicle body. Disconnect and remove the lead. 2. Disconnect the multi-plug from the motor. 3. Disconnect the antenna lead. 4. Remove the tie-strap which secures the harness to the antenna body.
2012-07-21
www.JagDocs.com
3. Remove the antenna. 1. Remove the two bolts which secure the antenna mounting bracket to the vehicle body. 2. Reposition the drain tube of the antenna, through the body grommet in the luggage compartment floor. 3. Remove the antenna from through the body grommet. 4. Remove the drain tube from the antenna.
Installation 1. Installation is the reverse of removal. Lubricate the vehicle body grommets with soap solution or rubber lubricant.
2012-07-21
1999 XK RANGE - Speakers - 415-03
Speakers
Speaker Location - Coupe
Item 1 1 3 4 5 6
Description Base System - 152 mm Triple Cone Base System - 152 mm Triple cone Premium System - Mirror Panel Tweeter Premium System - 200 mm Sub Woofer Premium System - Amplifier Premium System - CD Autochanger
Both coupe and convertible with the standard entertainment system use a common speaker configuration. Vehicles with the premium entertainment system have a different configuration for each model.
2012-07-21

Speaker Location - Convertible
www.JagDocs.com
Item 1 2 1 2 3 4 5 6
Description Base System - 152 mm Triple Cone Base System - 152 mm Triple Cone Premium System - 152 mm Mid / Bass Premium System - Enclosure with 152 mm Long Throw Sub-Woofer and 64 mm Mid Range Premium System - Mirror Panel Tweeter Premium System - Fascia 64 mm Mid Range Premium System - Amplifier Premium System - CD Autochanger
2012-07-21
Speakers
PDU can test whether or not each speaker operates correctly and analyses why it is not operating. It indicates problems such as a faulty radio head output power signal, faulty power amplifier (where fitted), faulty wiring, loss of power due to a blown fuse.
2012-07-21
Door Speaker 86.50.13

www.JagDocs.com
2. Disconnect the battery ground cable. Remove the battery cover. 3. Remove the trim pad from the door; refer to <<501-05>>.
4. Remove the door speaker from the door. 1. Remove the four bolts which secure the speaker.
2012-07-21
5. Disconnect and remove the speaker. 1. Support the speaker, disconnect the multi-plug and remove the speaker.
Installation 1. Installation is the reverse of removal, noting that the battery must be reconnected in accordance with <<414-01>>.
2012-07-21
Instrument Panel Tweeter Speaker 86.51.02

Removal 1. Using a wide flat blade, carefully ease the speaker / grille assembly from the fascia. Disconnect the speaker multi-plug.
www.JagDocs.com
2. Remove the speaker from the speaker grille. 1. Remove the two screws which secure the speaker to the grille. 2. Place the grille aside
2012-07-21
Instrument Panel Tweeter Speaker Grille 86.51.04

Removal 1. Using a wide flat blade, carefully ease the speaker / grille assembly from the fascia. Disconnect the speaker multi-plug.
2. Remove the speaker from the speaker grille. 1. Remove the two screws which secure the speaker to the grille. 2. Place the grille aside
2012-07-21
Quarter Panel Speaker Vehicles Without: Convertible Top 86.50.12

Removal 1. Remove the rear quarter armrest / speaker cover for access; refer to <<501-05>>.
www.JagDocs.com
2. Remove the rear speaker. Remove the three screws which secure the speaker. Support the speaker, disconnect the multi-plug and remove the speaker.
2012-07-21
Quarter Panel Speaker Vehicles With: Convertible Top 86.50.12

Removal 1. Remove rear seat cushion. Refer to <<76.70.37>>. 2. On convertible model only, remove rear seat squab. Refer to <<76.70.38>>. 3. On convertible model only, remove rear quarter casing capping. refer to <<76.13.73>>. 4. Remove rear quarter casing. Refer to <<76.13.73>>
5. Disconnect harness mutliplugs from speaker assembly.
6. Release security aerial retaining clip from speaker assembly and position aerial clear.
2012-07-21
7. Remove nuts and bolts securing speaker assembly to BIW. 8. Remove speaker assembly from vehicle.
www.JagDocs.com
Installation 1. Position speaker assembly in vehicle. 2. Install speaker assembly securing nuts and bolts. 3. Install security aerial clip on speaker assembly. 4. Connect speaker harness multiplugs. 5. Install rear quarter casing. Refer to <<76.13.73>>. 6. Install rear quarter casing capping. Refer to <<76.13.73>>. 7. Install rear seat squab. Refer to <<76.70.38>>. 8. Install rear seat cushion. Refer to <<76.70.37>>.
2012-07-21
Quarter Panel Speaker Grille Vehicles Without: Convertible Top 76.13.70

Removal 1. Using rear passenger entry knob, fold seat back fully forward.
2. Remove speaker cover from casing. 1. Lift the two speaker cover front fasteners out of rear quarter casing spring clips. 2. Move cover forward to release two rear plastic tangs from casing and remove cover from the casing.
Installation 1. Fit speaker cover to rear quarter casing. Position speaker cover and locate rear retaining tangs in casing. Press and fully seat the two front retaining fasteners in the casing spring clips. 2. Return seat back to upright position.
2012-07-21
Subwoofer Speaker Vehicles Without: Convertible Top 86.51.05

Removal 1. Move front seat back to fully forward position.
www.JagDocs.com
2. Carefully lift front edge of speaker cover to release front and side clips from rear parcel shelf.
3. Move speaker cover forward to release rear clips from parcel shelf. 4. Remove speaker cover.
2012-07-21
5. Remove speaker securing screws.
6. Position sub-woofer speaker for access and disconnect harness connectors. 7. Remove speaker from parcel shelf.
2012-07-21

Installation
1. Position speaker on parcel shelf and connect harness connectors.
www.JagDocs.com
2. Install speaker securing screws.
2012-07-21
3. Position speaker cover on parcel shelf and engage rear clips in slots.
4. Lower front edge of speaker cover and engage side and front clips in parcel shelf. 5. Return seat back to upright position.
2012-07-21
Subwoofer Speaker Grille 76.13.72

Removal 1. Move front seat back to fully forward position.
www.JagDocs.com
2. Carefully lift front edge of speaker cover to release front and side clips from rear parcel shelf.
3. Move speaker cover forward to release rear clips from parcel shelf. 4. Remove cover from speaker.
2012-07-21

Installation
1. Position speaker cover on parcel shelf and engage rear clips in slots.
2. Lower front edge of speaker cover and engage side and front clips in parcel shelf. 3. Return seat back to upright position.
2012-07-21
1999 XK RANGE - Exterior Lighting - 417-01
Bulbs Description Flasher Side Repeater Fog Lamp - Front Fog Lamp - Rear Guard Front Direction Indicator Front Parking (side) Lamp Headlamp - Main Headlamp - Dip License Plate Lamp Rear Direction Indicator Reverse Lamp Stop Lamp Tail Lamp Capacity 12V 5W 12V 55W 12V 21W 12V 21W 12V 5W 12V 60W 12V 55W 12V 5W 12V 21W 12V 21W 12V 21W 12V 5W Type Capless Long Life Halogen H3 Long Life P21W, Bayonet Long Life Bayonet Amber Long Life Capless Long Life Halogen HB3 Halogen H1 Long Life Capless Long Life PY21W, Bayonet Amber Long Life P21W, Bayonet Long Life 21W, Bayonet Long Life P5W, Bayonet Long Life
www.JagDocs.com
Torques Component Rear Lamp Assembly to Body Nm 3
2012-07-21
Exterior Lighting
Front Lamps
Item 1 2 3 4 5
Description Headlamp Assembly Power Wash Jet Assembly Fog Lamp Side Marker / Reflex Repeater Lamp
Each headlamp assembly incorporates a main beam lamp, a dipped beam lamp, a direction indicator lamp and a side lamp. Access for bulb replacement is from the engine compartment except for the dipped beam bulb, which is accessible through a panel in the wheelarch liner. The fog lamps are located in recesses in the front bumper and secured by three screws. Access for bulb replacement is through the opening panel in the wheelarch liner. The lamps are not interchangeable, side to side, because of the orientation of the fixing holes. The side marker lamps (where fitted) incorporate a reflector and are secured by a spring clip at each end of the lamp unit. Access for bulb replacement is through the opening panel in the wheelarch liner. In markets where they are not specified, a reflector is fitted. The repeater lamps (where fitted) are secured by a spring clip at each end of the lamp unit. In markets where they are not specified, a leaping Jaguar badge is fitted.
2012-07-21

Rear Lamps
www.JagDocs.com
Item 1 2 3 4
Description Side Marker / Reflex Rear Lamp Assembly License Plate Lamps High Mounted Stop Lamp
Side marker lamps, incorporating reflectors, are secured by a spring clip at each end of the lamp. Access for bulb replacement is from beneath the rear of the vehicle. Not connected for all markets. Each rear lamp assembly incorporates a stop lamp, a tail lamp, a fog lamp, a reversing lamp and a direction indicator lamp. Access for bulb replacement is from the luggage compartment. The license plate lamps are located on a trim finisher panel, secured to the lid by four nuts. Each bulb is accessible after removing the relevant lens. A High Mounted Stop Lamp (not fitted to all markets) is fitted inside the rear screen on coupe models (as shown above) and externally, on the luggage compartment lid, on convertible models. These lamps operates using sixteen LEDs instead of conventional bulbs. Individual LEDs cannot be replaced; the complete lamp unit must be renewed if one LED is inoperative.
2012-07-21
Exterior Lighting
The complexity of the electronics involved with the various Electronic Control Modules and the two multiplexed communication networks, preclude the use of workshop general electrical test equipment. Therefore, reference should be made to the PDU User Guide for detailed instructions on testing the exterior lamps and circuits. The PDU systematically tests and analyses the lamp assemblies, the bulbs and the electrical connections to them. It should be noted that the lamps are not wired directly to the switches. Each switch provides a signal to the Body Processor which interprets the signal as a request to switch on a specific lamp. The Body Processor places the instruction onto the SCP Network. The module which is closest to the specific lamp, for example, the Security and Locking Module will translate the request which is currently on the network and switch on the rear fog lamps (also controls the reverse lamps). The remaining rear lamps and front lamps are controlled directly by the Body Processor (it has a sufficient number of high power output stages to drive the lamps / relays compared to other modules). The door hazard lamps are controlled locally by the relevant Door Module. Where a fault involving a lamp is indicated by the PDU, some basic diagnostic methods may be necessary to confirm that connections are good and that wiring is not damaged, before replacing the components.
2012-07-21
Brake Pedal Position (BPP) Switch

Removal
www.JagDocs.com
1. Disconnect the brake pedal position (BPP) switch electrical connector.
2. Remove and discard the BPP switch wiring harness retaining strap.
2012-07-21
3. Remove the BPP switch. 1. Loosen the upper retaining nut. 2. Remove the lower retaining nut. 3. Remove the BPP switch.
Installation 1. Press and hold down the brake pedal.
2.
CAUTION: Make sure the brake pedal is held clear of the BPP switch ratchet mechanism during installation. Failure to follow this instruction may result in incorrect adjustment of the BPP switch.
Install the BPP switch.
2012-07-21
3. Release the brake pedal.
www.JagDocs.com
4.
CAUTION: Make sure the brake pedal is fully raised. Failure to follow this instruction may result in incorrect adjustment of the BPP switch.
Fully raise the brake pedal.
5. Install a new BPP switch wiring harness retaining strap.
2012-07-21
6. Connect the BPP switch electrical connector.
2012-07-21
Front Fog Lamp 86.40.96

Removal 1. Turn the steering to full lock, as follows: Right- hand fog lamp - Left-hand lock. Left- hand fog lamp - Right-hand lock. (Access is possible around the reservoir)
www.JagDocs.com
2. Remove the access panel from the wheel arch liner. 1. Release the center fastener which secures the wheel arch liner access panel. 2. Lift the lower retaining catch and disconnect the lower edge of the access panel from the wheel arch liner. 3. Remove the access panel.
3. Remove the fog lamp from the vehicle (working through the access panel aperture). 1. Disconnect the electrical connector from the bulb holder. 2. Remove the three bolts which secure the lamp assembly. 3. Remove the lamp from the housing, rearwards through the access panel aperture.
2012-07-21
Installation 1. Installation is the reverse of removal. Return steering to straight ahead position.
2012-07-21
Front Fog Lamp Bulb 86.40.94

Removal 1. Turn the steering to full lock, as follows: Right- hand fog lamp - Left-hand lock. Left- hand fog lamp - Right-hand lock. (Access is possible around the reservoir)
www.JagDocs.com
3.
CAUTION: The bulb will be damaged if touched by bare hands or contaminated with oil or grease. It is important to use clean gloves or cloth when handling a bulb. A contaminated bulb may be cleaned
1 2012-07-21

with methylated spirit before fitting. Remove the fog lamp bulb from the vehicle (working through the access panel aperture). 1. Disconnect the bulb holder (quarter-turn) from the lamp. 2. Remove the bulb from the holder.
2012-07-21
Front Side Marker Lamp 86.40.59

Removal 1. Turn the steering to full lock, as follows: Right- hand marker - Left-hand lock. Left- hand marker - Right-hand lock.
www.JagDocs.com
3. Remove the marker lamp. 1. Disconnect the connector from the rear of the lamp. 2. Compress one of the retaining spring clips and remove the lamp.
2012-07-21
2012-07-21
Front Side Marker Lamp Bulb 86.40.58

Removal 1. Turn the steering to full lock, as follows: Right- hand marker - Left-hand lock. Left- hand marker - Right-hand lock.
www.JagDocs.com
2. Remove the access panel from wheel arch liner. 1. Release the center fastener which secures the wheel arch liner access panel. 2. Lift the lower retaining catch and disconnect the lower edge of the access panel from the wheel arch liner. 3. Remove the access panel.
3. Remove the marker lamp. 1. Working through the wheel arch liner access panel, compress one of the retaining spring clips and remove the lamp. 2. Disconnect bulb holder from rear of the lamp.
2012-07-21

3. Remove the bulb from the bulb holder.
2012-07-21
Front Turn Signal Lamp Bulb 86.40.41

Removal 1. Open hood and install front fender cover.
www.JagDocs.com
2. Release headlamp access panel inner retaining tangs and remove panel.
3. Rotate direction indicator lamp bulb holder 1/4 turn clockwise to release it from headlamp assembly. 4. Rotate bulb 1/4 turn to release and remove bulb from holder.
Installation 1. Install direction indicator lamp bulb in bulb holder and rotate 1/4 turn to fully engage.
2012-07-21
2. Install bulb holder to headlamp and rotate 1/4 turn counterclockwise to seat and fully engage. 3. Reposition water shedder. 4. Install headlamp access panel ensuring that seal is in position and retaining tangs are correctly engaged.
2012-07-21
Headlamp Assembly LH 86.41.33

Removal 1. Turn the steering to full lock, as follows: Right- hand headlamp - Left-hand lock. Left- hand headlamp - Right-hand lock.
www.JagDocs.com
2. Displace the wheel arch liner for access. 1. Release the center fastener which secures the wheel arch liner access panel. 2. Lift the lower retaining catch and disconnect the lower edge of the access panel from the wheel arch liner. 3. Remove the access panel. 4. Remove the fixings which secure the front of the wheel arch liner to the body. 5. Reposition the wheel arch liner for access.
3. Remove the headlamp fixings.
2012-07-21

1. Disconnect the multi-plug from the headlamp. 2. Remove the upper securing bolt and lower securing bolt. 3. Slacken the headlamp securing nut. Carefully reposition the headlamp for access to the washer jet.
4. Remove the headlamp. 1. Disconnect the washer jet assembly from the headlamp and reposition clear of the lamp. 2. Remove the headlamp assembly.
Installation 1. Installation is the reverse of removal. Return steering to straight ahead position. Realign both headlamps.
2012-07-21
Headlamp Assembly RH 86.41.36

Removal 1. Turn the steering to full lock, as follows: Right- hand headlamp - Left-hand lock. Left- hand headlamp - Right-hand lock.
www.JagDocs.com
2. Displace the wheel arch liner for access. 1. Release the center fastener which secures the wheel arch liner access panel. 2. Lift the lower retaining catch and disconnect the lower edge of the access panel from the wheel arch liner. 3. Remove the access panel. 4. Remove the fixings which secure the front of the wheel arch liner to the body. 5. Reposition the wheel arch liner for access.
3. Remove the headlamp fixings.
2012-07-21

1. Disconnect the multi-plug from the headlamp. 2. Remove the upper securing bolt and lower securing bolt. 3. Slacken the headlamp securing nut. Carefully reposition the headlamp for access to the washer jet.
4. Remove the headlamp. 1. Disconnect the washer jet assembly from the headlamp and reposition clear of the lamp. 2. Remove the headlamp assembly.
Installation 1. Installation is the reverse of removal. Return steering to straight ahead position. Realign both headlamps.
2012-07-21
Headlamp Lens 86.41.39

Removal 1. Remove headlamp assembly for access. Refer to <<86.41.33>>.
www.JagDocs.com
2. Release lens to headlamp assembly upper retaining tangs.
3. Release lens to headlamp assembly lower and side retaining tangs and remove lens from assembly
2012-07-21
4. Rotate direction indicator bulb holder 1/4 turn clockwise and remove from headlamp lens.
5. Rotate parking/side lamp bulb holder 1/4 turn counter-clockwise and remove from headlamp lens.
2012-07-21
6. Remove and discard headlamp lens to headlamp assembly seal.
www.JagDocs.com
Installation 1. Install new lens seal to headlamp assembly. 2. Position lens on headlamp. 3. Install parking/side lamp bulb holder to headlamp lens. 4. Install direction indicator lamp bulb holder to headlamp lens. 5. Install lens to headlamp assembly ensuring that retaining tangs are correctly engaged. 6. Install headlamp assembly on vehicle. Refer to <<86.41.33>>. 7. Carry out headlamp beam alignment check and adjust as necessary.
2012-07-21
Headlamp Leveling Motor LH 86.42.09

Removal 1. Open hood and fit cover to adjacent front fender.
2. Slacken power steering reservoir mounting bracket securing nuts, remove nuts together with rubber washers and position reservoir for access.
3. Disconnect harness multiplug from headlamp levelling actuator.
2012-07-21
4. Rotate actuator 1/4 turn, tilt forward end downward and withdraw assembly from headlamp.
www.JagDocs.com
Installation 1. With forward end tilted downward, position actuator assembly on headlamp. 2. Align actuator with headlamp and rotate it 1/4 turn to engage and fully seat. 3. Connect harness multiplug to actuator. 4. Position power steering reservoir, install rubber washers and securing nuts . 5. Carry out headlamp beam alignment to the appropriate alignment equipment instructions 6. Remove front fender cover and close hood.
2012-07-21
Headlamp Leveling Motor RH 86.42.10

Removal 1. Open hood and install cover on adjacent front fender.
2. Remove headlamp rear trim cover panel.
3. Disconnect harness multiplug from headlamp levelling actuator.
2012-07-21
4. Rotate actuator 1/4 turn, tilt forward end downward and withdraw assembly from headlamp.
www.JagDocs.com
Installation 1. With forward end tilted downward, position actuator assembly on headlamp. 2. Align actuator with headlamp and rotate it 1/4 turn to engage and fully seat. 3. Connect harness multiplug to actuator. 4. Install rear trim cover panel on headlamp. 5. Carry out headlamp beam alignment to the appropriate alignment equipment instructions 6. Remove front fender cover and close hood.
2012-07-21
High Beam Headlamp Bulb 86.40.12

Removal 1. Open the engine compartment cover.
2. Remove the access cap from the closing panel. Squeeze the lower two clips to release the cap.
3.
CAUTION: The bulb will be damaged if touched by bare hands or contaminated with oil or grease. It is important to use clean gloves or cloth when handling a bulb. A contaminated bulb may be cleaned with methylated spirit before fitting.
Remove the main beam bulb / bulb holder assembly from the vehicle (working through the access cap aperture). 1. Rotate the bulb holder anti-clockwise by approximately a quarter-turn to release it from the lamp.
2012-07-21
4. Remove the bulb / bulb holder assembly from the vehicle harness.
www.JagDocs.com
Installation 1. Installation is the reverse of removal. Check that the new bulb is orientated correctly and that the locating lugs are aligned. Check that the seal is in place before fitting the access cap to the closing panel.
2012-07-21
High Mounted Stoplamp Vehicles With: Convertible Top 86.41.01

Removal
1. With trunk lid fully open, remove and discard fasteners securing liner to forward edge of lid.
2. Disconnect stop lamp to trunk lid harness multiplug.
2012-07-21
3. Remove the three blanking plugs from forward underside of trunk lid.
www.JagDocs.com
4. Remove three nuts securing stop lamp to trunk lid. 5. Routing harness through aperture, remove stop lamp from trunk lid.
2012-07-21
6. Release retaining tangs and remove top cover from stop lamp.
Installation 1. Install top cover on stop lamp ensuring retaining tangs are fully seated. 2. Routing harness through aperture, position stop lamp assembly on trunk lid. 3. Install stop lamp to trunk lid securing nuts. 4. Install blanking plugs to underside of trunk lid. 5. Connect stop lamp multiplug to trunk lid harness. 6. Using new fasteners, secure forward edge of liner to trunk lid. 7. Close trunk lid.
2012-07-21
License Plate Lamp 86.40.86

Removal 1. Open the luggage compartment lid.
www.JagDocs.com
2. Remove the rearward fasteners (six, fir tree type) from the luggage compartment lid trim pad. Reposition the trim pad for access.
3. Remove the lamp assembly. 1. Disconnect the multi-plugs. 2. Remove the four nuts which secure the lamp assembly. 3. Remove the lamp assembly.
2012-07-21
4. Remove the individual lamp components. 1. Remove the lamp lens. 2. Remove the bulb holder. 3. Remove and discard the lamp assembly gasket.
2012-07-21
License Plate Lamp Bulb 86.40.85

www.JagDocs.com
2. Remove the rearward fasteners (six, fir tree type) from the luggage compartment lid trim pad. Reposition the trim pad for access.
3. Remove the bulb. 1. Disconnect the bulb holder from the lamp, complete with the multi-plug. 2. Remove the bulb.
2012-07-21
Low Beam Headlamp Bulb 86.40.08

Removal 1. Turn the steering to full lock, as follows: Right- hand fog lamp - Left-hand lock. Left- hand fog lamp - Right-hand lock.
3. Remove the protection cap from the rear of the lamp. 1. Release the spring clip and remove the bulb and harness plug from the lamp assembly.
2012-07-21
4.
www.JagDocs.com
CAUTION: The bulb will be damaged if touched by bare hands or contaminated with oil or grease. It is important to use clean gloves or cloth when handling a bulb. A contaminated bulb may be cleaned with methylated spirit before fitting.
Remove the bulb from the harness plug (working through the access panel aperture). 1. Remove the bulb from the harness plug.
2012-07-21
Rear Lamp Assembly 86.41.46

2. Remove the rear lamp assembly. 1. Release the two clips which secure the bulb holder. 2. Remove and reposition the bulb holder, for access. 3. Remove the three nuts which secure the lamp assembly. 4. Remove the lamp assembly.
2012-07-21
Rear Lamp Assembly Bulb 86.40.73

www.JagDocs.com
2. Remove the bulb holder assembly. 1. Release the two clips which secure the bulb holder. 2. Remove and reposition the bulb holder, for access to the bulbs.
3. Remove the bulb(s) as required. 1. Fog - Rear Guard. 2. Reverse. 3. Tail. 4. Direction Indicator. 5. Stop. Installation 1. Installation is the reverse of removal.
1 2012-07-21
Rear Side Marker Lamp 86.41.08

Removal
1. Remove the marker lamp. 1. Working from the underside of the bumper, disconnect the connector from the rear of the lamp. 2. Compress one of the retaining spring clips and carefully remove the lamp.
2012-07-21
Rear Side Marker Lamp Bulb 86.41.07

Removal
www.JagDocs.com
1. Remove the marker lamp. 1. Working from the underside of the bumper, compress one of the retaining spring clips and carefully remove the lamp. 2. Disconnect the bulb holder from the rear of the lamp. 3. Remove the bulb from the bulb holder.
2012-07-21
Side Lamp Bulb 86.40.27

Removal 1. Open the engine compartment cover.
2. Remove the access cap from the closing panel. Squeeze the lower two clips to release the cap.
3. Remove the bulb from the vehicle (working through the access cap aperture). 1. Rotate the bulb holder (quarter-turn) and harness plug to remove the assembly from the lamp. Pull the bulb from the bulb holder assembly.
Installation 1. Installation is the reverse of removal. Check that the seal is in place before fitting the access cap to the closing panel.
2012-07-21
Side Turn Signal Lamp Bulb 86.41.42

Removal
www.JagDocs.com
1. Remove the repeater lamp. 1. Carefully slide the lamp forward or rearward to compress one of the retaining spring clips and remove the lamp from the panel. 2. Disconnect the bulb holder from the rear of the lamp. 3. Remove the bulb from the bulb holder.
2012-07-21
Side Turn Signal Lamp LH 86.40.54

Removal
1. Remove the repeater lamp. 1. Carefully slide the lamp forward or rearward to compress one of the retaining spring clips and remove the lamp from the panel. 2. Disconnect the connector from the rear of the lamp.
2012-07-21
Side Turn Signal Lamp RH 86.40.53

Removal
www.JagDocs.com
1. Remove the repeater lamp. 1. Carefully slide the lamp forward or rearward to compress one of the retaining spring clips and remove the lamp from the panel. 2. Disconnect the connector from the rear of the lamp.
2012-07-21
1999 XK RANGE - Interior Lighting - 417-02
Bulbs Description Door Guard / Puddle Lamps Footwell Lamps Glovebox Lamp Luggage Compartment Lamps Roof Rear Courtesy Lamp - Coupe Roof Console Map / Courtesy Lamps Sun Visor Vanity Mirror Lamps Capacity 12V 5W 12V 5W 12V 4W 12V 5W 12V 5W 12V 6W 12V 3W Type Capless Long Life Capless Long Life Bayonet Long Life Festoon Long Life Festoon Long Life Capless Festoon
2012-07-21
Interior Lighting
www.JagDocs.com
Item 1 2 3 4 5 6 7
Description Footwell Lamps Glovebox Lamp Door Guard / Puddle Lamps Luggage Compartment Lamps Roof Rear Lamp (Coupe Only) Roof Console Map / Courtesy Lamps Sun Visor Vanity Mirror Lamps
Two footwell lamps are fitted, one at each end of the fascia lower rail. They are not fitted with manual switches and operate only when either or both doors are opened. The glovebox lamp operates whenever the glovebox lid is opened. The lamp comprises a combined switch and bulb holder assembly, and a white lens. A lamp is fitted to the rear lower corner of each door. Each has a double lens; red to project rearwards to warn oncoming traffic that the door is open and white to project down onto the ground. They are not fitted with manual switches and operate only when either or both doors are opened. A lamp is fitted to each rear corner of the luggage compartment, adjacent to the rear lamp assemblies. They are operated automatically whenever the luggage compartment lid is opened; the switch is incorporated within the latch mechanism. The roof rear lamp is fitted to the coupe only. It is not fitted with a manual switch and operates only when either or both doors are opened. The two lamps located in the roof console, function as map reading lamps and as courtesy lamps. Individual switches control each lamp manually and the door switches control the lamps automatically to provide the courtesy lamp function The vanity mirror lamps, two on each sun visor, operate automatically when the mirror flap is opened. The lamps will operate only when the sun visor spindle is engaged in the stowage clip. 1
Interior Lighting
The complexity of the electronics involved with the various Electronic Control Modules and the two multiplexed communication networks, preclude the use of workshop general electrical test equipment. Therefore, reference should be made to the PDU User Guide for detailed instructions on testing the interior lamps and circuits. The PDU systematically tests and analyses the lamp assemblies, the bulbs and the electrical connections to them. It should be noted that the lamps are not wired directly to the switches. Each manual switch provides a signal to the Body Processor which interprets the signal as a request to switch on a specific lamp. The lamps are controlled directly by the Body Processor (it has a sufficient number of high power output stages to drive the lamps / relays compared to other modules) except for the door mounted hazard / puddle lamps. The door hazard / puddle lamps are controlled locally by the relevant Door Module. The Body Processor Module receives messages on the SCP network from the door modules relating to door ajar / closed / locked status, sensed by the door courtesy switch(es). Where a fault involving a lamp is indicated by the PDU, some basic diagnostic methods may be necessary to confirm that connections are good and that wiring is not damaged, before replacing the components.
2012-07-21
Door Courtesy Lamp 86.40.38

Removal 1. Remove door casing for access. Refer to <<76.34.01>>.
www.JagDocs.com
2. Remove two screws securing guard lamp to door casing. 3. Remove guard lamp from door casing.
Installation 1. Position guard lamp on door casing. 2. Install securing screws. 3. Install door casing. Refer to <<76.34.01>>.
2012-07-21
Door Courtesy Lamp Bulb 86.40.47

Removal
1. Using a small flat-bladed screwdriver, release guard lamp lens retaining tang and withdraw lens from door. 2. Rotate bulb 1/4 turn and remove bulb from guard lamp.
Installation 1. Install bulb in guard lamp and rotate 1/4 turn to engage. 2. Install lens on guard lamp, ensuring that securing tang is correctly engaged
2012-07-21
Door Lock Control Switch Bulb 86.46.23

1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 2. Remove 'J' gate surround. Refer to <<76.25.24>>. 3. Remove centre console for access. Refer to <<76.25.01>>. 4. Remove radio console for access. Refer to <<76.25.15>>.
www.JagDocs.com
5. Disconnect switch module harness multiplug, release module end locaters and lightly press module out of console.
6. Rotate bulb holder 1/4 turn counter-clockwise and remove from module.
2012-07-21
7. Remove bulb from holder. Installation 1. Install bulb in holder. 2. Install bulb and holder in module and rotate 1/4 turn clockwise to fully seat. 3. Install switch module in console ensuring that end locaters are fully seated. 4. Connect switch module harness multiplug. 5. Install radio console. Refer to <<76.25.15>>. 6. Install centre console. Refer to <<76.25.01>>. 7. Install 'J' gate surround. Refer to <<76.25.24>>. 8. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
2012-07-21
Footwell Lamp 86.46.20

Removal
www.JagDocs.com
1. Remove the footwell Lamp. 1. Use a screwdriver with a wide flat blade to push the lamp assembly towards the front of the car. This movement will release the rear spring clip which is adjacent to the screwdriver blade. Release the front spring clip of the lamp by pulling the lamp rearwards. Remove the lamp from the aperture. 2. Turn the lamp through 90 to allow the connector to pass through the aperture, tilt it slightly and fully remove it. 3. Disconnect the harness connector and remove the lamp. 4. If required, remove the bulb holder and replace the bulb.
Installation 1. Installation is the reverse of removal. Install the new lamp so that the face marked 'REAR' is towards the rear of the vehicle; failure to do this will make the lamp very difficult to remove.
2012-07-21
Footwell Lamp Bulb 86.46.24

Removal
1. Remove the footwell Lamp. 1. Use a screwdriver with a wide flat blade to push the lamp assembly towards the front of the car. This movement will release the rear spring clip which is adjacent to the screwdriver blade. Release the front spring clip of the lamp by pulling the lamp rearwards. Remove the lamp from the aperture. 2. Turn the lamp through 90 to allow the connector to pass through the aperture, tilt it slightly and fully remove it. 3. Disconnect the harness connector and remove the lamp. 4. If required, remove the bulb holder and replace the bulb.
Installation 1. Installation is the reverse of removal. Install the new lamp so that the face marked 'REAR' is towards the rear of the vehicle; failure to do this will make the lamp very difficult to remove.
2012-07-21
Front Interior Lamp 86.45.12

Removal 1. Power front seat fully forward.
www.JagDocs.com
2. Carefully withdraw interior lamp assembly from headlining
3. Disconnect harness multiplug and remove lamp assembly.
Installation 1. Ensure that interior lamp finisher is correctly positioned on headlining. 2. Position lamp assembly at headlining and connect harness multriplug. 3. Install lamp assembly in finisher. 4. Return front seat to original position.
1 2012-07-21
Glove Compartment Lamp 86.45.08

Removal 1. Open glovebox lid.
2. Carefully release and remove plastic lens from glovebox light. 3. Remove bulb from glovebox light.
4. Release light/switch assembly retaining tangs and partially withdraw assembly from glovebox exterior.
2012-07-21
5. Position light/switch assembly for access, disconnect harness spade connectors and remove assembly from glovebox aperture.
www.JagDocs.com
Installation 1. Position light/switch assembly at glovebox aperture and connect harness spade connectors. 2. Install light/switch assembly in aperture, ensuring that retaining tangs are fully seated. 3. Install bulb in light/switch assembly. 4. Check that harness leads are not in contact with the bulb glass. 5. Install plastic lens on light/switch assembly. 6. Close glovebox lid.
2012-07-21
Glove Compartment Lamp Bulb 86.45.07

Removal
1. Remove the bulb from the glovebox lamp. 1. With the glovebox lid open, carefully prise away the lens. 2. Working through the lens aperture, carefully remove the bulb.
2012-07-21
Luggage Compartment Lamp 86.45.16

Removal 1. Open trunk lid.
www.JagDocs.com
2. Using a thin plastic lever, carefully release lamp retaining tangs from trunk rear finisher.
3. Withdraw lamp for access and disconnect harness.
Installation 1. Position lamp for access and connect harness multiplug. 2. Install and fully seat lamp assembly on trunk rear finisher ensuring that retaining tangs correctly engage. 3. Close trunk lid.
1 2012-07-21
Luggage Compartment Lamp Bulb 86.45.15

Removal
1. Carefully prise the lamp from the luggage compartment trim panel.
2. Remove the bulb. 1. Squeeze the lens retaining lugs, located one each side of the bulb, and remove the lens. 2. Remove the bulb.
2012-07-21
Map Reading Lamp Bulb 86.45.09

Removal
www.JagDocs.com
1. Remove the roof console. Very carefully prise the console from the roof trim panel.
2. Remove the bulb from the console. 1. Remove the relevant bulb holder. 2. Remove the bulb.
2012-07-21
Rear Interior Lamp Bulb Vehicles Without: Convertible Top 86.45.06

Removal 1. Remove the lamp from the roof. Carefully prise one side of the lamp assembly from the roof panel. Lower the lamp assembly.
2. Remove the bulb from the roof lamp. 1. Squeeze the lens retaining lugs, located one each side of the bulb, and remove the lens. 2. Remove the bulb.
2012-07-21
Vanity Mirror Lamp 76.10.50

Removal
www.JagDocs.com
1. Move sun visor to downward position and turn mirror cover upwards.
2. Using a small screwdriver or similar thin blade, carefully release illumination lens lower tangs and remove both lenses from mirror assembly.
2012-07-21
3. Using a small screwdriver or similar thin blade, carefully release side tangs and remove mirror assembly from base.
Installation 1. Ensure that bulbs, bulb holders and switch contactors are correctly positioned and seated. 2. Position mirror assembly on base and press firmly at each side to fully engage tangs. 3. Fit and fully seat mirror illumination lenses. 4. Turn mirror cover downwards and reposition sun visor upwards.
2012-07-21
Vanity Mirror Lamp Bulb 86.45.95

Removal 1. Rotate the sun visor down and open the vanity mirror flap.
www.JagDocs.com
2. Remove the mirror / lens assembly. 1. Use a flat screwdriver to very carefully prise the mirror / lens assembly from the visor.
3. Remove the bulb from the vanity mirror lamp(s). 1. Remove the bulb(s) from the holder.
2012-07-21
1999 XK RANGE - Daytime Running Lamps (DRL) - 417-04
Daytime Running Lamps (DRL)

Refer to the Driver's Handbook for details which are specific to the intended market - Canada and Scandinavia.
2012-07-21
1999 XK RANGE - Daytime Running Lamps (DRL) - 417-04
Daytime Running Lamps (DRL)

The complexity of the electronics involved with the Body Processor and the two multiplexed communication networks which are associated with it, preclude the use of workshop general electrical test equipment. Therefore, reference should be made to the PDU User Guide for detailed instructions on testing the Daytime Running Function. The Daytime Running function is exactly the same as for the normal operation of the side lamps (or dipped beam, where specified) in as much as the body processor drives the same lamps from the same outputs. The body processor has been programmed to respond to an alternative set of conditions in order to operate the lamps, instead of waiting for a signal from the normal light switch. The conditions which have to be set are; ignition switch set to position II or III and sidelight switch set to OFF. The sidelights, side marker lamps (if fitted and enabled), tail lights and number plate lights will all be switched ON. The PDU systematically tests and analyses all functions of the daytime running lamps. Where a fault is indicated, some basic diagnostic methods may be necessary to confirm that connections are good and that wiring is not damaged, before replacing a component.
www.JagDocs.com
2012-07-21
1999 XK RANGE - Module Communications Network - 418-00
Communications Network
Fuse-boxes
Parts List Item 1 2 3 4 5 6 7 Description Engine Compartment Engine Management - RHD Only Engine Management - LHD Only Fascia End - Right Hand Side Luggage Compartment High Power Protection module Fascia End - Left Hand Side
There are six fusebox assemblies per vehicle, five of which have conventional, replaceable fuses. The High Power Protection Module does not have conventional fuses. Two Engine Management fuse-boxes are shown. Only one is fitted (LHD or RHD) to any vehicle, on the opposite side to the pedal box. The High Power Protection Module comprises three 250amp fusible links to protect the starting circuit (two connected in parallel) and the battery positive supply to the other fuse-boxes.
Location of J1962 socket

The J1962 socket is located on the fascia, adjacent to the 'A' pillar on the driver side.
2012-07-21
Communications Network
Principles of Operation
There are three module communication networks connected to the Data Link Connector (DLC), Controller Area Network, (CAN), Standard Corporate Protocol (SCP), and International Standards Organisation (ISO). CAN and SCP are unshielded twisted pair cable; data bus + and data bus -, while ISO is a single wire system. (The exceptions to this are the Adaptive Damping Control Module (ADCM), the Engine Control Module (ECM), and the Air Conditioning Control Module, (A/CCM) which have two wires). The networks can be connected to the Jaguar approved diagnostic system or scan tool by the DLC. The SCP communication network remains operational even with the severing of one of the bus wires. Communications will also continue if one of the bus wires is shorted to ground or battery positive voltage (B+), or if some, but not all, termination resistors are lost. The ISO network, however, will not function if the circuit is damaged. Modules may log DTCs if power supply or ground is interrupted. Supply and ground tests are in this section under the DTC number flagged, or by module name in the pinpoint tests. Some faults may occur without logging a network DTC. If this is the case, refer to the wiring diagrams to determine which network includes the faulty circuit, and follow the pinpoint test indicated in the DTC index. The instrument cluster (IC) is connected to the CAN and SCP communication networks, and forms a 'gateway' between the networks. The networks share information, allowing sensors to serve more than one network.
www.JagDocs.com

1. Verify the customer concern. 2. Confirm which, if any, warning lights and/or messages were displayed on the instrument cluster. NOTE: If any warning lights and/or messages were displayed when the fault occurred, refer to the Driver Information table for DTCs associated with the display, then to the DTC index table for possible sources and actions. Some warnings will appear to clear when the ignition is cycled. This is often because the warning has flagged as a result of one of the vehicle's on-board diagnostic routines having run to detect the fault. If the same routine is not run when the ignition is switched ON, the warning will not reflag until the routine does run. See the DTC summaries for drive cycle routines. 3. Visually inspect for obvious signs of mechanical or electrical damage.
2012-07-21

Visual Inspection Chart Electrical General Fuses (see table) Wiring harness Correct engagement of electrical connectors Loose or corroded connections Controller Area Network (CAN) Instrument cluster (IC) J-Gate (gear shift) illumination module (GSI) Engine control module (ECM) Transmission control module (TCM) ABS/Traction control module (ABS/TCCM) Vehicle speed interface module (VSIM) Standard Corporate Protocol (SCP) Instrument cluster (IC) Body processor module (BPM) Security and locking control module (SLCM) Passenger door control module (PDCM) Driver door control module (DDCM) Passenger seat control module (PSCM) Driver seat control module (DSCM) International Standards Organisation (ISO) Restraints control module (RCM) Adaptive damping control module (ADCM) Engine control module (ECM) Key transponder module (KTM) Air conditioning control module (A/CCM) Body processor module (BPM)
2012-07-21

Fuse Identification Chart Fuse 04 05 10 17 05 07 04 05 14 04 01 16 18 16 04 01 02 04 06 12 18 14 01 15 15 01 01 06 Rating 5 Amp, naturally aspirated, 10 Amp supercharged 10 Amp 5 Amp 15 Amp 15 Amp 15 Amp 10 Amp 5 Amp 10 Amp 5 Amp, naturally aspirated, 10 Amp supercharged 10 Amp 5 Amp 30 Amp 30 Amp 5 Amp 10 Amp 20 Amp 05 Amp 10 Amp 10 Amp 5 Amp 10 Amp 5 Amp 25 Amp 25 Amp 20 Amp 20 Amp 5 Amp Circuit Engine control module Engine control module Engine control module Body processor module Body processor module Body processor module Restraints control module Restraints control module Restraints control module Transmission control module Transmission control module J-Gate illumination module ABS/Traction control module ABS/Traction control module ABS/Traction control module Vehicle speed interface module Adaptive damping control module Adaptive damping control module Air conditioning control module Air conditioning control module Instrument cluster Instrument cluster Security and locking control module Driver door control module Passenger door control module Driver seat control module Passenger seat control module Key transponder module Location EMS fuse box Engine compartment fuse box EMS fuse box Passenger side fuse box Driver side fuse box Driver side fuse box Driver side fuse box Driver side fuse box Driver side fuse box EMS fuse box Engine compartment fuse box Driver side fuse box Engine compartment fuse box Engine compartment fuse box Engine compartment fuse box Engine compartment fuse box Luggage compartment fuse box Luggage compartment fuse box Passenger side fuse box Driver side fuse box Driver side fuse box Driver side fuse box Luggage compartment fuse box Driver side fuse box Passenger side fuse box Driver side fuse box Passenger side fuse box Driver side fuse box
www.JagDocs.com
4. Where the Jaguar approved diagnostic system is available, complete the S93 report before clearing any or all fault codes from the vehicle. NOTE: If a DTC cannot be cleared, then there is a permanent fault present that flags again as soon as it is cleared. (The
2012-07-21

exception to this is P1260, which will only clear following an ignition OFF, wait one minute, ignition ON cycle after rectification.) 5. If the cause is not visually evident and the Jaguar approved diagnostic system is not available, use a scan tool to retrieve the fault codes before proceeding to the DTC index chart, or the symptom chart if no DTCs are set. CAUTION: Diagnosis by substitution from a donor vehicle is NOT acceptable. Each vehicle is configured to it's own VID block, and substitution of control modules may not only not confirm a fault, but may cause faults in the vehicle being tested and/or the donor vehicle.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result.
CAUTION: When probing connectors to take measurements in the course of the pinpoint tests, use the adaptor kit, part number 3548-1358-00. NOTE: When performing electrical voltage or resistance tests, always use a digital multimeter (DMM) accurate to 3 decimal places, and with an up-to-date calibration certificate. When testing resistance, always take the resistance of the DMM leads into account. NOTE: Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests. 6. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step 7. If the cause is not visually evident, verify the symptom and refer to the DTC index.

2012-07-21

Warning light Amber Amber Amber Amber Amber Amber Amber Message Restricted performance, DSC fault, DSC system fault Restricted performance Restricted performance Restricted performance Cruise not available Restricted performance/gearbox fault Restricted performance/gearbox fault Default Mode Engine speed limited, reverse throttle progression enabled Engine speed limited, reverse throttle progression enabled Engine speed limited, reverse throttle progression enabled Engine speed limited, reverse throttle progression enabled Cruise (speed) control inhibited Gearbox default to set gear Engine speed limited, reverse throttle progression enabled DTC P1637 P1638 P1642 P1643 P1696 P1796 P1797

LIMP-HOME MODE Throttle motor off Throttle motor relay off Throttle motor circuit off Fuel intervention Cruise (speed) control Inhibited LIMP-HOME UNAVAILABLE Power limitation Vehicle speed limited to 74.5 mph (120 kph) Reverse throttle progression enabled * Cruise (speed) control Inhibited REVERSE THROTTLE PROGRESSION Throttle opening limited to maximum 30% NOTE: * The throttle operation uses the same map as for reverse gear. ENGINE SPEED LIMITED Engine runs normally, up to 3000 RPM Engine speed restricted to 3000 RPM maximum, by fuel cut-off HIGH IDLE Throttle valve kept in fixed position by motor Cruise (speed) control Inhibited SAFETY REDUNDANCY Power limitation Vehicle speed limited to 74.5 mph (120 kph) Reverse throttle progression enabled Cruise (speed) control Inhibited
www.JagDocs.com
2012-07-21

DTC P1637 Description CAN ABS/TCCM token missing Possible Source CAN open circuit fault: ABS/TCCM to ECM CAN short circuit fault ABS/TCCM failure ECM failure Action For CAN open circuit tests, Goto <<R>> for vehicles with supercharger, Goto <<S>> for vehicles without supercharger. For CAN short circuit tests, Goto <<T>> . Contact dealer technical support for advice on possible module failure. For CAN open circuit tests, Goto <<R>> for vehicles with supercharger, Goto <<S>> for vehicles without supercharger. For CAN short circuit tests, Goto <<T>> . Contact dealer technical support for advice on possible module failure. For CAN short circuit tests, Goto <<T>> . Contact dealer technical support for advice on possible module failure. For CAN open circuit tests, Goto <<R>> for vehicles with supercharger, Goto <<S>> for vehicles without supercharger. For CAN short circuit tests, Goto <<T>> . Contact dealer technical support for advice on possible module failure. For ECM flash programming circuit tests, Goto <<W>> . For SCP circuit tests, Goto <<U>> . For ISO circuit tests, Goto <<V>> .
P1638
CAN IC token missing
CAN open circuit fault: IC to ECM CAN short circuit fault IC failure ECM failure
P1642
P1643
CAN open circuit fault: TCM to ECM CAN short circuit fault TCM failure ECM failure
P1649
ECM flash programming circuit malfunction
ECM to DLC circuit: short circuit to ground, short circuit to battery
None
SCP circuit malfunction
Short circuit fault in SCP network
None
ISO circuit malfunction
Short circuit fault in ISO network
2012-07-21

Power Supply/Ground test index
Description BPM supply or GROUND failure Possible Source BPM permanent supply fault BPM GROUND fault SLCM supply or GROUND failure SLCM permanent supply fault SLCM GROUND fault PDCM supply or GROUND failure Action For BPM circuit tests, Goto <<A>> . For SCLM circuit tests, Goto <<B>> . For PDCM circuit tests, Goto <<C>> . For DDCM circuit tests, Goto <<D>> . For PSCM circuit tests, Goto <<E>> . For DSCM circuit tests, Goto <<F>> . For IC circuit tests, Goto <<G>> .
PDCM permanent supply fault PDCM GROUND fault
DDCM supply or GROUND failure
DDCM permanent supply fault DDCM GROUND fault
PSCM supply failure
PSCM permanent supply fault
DSCM supply failure
DSCM permanent supply fault
www.JagDocs.com
IC supply or GROUND failure
IC permanent supply fault IC ignition switched supply fault IC GROUND fault
RCM supply or GROUND failure
RCM ignition switched supply fault RCM GROUND fault ADCM permanent supply fault ADCM ignition switched supply fault ADCM GROUND fault
For RCM circuit tests, Goto <<H>> . For ADCM circuit tests, Goto <<I>> . For KTM circuit tests, Goto <<J>> .
ADCM supply or GROUND failure
KTM supply or GROUND failure
KTM permanent supply fault KTM accessory switched GROUND fault KTM ignition switched GROUND fault KTM GROUND fault
A/CCM supply or GROUND failure
A/CCM permanent supply fault A/CCM ignition switched supply fault A/CCM ignition switched GROUND fault A/CCM GROUND fault
For A/CCM circuit tests, Goto <<K>> .
ECM supply or GROUND failure
ECM permanent supply fault ECM ignition switched supply fault ECM GROUND fault
For ECM circuit tests, Goto <<L>> .
2012-07-21

TCM supply or GROUND failure TCM permanent supply fault TCM ignition switched supply fault TCM GROUND fault ABS/TCCM supply or GROUND failure ABS/TCCM permanent supply fault ABS/TCCM ignition switched supply fault ABS/TCCM GROUND fault GSI module supply or GROUND failure GSI module ignition switched supply fault GSI module GROUND fault Data Link Connector (DLC) supply or GROUND failure DLC permanent supply fault DLC ignition switched supply fault DLC ignition switched GROUND fault DLC logic GROUND fault Vehicle speed interface module (VSIM) supply or GROUND failure VSIM ignition switched supply fault VSIM GROUND fault For VSIM circuit tests, Goto <<Q>> . For GSI module circuit tests, Goto <<O>> . For DLC circuit tests, Goto <<P>> . For ABS/TCCM circuit tests, Goto <<N>> . For TCM circuit tests, Goto <<M>> .
Pinpoint tests A : BPM POWER SUPPLY OR GROUND FAULT

NOTE: Before beginning any power supply tests, make sure the vehicle battery is fully charged and in good condition. NOTE: Turn the ignition switch to the OFF position after testing.
A1 : CHECK THE PERMANENT SUPPLY (1) TO THE BPM

1. Disconnect the BPM electrical connector, FC14. 2. Measure the voltage between FC14, pin 80 (N) and GROUND. Is the voltage less than 10 volts? -> Yes REPAIR the circuit between the BPM and battery. This circuit includes the driver side fuse box, (fuse 05) and the high power protection module. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<A2>>

1. Measure the voltage between FC14, pin 104 (NW) and GROUND.
2012-07-21

Is the voltage less than 10 volts? -> Yes REPAIR the circuit between the BPM and battery. This circuit includes the driver side fuse box, (fuse 07) and the high power protection module. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<A3>>

1. Measure the voltage between FC14, pin 79 (NG) and GROUND. Is the voltage less than 10 volts? -> Yes REPAIR the circuit between the BPM and battery. This circuit includes the passenger side fuse box, (fuse 17) and the high power protection module. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<A4>>
www.JagDocs.com
A4 : CHECK THE IGNITION SWITCHED GROUND (1) TO THE BPM

1. Turn the ignition switch to the ON position. 2. Measure the resistance between FC14, pin 41, (RW) and GROUND. Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. This circuit includes the ignition switch. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<A5>>
A5 : CHECK THE IGNITION SWITCHED GROUND (2) TO THE BPM

1. Measure the resistance between FC14, pin 15, (WU) and GROUND. Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. This circuit includes the ignition switch. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<A6>>
A6 : CHECK THE ACCESSORY SWITCHED GROUND TO THE BPM

1. Turn the ignition switch to the ACC position. 2. Measure the resistance between FC14, pin 32, (WR) and GROUND. Is the resistance greater than 5 ohms? -> Yes
2012-07-21

REPAIR the high resistance circuit. This circuit includes the ignition switch. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No CONTACT dealer technical support for advice on possible BPM failure.
B : SLCM POWER SUPPLY OR GROUND FAULT

B1 : CHECK THE PERMANENT SUPPLY (1) TO THE SLCM

1. Disconnect the SLCM electrical connector, BT40. 2. Measure the voltage between BT40, pin 06 (NR) and GROUND. Is the voltage less than 10 volts? -> Yes REPAIR the circuit between the SLCM and battery. This circuit includes the luggage compartment fuse box, (fuse 01) and the high power protection module. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<B2>>
B2 : CHECK THE PERMANENT SUPPLY (2) TO THE SLCM

1. Measure the voltage between BT40, pin 15 (NW) and GROUND. Is the voltage less than 10 volts? -> Yes REPAIR the circuit between the SLCM and battery. This circuit includes the luggage compartment fuse box, (fuse 10) and the high power protection module. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<B3>>
B3 : CHECK THE LOGIC GROUNDS TO THE SLCM

1. Measure the resistance between BT40, pins 13, 14 and 15 (BK) and GROUND. Is any resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No CONTACT dealer technical support for advice on possible SLCM failure.
C : PDCM POWER SUPPLY OR GROUND FAULT
10
2012-07-21
C1 : CHECK THE PERMANENT SUPPLY TO THE PDCM

1. Disconnect the PDCM electrical connector, DP10. 2. Measure the voltage between DP10, pin 01 (N) and GROUND. Is the voltage less than 10 volts? -> Yes REPAIR the circuit between the PDCM and battery. This circuit includes the passenger side fuse box, (fuse 15) and the high power protection module. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<C2>>
www.JagDocs.com
C2 : CHECK THE LOGIC GROUND TO THE PDCM

1. Measure the resistance between DP10, pin 08 (BK) and GROUND. Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<C3>>
C3 : CHECK THE POWER GROUND TO THE PDCM

1. Measure the resistance between DP10, pin 17 (B) and GROUND. Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No CONTACT dealer technical support for advice on possible PDCM failure.
D : DDCM POWER SUPPLY OR GROUND FAULT

D1 : CHECK THE PERMANENT SUPPLY TO THE DDCM

1. Disconnect the DDCM electrical connector, DD10.
11
2012-07-21

2. Measure the voltage between DD10, pin 01 (N) and GROUND. Is the voltage less than 10 volts? -> Yes REPAIR the circuit between the DDCM and battery. This circuit includes the driver side fuse box, (fuse 15) and the high power protection module. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<D2>>
D2 : CHECK THE LOGIC GROUND TO THE DDCM

1. Measure the resistance between DD10, pin 08 (BK) and GROUND. Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<D3>>
D3 : CHECK THE POWER GROUND TO THE DDCM

1. Measure the resistance between DD10, pin 17 (B) and GROUND. Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No CONTACT dealer technical support for advice on possible DDCM failure.
E : PSCM POWER SUPPLY OR GROUND FAULT

E1 : CHECK THE PERMANENT SUPPLY TO THE PSCM

1. Disconnect the PSCM electrical connector, SP05. 2. Measure the voltage between SP05, pin 05 (NR) and GROUND. Is the voltage less than 10 volts? -> Yes REPAIR the circuit between the PSCM and battery. This circuit includes the passenger side fuse box, (fuse 1) and the high power protection module. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<E2>>
12
2012-07-21
E2 : CHECK THE GROUND TO THE PSCM

1. Measure the resistance between SP05, pin 02 (B) and GROUND. Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No CONTACT dealer technical support for advice on possible PSCM failure.
F : DSCM POWER SUPPLY OR GROUND FAULT

www.JagDocs.com
F1 : CHECK THE PERMANENT SUPPLY TO THE PSCM

1. Disconnect the DSCM electrical connector, SD05. 2. Measure the voltage between SD05, pin 05 (NR) and GROUND. Is the voltage less than 10 volts? -> Yes REPAIR the circuit between the DSCM and battery. This circuit includes the driver side fuse box, (fuse 1) and the high power protection module. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<F2>>
F2 : CHECK THE GROUND TO THE DSCM

1. Measure the resistance between SD05, pin 02 (B) and GROUND. Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No CONTACT dealer technical support for advice on possible DSCM failure.
G : IC POWER SUPPLY OR GROUND FAULT

13
2012-07-21
G1 : CHECK THE PERMANENT SUPPLY TO THE IC

1. Disconnect the IC electrical connector, FC25. 2. Measure the voltage between FC25, pin 15 (R) and GROUND. Is the voltage less than 10 volts? -> Yes REPAIR the circuit between the IC and battery. This circuit includes the driver side fuse box, (fuse 18) and the high power protection module. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<G2>>
G2 : CHECK THE IGNITION SWITCHED SUPPLY TO THE IC

1. Turn the ignition switch to the ON position. 2. Measure the voltage between FC25, pin 01 (WG) and GROUND. Is the voltage less than 10 volts? -> Yes REPAIR the circuit between the IC and battery. This circuit includes the driver side fuse box, (fuse 18) and the ignition switch. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<G3>>
G3 : CHECK THE LOGIC GROUND TO THE IC

1. Measure the resistance between FC25, pin 04 (BK) and GROUND. Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<G4>>
G4 : CHECK THE POWER GROUND TO THE IC

1. Measure the resistance between FC25, pin 16 (B) and GROUND. Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No CONTACT dealer technical support for advice on possible IC failure.
H : RCM POWER SUPPLY OR GROUND FAULT
14
2012-07-21
H1 : CHECK THE PERMANENT SUPPLY (1) TO THE RCM

1. Disconnect the RCM electrical connector, FC30. 2. Measure the voltage between FC30, pin 07 (RW) and GROUND. Is the voltage less than 10 volts? -> Yes REPAIR the circuit between the RCM and battery. This circuit includes the driver side fuse box, (fuse 04) and the high power protection module. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<H2>>
www.JagDocs.com
H2 : CHECK THE PERMANENT SUPPLY (2) TO THE RCM

1. Measure the voltage between FC30, pin 08 (RW) and GROUND. Is the voltage less than 10 volts? -> Yes REPAIR the circuit between the RCM and battery. This circuit includes the driver side fuse box, (fuse 04) and the high power protection module. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<H3>>
H3 : CHECK THE IGNITION SWITCHED SUPPLY (1) TO THE RCM

1. Turn the ignition switch to the ON position. 2. Measure the voltage between FC30, pin 06 (W) and GROUND. Is the voltage less than 10 volts? -> Yes REPAIR the circuit between the RCM and battery. This circuit includes the driver side fuse box, (fuse 14) and the ignition switch. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<H4>>
H4 : CHECK THE IGNITION SWITCHED SUPPLY (2) TO THE RCM

1. Turn the ignition switch to the ON position. 2. Disconnect the RCM electrical connector, FC29. 3. Measure the voltage between FC29, pin 07 (WG) and GROUND. Is the voltage less than 10 volts?
15
2012-07-21

-> Yes REPAIR the circuit between the RCM and battery. This circuit includes the luggage compartment fuse box, (fuse 05) and the ignition switch. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<H5>>
H5 : CHECK THE LOGIC GROUNDS TO THE RCM

1. Measure the resistance between FC30, pin 12 (BK) and GROUND. 2. Measure the resistance between FC29, pin 04 (BK) and GROUND. Is either resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No CONTACT dealer technical support for advice on possible RCM failure.
I : ADCM POWER SUPPLY OR GROUND FAULT

I1 : CHECK THE PERMANENT SUPPLY TO THE ADCM

1. Disconnect the ADCM electrical connector, BT69. 2. Measure the voltage between BT69, pin 27 (NW) and GROUND. Is the voltage less than 10 volts? -> Yes REPAIR the circuit between the ADCM and battery. This circuit includes the luggage compartment fuse box (fuse 02). For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<I2>>
I2 : CHECK THE IGNITION SUPPLY TO THE ADCM

1. Turn the ignition switch to the ON position. 2. Measure the voltage between BT69, pin 11 (WR) and GROUND. Is the voltage less than 10 volts? -> Yes REPAIR the circuit between the ADCM and battery. This circuit includes the luggage compartment fuse box (fuse 04). For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<I3>>
16
2012-07-21
I3 : CHECK THE GROUND TO THE ADCM

1. Measure the resistance between ADCM, pin 18 (B) and GROUND. Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No CONTACT dealer technical support for advice on possible ADCM failure.
J : KTM POWER SUPPLY OR GROUND FAULT

www.JagDocs.com
J1 : CHECK THE PERMANENT SUPPLY TO THE KTM

1. Disconnect the KTM electrical connector, FC22. 2. Measure the voltage between FC22, pin 04 (NR) and GROUND. Is the voltage less than 10 volts? -> Yes REPAIR the circuit between the KTM and battery. This circuit includes the driver side fuse box (fuse 06). For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<J2>>
J2 : CHECK THE LOGIC GROUND TO THE KTM

1. Measure the resistance between FC22, pin 12 (BK) and GROUND. Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<J3>>
J3 : CHECK THE IGNITION SWITCHED GROUND (1) TO THE KTM

1. Turn the ignition switch to the ON position. 2. Measure the resistance between FC22, pin 14 (WU) and GROUND. Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system
17
2012-07-21

for normal operation. -> No Goto <<J4>>
J4 : CHECK THE IGNITION SWITCHED GROUND (2) TO THE KTM

1. Turn the ignition switch to the ON position. 2. Measure the resistance between FC22, pin 13 (WR) and GROUND. Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No CONTACT dealer technical support for advice on possible KTM failure.
K : A/CCM POWER SUPPLY OR GROUND FAULT

K1 : CHECK THE PERMANENT SUPPLY TO THE A/CCM

1. Disconnect the A/CCM electrical connector, AC04. 2. Measure the voltage between AC04, pin 05 (NW) and GROUND. Is the voltage less than 10 volts? -> Yes REPAIR the circuit between the A/CCM and battery. This circuit includes the passenger side fuse box (fuse 06). For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<K2>>
K2 : CHECK THE RELAY SWITCHED SUPPLY TO THE A/CCM

1. Make sure the air conditioning isolate relay is engaged. 2. Measure the voltage between AC04, pin 02 (GW) and GROUND. Is the voltage less than 10 volts? -> Yes REPAIR the circuit between the A/CCM and battery. This circuit includes the passenger side fuse box (fuse 06) and the isolate relay. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<K3>>
K3 : CHECK THE IGNITION SWITCHED SUPPLY TO THE A/CCM
18
2012-07-21
1. Turn the ignition switch to the ON position. 2. Measure the voltage between AC04, pin 01 (WU) and GROUND. Is the voltage less than 10 volts? -> Yes REPAIR the circuit between the A/CCM and battery. This circuit includes the driver side fuse box (fuse 12) and the ignition switch. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<K4>>
K4 : CHECK THE IGNITION SWITCHED GROUND TO THE A/CCM

1. Turn the ignition switch to the ON position. 2. Measure the resistance between AC04, pin 03 (WR) and GROUND. Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<K5>>
www.JagDocs.com
K5 : CHECK THE GROUND TO THE A/CCM

1. Turn the ignition switch to the OFF position. 2. Measure the resistance between AC04, pins 13 (B) and 20 (BK) and GROUND. Is either resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No CONTACT dealer technical support for advice on possible A/CCM failure.
L : ECM POWER SUPPLY OR GROUND FAULT

L1 : CHECK THE PERMANENT SUPPLY TO THE ECM

1. Disconnect the ECM electrical connector, EM83. 2. Measure the voltage between EM83, pin 20 (NR) and GROUND. Is the voltage less than 10 volts? -> Yes REPAIR the circuit between the ECM and battery. This circuit includes the EMS fuse box (fuse 04). For
19
2012-07-21

additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<L2>>
L2 : CHECK THE IGNITION SUPPLY TO THE ECM

1. Reconnect the ECM electrical connector, EM83. 2. Disconnect the ECM electrical connector, EM82. 3. Turn the ignition switch to the ON position. 4. Measure the voltage between EM82, pin 09 (W) and GROUND. Is the voltage less than 10 volts? -> Yes REPAIR the circuit between the ECM and battery. This circuit includes the engine compartment fuse box (fuse 05). For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<L3>>
L3 : CHECK THE EMS SWITCHED SUPPLY (1) TO THE ECM

1. Turn the ignition switch to the ON position. 2. Make sure the EMS relay is energised. 3. Measure the voltage between EM82, pin 13 (WR) and GROUND. Is the voltage less than 10 volts? -> Yes REPAIR the circuit between the ECM and battery. This circuit includes the EMS fuse box (fuse 10). For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<L4>>
L4 : CHECK THE EMS SWITCHED SUPPLY (2) TO THE ECM

1. Reconnect the ECM electrical connector, EM82. 2. Disconnect the ECM electrical connector, EM81. 3. Turn the ignition switch to the ON position. 4. Make sure the EMS relay is energised. 5. Measure the voltage between EM81, pin 17 (WR) and GROUND. Is the voltage less than 10 volts? -> Yes REPAIR the circuit between the ECM and battery. This circuit includes the EMS fuse box (fuse 10). For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<L5>>
L5 : CHECK THE GROUND TO THE ECM
20
2012-07-21
1. Turn the ignition switch to the OFF position. 2. Disconnect the ECM electrical connector, EM84. 3. Disconnect the ECM electrical connector, EM85. 4. Disconnect the ECM electrical connector, EM80. 5. Measure the resistance between the ECM pins and GROUND as follows: EM80, pins 29, 21, 03, 31 and GROUND. EM81, pins 21, 08 and GROUND. EM84, pins 01, 16, 22 and GROUND. EM85, pins 07,06 and GROUND. Are any of the resistances greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No CONTACT dealer technical support for advice on possible ECM failure.
www.JagDocs.com
M : TCM POWER SUPPLY OR GROUND FAULT

M1 : CHECK THE PERMANENT SUPPLY TO THE TCM

1. Disconnect the TCM electrical connector, EM07. 2. Measure the voltage between EM07, pin 26 (NR) and GROUND. Is the voltage less than 10 volts? -> Yes REPAIR the circuit between the ECM and battery. This circuit includes the EMS fuse box (fuse 04). For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<M2>>
M2 : CHECK THE IGNITION SUPPLY (1) TO THE TCM

1. Turn the ignition switch to the ON position. 2. Measure the voltage between EM07, pin 54 (WB) and GROUND. Is the voltage less than 10 volts? -> Yes REPAIR the circuit between the ECM and battery. This circuit includes the engine compartment fuse box (fuse 01). For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<M3>>
21
2012-07-21
M3 : CHECK THE IGNITION SUPPLY (2) TO THE TCM

1. Turn the ignition switch to the ON position. 2. Measure the voltage between EM07, pin 55 (WB) and GROUND. Is the voltage less than 10 volts? -> Yes REPAIR the circuit between the ECM and battery. This circuit includes the engine compartment fuse box (fuse 01). For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<M4>>
M4 : CHECK THE GROUND TO THE TCM

1. Turn the ignition switch to the OFF position. 2. Measure the resistance between EM07, pin 06 (B) and GROUND. 3. Measure the resistance between EM07, pin 34 (B) and GROUND. Is either resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No CONTACT dealer technical support for advice on possible TCM failure.
N : ABS/TCCM POWER SUPPLY OR GROUND FAULT

N1 : CHECK THE PERMANENT SUPPLY (1) TO THE ABS/TCCM

1. Disconnect the ABS/TCCM electrical connector, LF37. 2. Measure the voltage between LF37, pin 09 (NR) and GROUND. Is the voltage less than 10 volts? -> Yes REPAIR the circuit between the ECM and battery. This circuit includes the engine compartment fuse box (fuse 18). For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<N2>>
N2 : CHECK THE PERMANENT SUPPLY (2) TO THE ABS/TCCM

1. Measure the voltage between LF37, pin 25 (NW) and GROUND. Is the voltage less than 10 volts?
22
2012-07-21

-> Yes REPAIR the circuit between the ECM and battery. This circuit includes the engine compartment fuse box (fuse 16). For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<N3>>
N3 : CHECK THE IGNITION SUPPLY TO THE ABS/TCCM

1. Turn the ignition switch to the ON position. 2. Measure the voltage between LF37, pin 20 (WU) and GROUND. Is the voltage less than 10 volts? -> Yes REPAIR the circuit between the ECM and battery. This circuit includes the engine compartment fuse box (fuse 04). For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<N4>>
www.JagDocs.com
N4 : CHECK THE GROUND TO THE ABS/TCCM

1. Turn the ignition switch to the OFF position. 2. Measure the resistance between LF37, pin 08 (B) and GROUND. 3. Measure the resistance between LF37, pin 24 (B) and GROUND. Is either resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No CONTACT dealer technical support for advice on possible ABS/TCCM failure.
O : GSI MODULE POWER SUPPLY OR GROUND FAULT

O1 : CHECK THE IGNITION SUPPLY TO THE GSI MODULE

1. Disconnect the GSI module electrical connector, FC88. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between FC88, pin 01 (WR) and GROUND. Is the voltage less than 10 volts? -> Yes REPAIR the circuit between the GSI module and battery. This circuit includes the driver side fuse box (fuse 16). For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<O2>>
23
2012-07-21
O2 : CHECK THE LOGIC GROUND TO THE GSI MODULE

1. Measure the resistance between FC88, pin 06 (BK) and GROUND. Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No CONTACT dealer technical support for advice on possible GSI module failure.
P : DLC POWER SUPPLY OR GROUND FAULT

P1 : CHECK THE PERMANENT SUPPLY TO THE DLC

1. Measure the voltage between the DLC, pin 16 (NW) and GROUND. Is the voltage less than 10 volts? -> Yes REPAIR the circuit between the DLC and battery. This circuit includes the driver side fuse box (fuse 13). For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<P2>>
P2 : CHECK THE IGNITION SUPPLY TO THE DLC

1. Turn the ignition switch to the ON position. 2. Measure the voltage between the DLC, pin 09 (WU) and GROUND. Is the voltage less than 10 volts? -> Yes REPAIR the circuit between the DLC and battery. This circuit includes the luggage compartment fuse box (fuse 05). For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<P3>>
P3 : CHECK THE IGNITION SWITCHED GROUND TO THE DLC

1. With the ignition switch still in the ON position. 2. Measure the resistance between the DLC, pin 01 (WU) and GROUND. Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system
24
2012-07-21

for normal operation. -> No Goto <<P4>>
P4 : CHECK THE ACCESSORY SWITCHED GROUND TO THE DLC

1. Turn the ignition switch to the ACC position. 2. Measure the resistance between the DLC, pin 08 (WR) and GROUND. Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<P5>>
P5 : CHECK THE LOGIC GROUND TO THE DLC

1. Turn the ignition switch to the OFF position. 2. Measure the resistance between the DLC, pins 04 and 05 (BK) and GROUND. Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No NO fault found with supplies and grounds to the DLC. Check DTCs. Refer to the DTC index for actions.
www.JagDocs.com
Q : VSIM POWER SUPPLY OR GROUND FAULT

Q1 : CHECK THE IGNITION SUPPLY TO THE VSIM

1. Disconnect the VSIM electrical connector, EM74. 2. Turn the ignition switch to the ON position. 3. Measure the voltage between EM74, pin 03 (WB) and GROUND. Is the voltage less than 10 volts? -> Yes REPAIR the circuit between EM74, pin 03 and battery. This circuit includes the engine compartment fuse box (fuse 01) and the ignition switch. For additional information, refer to the wiring diagrams. -> No Goto <<Q2>>
Q2 : CHECK THE GROUND TO THE VSIM

25 2012-07-21
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between EM74, pin 04 (B) and GROUND. Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. -> No CONTACT dealer technical support for advice on possible module failure.
R : CHECK THE CONTROLLER AREA NETWORK INTEGRITY, VEHICLES WITH SUPERCHARGER

NOTE: A tolerance of +/- 10% should be used when testing the network. NOTE: For vehicles without adaptive speed control, bypass the tests for vehicle speed interface module and adaptive speed control module.
R1 : CHECK THE CAN NETWORK FOR CONTINUITY

1. Measure the resistance between DLC, pins 06 (Y) and 14 (G). Is the resistance 180 ohms? -> Yes Goto <<R2>> -> No Goto <<R10>>
R2 : CHECK THE ABS/TCCM CAN + CIRCUIT FOR CONTINUITY

1. Disconnect the ABS/TCCM electrical connector, LF37. 2. Measure the resistance between LF37, pin 05 (Y) and DLC, pin 06 (Y). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<R3>>
R3 : CHECK THE ABS/TCCM CAN - CIRCUIT FOR CONTINUITY

1. Measure the resistance between LF37, pin 15 (G) and DLC, pin 14 (G). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<R4>>
26
2012-07-21
R4 : CHECK THE ASCCM (WHERE FITTED) CAN + CIRCUIT FOR CONTINUITY

1. Disconnect the ASCCM electrical connector, LF61. 2. Measure the resistance between LF61, pin 12 (Y) and DLC, pin 06 (Y). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<R5>>
R5 : CHECK THE ASCCM (WHERE FITTED) CAN - CIRCUIT FOR CONTINUITY

1. Measure the resistance between LF61, pin 11 (G) and DLC, pin 14 (G). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<R6>>
www.JagDocs.com
R6 : CHECK THE CAN + CIRCUIT BETWEEN THE ASCCM (WHERE FITTED) AND THE ABS/TCCM FOR CONTINUITY
1. Measure the resistance between LF37, pin 05 (Y) and LF61, pin 13 (Y). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<R7>>
R7 : CHECK THE CAN - CIRCUIT BETWEEN THE ASCCM (WHERE FITTED) AND THE ABS/TCCM FOR CONTINUITY
1. Measure the resistance between LF37, pin 15 (G) and LF61, pin 14 (G). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<R8>>
R8 : CHECK THE CAN + CIRCUIT BETWEEN THE VSIM (WHERE FITTED) AND THE DLC FOR
27
2012-07-21

CONTINUITY
1. Disconnect the VSIM electrical connector, EM74. 2. Measure the resistance between EM74, pin 15 (Y) and DLC, pin 06 (Y). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<R9>>
R9 : CHECK THE CAN - CIRCUIT BETWEEN THE VSIM (WHERE FITTED) AND THE DLC FOR CONTINUITY
1. Measure the resistance between EM74, pin 16 (G) and DLC, pin 14 (G). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<R10>>
R10 : CHECK THE CAN NETWORK FOR SHORT CIRCUIT

1. Measure the resistance between DLC, pins 06 (Y) and 14 (G). Is the resistance less than 180 ohms? -> Yes Goto <<R19>> -> No Goto <<R11>>
R11 : CHECK THE CAN + CIRCUIT BETWEEN THE DLC AND THE INSTRUMENT CLUSTER FOR CONTINUITY
1. Disconnect the battery negative terminal. 2. Disconnect the IC electrical connector, FC25. 3. Measure the resistance between FC25, pin 10 (Y) and DLC, pin 06 (Y). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<R12>>
R12 : CHECK THE CAN - CIRCUIT BETWEEN THE DLC AND THE INSTRUMENT CLUSTER FOR CONTINUITY
28
2012-07-21
1. Measure the resistance between FC25, pin 24 (G) and DLC, pin 14 (G). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<R13>>
R13 : CHECK THE CAN + CIRCUIT BETWEEN THE INSTRUMENT CLUSTER AND THE GSI MODULE FOR CONTINUITY
1. Disconnect the GSI module electrical connector, FC88. 2. Measure the resistance between FC88, pin 09 (Y) and FC25, pin 11 (Y). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<R14>>
www.JagDocs.com
R14 : CHECK THE CAN - CIRCUIT BETWEEN THE INSTRUMENT CLUSTER AND THE GSI MODULE FOR CONTINUITY
1. Measure the resistance between FC88, pin 08 (G) and FC25, pin 23 (G). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<R15>>
R15 : CHECK THE CAN + CIRCUIT BETWEEN THE GSI MODULE AND THE ECM FOR CONTINUITY
1. Disconnect the ECM electrical connector, EM10. 2. Measure the resistance between EM10, pin 28 (Y) and FC88, pin 04 (Y). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<R16>>
R16 : CHECK THE CAN - CIRCUIT BETWEEN THE GSI MODULE AND THE ECM FOR CONTINUITY
1. Measure the resistance between EM10, pin 27 (G) and FC88, pin 03 (G). Is the resistance greater than 5 ohms?
29
2012-07-21

-> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<R17>>
R17 : CHECK THE CAN + CIRCUIT BETWEEN THE ECM AND THE ABS/TCCM FOR CONTINUITY
1. Disconnect the ABS/TCCM electrical connector, LF37. 2. Measure the resistance between LF37, pin 05 (Y) and EM10, pin 26 (Y). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<R18>>
R18 : CHECK THE CAN - CIRCUIT BETWEEN THE ECM AND THE ABS/TCCM FOR CONTINUITY
1. Measure the resistance between LF37, pin 15 (G) and EM10, pin 25 (G). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No NO circuit fault found in network. Recheck DTCs.
R19 : CHECK THE CAN + AND - CIRCUITS BETWEEN THE DLC AND THE INSTRUMENT CLUSTER FOR SHORT CIRCUIT TO EACH OTHER
1. Disconnect the instrument cluster electrical connector, FC25. 2. Measure the resistance between FC25, pins 10 (Y) and 24 (G). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<R20>>
R20 : CHECK THE CAN + AND - CIRCUITS BETWEEN THE INSTRUMENT CLUSTER AND THE GSI MODULE FOR SHORT CIRCUIT TO EACH OTHER
1. Disconnect the GSI module electrical connector, FC88. 2. Measure the resistance between FC88, pins 09 (Y) and 08 (G). Is the resistance greater than 5 ohms? -> Yes
30
2012-07-21

REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<R21>>
R21 : CHECK THE CAN + AND - CIRCUITS BETWEEN THE GSI MODULE AND THE ECM FOR SHORT CIRCUIT TO EACH OTHER
1. Disconnect the ECM electrical connector, EM83. 2. Measure the resistance between EM83, pins 25 (Y) and 16 (G). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<R22>>
www.JagDocs.com
R22 : CHECK THE CAN + AND - CIRCUITS BETWEEN THE ECM AND THE TCM FOR SHORT CIRCUIT TO EACH OTHER
1. Disconnect the TCM electrical connector, EM72. 2. Measure the resistance between EM72, pins H (Y) and L (G). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<R23>>
R23 : CHECK THE CAN + AND - CIRCUITS BETWEEN THE ECM AND THE ASCCM (WHERE FITTED) FOR SHORT CIRCUIT TO EACH OTHER
1. Disconnect the ASCCM electrical connector, LF61. 2. Measure the resistance between LF61, pins 12 (Y) and 11 (G). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<R24>>
R24 : CHECK THE CAN + AND - CIRCUITS BETWEEN THE ASCCM (WHERE FITTED) AND THE ABS/TCCM FOR SHORT CIRCUIT TO EACH OTHER
1. Disconnect the ABS/TCCM electrical connector, LF37. 2. Measure the resistance between LF37, pins 05 (Y) and 15 (G). Is the resistance greater than 5 ohms?
31 2012-07-21

-> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<R25>>
R25 : CHECK THE CAN + AND - CIRCUITS BETWEEN THE GSI MODULE AND THE ASCBCM (WHERE FITTED) FOR SHORT CIRCUIT TO EACH OTHER
1. Disconnect the ASCBCM electrical connector, EM87. 2. Measure the resistance between EM87, pins 0 (Y) and 07 (G). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No NO circuit fault found in network. Recheck DTCs.
S : CHECK THE CONTROLLER AREA NETWORK INTEGRITY, VEHICLES WITHOUT SUPERCHARGER

NOTE: A tolerance of +/- 10% should be used when testing the network. NOTE: For vehicles without adaptive speed control, bypass the tests for vehicle speed interface module and adaptive speed control module.
S1 : CHECK THE CAN NETWORK FOR CONTINUITY

1. Measure the resistance between DLC, pins 06 (Y) and 14 (G). Is the resistance 180 ohms? -> Yes Goto <<S2>> -> No Goto <<S4>>
S2 : CHECK THE CAN + CIRCUIT BETWEEN THE VSIM (WHERE FITTED) AND THE DLC FOR CONTINUITY
1. Disconnect the VSIM electrical connector, EM74. 2. Measure the resistance between EM74, pin 15 (Y) and DLC, pin 06 (Y). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<S3>>
32
2012-07-21
S3 : CHECK THE CAN - CIRCUIT BETWEEN THE VSIM (WHERE FITTED) AND THE DLC FOR CONTINUITY
1. Measure the resistance between EM74, pin 16 (G) and DLC, pin 14 (G). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No NO circuit fault found in network. Recheck DTCs.
S4 : CHECK THE CAN NETWORK FOR SHORT CIRCUIT

1. Measure the resistance between DLC, pins 06 (Y) and 14 (G). Is the resistance less than 180 ohms? -> Yes Goto <<S15>> -> No Goto <<S5>>
www.JagDocs.com
S5 : CHECK THE CAN + CIRCUIT BETWEEN THE DLC AND THE INSTRUMENT CLUSTER FOR CONTINUITY
1. Disconnect the battery negative terminal. 2. Disconnect the IC electrical connector, FC25. 3. Measure the resistance between FC25, pin 10 (Y) and DLC, pin 06 (Y). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<S6>>
S6 : CHECK THE CAN - CIRCUIT BETWEEN THE DLC AND THE INSTRUMENT CLUSTER FOR CONTINUITY
1. Measure the resistance between FC25, pin 24 (G) and DLC, pin 14 (G). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<S7>>
33
2012-07-21
S7 : CHECK THE CAN + CIRCUIT BETWEEN THE INSTRUMENT CLUSTER AND THE GSI MODULE FOR CONTINUITY
1. Disconnect the GSI module electrical connector, FC88. 2. Measure the resistance between FC88, pin 09 (Y) and FC25, pin 11 (Y). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<S8>>
S8 : CHECK THE CAN - CIRCUIT BETWEEN THE INSTRUMENT CLUSTER AND THE GSI MODULE FOR CONTINUITY
1. Measure the resistance between FC88, pin 08 (G) and FC25, pin 23 (G). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<S9>>
S9 : CHECK THE CAN + CIRCUIT BETWEEN THE GSI MODULE AND THE ECM FOR CONTINUITY
1. Disconnect the ECM electrical connector, EM83. 2. Measure the resistance between EM83, pin 25 (Y) and FC88, pin 04 (Y). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<S10>>
S10 : CHECK THE CAN - CIRCUIT BETWEEN THE GSI MODULE AND THE ECM FOR CONTINUITY
1. Measure the resistance between EM83, pin 16 (G) and FC88, pin 03 (G). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<S11>>
34
2012-07-21
S11 : CHECK THE CAN + CIRCUIT BETWEEN THE ECM AND THE TCM FOR CONTINUITY
1. Disconnect the TCM electrical connector, EM07. 2. Measure the resistance between EM07, pin 86 (Y) and EM83, pin 24 (Y). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<S12>>
S12 : CHECK THE CAN - CIRCUIT BETWEEN THE ECM AND THE TCM FOR CONTINUITY
1. Measure the resistance between EM07, pin 85 (G) and EM83, pin 15 (G). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<S13>>
www.JagDocs.com
S13 : CHECK THE CAN + CIRCUIT BETWEEN THE TCM AND THE ABS/TCCM FOR CONTINUITY
1. Measure the resistance between EM07, pin 83 (Y) and LF37, pin 05 (Y). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<S14>>
S14 : CHECK THE CAN - CIRCUIT BETWEEN THE ASCCM AND THE ABS/TCCM FOR CONTINUITY
1. Measure the resistance between EM07, pin 82 (G) and LF37, pin 15 (G). Is the resistance greater than 5 ohms? -> Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No NO continuity fault found in CAN circuit. CHECK DTCs for possible module fault.
S15 : CHECK THE CAN + AND - CIRCUITS BETWEEN THE DLC AND THE INSTRUMENT CLUSTER FOR SHORT CIRCUIT TO EACH OTHER
35 2012-07-21

2. Disconnect the IC electrical connector, FC25. 3. Measure the resistance between DLC, pins 06 (Y) and 14 (G). Is the resistance less than 10.000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<S16>>
S16 : CHECK THE CAN + AND - CIRCUITS BETWEEN THE INSTRUMENT CLUSTER AND THE GSI MODULE FOR SHORT CIRCUIT TO EACH OTHER
1. Disconnect the GSI module electrical connector, FC88. 2. Measure the resistance between FC25, pins 11 (Y) and 23 (G). Is the resistance less than 10.000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<S17>>
S17 : CHECK THE CAN + AND - CIRCUITS BETWEEN THE GSI MODULE AND THE ECM FOR SHORT CIRCUIT TO EACH OTHER
1. Disconnect the ECM module electrical connector, EM83. 2. Measure the resistance between FC88, pins 04 (Y) and 03 (G). Is the resistance less than 10.000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<S18>>
S18 : CHECK THE CAN + AND - CIRCUITS BETWEEN THE ECM AND THE TCM FOR SHORT CIRCUIT TO EACH OTHER
1. Disconnect the TCM module electrical connector, EM07. 2. Measure the resistance between EM07, pins 86 (Y) and 85 (G). Is the resistance less than 10.000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<S19>>
S19 : CHECK THE CAN + AND - CIRCUITS BETWEEN THE TCM AND THE ABS/TCCM FOR SHORT
36 2012-07-21

CIRCUIT TO EACH OTHER
1. Disconnect the ABS/TCCM module electrical connector, LF37. 2. Measure the resistance between LF37, pins 05 (Y) and 15 (G). Is the resistance less than 10.000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<S20>>
S20 : CHECK THE CAN + AND - CIRCUITS BETWEEN THE ECM AND THE VSIM (WHERE FITTED) FOR SHORT CIRCUIT TO EACH OTHER
1. Disconnect the VSIM module electrical connector, EM74. 2. Measure the resistance between EM74, pins 15 (Y) and 16 (G). Is the resistance less than 10.000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No NO circuit fault found in network. Recheck DTCs.
www.JagDocs.com
T : CHECK THE CONTROLLER AREA NETWORK FOR SHORT CIRCUIT T1 : CHECK THE CAN + FOR SHORT CIRCUIT TO BATTERY
1. Measure the resistance between pins 06 (Y) and 16 (NW) of the DLC. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<T2>>
T2 : CHECK THE CAN + FOR SHORT CIRCUIT TO IGNITION POSITIVE

1. Turn the ignition switch to the ON position. 2. Measure the resistance between pins 06 (Y) and 09 (WU) of the DLC. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<T3>>
37
2012-07-21
T3 : CHECK THE CAN + FOR SHORT CIRCUIT TO GROUND

1. Turn the ignition switch to the OFF position. 2. Measure the resistance between pins 06 (Y) and 04 (BK) of the DLC. 3. Measure the resistance between pins 06 (Y) and 05 (BK) of the DLC. Is either resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<T4>>
T4 : CHECK THE CAN + FOR SHORT CIRCUIT TO ACCESSORY SWITCHED GROUND

1. Turn the ignition switch to the ACC position. 2. Measure the resistance between pins 06 (Y) and 08 (WR) of the DLC. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<T5>>
T5 : CHECK THE CAN + FOR SHORT CIRCUIT TO IGNITION SWITCHED GROUND

1. Turn the ignition switch to the ON position. 2. Measure the resistance between pins 06 (Y) and 01 (WU) of the DLC. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<T6>>
T6 : CHECK THE CAN - FOR SHORT CIRCUIT TO BATTERY

1. Measure the resistance between pins 14 (G) and 16 (NW) of the DLC. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<T7>>
38
2012-07-21
T7 : CHECK THE CAN - FOR SHORT CIRCUIT TO IGNITION POSITIVE

1. Turn the ignition switch to the ON position. 2. Measure the resistance between pins 14 (G) and 09 (WU) of the DLC. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<T8>>
T8 : CHECK THE CAN - FOR SHORT CIRCUIT TO GROUND

1. Turn the ignition switch to the OFF position. 2. Measure the resistance between pins 14 (G) and 04 (BK) of the DLC. 3. Measure the resistance between pins 14 (G) and 05 (BK) of the DLC. Is either resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<T9>>
www.JagDocs.com
T9 : CHECK THE CAN - FOR SHORT CIRCUIT TO ACCESSORY SWITCHED GROUND

1. Turn the ignition switch to the ACC position. 2. Measure the resistance between pins 14 (G) and 08 (WR) of the DLC. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<T10>>
T10 : CHECK THE CAN - FOR SHORT CIRCUIT TO IGNITION SWITCHED GROUND
1. Turn the ignition switch to the ON position. 2. Measure the resistance between pins 14 (G) and 01 (WU) of the DLC. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No NO short circuit fault found in CAN circuit. CHECK DTCs for possible module fault.
39
2012-07-21
U : CHECK THE SCP NETWORK CIRCUIT U1 : CHECK FOR CORRECT BUS TERMINATION IN THE SCP + NETWORK
1. Measure the resistance between pins 02 (Y) and 05 (BK) of the DLC. Is the resistance between 90 and 150 ohms? -> Yes TERMINATION is correct. Check for DTCs indicating a module or circuit fault. Refer to the DTC index. -> No Goto <<U2>>
U2 : CHECK THE SCP NETWORK + AND - FOR SHORT CIRCUIT TO EACH OTHER
1. Measure the resistance between pins 02 (Y) and 05 (BK) of the DLC. Is the resistance less than 90 ohms? -> Yes A short circuit to each other in the SCP network will mean the disconnection of the modules and tracing the short by traditional methods. -> No Goto <<U3>>
U3 : CHECK THE SCP + FOR SHORT CIRCUIT TO BATTERY

1. Measure the voltage between pins 02 (Y) and 16 (NW) of the DLC. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<U4>>
U4 : CHECK THE SCP + FOR SHORT CIRCUIT TO IGNITION POSITIVE

1. Turn the ignition switch to the ON position. 2. Measure the voltage between pins 02 (Y) and 09 (WU) of the DLC. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<U5>>
U5 : CHECK THE SCP + FOR SHORT CIRCUIT TO GROUND
40
2012-07-21
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between pins 02 (Y) and 04 (BK) of the DLC. 3. Measure the resistance between pins 02 (Y) and 05 (BK) of the DLC. Is either resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<U6>>
U6 : CHECK THE SCP + FOR SHORT CIRCUIT TO ACCESSORY SWITCHED GROUND

1. Turn the ignition switch to the ACC position. 2. Measure the resistance between pins 02 (Y) and 08 (WR) of the DLC. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<U7>>
www.JagDocs.com
U7 : CHECK THE SCP + FOR SHORT CIRCUIT TO IGNITION SWITCHED GROUND

1. Turn the ignition switch to the ON position. 2. Measure the resistance between pins 02 (Y) and 01 (WU) of the DLC. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<U8>>
U8 : CHECK THE SCP - FOR SHORT CIRCUIT TO BATTERY

1. Measure the voltage between pins 10 (U) and 16 (NW) of the DLC. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<U9>>
U9 : CHECK THE SCP - FOR SHORT CIRCUIT TO IGNITION POSITIVE

1. Turn the ignition switch to the ON position.
41
2012-07-21

2. Measure the voltage between pins 10 (U) and 09 (WU) of the DLC. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<U10>>
U10 : CHECK THE SCP - FOR SHORT CIRCUIT TO GROUND

1. Turn the ignition switch to the OFF position. 2. Measure the resistance between pins 10 (U) and 04 (BK) of the DLC. 3. Measure the resistance between pins 10 (U) and 05 (BK) of the DLC. Is either resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<U11>>
U11 : CHECK THE SCP - FOR SHORT CIRCUIT TO ACCESSORY SWITCHED GROUND
1. Turn the ignition switch to the ACC position. 2. Measure the resistance between pins 10 (U) and 08 (WR) of the DLC. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<U12>>
U12 : CHECK THE SCP - FOR SHORT CIRCUIT TO IGNITION SWITCHED GROUND
1. Turn the ignition switch to the ON position. 2. Measure the resistance between pin 10 (U) and 01 (WU) of the DLC. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No NO circuit fault found in SCP circuit. CHECK DTCs for possible module fault.
V : CHECK THE ISO DATA CIRCUIT V1 : CHECK THE BIDIRECTIONAL CIRCUIT FOR SHORT CIRCUIT TO BATTERY
42
2012-07-21
1. Measure the voltage between pins 07 (O) and 16 (NW) of the DLC. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<V2>>
V2 : CHECK THE BIDIRECTIONAL CIRCUIT FOR SHORT CIRCUIT TO IGNITION POSITIVE

1. Turn the ignition switch to the ON position. 2. Measure the voltage between pins 07 (O) and 09 (WU) of the DLC. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<V3>>
www.JagDocs.com
V3 : CHECK THE BIDIRECTIONAL CIRCUIT FOR SHORT CIRCUIT TO GROUND

1. Turn the ignition switch to the OFF position. 2. Measure the resistance between pins 07 (O) and 04 (BK) of the DLC. 3. Measure the resistance between pins 07 (O) and 05 (BK) of the DLC. Is either resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<V4>>
V4 : CHECK THE BIDIRECTIONAL CIRCUIT FOR SHORT CIRCUIT TO ACCESSORY SWITCHED GROUND
1. Turn the ignition switch to the ACC position. 2. Measure the resistance between pin 07 (O) and 08 (WR) of the DLC. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<V5>>
V5 : CHECK THE BIDIRECTIONAL CIRCUIT FOR SHORT CIRCUIT TO IGNITION SWITCHED GROUND
43
2012-07-21
1. Turn the ignition switch to the ON position. 2. Measure the resistance between pin 07 (O) and 08 (WR) of the DLC. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<V6>>
V6 : CHECK THE SERIAL INPUT CIRCUIT FOR SHORT CIRCUIT TO BATTERY

1. Turn the ignition switch to the OFF position. 2. Measure the voltage between pins 15 (W) and 16 (NW) of the DLC. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<V7>>
V7 : CHECK THE SERIAL INPUT CIRCUIT FOR SHORT CIRCUIT TO IGNITION POSITIVE
1. Turn the ignition switch to the ON position. 2. Measure the voltage between pins 15 (W) and 09 (WU) of the DLC. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<V8>>
V8 : CHECK THE SERIAL INPUT CIRCUIT FOR SHORT CIRCUIT TO GROUND

1. Turn the ignition switch to the OFF position. 2. Measure the resistance between pins 15 (W) and 04 (BK) of the DLC. 3. Measure the resistance between pins 15 (W) and 05 (BK) of the DLC. Is either resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<V9>>
V9 : CHECK THE SERIAL INPUT CIRCUIT FOR SHORT CIRCUIT TO ACCESSORY SWITCHED GROUND
44 2012-07-21
1. Turn the ignition switch to the ACC position. 2. Measure the resistance between pin 15 (W) and 08 (WR) of the DLC. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<V10>>
V10 : CHECK THE BIDIRECTIONAL CIRCUIT FOR SHORT CIRCUIT TO IGNITION SWITCHED GROUND
1. Turn the ignition switch to the ON position. 2. Measure the resistance between pin 15 (W) and 08 (WR) of the DLC. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No NO circuit fault found in SCP circuit. CHECK DTCs for possible module fault.
www.JagDocs.com
W : P1649; ECM FLASH PROGRAMMING CIRCUIT MALFUNCTION W1 : CHECK THE ECM FCCP CIRCUIT FOR SHORT CIRCUIT TO GROUND
1. Measure the resistance between DLC, pin 12 (U) and GROUND. Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<W2>>
W2 : CHECK THE ECM FCCP CIRCUIT FOR SHORT CIRCUIT TO BATTERY

1. Measure the voltage between DLC, pin 12 (U) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<W3>>
W3 : CHECK THE ECM VFP CIRCUIT FOR SHORT CIRCUIT TO GROUND

1. Measure the resistance between DLC, pin 20 (W) and GROUND.
45 2012-07-21

Is the resistance less than 10,000 ohms? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No Goto <<W4>>
W4 : CHECK THE ECM VFP CIRCUIT FOR SHORT CIRCUIT TO BATTERY

1. Measure the voltage between DLC, pin 20 (W) and GROUND. Is the voltage greater than 3 volts? -> Yes REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal operation. -> No No fault found in the flash programming circuit. RECHECK the DTCs.
46
2012-07-21
Auxiliary Junction Box 86.70.55

www.JagDocs.com
2. Disconnect the battery ground cable. Remove the battery cover. 3. Open the bonnet and fit body paintwork protection sheets.
4. Remove the positive supply power cable. 1. Remove the fuse-box from the mounting panel. 2. Reposition the cover from the positive cable. 3. Remove the nut which secures the positive cable to the fuse-box. 4. Disconnect the positive power cable.
2012-07-21
5. Remove the fuse-box from the mounting panel. 1. Release the securing latch, upwards. Reposition the fuse-box, inwards. Remove the fuse-box from the mounting panel. 2. Releases the securing tangs and remove the cover from the fuse-box.
6. Remove the fuse-box. 1. Identify and disconnect the harness multi-plugs from the fuse-box. Remove the fuse-box from the vehicle.
2012-07-21
www.JagDocs.com
7. Remove the fuses and relays. 1. Note the position of each relay and remove them. 2. Identify each fuse and remove them. The value and position of each fuse is illustrated on the lid of the luggage compartment fuse-box - for all fuse-boxes on the vehicle.
Installation 1. Installation is the reverse of removal. 2. Perform the Battery Reconnection Procedure described in Section <<414-01>>.
2012-07-21
Battery Junction Box (BJB) 86.70.69

3. Remove the cover from the fuse-box. 1. Release the securing tangs of the cover. 2. Remove the cover from the fuse-box housing.
2012-07-21
www.JagDocs.com
4. Remove the positive supply power cable. 1. Reposition the cover from the positive cable. 2. Remove the nut which secures the positive cable to the fuse-box. 3. Disconnect the positive power cable.
5. Remove the fuse-box from the mounting panel. 1. Release the securing latch, upwards. Reposition the fuse-box, inwards. Remove the fuse-box from the mounting panel.
2012-07-21
6. Remove the fuse-box. 1. Identify and disconnect the harness multi-plugs from the fuse-box. Remove the fuse-box from the vehicle.
7. Remove the fuses and relays. 1. Note the position of each relay and remove them. 2. Identify each fuse and remove them. The value and position of each fuse is illustrated on the lid of the luggage compartment fuse-box - for all fuse-boxes on the vehicle.
2012-07-21
Central Junction Box (CJB) LH 86.70.57

www.JagDocs.com
3. Remove the cover from the fuse-box. 4. Remove the glovebox assembly, for access to the connectors. Refer to Section <<501-12>>. 5. From behind the fuse-box (in the glovebox area) disconnect the harness multi-plug.
2012-07-21
6. Remove the positive supply power cable. 1. Remove the nut which secures the positive cable to the fuse-box. 2. Disconnect the positive power cable.
7. Remove the fuse-box. 1. Remove the two nuts which secure the fuse-box to the fascia. 2. Remove the fuse-box from the vehicle.
2012-07-21
www.JagDocs.com
8. Remove the fuses and relay. 1. Remove the relay. 2. Identify each fuse and remove them. The value and position of each fuse is illustrated on the lid of the luggage compartment fuse-box - for all fuse-boxes on the vehicle.
2012-07-21
Central Junction Box (CJB) RH 86.70.56

3. Remove the cover from the fuse-box. 4. Remove the underscuttle assembly, for access to the connectors. <<501-12>> 5. From behind the fuse-box (in the underscuttle area) disconnect the harness multi-plug.
2012-07-21
www.JagDocs.com
6. Remove the positive supply power cable. 1. Remove the nut which secures the positive cable to the fuse-box. 2. Disconnect the positive power cable.
7. Remove the fuse-box. 1. Remove the two nuts which secure the fuse-box to the fascia. 2. Remove the fuse-box from the vehicle.
2012-07-21
8. Remove the fuses and relay. 1. Remove the relay. 2. Identify each fuse and remove them. The value and position of each fuse is illustrated on the lid of the luggage compartment fuse-box - for all fuse-boxes on the vehicle.
2012-07-21
1999 XK RANGE - Navigation System - 419-07
Navigation System
Description
A fully integrated navigation system installed as an option, employs visual displays and voice commands to provide various types of route guidance information to the driver. Using signals from the global positioning satellite (GPS) system together with terrestrial map data, vehicle road speed and yaw rate, the system calculates the position of the vehicle to an accuracy of a few metres. Following receipt of information on the desired destination and selected route, the system provides both visual and/or voice instructions as progress is made along that route. In the event of deviation from the original route, the navigation system determines vehicle position and revises the route accordingly.
Operation
With a DVD for the appropriate region or country loaded into the DVD reader, information on the destination is fed into the system using the screen menus and panel controls to make selections and input text as directed. Addresses can be entered or selections made from the DVD database list of 'Points of Interest'. Other types of destination such as road intersections, recent destinations, map cursor positions or local points of interest within a specified radius can also be requested. In addition to DVD stored data, 'memory point' map locations for subsequent selection as route destinations or 'landmarks' can be created. The route initially specified can also be split into sections, or modified to include or avert selected roads or highways.
www.JagDocs.com
Screen Guidance
Three types of screen guidance view are available: Map View displays the appropriate map area with the route highlighted and the vehicle icon arrowed. The map automatically scrolls to maintain the vehicle icon on screen. Arrow View is a diagrammatic display providing a detailed view of the junction approached and the direction to be taken together with distance information. With Hybrid View selected, the map and highlighted route are displayed until, on approaching the next junction or manoeuvre point, Arrow View appears.
Voice Guidance
Synthesised Voice Guidance provides audible instructions for the junction or manoeuvre point approached (e.g. 'Turn Left') and a pushbutton on the control panel enables these instructions to be repeated. Voice Guidance instructions are broadcast through the ICE system and can be adjusted using the MODE and volume controls on the radio/cassette panel. The balance between Voice Guidance and ICE volume can also be varied.
Clock
A digital clock displays 12 hour format time in the lower left hand corner of the screen when the navigation system is switched on. No adjustment is provided as the correct time is automatically maintained from GPS satellite signals. Time zone and Summer Time settings are selectable from a screen menu and must be adjusted to suit vehicle location and time of year.
System Components
The navigation system comprises the following components:
2012-07-21
The integral display and controls panel is installed in the central facia area otherwise occupied by the clock and minor gauge module. The panel is secured by four screws and finished by a clip-in veneer panel.
The navigation system DVD reader provides data storage, processing and system control and incorporates a gyrometer for measurement of vehicle yaw rate. Maps and associated data for the relevant country or region are received from digital versatile disks (DVD) loaded into the reader. The navigation DVD reader is located between the CD autochanger and the power amplifier (premium audio only) in the trunk.
2012-07-21
The navigation system vehicle speed module receives wheel speed signals fed to the CAN data bus by the ABS/traction control module. The vehicle speed module is secured by velcro to the underside of the engine compartment coolbox cover.
www.JagDocs.com
The global positioning system (GPS) antenna is connected to the DVD reader by a co-axial cable, the inner conductor of which carries a 5Vdc power supply. The antenna is secured to the rear parcel shelf (coupe) or the convertible top stowage compartment by a self-adhesive coating on the base.
2012-07-21
Navigation System Antenna 86.62.06

Removal 1. Remove trim from rear parcel shelf/convertible top compartment. Refer to <<76.67.06>> (coupe only).
2. Disconnect antenna flying lead connector.
3. Using a thin blade, carefully release antenna base from parcel shelf panel/convertible top compartment. 4. Clean antenna mounting area of parcel shelf panel/convertible top compartment ensuring that any residual adhesive is removed. 5. If original antenna is to be re-used, remove adhesive pad and clean any residual adhesive from base.
2012-07-21
Installation 1. Remove paper backing from one side of adhesive pad and press firmly onto antenna base. 2. Position antenna at parcel shelf panel/convertible top compartment and connect flying lead connector. 3. Remove paper backing from adhesive pad and press base firmly into position on parcel shelf/convertible top compartment. 4. Install rear parcel shelf/convertible top compartment trim. Refer to <<76.67.06>> (coupe only).
www.JagDocs.com
2012-07-21
Navigation System Compact Disc (CD) Unit 86.62.05

Removal 1. Remove battery cover and disconnect ground lead from battery terminal. Refer to <<86.15.19>> 2. Remove trunk RH side liner. Refer to <<76.19.22>>.
3. Disconnect three connectors from side of amplifier unit (premium audio only).
4. Remove four bolts securing audio/DVD reader module stack to mounting frame.
2012-07-21
www.JagDocs.com
5. Carefully withdraw audio/DVD reader module stack and disconnect four connectors from rear of DVD reader module 6. Remove audio/DVD reader module stack from trunk.
7. Remove four DVD reader module to mounting bracket screws and withdraw module from bracket.
2012-07-21

Installation
1. Position DVD reader module in mounting bracket and install screws.
2. Position audio/DVD reader module stack at mounting bracket and connect DVD reader harness connectors. 3. Ensure that amplifier and CD autochanger harnesses will not obstruct stack installation.
2012-07-21
4. Finally position stack in mounting bracket and install bolts.
www.JagDocs.com
5. Connect amplifier unit harness connectors (premium audio only). 6. Install trunk RH side liner. Refer to <<76.19.22>>. 7. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
2012-07-21
Navigation System Display Module 86.62.07

Removal 1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>
2. Position protective tape along adjacent veneer edges.
3. Commencing at bottom, use a thin plastic blade to release four centre veneer clips.
2012-07-21
4. Remove the four display and controls panel to facia screws.
www.JagDocs.com
5. Remove Panel. Partially withdraw panel for access. Depressing tangs, disconnect harness connectors. Remove panel from facia
2012-07-21

Installation
1. Position panel at facia and connect harness connectors.
2. Fully seat panel in facia and install screws.
2012-07-21
3. Position and fully seat veneer panel ensuring all securing clips are engaged. 4. Remove protective tape from adjacent veneers. 5. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
www.JagDocs.com
2012-07-21
Navigation System Module 86.62.05

2. Remove passenger side false bulkhead cover. Pull forward then lift cover inner edge to release tangs. Pull cover inwards to release outer tabs and lift clear.
3. Remove engine compartment coolbox cover screws.
2012-07-21
www.JagDocs.com
4. Remove module from coolbox lid. Carefully lift and invert lid for access. Disconnect module harness connector. Release module from velcro pad.
Installation
1. Install Module. Connect harness connector to module. Position module on underside of coolbox lid and firmly seat module on velcro pad.
2012-07-21
2. Position lid on coolbox and install screws. 3. Install passenger side false bulkhead cover. 4. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
2012-07-21
1999 XK RANGE - Multifunction Electronic Modules - 419-10
Driver Door Module (DDM) 86.80.29

www.JagDocs.com
2. Disconnect the battery ground cable. Remove the battery cover. 3. Remove the trim pad from the door; refer to Section <<501-05>>.
2012-07-21
6. Disconnect the door module. 1. Remove the three screws which secure the module to the door. Reposition the module outwards through the speaker aperture.
2012-07-21
www.JagDocs.com
7. Disconnect the harness from the module. 1. Disconnect the two multi-plugs. 2. Remove the module. 8. If necessary remove the foam gasket from the module; note that a new gasket must be fitted when installing a new module.
2012-07-21
Driver Seat Module (DSM) 86.75.28

3. Remove the module from the mounting bracket. 1. Remove the two screws which secure the module to the mounting bracket. Reposition the module from the mounting bracket slots.
2012-07-21
www.JagDocs.com
4. Disconnect the harness from the module. 1. Disconnect the multi-plugs. 2. Remove the module.
2012-07-21
Multifunction Electronic Module 86.80.31

Removal 1. Switch ON the ignition. Move the passenger seat fully rearwards. Switch OFF the ignition. Whilst the door(s) is still open and the window down, disconnect the battery ground cable.
2. Disconnect the battery ground cable. Remove the battery cover. 3. Remove the glove box. Refer to Section <<501-12>>.
4. Remove the air ducting from the footwell.
2012-07-21
www.JagDocs.com
5. Disconnect the harness from the module. 1. Release the bolt which secures the harness multi-plug to the module. 2. Disconnect the harness multi-plug.
6. Remove the module. 1. Remove the three nuts which secure the module to the fascia. 2. Remove the module.
2012-07-21
Passenger Door Module (PDM) 86.80.30

2. Disconnect the battery ground cable. Remove the battery cover. 3. Remove the trim pad from the door; refer to Section <<501-05>>.
2012-07-21
www.JagDocs.com
6. Disconnect the door module. 1. Remove the three screws which secure the module to the door. Reposition the module outwards through the speaker aperture.
2012-07-21
7. Disconnect the harness from the module. 1. Disconnect the two multi-plugs. 2. Remove the module. 8. If necessary remove the foam gasket from the module; note that a new gasket must be fitted when installing a new module.
2012-07-21
Passenger Seat Module (PSM) 86.75.16

www.JagDocs.com
3. Remove the module from the mounting bracket. 1. Remove the two screws which secure the module to the mounting bracket. Reposition the module from the mounting bracket slots.
2012-07-21
4. Disconnect the harness from the module. 1. Disconnect the multi-plugs. 2. Remove the module.
2012-07-21
1999 XK RANGE - Body System - General Information - 501-00
Body
Convertible Body Style
XK8 is produced in two door coupe and convertible styles. The convertible body style is a cut-down version of the coupe with tubular internal sill reinforcements and additional structure to suit.
www.JagDocs.com
Front
Front Bumper and Undertray
The hood is hinged at the front and supported by two non-locking gas struts when open. Hood release is by a lever located at the LHS 'A' post. The front bumper beam is in a GMT material or aluminum for N. American markets, and covered in polyurethane. N. American models also have energy absorbing strut mountings. Valance reinforcement is provided for front fender mounting.
2012-07-22
The front fenders are common parts to both coupe and convertible. A chrome-plated splitter vane with twin polyurethane overriders is installed in the front air intake of normally aspirated vehicles. On supercharged vehicles (XKR), a chromed mesh grill is installed in the front air intake. The front fenders carry Jaguar badges and direction indicator repeaters. A single front towing eye stored in the trunk, screws in to either the left- or right-hand side of the lower cross member.
Center
Fascia and Center Console
The full width injection moulded fascia matches the 'A' posts and windshield valance assembly. Faced with a walnut burr veneer, it houses instrument panels appropriate to the market, and air conditioning vents The toeboard supports the steering column and air conditioning unit casing.
2012-07-22

Convertible and Coupe Bodyshells
For added rigidity, convertibles have internal sill reinforcing tubes and a tubular brace is installed between each BC post and the rear seat squab panel. 'A' post inners support the windshield and body side assemblies. The coupe body sides are one-piece assemblies each incorporating part of the outer sill, 'A' and 'B' posts and cantrail reinforcement and are joined to the rear tonneau. The convertible has cropped coupe monosides with the outer wheel arches bonded to the tonneau. Both treadplates are bright finish with the car designation, Jaguar XK8, inscription added. To accommodate the folded top, the convertible rear seats are of a dedicated design and are not interchangeable with the coupe seats. A one-piece soft tonneau cover, color keyed to the vehicle interior and secured by two Tenax fasteners, two velcro pads and two press studs, is retained by the trunk lid when in place. It is stowed in a bag on the front face of the trunk. The coupe rear parcel shelf is trimmed in headlining cloth. It has provision for air extraction and has child seat anchorage points. For some markets, the rear parcel shelf also incorporates a high mounted stop light cover. Acoustic cloth covered speakers, courtesy lamps, integral armrests and stowage trays are incorporated in the coupe one-piece, moulded rear quarter casing. The convertible rear quarter casing is similar to the coupe but does not have armrests fitted. The body has two-piece, LHS and RHS, carpets joined at the center console. Single color moulded carpets are fitted to the trunk. The coupe roof is trimmed in a one-piece moulded 6 mm thick cloth headlining supported by four body tangs, sun visor fixings at the front, and the rear quarter casings at the rear. The header console incorporates two courtesy lamps and switched map lights. The convertible has a padded serviceable headlining and header console. On some market versions, garage door opener switches are also fitted in the header console.
www.JagDocs.com
2012-07-22

Rear Internal and External Trunk Lid Releases
A welded double loop rear towing eye is installed on the right hand rear corner of the luggage floor. The trunk lid which is dedicated either to the coupe or the convertible, consists of inner and outer panels clinched together to minimise welding requirements. For some markets, warning triangle stowage is provided in the trunk lid liner. The trunk is opened from the car interior via a switch mounted in the driver side underscuttle. This switch is only operational when the valet mode is inactive, security disarmed (vehicle is unlocked) and the vehicle is stationary. A key operated lock situated on the RHS of the trunk rear panel, provides emergency external access to the trunk. Non-locking gas struts support the trunk lid when open. The fuel filler flap which incorporates a magnetic filler cap retainer, is unlocked via an illuminated switch in the driver's underscuttle. The filler flap can only be opened when the engine is not running, security is disarmed and the car is either unlocked or the key is in the ignition switch. A petrol/water drain is provided in the filler recess.
Convertible Top
Convertible Top Latching Mechanism
2012-07-22
The fully lined and padded convertible top is fitted to an aluminum frame with steel linkages, providing good structural strength with light weight. The top folds down to a low stack height in the body opening of the rear quarter and has a semi-rigid cover. The top is power latched and has a green tinted, heated, glass backlight incorporating a security antenna. The convertible top operating pump is located on the right-hand side of the trunk. To operate the top, the switch must be held depressed with the ignition switch in either position I or II. When the top starts to move, an audible warning sounds for 0.7 seconds. Latching and unlatching is automatic. Operation of the convertible top is inhibited at vehicle speeds in excess of 16 km/h (10 mph). If the vehicle exceeds this speed when the top is moving to the lowered position, it will continue to the fully down position. Should the vehicle exceed this speed when the top is being raised, further movement will be inhibited until the speed is reduced. Ensure that all passengers, personnel and equipment are clear of top before raising or lowering it. Raising and lowering of the convertible top is controlled from the SCP network via the Security and Locking Module (SLM) and the Body Processor Module (BPM). In the event of latch failure when raising the top, a visual warning is illuminated on the instrument panel. A center pull down feature facilitates manual latching of the top in emergency circumstances. Provision is also made for manual raising of the top should loss of electrics occur.
Doors
www.JagDocs.com
Door Seal Assembly
Doors are common to both coupe and convertible, with a frameless glass system, dual door-mounted seals and demountable hinges with separate multi-stage check arms. The door casings and top rolls are UEV trimmed with cloth center pads. Leather center pads are fitted for some markets. Combined armrests/door pockets are trimmed in leather and have burr walnut veneer insets. The colour-keyed exterior door handles each have an integrated switch for glass drop on opening. Additionally, the driver's door handle has an integrated key barrel. The cheater is formed by the door mirror base and a black injection moulded inner cheater. The cheater seal is integral with the secondary door seal. Tweeters are fitted in the inner cheater as part of the premium in-car entertainment option. Each door has a combined rearguard/puddle lamp mounted in the door pocket casing. Both the driver and passenger door incorporate Door Control Modules (DDM and PDM) which are connected to the SCP network and control the raising and lowering of the window glass, locking and security, puddle lamp and door mirror movement and heating functions. A drive-away door locking function incorporated in the DDM and PDM
2012-07-22

software is activated when the transmission is taken out of Park or Neutral position. Adjustment of driver and passenger door mirrors including memory functions is controlled by the driver door switchpack through each door module. Door mirror heating is controlled via the rear windshield heating switch on the air conditioning control panel. Electrochromic mirrors available as an option are automatically heated at very low ambient temperatures. A mirror fold back function enabling the door mirrors to fold back against the body/glass when parking the car, is featured for some markets. Dipping of the passenger door mirror when reverse gear is selected is also featured on some vehicles/markets. Dipping is either 7 degrees in a downward direction, bottom of travel or 5 seconds dependent upon which condition is satisfied first. When the gear selector is moved from reverse the door mirror will return to the original position.
Glass
Door Glass Operating Mechanism
The windshield, which is common to the coupe and convertible, is in 5 mm laminated glass with a black obscuration band and has a rear-view mirror direct-mounted. The windshield finisher is a one-piece, single color unit with seal. The backlight is 4 mm tempered glass, green tinted and heated. The windshield, backlights and quarter lights, except for the convertible model, are direct glazed to body. The windshield and coupe backlight are supplied as assemblies complete with trim which is secured to the glass by clips and is fully demountable when the assembly is bonded to the vehicle. The convertible backlight and outer seal are conventionally glazed to the inner seal, which is stitched and bonded to the top. On both models, the heated backlight remains 'on' for 21 minutes after being switched on unless the driver switches it off before the time delay expires. Some backlights are fitted with a security antenna. A fine wire heated windshield offered as an option on some markets, is controlled from the air conditioning panel. The door glass on both models is a frameless system with 5 mm green tempered glass. The door glass is operated electrically and raised and lowered by a scissor mechanism. Each door glass automatically drops 12 mm when the door is opened or when the convertible top is raised or lowered, closing when either the door is shut or the top is fully raised and latched in position. The door glass can be closed via the remote control unit. Operation is internally controlled from switchpacks located in the driver and passenger arm rests via the driver and passenger door modules. The switchpacks are illuminated when the sidelights are on. One-touch up operation causes the glass to fully close unless an object is detected or if the glass is already within 45
2012-07-22

mm of top of travel when the door is opened. On detection of an object, the glass will drop fully open or to 200 mm below the obstruction. All drop-glass operates with the ignition switch in either position I or II and for 30 seconds after ignition is switched off or the associated door is opened.
Rear Quarter Glass Operating Mechanism
www.JagDocs.com
The coupe rear quarter glass is a fixed 4 mm, tempered, green-tinted unit direct glazed to the tonneau. The rear quarters of the convertible are 5 mm, tempered, semi-flush, green tinted units with a drum and wire lowering and raising system which provides full glass drop when the top is lowered. Control is incorporated in the convertible top switch. With the convertible top up, the rear quarter glass is raised by pressing and releasing the front of the switch and lowered by pressing and releasing the rear of the switch (one touch down). The rear quarter glass is automatically powered to the bottom position when the top is lowered and further operation is inhibited until the top is raised and latched. When lowering the rear quarter glass at vehicle speeds up to 16 km/h (10 mph), failure to release the switch on operation of the audible alarm will result in lowering of the top. The rear quarter glass is operated automatically up or down respectively when raising or lowering the convertible top. When the top is raised, with the door glass at the top of its travel, the glass will be powered down 12 mm and the rear quarters will be powered to the bottom of their travel. When the top is fully raised all glass will be powered up to close to form a seal with the top. If the front glass has been either fully or partially lowered manually, the rear quarters only will be powered up. If the power supply to the driver or passenger module is disconnected (battery disconnected, module unplugged or fuse removed), then the system must re-learn the characteristics. The last known glass position is regarded as top of travel by one touch operation until re-learning has taken place. One touch down, manual up and down control and the automatic lowering of the glass for door opening are unaffected. To re-learn the positioning characteristics, the associated door must be closed (door ajar switch inactive). The glass must then be driven fully down and held stalled at the bottom of its travel for a minimum of one second. The glass is finally driven to the fully up position and held stalled for a minimum of one second. The re-learning procedure must also be accomplished to regain the automatic closing sequence.
2012-07-22

Wipers/Washers Windshield Washer Jet Assembly
The windshield wiper motor, with integral microswitch for overload protection, is mounted in the plenum below the windshield and is handed for market requirements. The vehicle has a conventional twin wiper arm system with synthetic rubber blades and wiper arm mounted windshield wash jets. Jets are designed to resist freezing, eliminating the need for heated nozzles. Wiper modes are 2-speed, flick wipe and six settings of intermittent wipe. Screen wash tubing is supplied assembled in the wiper arm and is fitted to a connector which is part of the plenum cover assembly. The wipers park on the windshield. The washer fluid reservoir is located in the cavity formed by the front bumper, LH front valance and the front wing liner. The reservoir has a fluid capacity of 7 liters of liquid and is fitted with a low level sensor. When screenwash is selected, the wipers complete three cycles followed by a 4 second delay and a further cycle to clear residual fluid from the screen until either the switch is released or the ignition is moved from position II.
Headlamp Power Wash Jet Assembly (Retracted and extended)
2012-07-22
Some markets and options have a headlamp telescopic power wash mounted below each lamp glass. These washers will operate in conjunction with the screen-washers, when the headlights are on dip or main beam, or daylight running is enabled, the washer fluid does not indicate low level, and the ignition switch is in position II. When wash/wipe is selected and held, the headlamp wash pump is activated and sprays for 800 ms, waits 6 seconds and then sprays again. This spray is repeated after each six second interval until the switch is released or 20 seconds has elapsed. When the switch is released, further power wash cycles will be inhibited for the next 5 wash/wipe operations to conserve wash fluid. All power wash fittings are snap fit, cover to jet, jet to headlamp, jet to hose. The wash/wipe system is operated from switches on the steering column via the Body Processor Module (BPM), part of the SCP network.
Seats
Front Seat (Underside and upper frame)
www.JagDocs.com
The driver and passenger seat control modules (DSM and PSM) which control seat and squab movement, and seat heating where fitted, are mounted on brackets below the seat frames and are connected to the SCP network. Seat movement control switch assemblies fitted in the outboard side of both the driver and front passenger seats, are color keyed to the seats. These switches, through the seat control modules, operate motors for fore and aft, recline and raise and lower movements of the seat. On some markets/options, another motor operates the lumbar adjustment pump which is also controlled by a switch mounted in the seat. Only one of the slide, recline or height motor outputs can be driven at any one time under manual control. Additionally, some markets/options have passenger seat height adjustment, seat and squab heaters and driver's seat position memory. On cars fitted with driver seat memory, each motor is fitted with feedback potentiometers. The illuminated on/off switches for seat heating where fitted as options or standard fit in cold climate territories, are mounted in the center console. Rear passenger access/egress is made easier by a lever mounted on the upper outside of driver and passenger seats allowing the seat squabs to fold forward. Each front seat has a rear map pocket. The rear seats are wire-framed units trimmed to match the front seats and specifically tailored to fit either the coupe or the convertible. No adjustment of the rear seats is provided. Provision is made for the fitting of child seats where legally required.
2012-07-22

Body Structure Zinc Coated BIW Components
Produced in coupe and convertible styles complete with doors, hood and trunk lid, the body comprises almost 200 components. For service requirements, each body shell is available less doors, front fenders, hood and trunk lid. The convertible body is a cut-down version of the coupe, incorporating tubular internal sill reinforcements and associated structures. To fully satisfy requirements for a minimum of six years corrosion resistance, more than 70% by weight of steel panels are zinc coated on both sides (ref. illustration above) and all panel joints below the roof line have zinc protection between them prior to welding together. Close tolerance apertures together with water tight joints and seals ensure low interior noise levels and general travel refinement. For additional torsional strength and anti-flutter properties at key points, metal to metal adhesives or interweld seals are applied to mating surfaces before welding. Whilst during manufacture, bodyshell aperture gaps are set to dedicated panels, these components are available as service items.
10
2012-07-22
1999 XK RANGE - Front End Body Panels - 501-02
Torques Component Nut and bolt front cruciform brace - normally aspirated Bolt front cruciform brace - supercharged Nm 20 - 26 41 - 54
www.JagDocs.com
2012-07-22
Front End Body Panels
Front Bumper Assembly and Undertray
The front body structure is designed to satisfy bumper impact requirements and primarily comprises the front bumper assembly which is fully described in Section <<501-19>>. The front fenders which are common to coupe and convertible models, are each bolted to the front valance, front bumper casing and 'A' post. Removal and installation of the fenders is detailed in the Body and Paint Repair manual. Description and removal and installation instructions for the hood are included in Section <<501-03>>. A GMT undertray fitted to assist air flow through the cooling pack, is secured to the bottom of the bumper casing and the body front cross-member. A small GMT air deflector fitted to the undertray at each wheelarch improves air flow in the front wheel area.
2012-07-22

Plenum Cover and Front Seals
www.JagDocs.com
Protective GMT liners fitted in the wheelarches each incorporate a readily detachable panel for access to the headlamp assembly. An injection moulded plenum cover, painted Dorchester grey on all vehicles and secured to the bodywork by screws and plastic fasteners, incorporates windshield and fender seals, and screenwash connectors.
2012-07-22
Bulb Access Panel 76.10.91

Removal 1. Position road wheel for access. With vehicle handbrake on, start engine. Turn steering wheel until road wheel permits access to liner cover. Stop engine.
2. Remove front wheel arch liner access cover. Rotate liner access cover fastener 1/4 turn and remove cover from vehicle. Ensure that cover fastener is retained.
Installation 1. Fit front wheel arch liner access cover. Position and seat access cover on wheel arch liner. Fit fastener to cover and rotate 1/4 turn to secure. 2. Reposition road wheels. Start engine and reposition road wheels to straight ahead position. Stop engine.
2012-07-22
Cowl Panel Grille 76.10.01

Removal 1. Remove wiper arms and blades. Refer to Section <<501-16>>.
www.JagDocs.com
2. Remove cover retaining screws and fasteners. Remove plastic covers from the rear screw locations. Slacken and remove the eight plenum cover retaining screws and two plastic central fasteners.
3. Disconnect and remove plenum cover. Position plenum cover for access to drain hoses and screenwasher tubes. Disconnect drain hoses and screenwasher tubes from plenum cover and remove plenum cover from vehicle.
Installation 1. Position plenum cover for access and connect drain hoses and screenwasher tubes.
2012-07-22
2. Reposition and seat plenum cover. 3. Fit but do not tighten the retaining screws and plastic fasteners. 4. Commencing in the center, tighten the retaining screws and plastic fasteners. 5. Fit plastic covers over rear screw locations. 6. Fit wiper arms and blades. Refer to Section <<501-16>>.
2012-07-22
Cowl Vent Screen 76.10.01

Removal 1. Open hood and fit fender covers. 2. Remove wiper arm and blade assemblies. Refer to 84.15.44.90. 3. Remove plenum chamber cover. Refer to <<76.10.01>>.
www.JagDocs.com
4. NOTE: Driver side water deflector is captive to throttle cable. Slacken and remove bolts securing plenum chamber water deflectors to BIW and remove passenger side deflector from vehicle.
2012-07-22

5. Rotate throttle quadrant to fully open position and disconnect throttle inner cable nipple from quadrant.
6. Cut through and discard tie strap securing throttle cable and adjuster to abutment bracket and lift cable and adjuster clear of bracket.
7. Pass throttle cable through plenum closing panel grommet.
2012-07-22
8. Pass throttle cable through driver side water deflector and remove deflector.
www.JagDocs.com
9. NOTE: This step is not applicable to N/A vehicles from 1999 Model Year onwards. Disconnect both ignition amplifier harness multiplugs.
2012-07-22
10. Slacken and remove plenum chamber closing panel to BIW securing nuts and remove panel from vehicle.
11. Remove nuts securing ignition amplifiers to closing panel and remove amplifiers from panel.
Installation 1. Position ignition amplifiers on closing plate and fit and tighten securing nuts.
2012-07-22
2. Fit closing plate to BIW ensuring that lower clips locate correctly on body flange.
www.JagDocs.com
3. Fit and tighten closing plate to BIW securing nuts.
2012-07-22
4. NOTE: This step is not applicable to N/A vehicles from 1999 Model Year onwards. Connect both ignition amplifier harness multiplugs.
5. Pass throttle cable through driver side water deflector.
2012-07-22
6. Pass throttle cable through closing plate grommet.
www.JagDocs.com
7. Position throttle quadrant to fully open position and fit throttle cable inner to quadrant ensuring that nipple fully seats in slot.
2012-07-22
8. Release throttle quadrant and fit and fully seat throttle cable adjuster in abutment bracket. 9. Check and as necessary adjust throttle cable. Refer to 19.20.08. 10. Using new tie strap, secure throttle cable adjuster in abutment bracket.
11. Position plenum water deflectors and fit and tighten securing bolts. 12. Fit plenum chamber cover. Refer to <<76.10.01>>. 13. Fit wiper arm and blade assemblies. Refer to 84.15.44.90. 14. Remove fender covers and close hood.
2012-07-22
Fender Splash Shield 76.10.90

Removal 1. Remove front wheel and tire assembly. Refer to Section <<204-04>>.
www.JagDocs.com
2. Remove wheel arch liner access cover. Rotate access cover fastener 1/4 turn and remove cover from vehicle.
3. Remove wheel arch liner. 1. Slacken and remove three plastic nuts longitudinally securing wheel arch liner to body. 2. Slacken and remove screw securing liner to front of sill. 3. Remove expander pegs or screws from four liner retainers, remove and discard retainers and remove liner and spoiler from vehicle.
2012-07-22
Installation 1. Fit front wheel arch liner. Position and seat wheel arch liner and spoiler. Fit the four new wheel arch liner retainers. Drive expander pegs into the liner retainers. Fit and tighten screw securing liner to front of sill. Fit and tighten plastic liner securing nuts. Position and secure liner access cover, rotating fastener 1/4 turn. 2. Fit wheel and tire assembly. Refer to Section <<204-04>>.
2012-07-22
Radiator Grille Opening Cross Brace Vehicles Without: Supercharger 76.10.03

Removal 1. Raise front of vehicle to working height and support on stands. 2. Remove undertray. Refer to 76.22.28.
www.JagDocs.com
3. Slacken and remove four bolts securing front cruciform assembly to BIW. 4. Remove front cruciform from vehicle.
Installation 1. Position cruciform assembly on vehicle. 2. Fit and tighten cruciform securing bolts. 3. Position undertray on vehicle and secure with new plastic rivets. Refer to 76.22.28. 4. Raise front of vehicle, remove stands and lower vehicle onto wheels.
2012-07-22
Radiator Grille Opening Cross Brace Vehicles With: Supercharger 76.10.03

Removal 1. Remove radiator closing panel. Refer to <<76.10.06>> 2. Raise front of vehicle to working height and support on stands. 3. Remove undertray. Refer to 76.22.28.
4. Slacken and remove two lower bolts securing front cruciform brace to BIW.
5. Supporting front cruciform brace, slacken and remove two bolts and nuts securing brace to upper support brackets. 6. Exercising care to avoid damaging radiator and condenser, lift front cruciform brace from vehicle.
1 2012-07-22
Installation
www.JagDocs.com
1. Carefully lower cruciform brace into position between radiator and condenser.
2. Fit but do not tighten upper securing bolts and nuts. 3. Fit and tighten cruciform brace lower securing bolts. 4. Tighten cruciform brace upper securing nuts and bolts. 5. Position undertray on vehicle and secure with new plastic rivets. Refer to 76.22.28. 6. Fit radiator closing panel. Refer to <<76.10.06>> 7. Raise front of vehicle, remove stands and lower vehicle onto wheels.
2012-07-22
Radiator Grille Opening Panel 76.10.06

Removal 1. Open hood and fit fender covers.
2. Slacken and remove the closing panel securing bolts. 3. Remove closing panel from vehicle.
Installation 1. Position closing panel over radiator. 2. Fit and tighten closing panel securing bolts. 3. Remove fender covers and close hood.
2012-07-22
Radiator Splash Shield 76.22.90

Removal 1. Position vehicle on 4-post ramp and raise to working height. 2. Remove wheelarch spoilers.
www.JagDocs.com
3. Remove and discard scrivets securing undertray to bumper cover and wheelarch liners.
4. Remove and discard screws securing undertray to lower crossmember and remove undertray.
2012-07-22

Installation
1. Fit undertray. Position undertray on vehicle and secure to lower cross-member with screws.
2. Secure undertray to bumper cover and wheelarch liners using new scrivets. 3. Lower 4-post ramp.
2012-07-22
1999 XK RANGE - Body Closures - 501-03
Luggage Compartment Lid Alignment

1. Supporting trunk lid in the open position, disconnect support struts from lid.
www.JagDocs.com
2. Slacken but do not remove bolts securing hinges to trunk lid.
3. Carefully close trunk lid and check alignment with BIW. 4. Open trunk lid, adjust position on hinges as necessary and tighten one securing bolt on each side. 5. Close trunk lid and re-check alignment. 6. Open trunk lid and tighten remaining hinge bolts. 7. Fit support struts to trunk lid pivots ensuring that retaining clips are fully seated. 8. Check that trunk lid closes satisfactorily.
1 2012-07-22
Body Closures
Doors
Door Seal
The doors, which are common to coupe and convertible models and have a frameless glass system, each comprise inner and outer panels, clinched and bonded together to form a door assembly. Both panels incorporate extensions spot welded together to form a cheater assembly and a PVC sealant is applied in cosmetic bead form to all clinch joints. Both the door assembly and separate outer panel are available as service items. A dual, joint-less EPDM sponge seal is installed on each door together with a water shedder and separate vacuum formed speaker cup.Upper and lower door hinges and multi-stage check arms require no lubrication throughout vehicle life
2012-07-22

Hood Front Seal Locations
www.JagDocs.com
Common to coupe and convertible models, the hood assembly consists of one piece inner and outer panels, clinched and bonded together, with cosmetic bead PVC sealant applied to all clinch joints. Hinge assemblies, hinge reinforcements, gas strut brackets and a hood lock striker are attached to the inner panel which also accommodates a hood liner. The hinge assemblies are of double link design to permit minimum clearance between the hood leading edge and the top of the bumper casing. The hood seats on EPDM sponge bulb seals on the BIW front cross member and four flanges on the secondary bulkhead, and on a transverse seal bonded to the plenum cover.
Trunk Lid
Trunk Lid Gas Support Strut
2012-07-22
Dedicated either to the coupe or convertible, the trunk lid comprises one piece inner and outer panels clinched and bonded together, with cosmetic bead PVC sealant applied to all clinch joints.Hinge reinforcements and a lock striker mounting reinforcement are attached to the lid inner panel and combined hinge and gas strut mounting assemblies are secured by bolts to the inner panel and the tonneau/trunk flange at each side. The trunk lid seats on a single joint, EPDM sponge, single profile bulb seal, mounted on the trunk flange.
2012-07-22
Door Opening Lower Weatherstrip Vehicles Without: Convertible Top 76.40.30

Removal
www.JagDocs.com
1. Remove the draught welt. NOTE: The finisher can be easily damaged, care must therefore be exercised during removal. 1. Remove the treadplate finisher and place face uppermost on sheet of clean dry polythene. 2. Slacken and remove treadplate securing screws and remove treadplate. 3. Remove front of welt from aperture flange. NOTE: The rear welt section is integral with the seal and must not be separated from it. 4. Withdraw rear draught welt section from aperture flange.
2. Remove the door aperture seal. 1. Remove the three fasteners securing seal to 'A' post and cut through Alphaseal. 2. Remove fastener securing seal to 'B' post.
1 2012-07-22

3. Remove seal complete with rear draught welt section from door aperture.
Installation
1. Fit door aperture seal. 1. Position seal on 'A' post and fitting lower one first, secure with three fasteners. 2. Fit and firmly seat seal in aperture channel. 3. Secure to 'B' post with fastener. Apply Alphaseal .
2. Fit draught welt section. 1. Fit and fully seat rear draught welt section over aperture flange. 2. Fit and fully seat front welt section over aperture flange aligning end with panel joint. 3. Position sill tread plate and fit and tighten three securing screws. 4. Fit treadplate finisher. If finisher has been renewed, remove protective film.
2012-07-22
Door Opening Upper Weatherstrip 76.40.01

Removal 1. Remove exterior door mirror. Refer to Section <<501-09>>. 2. Remove door casing. Refer to Section <<501-05>>. 3. Remove door waist rail finisher. 4. Remove door inner waist seal.
www.JagDocs.com
5. Release door edge seal fixings.
6. Using clip removal tool, remove seal fixings from door inner face and lock face.
2012-07-22
7. Ensuring that door paintwork is not damaged, cut through sealant between cheater seal and cheater frame.
8. Release seal upper fixings from door hinge face.
9. Carefully pull seal upwards to clear cheater frame and remove seal from door. 10. Clean any residual sealant and butyl strip from cheater frame. 11. If original seal is to be re-fitted, carefully remove residual butyl strip from seal interior.
2012-07-22

Installation
1. Apply butyl strip to inner leading edge of cheater frame.
www.JagDocs.com
2. Apply Alphaseal bead to seal contact area of door rear face. 3. Position and fully seat seal on door cheater frame. 4. Fit and fully seat seal fixings to upper door lock face. 5. Fit seal inner face fixings to door. 6. Fit seal edge fixings to door.
2012-07-22
7. Apply Alphaseal to leading edge of cheater seal. 8. Fit door waist rail finisher, aligning rear end with edge of door and maintaining a 4mm gap at other end. 9. Fit door inner waist rail seal ensuring that it is fully forward and contacting the front guide leg. 10. Fit door casing. Refer to Section <<501-05>>. 11. Fit exterior door mirror. Refer to Section <<501-09>>.
2012-07-22
Fuel Filler Door 76.10.25

Removal 1. Remove battery cover. 2. Remove trunk floor carpet. 3. Remove trunk front liner. Refer to <<76.19.31>>. 4. Remove trunk rear finisher. Refer to <<76.19.44>>. 5. Remove cover from LH rear lamp assembly. 6. If fitted pass fuel filler flap emergency release cord through slot and remove LH liner from trunk. Refer to <<76.10.25>>.
www.JagDocs.com
7. Supporting fuel filler flap, slacken and remove securing nuts and remove filler flap from vehicle.
Installation 1. Position fuel filler flap on vehicle and fit and tighten securing nuts. 2. Position LH side liner in trunk and if fitted pass emergency release cord through slot. Refer to <<76.10.25>>. 3. Fully seat LH liner. 4. Fit and fully seat cover on LH rear lamp. 5. Fit trunk rear finisher. Refer to <<76.19.44>>.
2012-07-22
6. Fit trunk front liner. Refer to <<76.19.31>>. 7. Fit trunk floor carpet. 8. Fit battery cover.
2012-07-22
Hood 76.16.01
Removal 1. Open hood and fit fender covers. 2. Apply protective masking tape to leading edge of hood.
www.JagDocs.com
3. Slacken but do not remove hood securing bolts.
4. With assistance, supporting hood, release support strut upper retaining clips and remove struts from hood pivots. 5. Fully supporting hood to prevent paintwork damage, remove securing bolts and remove hood from vehicle.
2012-07-22
6. Slacken and remove expander screws from hood insulation pad retainers.
7. Commencing at bottom, remove retainers from insulation pad. 8. Remove insulation pad from hood.
2012-07-22
9. Slacken and remove bolts securing striker/buffer assemblies to hood and remove assemblies.
www.JagDocs.com
10. Slacken and remove hood support pivots.
Installation 1. Fit and fully tighten support pivots to hood. 2. Position both hood striker/buffer assemblies and fit but do not tighten securing bolts. 3. Position insulation pad on hood and commencing at top, fit and fully seat new plastic retainers. 4. Fully tighten retainer expander screws.
2012-07-22
5. With assistance, carefully lift hood into position on vehicle and fit but do not tighten securing bolts. 6. Fit and fully seat upper end of each support strut on hood pivot 7. Exercising care to avoid damaging paintwork, close hood and check alignment. 8. Open hood, adjust alignment on hinges as necessary and fully tighten securing bolts. 9. Close hood and check positioning of striker/buffer assemblies. 10. Open hood and adjust striker/buffer assembly positions as necessary 11. Close hood and re-check striker/buffer alignment. 12. Open hood, fully tighten striker/buffer securing bolts and fully tighten hood securing bolts. 13. Remove masking tape and fender covers and close hood.
2012-07-22
Hood Insulation 76.16.06

Removal 1. Open hood and fit fender covers.
www.JagDocs.com
2. Slacken and remove expander screws from pad retainers.
3. Commencing at bottom, remove insulation pad plastic retainers and remove pad from hood.
Installation 1. Position insulation pad on hood and commencing at top, fit and fully seat plastic retainers. 2. Gently drive in and fully seat expander screws in retainers. 3. Remove fender covers and close hood.
1 2012-07-22
Hood Strut 76.16.15

Removal 1. Open hood and fit fender covers. 2. Fit supports to hood.
3. Release strut upper retaining clip and remove strut from hood pivot.
4. Release strut lower retaining clip and remove strut from vehicle.
Installation 1. Fit strut onto lower pivot ensuring that retaining clip is fully seated.
2012-07-22
2. Extend strut and fit onto hood pivot ensuring that retaining clip is fully seated. 3. Remove hood supports and fender covers. 4. Check that hood closes correctly.
www.JagDocs.com
2012-07-22
Luggage Compartment Lid 76.19.01

2. Remove and discard the twenty fasteners securing insulation pad to trunk lid and remove insulation pad. 3. Remove trunk lid wiring harness. 4. Remove rear number plate lamp assembly.
5. Release rubber grommet from trunk aperture and pass rear harness and multiplug through aperture.
2012-07-22
6. Position rear harness to trunk hinge shield for access.
www.JagDocs.com
7. Remove trunk lid rubber stops. 8. Fit supports to trunk lid.
2012-07-22
9. Release gas support struts from trunk lid pivots.
10. With assistance to prevent trunk lid from moving, slacken and remove bolts securing hinges to trunk lid. 11. Remove trunk lid from vehicle. 12. Slacken and remove number plate securing screws and remove number plate from mounting bracket.
2012-07-22
13. Drill out rivets securing number plate mounting bracket to trunk lid.
www.JagDocs.com
Installation 1. Position number plate mounting bracket on trunk lid and secure with new rivets. 2. Position number plate on mounting bracket and fit and tighten securing screws. 3. With assistance, position trunk lid on vehicle and fit but do not tighten lid to hinge securing bolts. 4. Check and as necessary adjust trunk lid alignment. Refer to <<76.19.03>>. 5. Fit rubber stops to trunk lid. 6. Reposition rear harness to trunk lid hinge shield. 7. Pass rear harness and multiplug through trunk aperture and rubber grommet and seat grommet in aperture. 8. Install harness in trunk lid. 9. Fit rear number plate lamp assembly. Refer to <<86.40.86>>. 10. Position insulation pad on trunk lid underside and secure with twenty new fasteners. 11. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
2012-07-22
Luggage Compartment Lid Opening Weatherstrip 76.19.06

Removal
1. Remove trunk lid seal. 1. Open trunk lid. 2. Starting at front of trunk aperture, withdraw seal from flange exercising care on reaching bonded joint at rear.
Installation
1. Fit trunk lid seal. 1. Ensure that trunk flange is clean and free from oil or grease. 2. Position seal with bonded joint adjacent to trunk latch. 3. Commencing at bonded joint, fit and fully seat seal onto trunk flange, guiding it between rear trunk trim and rear panel. Leave radius 3 until last, then stretch to tension in position.
1 2012-07-22

4. Check that trunk lid closes correctly.
www.JagDocs.com
2012-07-22
Luggage Compartment Lid Strut 76.19.27

Removal 1. Open trunk lid and fit a suitable temporary support under.
2. Release strut upper retaining clip and remove strut from trunk lid pivot.
3. Release strut lower retaining clip, remove strut from trunk pivot and remove strut from trunk.
Installation 1. Fit strut lower end to trunk pivot ensuring that retaining clip fully seats. 2. Extend strut and fit upper end to trunk lid pivot ensuring that retaining clip fully seats. 3. Remove temporary support and check that trunk lid closes satisfactorily.
1 2012-07-22
1999 XK RANGE - Interior Trim and Ornamentation - 501-05
Interior Trim
Carpets
The interior carpets which incorporate floor insulation and are molded in two pieces joined at the center line below the center console, cover the entire floor area and the inner door sills, and are color co-ordinated to the interior trim and seats. The door sills are additionally fitted with polished tread plates bearing 'Jaguar XK8' inscriptions. While the floor carpets are common to the convertible and coupe models, an additional section of carpet trims the convertible top stowage area. The coupe rear parcel shelf is trimmed to match the headlining cloth. The shelf trim is secured to the rear seat squab by two screws and to the center of the shelf by four speaker or blank plate screws, and is supported at the rear by two foam blocks.
Fascia
www.JagDocs.com
The full width, slush molded, soft feel PVC fascia is faced with maple or walnut burr veneer. In addition to the air conditioning and central, outer and demisting vents, it accepts instrument packs dedicated to market requirements. A center switchpack and the ICE head unit are also incorporated in the fascia. A lockable and illuminated glove box is provided on the passenger side, and fuse panels are installed at each end.
2012-07-22

'A' Posts 'A' Post Finishers
Grained UEV post finishers color matched to upper trim, are common to convertible and coupe. The inner finishers are secured to the pillars by studs and BIW retainers, the upper finishers are molded to the pillar contours and wiring channels and secured by steel clips inserted into BIW slots. A hood release lever is located in the LH side inner finisher.
Coupe Roof
Coupe Roof Lining Fixing Points
The 6 mm thick, molded, single piece cloth roof lining is color keyed to the interior trim and supported by sun-visor fixings at the front, a concealed fixing behind the central interior lamp and two body tangs at each side. An overhead console installed centrally at the front of the roof is common to both models and incorporates two courtesy lamps, switchable map/reading lights and a glass breakage sensor. An additional courtesy lamp is installed centrally in the roof over the rear seats.
2012-07-22
Convertible Top
The convertible top has a transverse external seam and a fully padded interior incorporating a full length headlining with backlight surround panel. The heated backlight is bonded in position to achieve a semi-flush finish. The windshield header seal has been specifically designed to achieve reductions in noise levels and superior weatherproofing and aerodynamics. A grained UEV head rail finisher is secured in position by the sun visor fixings.
Doors
Door Trim and Water Shedder
www.JagDocs.com
The doors are common to coupe and convertible and have dual seals and vacuum-formed water shedders with separate speaker curtains to provide internal insulation. The door casings are trimmed in UEV with cloth or ambla center pads and integral pockets are attached to the inner panels by plastic studs and retainers and a large dowel. The top rolls are integral with the door casings and trimmed to match the upper fascia. A leather trimmed armrest attached to each door casing by plastic fixings, is secured to the door by a screw passed through a pull cup into a bracket. An inset maple or burr walnut veneer switch pack is held in position by a single screw and captive nut.
2012-07-22

Rear Quarter Casings
The rear quarter casings are individually styled to suit installation in either the coupe or convertible. Both styles are trimmed in ambla and incorporate acoustic cloth-covered speakers. Coupe casings are additionally fitted with ambla trimmed armrests and stowage trays. Convertible rear quarter casings are secured at the rear by dowels locating in the seat squab panel, and at the front by spring steel clips locating in the 'B' posts. Coupe rear quarter casings are retained by spring steel clips located in the cantrails and 'B' posts and a screw passed through each front seat belt escutcheon. A plastic clip in each coupe rear quarter engages in the parcel shelf.
Trunk
The trunk has a two-height load floor structure in order to accommodate either the full size or space-saver spare wheel. When the space saver wheel is carried, a removable center floor section is recessed in the spare wheel well.
2012-07-22

For the full size spare wheel, the floor is a one piece full-width removable section. The trunk lid, front and side casings and floor are lined with molded single color carpet. The trunk lid is produced in two styles to suit convertible and coupe. For some markets, a warning triangle is located in the trunk lid lining.
www.JagDocs.com
2012-07-22
A-Pillar Trim Panel 76.13.31

Removal 1. Using a suitable plastic lever, carefully ease trim pad spring clips free from 'A' post. 2. Remove and discard trim spring clips.
Installation 1. Fit new spring clips to 'A' post trim pad. 2. Lifting aperture seal at 'A' post, position trim pad and press firmly to fully seat spring clips.
2012-07-22
Coat Hanger 76.10.54

Removal 1. Move seat back to fully forward position.
www.JagDocs.com
2. Carefully lift screw cover flap for access.
3. Remove hanger hook securing screw. 4. Remove hanger hook from cantrail aperture.
2012-07-22

Installation
1. Position hanger hook in cantrail aperture and install securing screw. 2. Fully seat screw cover flap. 3. Return seat back to upright position.
2012-07-22
Cowl Side Trim Panel 76.13.30

Removal
www.JagDocs.com
1. Remove the treadplate. NOTE: The finisher can be easily damaged, extra care must therefore be exercised during removal. 1. Using a thin plastic lever, carefully remove the treadplate finisher and place face uppermost on sheet of clean dry polythene. 2. Slacken and remove treadplate securing screws and remove treadplate. 3. Remove front of draught welt from aperture flange.
2. Exercising care to avoid damaging surface, pull pad rearwards to release retainer from 'A' post stud. On driver side it will be necessary to pull and hold hood release rearwards.
2012-07-22
3. Withdraw trim pad front tang from toeboard and remove trim pad.
Installation 1. Position trim pad at 'A post and engage retainer on securing stud. For access at driver side it will be necessary to pull and hold hood release lever rearwards. 2. Ensuring that tang engages in toeboard carpet slot, push trim pad forward to fully seat retainer on stud.
3. Fit draught welt section and treadplate. 1. Ensure that lower rear draught welt section is fully seated on aperture flange. 2. Fit and fully seat front welt section over aperture flange aligning end with panel joint. 3. Position sill tread plate and fit and tighten three securing screws. 4. Fit treadplate finisher. If finisher has been renewed, remove protective film.
2012-07-22
Door Trim Panel 76.34.01

Removal
www.JagDocs.com
1. Remove door escutcheon. 1. Holding door handle in the open position, remove the escutcheon securing screw cover. 2. Slacken and remove the escutcheon securing screw, remove escutcheon from door casing and return door handle to closed position.
2. Remove trim mat from rear of door pocket and slacken and remove the securing screw.
2012-07-22
3. Position door switch pack for access. 1. Using a suitable plasrtic hook, release plastic stud and remove trim from front of door pocket. 2. Slacken and remove screw securing switch pack to door casing and position switch pack for access.
4. Slacken and remove screw securing casing to door bracket.
2012-07-22
www.JagDocs.com
5. Remove door casing for access to multiplugs. 1. Release eight studs securing the casing to the door. 2. Position the casing for access and disconnect the door switch pack and puddle lamp multiplugs. 6. Remove door casing from vehicle and detach switch pack.
7. Remove puddle lamp lens. 1. Move puddle lamp lens securing tab downwards. 2. Slide lens downwards to release it from the lamp assembly. 3. Slacken and remove two screws securing the puddle lamp assembly to the casing and remove puddle lamp from casing.
2012-07-22
8. Slacken and remove the door speaker cover securing screws from lower face of trim pad and remove cover from casing.
9. Slacken and remove four screws securing armrest to door casing and remove armrest from casing. 10. Remove securing studs from door casing.
Installation 1. Fit new securing studs to casing. 2. Position armrest on casing and fit and tighten the four securing screws. 3. Position speaker cover on casing and fit and tighten securing screws.
2012-07-22
4. Position and align puddle lamp assembly on casing and fit and tighten two securing screws. 5. Fit lens to puddle light assembly. 6. Position but do not secure switch pack on casing. 7. Position casing at door and connect switch pack and puddle lamp multiplugs. 8. Align casing to door and press and fully seat securing studs into door locations. 9. Fit and tighten casing securing screw at front of switch pack location. 10. Align switch pack to casing and fit and tighten securing screw at rear. 11. Fit trim to front of door pocket and fully seat plastic fastener. 12. Fit and tighten casing securing screw to rear of door pocket. 13. Fit trim mat to rear of door pocket. 14. Holding door handle in open position, fit escutcheon to casing. 15. Fit and tighten securing screw and fit securing screw cover. 16. Return door handle to closed position.
www.JagDocs.com
2012-07-22
Driver Side Floor Covering 76.49.09

Removal 1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 2. Remove door sill treadplate. Refer to 76.76.01. 3. Remove driver seat. Refer to 76.70.01.90. 4. Remove 'J' gate surround. Refer to <<76.25.24>>. 5. Remove centre console for access. Refer to <<76.25.01>> 6. Remove rear quarter casing for access. Refer to <<76.13.73>>. 7. Remove rear seat cushion. Refer to <<76.70.37>>. 8. Remove 'A' post lower trim pad. Refer to <<76.13.30>>.
9. Exercising care, use a thin blade to release footrest tangs and spigots from mounting plate.
2012-07-22
10. Remove footrest mounting plate securing bolts and remove mounting from vehicle.
www.JagDocs.com
11. Slacken and remove toeboard fastener.
2012-07-22
12. Release carpet from around kickdown switch and toeboard area.
13. Remove and discard fastener securing carpet at fascia/console area. 14. Remove handbrake lever trim and ensure that lever is left in fully upright position. Refer to <<76.13.63>>.
2012-07-22
15. Withdraw draught welt and release carpet retaining clips from door aperture flange. 16. Free rear of carpet from rear seat cushion locater.
www.JagDocs.com
17. Lift rear of carpet and pass seat harness and connector through. 18. Fold front of carpet back from footwell. 19. Lift carpet over handbrake lever, ensuring carpet is free, pull rearwards and remove it from vehicle.
Installation 1. Position carpet in vehicle fitting it over handbraken lever. 2. Align carpet with toeboard and kickdown switch.
2012-07-22
3. Install carpet to door aperture retaining clips. 4. Install and fully seat draught welt on door aperture flange. 5. Install cover on handbrake lever. Refer to <<76.13.63>>. 6. Position carpet over rear seat cushion locater. 7. Install and fully seat new fastener securing carpet to fascia/console area. 8. Install fastener securing carpet to toeboard. 9. Position driver footrest mounting bracket and install securing bolts. 10. Install driver foot rest on mounting bracket. 11. Install 'A' post lower trim pad. Refer to <<76.13.30>>. 12. Install rear seat cushion. Refer to <<76.70.37>>. 13. Install rear quarter casing. Refer to <<76.13.73>> 14. Install centre console. Refer to <<76.25.01>>. 15. Install 'J' gate surround. Refer to <<76.25.24>>. 16. Install driver seat and adjust to original position. Refer to 76.70.01.90. 17. Install door sill treadplate. Refer to 76.76.01. 18. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
2012-07-22
Headliner 76.64.01
Removal 1. Remove front seats. Refer to 76.70.01.90. 2. Remove rear seat cushion and squab. Refer to <<76.70.37>> and <<76.70.38>>. 3. Remove battery cover and disconnect earth cable from battery terminal. Refer to <<86.15.19>> 4. Remove rear quarter casings. Refer to <<76.13.73>>. 5. Remove combined grab handles and coat hanger hooks. 6. Remove 'J' gate surround. Refer to <<76.25.24>>. 7. Remove center console. Refer to <<76.25.01>>. 8. Remove 'A' post upper trim panels. Refer to <<76.13.31>>. 9. Remove sun visors. Refer to 76.10.47. 10. Remove sun visor retention bezels. Refer to <<76.10.58>> 11. Remove roof console. Refer to <<76.13.69>>.
www.JagDocs.com
12. Withdraw each door aperture seal from flange upper section.
2012-07-22
13. Position headlining for access. Easing the body tabs back to release the headlining, progressively move the headlining downwards to access interior light multiplug. Disconnect interior light multiplug and free headlining from remaining body tabs.
14. Avoiding damage to fascia, door aperture seals and door casings, lift and turn headlining through 90 degrees, tilt into passenger footwell and remove from vehicle. 15. Remove interior light from headlining.
Installation 1. Fit interior light to headlining. 2. Place headlining in vehicle tilted to position with one end in footwell and opposite end at top of door aperture. 3. Lift and rotate headlining through 90 degrees.
2012-07-22
4. Position headlining at roof and reposition door aperture seals to retain it. 5. Connect interior light multiplug. 6. Fully seat headlining ensuring correct positioning over backlight flange. 7. Bend body tabs into position to secure headlining. 8. Fit roof console. Refer to <<76.13.69>>. 9. Fit both sun visors. Refer to 76.10.47 10. Fit 'A' post upper trim panels. Refer to <<76.13.31>>. 11. Fit center console assembly. Refer to <<76.25.01>>. 12. Fit 'J' gate surround. Refer to <<76.25.24>>. 13. Fit combined grab handles and coat hanger hooks. 14. Fit rear quarter casings. Refer to <<76.13.73>>. 15. Fit rear seat squab and cushion. Refer to <<76.70.37>> and <<76.70.38>>. 16. Connect earth cable to battery terminal and fit battery cover. Refer to <<86.15.15>>. 17. Fit front seats. Refer to 76.70.01.90.
www.JagDocs.com
2012-07-22
Luggage Compartment Front Trim Panel 76.19.31

Removal 1. Remove battery cover. 2. Remove trunk floor carpet. 3. Remove front liner, exercising care when withdrawing ends from behind side liners.
Installation 1. Easing side liners inwards, fit and fully seat trunk front liner. 2. Fit trunk floor carpet. 3. Fit battery cover.
2012-07-22
Luggage Compartment Rear Trim Panel 76.19.44

Removal 1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 2. Remove trunk floor carpet.
www.JagDocs.com
3. Remove and discard the eight fir tree fasteners securing trunk rear finisher to rear panel.
4. Position trunk rear finisher for access, disconnect trunk lamp harness multiplugs and remove lamp assemblies. 5. Remove rear finisher from trunk.
2012-07-22
Installation 1. Fit and fully seat lamp assemblies in trunk rear finisher. 2. Position rear finisher in trunk and connect lamp harness multiplugs. 3. Fit and fully seat finisher on trunk rear panel and secure with new fir tree fasteners. 4. Fit trunk floor carpet. 5. Connect ground cable to battery and fit battery cover. Refer to <<86.15.15>>.
2012-07-22
Luggage Compartment Side Trim Panel 76.19.22

Removal 1. Remove battery cover. 2. Remove trunk floor carpet. 3. Remove trunk rear finisher. Refer to <<76.19.44>>. 4. Remove rear lamp covers. Refer to 86.40.74. 5. If fitted, pass fuel filler flapemergency release cord through slot in LH side liner and withdraw liner from trunk.
Installation 1. Position side liner in trunk and where fitted, pass fuel filler flap emergency release cord through slot . 2. Finally position and seat liner. 3. Fit and fully seat rear lamp cover. Refer to 86.40.74. 4. Fit trunk rear finisher. Refer to <<76.19.44>>. 5. Fit trunk front liner. Refer to <<76.19.31>>. 6. Fit trunk floor carpet. 7. Fit battery cover.
www.JagDocs.com
2012-07-22
Parcel Shelf Vehicles Without: Convertible Top 76.67.06

Removal 1. Remove rear seat cushion and squab. Refer to <<76.70.37>> and <<76.70.38>>. 2. Remove rear quarter casings. Refer to <<76.13.73>>. 3. Remove sub-woofer speaker cover and speaker. Refer to <<86.51.05>>.
4. Remove rear parcel shelf. 1. Slacken and remove the two rear parcel shelf securing screws, withdraw shelf and remove from vehicle.
Installation 1. Position and fully seat rear parcel shelf. 2. Fit and tighten the two shelf securing screws. 3. Fit sub-woofer speaker and cover. Refer to <<86.51.05>>. 4. Fit rear quarter casings. Refer to <<76.13.73>>. 5. Fit rear seat squab and cushion. Refer to <<76.70.37>> and <<76.70.38>>.
2012-07-22
Passenger Air Bag Module Finish Panel 76.47.40

Removal WARNING: FOLLOWING DISCONNECTION OF THE BATTERY, A PERIOD OF AT LEAST ONE MINUTE MUST BE ALLOWED TO ELAPSE BEFORE ANY WORK IS CARRIED OUT ON AN AIR BAG. NOTE: For safety reasons, the veneer panel is an integral part of the air bag deployment door and is not available as a separate service item. 1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 2. Remove passenger air bag complete with deployment door. Refer to <<76.73.37>>.
www.JagDocs.com
3. Slacken, remove and discard two bolts securing air bag tether bracket and deployment door to air bag module.
Installation 1. Position air bag tether bracket and deployment door on air bag module and secure with two new bolts. 2. Fit air bag assembly to fascia. Refer to <<76.73.37>>. 3. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
2012-07-22
Passenger Side Floor Covering 76.49.10

Removal 1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 2. Remove door sill treadplate. Refer to 76.76.01. 3. Remove front passenger seat. Refer to 76.70.01.90. 4. Remove 'J' gate surround. Refer to <<76.25.24>>. 5. Remove centre console for access. Refer to <<76.25.01>> 6. Remove rear quarter casing for access. Refer to <<76.13.73>>. 7. Remove rear seat cushion. Refer to <<76.70.37>>. 8. Remove 'A' post lower trim pad. Refer to <<76.13.30>>.
9. Remove 1/4 turn toeboard fastener.
2012-07-22
10. Remove and discard fastener securing carpet at facia/console area.
www.JagDocs.com
11. Withdraw draught welt and release carpet retaining clips from door aperture flange. 12. Free rear of carpet from rear seat cushion locater.
2012-07-22
13. Lift rear of carpet and pass seat harness and connector through. 14. Fold front of carpet back from footwell. 15. Ensuring carpet is free, pull rearwards and remove it from vehicle.
Installation 1. Position carpet in vehicle. 2. Align carpet with toeboard. 3. Align carpet with heelboard and secure with clip. 4. Install carpet to door aperture retaining clips. 5. Install and fully seat draught welt on door aperture flange. 6. Install new fastener securing carpet to fascia/console area. 7. Install fastener securing carpet to toeboard. 8. Install 'A' post lower trim pad. Refer to <<76.13.30>>. 9. Install rear seat cushion. Refer to <<76.70.37>>. 10. Install rear quarter casing. Refer to <<76.13.73>> 11. Install centre console. Refer to <<76.25.01>>.
2012-07-22
12. Install 'J' gate surround. Refer to <<76.25.24>>. 13. Install passenger seat and adjust to original position. Refer to 76.70.01.90. 14. Install door sill treadplate. Refer to 76.76.01. 15. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
www.JagDocs.com
2012-07-22
Rear Quarter Panel Armrest Vehicles Without: Convertible Top 76.13.66

2. Remove rear quarter armrest from casing. 1. Remove rubber mat from stowage tray. 2. Slacken and remove the two armrest securing screws and lift armrest clear of rear quarter casing.
Installation 1. Fit armrest to rear quarter casing. Position armrest on quarter casing and fit and tighten the two securing screws. Fit rubber mat to stowage tray. 2. Return seat back to upright position.
2012-07-22
Rear Quarter Panel Armrest and Speaker Grille Vehicles Without: Convertible Top 76.13.71
www.JagDocs.com
2. Remove rear quarter armrest from casing. 1. Remove rubber mat from stowage tray. 2. Slacken and remove the two armrest securing screws and lift armrest clear of rear quarter casing.
3. Remove speaker cover from casing. 1. Lift the two speaker cover front fasteners out of rear quarter casing spring clips. 2. Move cover forward to release two rear plastic tangs from casing and remove cover from the vehicle.
2012-07-22

Installation 1. Fit speaker cover to rear quarter casing. Position speaker cover and locate rear retaining tangs in casing. Press and fully seat the two front retaining fasteners in the casing spring clips. 2. Fit armrest to rear quarter casing. Position armrest on quarter casing and fit and tighten the two securing screws. Fit rubber mat to stowage tray. 3. Return seat back to upright position.
2012-07-22
Rear Quarter Trim Panel 76.13.73

Removal 1. Remove rear seat cushion and squab. Refer to <<76.70.37>> and <<76.70.38>>. 2. On coupe model, remove coat hanger hook.
www.JagDocs.com
3. On convertible model, remove rear quarter capping. 1. Remove fastener securing rear quarter capping to 'B' post extension. 2. Slacken and remove three screws securing the capping, lift capping clear and remove from vehicle.
4. On coupe model, detach rear seat belt anchor and remove escutcheon. Slacken and remove rear seat belt anchor plate securing bolt and retain card washer. Remove rear seat belt escutcheon from rear quarter casing.
1 2012-07-22
5. Remove front seat belt upper anchor plate and trim. 1. Unclip front seat belt upper anchor plastic cover and position for access to securing nut. 2. Slacken and remove seat belt upper anchor securing nut. 3. Remove seat belt upper anchor and plastic cover.
6. Remove front seat belt escutcheon. 1. On coupe model, slacken and remove securing screw from front seat belt upper escutcheon and remove escutcheon from rear quarter casing.
2012-07-22
www.JagDocs.com
7. Detach front seat belt lower anchor bar. 1. Slacken and remove front seat belt lower anchor bar securing bolt. 2. Remove anchor bar from body grommet and seat belt loop. 3. Retain anchor bar spacer and card washer.
8. On coupe model rear quarter casing, release clips from locations in the cantrail, 'B' post and rear parcel shelf, and position casing for access.
2012-07-22
9. On convertible model rear quarter casing, release clips from locations in the 'B' post and two dowels from seat squab panel, and position casing for access.
10. Pass seat belt anchor plates through rear quarter casing apertures and remove casing from vehicle.
2012-07-22

Installation
1. On coupe model, position rear quarter casing and engage plastic clip in rear parcel shelf.
www.JagDocs.com
2. On convertible model position rear quarter casing and engage two dowels in rear seat squab panel. 3. Pass seat belt anchor plates through casing apertures. 4. Press home and fully seat the remaining casing clips in body locations. 5. Position and seat front seat belt escutcheon to casing aperture. On coupe model, fit and tighten securing screw. 6. Fit front seat belt anchor bar. Pass front seat belt anchor bar through seat belt loop and body grommet. Fit securing bolt to seat belt anchor bar. Fit spacer and card washer and locate and fully tighten securing bolt.
2012-07-22
7. Fit front seat belt upper anchor plate. Fit plastic cover to front seat belt upper anchor plate securing stud. Position upper anchor plate on securing stud and fit and tighten securing nut. Fasten upper anchor plastic cover. 8. On coupe model: Fit rear seat belt anchor plate. Fit securing bolt to rear seat belt anchor plate. Fit card washer to securing bolt. Position anchor plate over bolt location and engage and fully tighten securing bolt. Position and seat rear seat belt escutcheon to casing aperture. Fit coat hanger hook. 9. On convertible model, position rear quarter capping, secure to 'B' post extension with fastener and fit and tighten three screws. 10. Fit rear seat squab and cushion. Refer to <<76.70.37>> and <<76.70.38>>.
2012-07-22
Rear Quarter Upper Trim Panel Vehicles With: Convertible Top

Removal 1. Fully lower convertible top.
www.JagDocs.com
2. Remove seat belt upper anchor. Remove seat belt upper anchor bolt cover. Remove seat belt upper anchor bolt. Remove seat belt anchor and spacer.
3. Remove rear quarter capping. 1. Remove fastener securing rear quarter capping to 'B' post extension. 2. Slacken and remove three screws securing the capping. 4. Lift rear quarter capping and remove from vehicle.
2012-07-22
Installation
1. Install rear quarter capping. 1. Using a new fastener secure rear capping to 'B' post extension. 2. Install the three capping screws. 2. Install seat belt anchor spacer. 3. Position anchor on spacer. 4. Install seat belt upper anchor bolt and tighten to 34-46Nm. 5. Install seat belt upper anchor bolt cover. 6. Raise convertible top.
2012-07-22
Scuff Plate Trim Panel 76.13.22

Removal
www.JagDocs.com
1. NOTE: The finisher can be easily damaged, care must therefore be exercised during removal. Using a thin plastic lever and starting at one end, carefully remove the treadplate finisher and place face uppermost on sheet of clean dry polythene.
2. Remove treadplate securing screws and withdraw treadplate.
Installation 1. Ensure that draught welt is correctly positioned and fully seated on aperture flange.
2012-07-22
2. Position sill tread plate and install three securing screws. 3. Ensure that sillcontact area is clean and dry. 4. Install treadplate finisher, pressing firmly into place. If finisher has been renewed, remove protective film.
2012-07-22
Sun Visor 76.10.48

Removal 1. Turn sun visor downward, release from retention bezel and pivot outwards.
www.JagDocs.com
2. Carefully ease visor securing screw cover from base.
3. Slacken and remove the two visor securing screws and remove visor from vehicle.
Installation 1. Position sun visor at location and fit and tighten securing screws. 2. Fit visor base cover. 3. Pivot visor inwards, position in retention bezel and return to upward position.
1 2012-07-22
Sun Visor Retaining Clip 76.10.58

2. Lower roof console, release bezel multiplug from retaining clip and disconnect multiplug from harness. 3. Turn sun visor downwards, release from retention bezel and pivot outwards.
4. Carefully open flap on retention bezel cover and slacken and remove bezel retaining screw.
2012-07-22
5. Withdraw bezel from location, carefully feeding multiplug through aperture and remove bezel from vehicle.
www.JagDocs.com
Installation 1. Position bezel for access and route multiplug through aperture to retaining clip. 2. Fully seat bezel and fit and tighten securing screw. 3. Close flap on securing screw cover. 4. Connect multiplug to harness and fit and fully seat multiplug on retaining clip. 5. Raise and fully seat roof console 6. Pivot sun visor inwards, locate in bezel and turn visor to upward position. 7. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
2012-07-22
Door Window Control Switch Finish Panel 76.47.33

Removal 1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>
2. Remove glass lift switch. 1. Remove glass lift switch end cover trim pad. 2. Remove the switch securing screw. 3. Disconnect the switch harness multiplug.
4. Release veneer panel clips.
2012-07-22
Installation 1. Install veneer panel on switch ensuring retaining clips are fully seated. 2. Connect harness multiplug to switch.
www.JagDocs.com
3. Install glass lift switch. 1. Position glass lift switch in door. 2. Install switch securing screw. 3. Install and fully seat switch end cover trim pad. 4. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
2012-07-22
1999 XK RANGE - Exterior Trim and Ornamentation - 501-08
Exterior Trim
Air Intake, Splitter Vane and Front Body Trim
Body Front
A chrome splitter vane assembly installed centrally in the bumper casing air intake incorporates polyurethane covers for the two bumper beam overriders. A Jaguar 'growler' badge is mounted centrally on the upper face of the front bumper casing.
Body Sides
For certain markets, a Jaguar 'leaper' badge is surface mounted on the rear of each fender in place of side repeater lamps. Three piece color-keyed body side mouldings are surface mounted to align with the side repeaters or Jaguar 'leaper' badges dependent upon the market. Chrome door handles are fitted for N. American markets.
Door Sills
Extruded, polished aluminum tread plates with 'Jaguar XK8' inscriptions are fitted to the door sills.
Body Rear
2012-07-22

Rear External Trim
Two script badges are surface mounted on the trunk rear panel. A 'Jaguar' badge is fitted on the LH side, and an 'XK8' badge on the RH side has external trunk lock key access between the letters X and K.
www.JagDocs.com
GLAZING
Door glass trims and one piece windshield and coupe backlight finishers are in extruded aluminum alloy and painted Dorchester grey on all cars. Coupe quarter-light trims are secured to the body at waist level by 'T' studs, and at the top by clips bonded with the glass as an assembly.
2012-07-22
Door Moulding 76.43.72

Removal 1. Apply suitable protective tape to immediately adjacent areas of paintwork. 2. Using a hand-held heat gun, appply heat uniformly along moulding length. 3. Applying local heat at one end and using a suitable thin lever to avoid damaging paintwork, progressively ease moulding away from door panel. 4. Discard moulding and remove protective tape. 5. Remove any residual adhesive and thoroughly clean area using white spirit.
Installation 1. NOTE: Optimum adhesion is achieved by warming body panel and moulding to 65deg C. Using white spirit ensure that mounting area is clean, dry and de-greased. 2. Remove protective backing tape from moulding. 3. NOTE: Do not allow moulding to contact the body panel until it is correctly aligned. Heat moulding and mounting area to 65deg C. 4. Aligning with adjacent fender moulding or to match opposite side of vehicle, press new moulding firmly onto body panel. 5. Apply hand pressure along moulding length to ensure satisfactory adhesion. 6. Allow moulding and door panel to cool , then thoroughly clean both using white spirit. 7. Apply a coat of suitable polish to moulding and body panel.
2012-07-22
Door Window Moulding 76.43.04

Removal 1. Remove door mirror. Refer to <<76.10.52>>.
www.JagDocs.com
2. Exercising care to avoid damaging paintwork, lift and release waist rail moulding from door flange.
Installation 1. Fit and fully seat waist rail moulding on door flange. 2. Fit door mirror. Refer to <<76.10.52>>.
2012-07-22
Fender Moulding 76.43.73

Removal 1. Apply suitable protective tape to immediately adjacent areas of paintwork. 2. Using a hand-held heat gun, appply heat uniformly along moulding length. 3. Applying local heat at one end and using a suitable thin lever to avoid damaging paintwork, progressively ease moulding away from fender. 4. Discard moulding and remove protective tape. 5. Remove any residual adhesive and thoroughly clean area using white spirit.
Installation 1. NOTE: Optimum adhesion is achieved by warming body panel and moulding to 65deg C. Using white spirit ensure that mounting area is clean, dry and de-greased. 2. Remove protective backing tape from moulding. 3. NOTE: Do not allow moulding to contact the fender until it is correctly aligned. Heat moulding and mounting area to 65deg C. 4. Aligning with adjacent door moulding or to match opposite side of vehicle, press new moulding firmly onto fender. 5. Apply hand pressure along moulding length to ensure satisfactory adhesion. 6. Allow moulding and fender to cool , then thoroughly clean both using white spirit. 7. Apply a coat of suitable polish to moulding and fender.
2012-07-22
Hood Grille 76.16.37

Removal 1. Open hood. 2. Fit fender covers.
www.JagDocs.com
3. Remove louvre from hood. From hood underside, release the six louvre securing tangs. Carefully withdraw louvre from hood upper surface.
4. Clean hood mating surface. Remove any residual foam strip. Using a suitable cleaning agent, remove any adhesive.
2012-07-22
Installation
1. Install new foam strip on louvre. Remove paper backing from foam strip. Ensuring correct alignment, fully seat foam on louvre.
2. Install louvre on hood. Carefully position louvre on hood aperture. Using a clean soft cloth, firmly press louvre into position.
2012-07-22
3. From hood underside, check that all louvre tangs are fully seated. 4. Remove fender covers. 5. Close hood.
www.JagDocs.com
2012-07-22
License Plate Housing 76.43.22

Removal 1. Remove covers from number plate securing screws. 2. Slacken and remove number plate securing screws and remove number plate.
3. Drill out pop rivets securing number plate trim surround to trunk lid.
Installation 1. Position trim surround on trunk lid and secure with new pop rivets. 2. Align number plate with trunk lid and fit and tighten securing screws.
2012-07-22
Luggage Compartment Lid Moulding 76.43.79

Removal
www.JagDocs.com
1. Slacken and remove trunk stowage strap securing screw and remove strap.
2. Release eight fasteners securing the insulating pad to rear of the trunk lid and position pad for access.
2012-07-22
3. Disconnect number plate lamp harness multiplugs.
4. Slacken and remove the four trim finisher/number plate lamp assembly securing nuts and remove assembly from trunk lid.
2012-07-22
5. Remove lenses and bulb holders and discard gaskets from number plate lamps.
Installation 1. Fit new gaskets to number plate lamps 2. Fit and fully seat bulb holders and lenses to number plate lamps. 3. Position trim finisher/number plate lamp assembly on trunk lid and fit and tighten the securing nuts. 4. Connect number plate lamp harness multiplugs. 5. Re-position insulation pad on trunk lid and fit and fully seat fasteners. 6. Position trunk stowage strap and fit and tighten securing screw.
www.JagDocs.com
2012-07-22
Radiator Grille 76.55.03

Removal 1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 2. Raise front of vehicle and support on stands. Refer to Section <<100-02>>. 3. Remove road wheels. Refer to Section <<100-02>>. 4. Remove wheel arch liners for access. Refer to <<76.10.90>>. 5. Using a thin plastic lever, carefully release front number plate from plinth. 6. Remove screws securing number plate plinth to overriders.
7. Remove and discard rivets securing undertray to the bumper cover.
2012-07-22

8. Remove three screws securing undertray to lower cross-member and remove undertray.
www.JagDocs.com
9. At each side of vehicle: Disconnect fog lamp harness multiplug and where fitted, disconnect sidemarker lamp. Remove three bolts securing bumper cover to to fender lower flange. 10. Raise vehicle, remove stands and lower 4-post ramp.
11. Remove bumper cover from vehicle. Remove and discard the three fir tree fasteners securing bumper cover to body front upper cross-member. Remove six bolts securing bumper cover to front upper cross-member and remove cover from vehicle.
2012-07-22
12. Remove and discard fastener securing bottom of radiator grill to bumper beam.
13. Remove and discard fasteners securing top of radiator grill to bumper beam.
2012-07-22

14. Remove grill surround strips. Withdraw radiator grill. Sever and discard tie straps. Remove surround strips.
Installation
www.JagDocs.com
1. Install surround strips on grill and secure with new tie straps.
2. Position grill on bumper beam and secure top with new fasteners.
2012-07-22
3. Secure bottom of grill with new fastener.
4. Position and secure bumper cover to front upper cross-member. Position bumper cover over bumper beam and secure on upper cross-member using three new fir tree fasteners. Install six cover to upper cross-member securing bolts. 5. Raise vehicle and support on stands. Refer to Section <<100-02>>.
2012-07-22
www.JagDocs.com
6. At each side of vehicle: Install three bolts securing bumper cover to fender lower flange. Connect harness multiplugs to fog lamps and where fitted, side marker lamps.
7. Install undertray. Position undertray on vehicle and secure to lower cross-member with three screws. Secure undertray to bumper cover using new rivets. 8. Using new fasteners, install wheel arch liner. Refer to <<76.10.90>>. Repeat procedure on opposite side of vehicle. 9. Install road wheels. Refer to Section <<100-02>>. 10. Raise vehicle, remove stands and lower vehicle onto wheels. Refer to Section <<100-02>>. 11. Position front number plate plinth on overriders, fit and tighten securing screws and fit number plate to plinth. 12. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
2012-07-22
Rear Quarter Window Moulding 76.43.81

Removal 1. Remove door aperture seal for access. Refer to <<76.40.30>>. 2. Remove gutter finisher. Refer to <<76.43.11>>.
3. Exercising care to avoid damaging paintwork, release quarter light finisher from edge securing clips.
Installation 1. Position quarter light finisher on BIW and press firmly to fully seat in securing clips.
2012-07-22

2. Apply wet sealant behind finisher butt joint between the two adjacent screw locations. 3. Fit gutter finisher. Refer to <<76.43.11>>. 4. Fit door aperture seal. Refer to <<76.40.30>>.
www.JagDocs.com
2012-07-22
Rear Window Moulding Vehicles Without: Convertible Top 76.43.46

Removal 1. Using masking tape, mark finisher centre points on BIW.
2. Carefully release backlight finishers from retaining clips. 3. Clean mating surface of backlight. 4. If original finisher is to be re-fitted, clean mating surface.
Installation
1. Aligning centre points with masking tape markers, position finisher on backlight and press firmly to fully seat on retaining clips.
1 2012-07-22
Roof Moulding Vehicles Without: Convertible Top 76.43.11

Removal 1. Remove door aperture seal for access. Refer to <<76.40.30>>.
www.JagDocs.com
2. Slacken and remove the ten screws securing gutter finisher to BIW. 3. Carefully release gutter finisher from rear quarter light finisher and remove gutter finisher.
Installation 1. Position gutter finisher on BIW aligning it with rear quarter light finisher.
2012-07-22

2. Apply wet sealant behind finisher butt joint between the two adjacent screw locations.
3. Fit and tighten the ten finisher to BIW securing screws. 4. Fit door aperture seal. Refer to <<76.40.30>>.
2012-07-22
1999 XK RANGE - Rear View Mirrors - 501-09
Rear View Mirrors
Interior Rear View Mirror
www.JagDocs.com
The interior rear view mirror is an electrochromic unit that automatically darkens to prevent glare from following vehicle lights. This automatic function is selected by pressing the switch at the bottom of the mirror. Pressing the switch again cancels this function. An LED then illuminates when automatic dipping is operative. A Night Sentinel light sensing unit also incorporated in the mirror casing, provides for automatic control of the vehicle lights.
Door Rear View Mirrors
The door mirrors are cheater mounted, color-keyed units, remote electrically adjustable and heated. Adjustment of
2012-07-22

both mirrors is carried out from the driver's door switchpack. A slider switch selects the mirror to be adjusted, and a disc switch adjusts the selected mirror to the required position. Mirror adjustment can only be made when the ignition switch is in position I or II or the driver's door is open, and the selector switch is moved from the central position. When fitted, electrochromic door mirrors automatically darken under control of the interior rear view mirror. Mirror heating elements operate on selection of backlight heating. Automatic dipping of passenger door mirror for kerb view when reversing, is fitted as part of the memory pack. With the ignition switch in position II, the mirror selector switch in the left or right position and reverse gear selected, automatic dipping is initiated by moving the mirror toggle switch rearwards and releasing. On receipt of the dip signal, the passenger door mirror is driven downwards either 7 degrees, bottom of travel, or 4,5 to 5,5 seconds, whichever occurs first. Subsequent rearward movement of the toggle switch achieves further dipping of the mirror in the same increments and sequence. The mirror can be manually returned to the normal memorised position by moving the toggle switch forward with reverse gear selected. The mirror will automatically return to memorised position on deselection of reverse gear, or moving ignition switch from position II. Door mirror fold-back where fitted, to facilitate parking in confined spaces, can be initiated when the ignition switch is in position I or II, the mirror selector switch is in the central position and vehicle speed is below 19 km/h (12 mph). Mirror fold-back is then initiated by moving the toggle switch rearwards and releasing it. The door mirrors are returned to the normal driving position by again moving toggle switch rearwards. There is no speed constraint on this operation. In the event of a fold-back mirror becoming 'out of position' due to accidental impact, it must only be re-positioned by initiating the fold-back sequence. Loss of power supplies will result in loss of mirror fold-back memory. In the event of such a memory loss with mirrors in the normal position, fold-back will operate on second movement of the toggle switch. On loss of memory with mirrors in the fold-back position, they will return to the normal position on next fold-back operation. Automatic dipping of passenger door mirror for kerb view when reversing, is fitted as part of the memory pack. With the ignition switch in position II, the mirror selector switch in the left or right position and reverse gear selected, automatic dipping is initiated by moving the mirror toggle switch rearwards and releasing. On receipt of the dip signal, the passenger door mirror is driven downwards either 7 degrees, bottom of travel, or 4,5 to 5,5 seconds, whichever occurs first. Subsequent rearward movement of the toggle switch achieves further dipping of the mirror in the same increments and sequence. The mirror can be manually returned to the normal memorised position by moving the toggle switch forward with reverse gear selected. The mirror will automatically return to memorised position on deselection of reverse gear, or moving ignition switch from position II. Door mirror fold-back where fitted, to facilitate parking in confined spaces, can be initiated when the ignition switch is in position I or II, the mirror selector switch is in the central position and vehicle speed is below 19 km/h (12 mph). Mirror fold-back is then initiated by moving the toggle switch rearwards and releasing it. The door mirrors are returned to the normal driving position by again moving toggle switch rearwards. There is no speed constraint on this operation. In the event of a fold-back mirror becoming 'out of position' due to accidental impact, it must only be re-positioned by initiating the fold-back sequence. Loss of power supplies will result in loss of mirror fold-back memory. In the event of such a memory loss with mirrors in the normal position, fold-back will operate on second movement of the toggle switch. On loss of memory with mirrors in the fold-back position, they will return to the normal position on next fold-back operation.
2012-07-22
Auto-dimming Interior Mirror 76.10.56

Removal CAUTION: When removing mirror from base, care must be exercised to ensure that base is not detached from windshield.
1. Remove roof console for access and disconnect interior mirror harness multiplugs. Refer to <<76.13.69>>.
www.JagDocs.com
2. Remove upper cover from mirror stem.
3. Applying firm downward pressure, remove mirror assembly from base.
Installation 1. Position mirror at bottom of base and apply firm upward pressure to fully seat and secure in position.
1 2012-07-22
2. Fit upper cover to mirror stem. 3. Position roof console at header and connect mirror harness multiplugs. 4. Fit and fully seat roof console. Refer to <<76.13.69>>.
2012-07-22
Exterior Mirror 76.10.52

Removal 1. Fully open door glass. 2. Remove door frame cheater trim and memory foam for access.
www.JagDocs.com
3. Remove mirror assembly from door. 1. Disconnect mirror harness multiplug. 2. Supporting mirror, slacken and remove securing screw and remove mirror assembly from door.
Installation
1. Fit exterior mirror assembly to door.
2012-07-22

1. Pass harness and multiplug through cheater aperture and position mirror foot on cheater, locating the two dowels correctly and ensuring correct seating on seal. Fit and tighten the mirror assembly securing screw. Connect mirror assembly harness multiplug, position in door and reposition door foam. 2. Fit memory foam and door frame cheater trim. 3. Close door glass.
2012-07-22
Exterior Mirror Cover 76.10.55

Removal 1. Remove exterior mirror glass. Refer to <<76.10.53>>.
www.JagDocs.com
2. Remove exterior mirror cap. 1. From housing interior, press out the three cap dowels complete with securing clips. Remove mirror cap from casing. Remove and discard the securing clips.
Installation
1. Fit cap to mirror housing. 1. Fit and fully seat new cap securing clips in mirror base. 2. Align mirror cap dowels with the securing clips and press firmly into place. 3. Fit mirror glass. Refer to <<76.10.53>>.
1 2012-07-22
Exterior Mirror Glass 76.10.53

Removal CAUTION: If as a result of accidental impact, a powered fold-back mirror is moved 'out of position', it must only be re-positioned by initiating the fold-back sequence as described in this section. No attempt must be made to manually return the mirror to the normal position. Failure to adopt this procedure will result in vibration of the unlocked mirror head and consequent loss or distortion of rear vision.
1. Remove exterior mirror glass. 1. Motor glass to fully inward position. 2. Pressing inner edge of glass outwards, ease outer extremity rearwards away from mirror housing.
2. Disconnect and remove mirror glass. 1. Ease glass clear of base, disconnect the two spade connectors and remove glass from mirror housing.
2012-07-22
Installation
www.JagDocs.com
1. Fit glass to mirror housing. Holding glass in position, connect the two spade connectors. Engage the mirror inner retainer on the motor lug and press the mirror outer edge forward to engage the outer retainer.
2012-07-22
Exterior Mirror Motor 76.10.57

Removal 1. Remove exterior mirror glass. Refer to <<76.10.53>>.
2. Remove movement motor pack from housing. 1. Slacken and remove the three self tapping screws securing motor pack to housing. 2. Partially withdraw motor pack, disconnect multiplug and remove motor pack from mirror housing.
Installation
1. Fit glass movement motor pack to housing. 1. Connect multiplug and position motor pack in housing ensuring that harness is correctly routed and not trapped. 2. Fit and tighten the three self tapping screws securing motor pack to housing and fold-back mounting.
2012-07-22
Interior Mirror 76.10.51

Removal CAUTION: When removing mirror from base, care must be exercised to ensure that base is not detached from windshield.
www.JagDocs.com
1. Remove upper cover from mirror stem.
2. Applying firm downward pressure, remove mirror assembly from base.
Installation 1. Position mirror at bottom of base and apply firm upward pressure to fully seat and secure in position. 2. Fit upper cover to mirror stem.
1 2012-07-22
Interior Mirror Mounting Block 76.10.62

Removal 1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 2. Position a protective cover over top of facia. 3. Remove roof console for access. Refer to 76.13.69.90. 4. Remove rain sensor unit. Refer to Section 501.16. 5. Remove mirror from mounting block. Refer to <<76.10.51>> or <<76.10.56>> (electrochromic).
6. Apply a suitable solvent around edge of mounting block.
2012-07-22
www.JagDocs.com
7. Commencing at the top and exercising care to avoid windshield damage, use a thin plastic knife to ease block free. 8. Using a suitable solvent, clean residual adhesive from block mounting area.
Installation
1. Using masking tape, mark block mounting area on windshield. 2. Apply Permabond F Grade 5 Initiator to mounting area of windshield.
2012-07-22
3. Apply a bead of Permabond F246 to bottom and each vertical side of block over 2/3 of block height.
4. Press mounting block onto marked area and hold in position for one minute. 5. After a period of 15 minutes, remove and discard masking tape. 6. Using a scraper, carefully remove any excess adhesive. 7. NOTE: The following time is the MINIMUM PERIOD required for adhesive curing. Failure to allow this period will result in bonding failure, necessitating repeat of the complete procedure. After a further period of at least 6 hours, install mirror on mounting block. Refer to <<76.10.51>> or <<76.10.56>>. 8. Install roof console. Refer to 76.13.69.90.
2012-07-22
9. Install rain sensor unit. Refer to Section 501.16. 10. Remove protective cover from facia. 11. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
www.JagDocs.com
2012-07-22
1999 XK RANGE - Seating - 501-10
Torques Component Cushion to slide Slide to floor Recline to squab frame Nm 22 - 28 22 - 28 7 - 10
2012-07-22
Seats
Front Seats
www.JagDocs.com
The front seat frames are common to the coupe and convertible. Standard seats have leather trimmed facings and cloth centers, with ambla cushions, squab borders and rear map pockets. Seat movement control switch assemblies installed in outboard side of driver and passenger seats, operate motors for fore and aft, recline and raise and lower adjustments via control modules installed below seat frames. Options and market variations include leather/ambla trim with lumbar support adjustment, seat heating, driver's seat position memory and passenger seat height adjustment. Only one of the slide recline or height adjustment motors can be driven under manual control at any one time. On vehicles fitted with driver's seat memory each motor is fitted with feedback potentiometers. When fitted, seat heating is controlled via illuminated on/off switches installed in the center console.
Rear Seats
2012-07-22
Styled for dedicated installation in the coupe or convertible, the rear seats are wire framed units trimmed to match the front seats. There is no provision for rear seat adjustment on either model. Child seat mountings are provided where legally required.
2012-07-22
Front Seat 76.70.01

Removal 1. Turn ignition key to position II and motor seat to fully rearward position.
www.JagDocs.com
2. Slacken and remove the two seat front securing bolts. 3. Motor seat to fully forward position and turn ignition key to position O. 4. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
5. Slacken and remove the two seat rear securing bolts.
2012-07-22
6. Position front seat for access, disconnect seat harness multiplug and remove seat from vehicle.
Installation 1. Position front seat in vehicle and connect seat harness multiplug. 2. Position seat to align bolt holes. 3. Fit the two seat rear securing bolts and screw them almost home but do not tighten. 4. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>. 5. Turn ignition key to position II and motor seat fully rearward. 6. Fit and tighten the two seat front securing bolts. 7. Motor seat fully forward and fully tighten the rear securing bolts. 8. Motor seat to original position and turn ignition key to O.
2012-07-22
Front Seat Backrest Cover 76.70.15

Removal 1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 2. Remove seat back finisher. Refer to <<76.70.03>>.
www.JagDocs.com
3. Remove the nine clips securing the squab cover to the seat frame.
4. Remove the squab heater element harness from the mounting undo the velcro strap and disconnect the multiplug.
2012-07-22
5. Remove squab from seat. 1. Release strap securing squab foam to frame. 2. Remove squab foam and cover from seat and remove from vehicle. 3. Undo velcro fasteners and tapes and carefully withdraw foam cushion from the squab cover. 4. If squab foam is to be renewed, carefully remove heater element.
Installation 1. If squab cushion has been renewed, apply suitable adhesive to foam and fit and fully seat heating element. 2. Carefully insert and position foam cushion in squab cover and secure with velcro fasteners. 3. Fasten strap securing squab foam to seat frame. 4. Connect seat harness multiplug, position in mounting and secure with velcro fastener. 5. Position squab to seat frame and secure with the nine clips. 6. Fit seat back finisher. Refer to <<76.70.03>>. 7. Connect earth cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
2012-07-22
Front Seat Backrest Heater Mat 86.75.14

Removal 1. Remove battery cover and disconnect ground cable from battery terminal. 2. Remove seat back finisher. Refer to <<76.70.03>>.
www.JagDocs.com
3. Remove the nine clips securing the squab cover to the seat frame.
4. Remove the squab heater element harness from the mounting undo the velcro strap and disconnect the multiplug.
2012-07-22
5. Remove squab from seat. 1. Release strap securing squab foam to frame. 2. Remove squab foam and cover from seat and remove from vehicle. 3. Undo velcro fasteners and tapes and carefully withdraw foam cushion from the squab cover. 4. Carefully remove heater element.
Installation 1. Apply suitable adhesive to foam and fit and fully seat heating element. 2. Carefully insert and position foam cushion in squab cover and secure with velcro fasteners. 3. Fasten strap securing squab foam to seat frame. 4. Connect seat harness multiplug, position in mounting and secure with velcro fastener. 5. Position squab to seat frame and secure with the nine clips. 6. Fit seat back finisher. Refer to <<76.70.03>>. 7. Connect earth cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
2012-07-22
Front Seat Backrest Trim Panel 76.70.03

Removal 1. Using rear passenger access knob, release the seat back and move it to the fully forward position.
www.JagDocs.com
2. Remove rear access knob and escutcheon. With a small flat bladed screwdriver, ease open the knob stem to clear the seat lever tang and remove the knob. Carefully ease knob escutcheon from two studs. Slacken and remove two screws.
3. Slacken and remove the two screws securing the lower section of the seat back finisher to the frame.
2012-07-22
4. Withdraw the trim and 32 clips from seat back finisher and position trim for access.
5. Remove seat back finisher from seat..
Installation 1. Align and fit back finisher to front seat. 2. Reposition back finisher trim and secure with the 32 clips. 3. Fit and tighten the two screws securing the lower section of the back finisher to the seat. 4. Fit escutcheon and rear passenger access knob and return seat back to the upright position.
2012-07-22
Front Seat Height Adjustment Motor 86.75.29

Removal 1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 2. Remove driver seat for access. Refer to 76.70.01.90.
www.JagDocs.com
3. Release seat cushion riser harness multiplug from mounting bracket clip and disconnect multiplug.
4. Remove and discard star securing clip from seat riser motor clevis pin.
2012-07-22
5. Slacken but do not remove the two driver seat fore and aft adjustment motor securing bolts.
6. Withdraw seat riser motor clevis pin from upper mounting bracket.
2012-07-22
7. Press seat riser motor out of upper mounting bracket.
www.JagDocs.com
8. Remove spring clip from runner to pivot bar clevis pin and withdraw pin.
2012-07-22
9. Remove motor/runner assembly from pivot bar.
Installation 1. Position motor on seat upper mounting bracket .
2. Fit and fully seat clevis pin and fit new star securing clip.
2012-07-22
www.JagDocs.com
3. Position motor runner on pivot bar and check position of clevis pin aperture.
4. Remove motor runner from pivot bar, adjust runner to required length and re-fit to pivot bar.
2012-07-22
5. Fit motor to pivot bar clevis pin and fit and fully seat securing clip.
6. Connect seat riser motor harness multiplug and fit multiplug onto mounting bracket securing clip.
2012-07-22
7. Fully tighten seat fore and aft adjustment motor securing bolts. 8. Fit seat to vehicle. Refer to 76.70.01.90. 9. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
www.JagDocs.com
2012-07-22
Front Seat Recliner Motor 86.75.04

Removal 1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 2. Remove front seat back finisher. Refer to <<76.70.03>>.
3. Detach motor harness multiplug from mounting.
4. Disconnect harness multiplug from motor and sever and remove tiestrap securing harness to seat frame.
2012-07-22
5. Remove bolt securing motor mounting bracket to seat frame.
www.JagDocs.com
6. Position motor and mounting bracket for access and remove the two motor to bracket securing bolts.
Installation 1. Position motor on mounting bracket and install securing bolts. 2. Position motor and bracket assembly on seat frame and install securing bolt. 3. Using new tiestrap, secure motor harness to seat frame. 4. Connect harness multiplug to motor and install seat multiplug on mounting. 5. Install seat back finisher. Refer to <<76.70.03>>. 6. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
2 2012-07-22
Front Seat Track Motor 86.75.33

Removal 1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 2. Remove front seat for access. Refer to 76.70.01.90.
3. Release seat motor harness multiplug from mounting bracket and disconnect multiplug.
4. Release seat cushion riser motor harness multiplug. from mounting bracket and disconnect multiplug.
2012-07-22
5. Remove and discard tiestrap securing seat harness and position harness for access.
www.JagDocs.com
6. Slacken and remove bolts securing seat motor to frame.
2012-07-22
7. Position motor from frame for access and withdraw drive cable from one side. 8. Release motor from remaining drive cable and remove motor from seat.
Installation 1. Noting drive cable positions, align motor drives to permit engagement.
2. Position motor to seat and engage drive cables.
2012-07-22
3. Finally position motor on seat frame ensuring locating tangs are fully seated.
www.JagDocs.com
4. Fit and fully tighten seat motor to frame securing bolts.
2012-07-22
5. Position seat harness, connect seat motor harness multiplug and fully seat multiplug on mounting bracket.
6. Connect seat cushion riser motor multiplug and fully seat multiplug on mounting bracket.
2012-07-22
7. Position seat harness and secure to mounting bracket with clip. 8. Fit front seat to vehicle. Refer to 76.70.01.90. 9. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
www.JagDocs.com
2012-07-22
Lumbar Motor 86.75.12

Removal 1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 2. Remove front seat back finisher. Refer to <<76.70.03>>.
3. Undo adjacent strap securing squab cushion to seat frame.
4. Position squab for access and release six hooks securing inflatable cushion to seat frame.
2012-07-22
5. Sever and remove tiestraps securing lumbar motor/bag assembly and harness to seat frame.
www.JagDocs.com
6. Disconnect multiplug from lumbar support motor harness. 7. Remove lumbar support motor/bag assembly from seat.
Installation 1. Install lumbar support motor/bag assembly in seat frame. 2. Hook inflatable cushion onto seat frame. 3. Connect harness multiplug to lumbar support motor. 4. Using a new tiestrap, secure lumbar support motor/bag assembly to seat frame.
2 2012-07-22
5. Position seat squab on seat frame and secure with retaining strap. 6. Install seat back finisher. Refer to <<76.70.03>>. 7. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
2012-07-22
Rear Seat Backrest 76.70.38

Removal 1. Remove rear seat cushion. Refer to <<76.70.37>>.
www.JagDocs.com
2. Slacken and remove the two rear seat squab securing screws.
3. Move seat squab upwards to release body tangs.
2012-07-22
4. Position rear seat belts for access and remove squab from vehicle.
Installation 1. Position seat squab placing seat belts over. 2. Finally position squab, engaging body tangs by applying downward hand pressure. 3. Fit and tighten the two squab securing screws. 4. Fit rear seat cushion. Refer to <<76.70.37>>.
2012-07-22
Rear Seat Cushion 76.70.37

Removal 1. Using the rear passenger access knobs, position the back of each front seat fully forward.
www.JagDocs.com
2. Slacken and remove the two rear seat cushion securing nuts.
3. Raise seat cushion for access, pass seat belt anchors through central penetration and remove seat cushion from vehicle.
2012-07-22

Installation 1. Position seat cushion for access and pass rear seat belt anchors through central penetration. 2. Finally position cushion and fit and tighten securing nuts. 3. Return front seat backs to the upright position.
2012-07-22
Seat Control Switch 86.75.23

Removal 1. Power seat to fully raised position. 2. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 3. Remove front seat from vehicle and place on clean work surface. Refer to 76.70.01.90.
www.JagDocs.com
4. Release seat harness multiplugs from mounting bracket and disconnect multiplugs.
5. Sever and discard tiestraps securing seat harness to seat frame.
2012-07-22
6. Sever and discard tiestrap securing seat harness to motor assembly.
7. Remove bolts securing seat slide assembly to seat frame and withdraw slide assembly.
2012-07-22
8. Disconnect switchpack harness multiplug.
www.JagDocs.com
9. Positioning cushion foam for access, use a screwdriver to release switchpack securing tab.
Installation 1. Fit and fully seat switchpack in seat. 2. Positioning cushion foam for access, connect harness multiplug to switchpack. 3. Position slide assembly on seat frame and install securing bolts. 4. Connect seat harness multiplugs. 5. Install harness multiplug onto mounting bracket.
2012-07-22
6. Using new tiestraps, secure harness to seat frame and motor. 7. Install seat assembly in vehicle. Refer to 76.70.01.90.
2012-07-22
1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
Door Window Glass Adjustment

1. Turn ignition key to position II and motor door glass to fully lowered position. 2. Turn ignition key to position O 3. Remove door switchpack and door casing and disconnect switchpack harness multiplug. Refer to <<76.34.01>>. 4. Remove door water shedders. Refer to <<76.58.07>>. 5. Reconnect door glass lift switch lead to glass regulator connector. 6. Remove door outer waist moulding. Refer to <<76.43.04>>.
www.JagDocs.com
7. Using a felt tip pen mark datum lines on glass. Draw a horizontal line across glass 6mm from the top edge on coupe or 9mm down on convertible. Draw a parallel line 6mm from glass leading edge. WARNING: THE FOLLOWING STEPS NECESSITATE WORKING IN THE DOOR INTERIOR WITH THE POWER SUPPLIES CONNECTED. TO AVOID INADVERTENT GLASS OPERATION AND POSSIBLE INJURY, NO OTHER WORK MUST BE CARRIED OUT SIMULTANEOUSLY.
2012-07-22
8. Turn ignition key to position II and motor door glass up until top edge is just below upper seal.
9. Adjust gap between glass and outer waist rail flange. Slacken rear guide upper securing screw Move guide to achieve a gap of 9mm and tighten securing screw.
2012-07-22
10. Using guide runner lower adjusters, laterally align glass top edge with the upper seal.
www.JagDocs.com
11. Remove tape from access hole in PVC secondary water shedder and slacken glass regulator stop adjuster bolt.
2012-07-22
12. Motor door glass further up until the horizontal datum line aligns with the upper seal.
13. Move glass regulator stop to abut quadrant and tighten adjuster bolt. 14. Motor door glass to fully up position, measure any lift adjustment required and re-mark glass in that position. 15. Motor door glass to partially lowered position.
2012-07-22
16. Slacken glass regulator stop adjuster bolt, move stop required amount and tighten bolt.
www.JagDocs.com
17. Motor door glass to fully raised position and check glass seating in upper seal. 18. Repeat operations 14 to 17 as necessary, until door glass seats satisfactorily in upper seal.
2012-07-22
19. With glass in fully raised position, slacken door waist adjuster lock nuts and hand screw adjusters in until they abut the door glass stops.
20. Adjust gap for parallelism between rear edge of door glass and front edge of quarter light. Slacken glass lift regulator channel adjuster lock nut. Move channel to achieve a parallel gap of 8mm on coupe model, 11mm on convertible. Tighten lock nut. 21. Motor door glass fully down and fully up and check all gaps and alignments. 22. Turn ignition key to position O. 23. Disconnect and remove door glass lift switch. 24. Thoroughly clean door glass, removing datum marker lines.
2012-07-22
25. Fit door outer waist moulding. 26. Fit new tape to access hole in PVC secondary water shedder 27. Fit water shedders. Refer to <<76.58.07>>. 28. Fit door switchpack to door casing, connect multiplug and fit casing. Refer to <<76.34.01>>.
www.JagDocs.com
2012-07-22
Glass, Frames and Mechanisms
Door Glass Operating Mechanism
The windshield, which is of 5 mm laminated glass with a black obscuration band and has the interior mirror fitted, is common to the coupe and convertible. The windshield finisher is a one-piece, single color unit with seal. The backlight is 4 mm tempered glass, green tinted and heated. The windshield, backlight and quarter lights, except for the convertible model, are direct glazed to the body. The windshield and coupe backlight are supplied as assemblies complete with trim which is secured to the glass by clips and is fully demountable when the assembly is bonded to the vehicle. The convertible backlight and outer seal are conventionally glazed to the inner seal, which is stitched and bonded to the top. On both models, the heated backlight remains on for 21 minutes after being switched on unless it is manually switched off before the time delay expires. Some backlights are fitted with a security antenna. A fine wire heated windshield offered as an option on some markets, is controlled from the air conditioning panel. The door glass on both models is a frameless system with 5 mm green tempered glass. The window glass is operated electrically and raised and lowered by a scissor mechanism. Each door glass automatically drops 12 mm when the door is opened or when the convertible top is raised or lowered, closing when either the door is shut or the top is fully raised and latched in position. The door glass can be closed via the remote control unit. Glass operation is internally controlled from switchpacks located in the driver and passenger arm rests via the driver and passenger door modules. The switchpacks are illuminated when the sidelights are on. One-touch up operation causes the door glass to fully close unless an object is detected or if the glass is already within 45 mm of top of travel when the door is opened. On detection of an object, the glass will drop fully open or to 200 mm below the obstruction. All door glass operates with the ignition switch in either position I or II and after ignition is switched off, until either door is opened. Before commencing work within a door interior, all Warnings and Notes within the appropriate Removal and Installation procedures must be read and fully understood.
2012-07-22

Rear Quarter Glass Operating Mechanism
www.JagDocs.com
The coupe rear quarter glass is a fixed 4 mm, tempered, green-tinted unit direct glazed to the tonneau. The rear quarter glass of the convertible is 5 mm, tempered, semi-flush and green tinted. A drum and wire lowering and raising system provides automatic full glass drop when the top is lowered. Rear glass control is incorporated in the convertible top switch and operation of the rear quarters is as follows.
Raising with convertible top raised:

Activate by pressing and releasing the front of the switch.
Lowering with convertible top raised:

Press and release the rear part of the convertible top switch (one touch down). When lowering the rear quarters at vehicle speeds up to 16 km/h (10 mph), failure to release the switch on operation of the audible alarm will result in lowering of the top. Rear quarter glass is automatically powered to the bottom position when the top is lowered and further operation is inhibited until the top is raised and latched.
General Operation
The rear quarters are operated automatically up or down respectively when raising or lowering the convertible top. When the top is raised, with the door glass at the top of its travel, the glass will be powered down 12 mm and the rear quarters will be powered to the bottom of their travel. When the top is fully raised all glass will be powered up to close, forming a seal with the top. If the front glass has been either fully or partially lowered manually, the rear quarters only will be powered up. If the power supply to the driver or passenger door module is disconnected (battery disconnected, module unplugged or fuse removed) then the glass/system must re-learn the glass operating characteristics. The last known glass position is regarded as top of travel by one touch operation until re-learning has taken place. One touch down, manual up and down control and the automatic lowering of the glass for door opening are unaffected. To re-learn the glass operating characteristics, the associated door must be closed (door ajar switch inactive). The glass must then be driven fully down and held stalled at the bottom of its travel for a minimum of one second. The glass is finally driven to the fully up position and held stalled for a minimum of one second. The re-learning procedure must also be accomplished to regain the automatic glass closing sequence.
2012-07-22
Automatic Window Control Switch 86.65.97

Removal 1. Turn ignition key to position II. 2. Motor door glass to fully raised position. 3. Turn ignition key to position O. 4. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.15>>. 5. Remove door casing for access. Refer to <<76.34.01>>. 6. Remove door primary water shedder. Refer to <<76.58.07>>. 7. Position PVC secondary water shedder for access. 8. Remove door latch assembly from vehicle. Refer to <<86.65.16>>.
9. Slacken and remove latch assembly cover securing screw.
2012-07-22
10. Release cover to latch inner locating boss and remove cover.
www.JagDocs.com
11. Release door glass drop switch securing tangs and remove switch from latch assembly. 12. Remove and discard switch harness securing tape 13. Remove harness multiplug pin protector and using special tool MS.1540, release switch terminal pins from multipug.
Installation 1. Fit and fully seat switch terminal pins in harness multiplug and fit terminal pin protector.
2012-07-22
2. Fit door glass drop switch to latch assembly, ensuring that both tangs are fully seated. 3. Secure switch harness with suitable tape.
4. Fit cover to latch assembly. Position cover over latch assembly, ensuring that internal boss locates correctly in latch housing. Fit and tighten cover securing screw. 5. Fit latch assembly to door. Refer to <<86.65.16>>. 6. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
2012-07-22
Door Window Glass 76.31.01

Removal 1. With door open, turn ignition key to position II. 2. Motor door glass to fully raised position. 3. Turn ignition key to position O. 4. Remove battery cover and disconnect ground cable from battery terminal. 5. Remove door casing for access. Refer to <<76.34.01>>. 6. Remove speaker. Refer to <<86.50.13>>. 7. Remove main water shedder and position secondary shedder clear of regulator assembly. Refer to <<76.58.07>>.
www.JagDocs.com
8. Slacken and remove glass rear guide runner upper retaining screw.
2012-07-22
9. Slacken and remove rear guide runner lower adjuster and securing screws and position guide runner clear of glass guide. 10. Reconnect door glass operating switch. 11. Connect ground cable to battery terminal. Refer to <<86.15.15>>. 12. Motor door glass to 50mm from bottom position. 13. Remove ground cable from battery terminal. Refer to <<86.15.15>>. 14. Remove door inner waist seal. Refer to <<76.31.55>>. 15. Remove door outer waist rail moulding. Refer to <<76.43.04>>.
2012-07-22

16. Slacken and remove screw securing door glass guide to front guide runner retaining bracket and remove bracket.
www.JagDocs.com
17. Remove clips from nylon fixings and retain for re-use.
18. Release glass regulator assembly from nylon fixings.
2012-07-22
19. Lift glass upwards, tilt rear end outwards pass upwards between top adjuster screws and remove glass from door.
20. Remove nylon fixings from lower channel and refit clips to fixings.
2012-07-22

Installation
1. Lubricate glass lower channel and fit nylon fixings ensuring that looped ends of clips face outwards.
www.JagDocs.com
2. Position glass in door aperture and fit front guide onto guide runner.
2012-07-22
3. Check that the three buffers are fitted to outer waist reinforcer.
4. Fit and align glass front guide retaining bracket and tighten securing screw.
2012-07-22
5. Fit glass regulator assembly onto nylon fixings and fit and fully seat retaining clips. 6. Connect ground cable to battery terminal. Refer to <<86.15.15>>. 7. Motor glass to 25mm from fully raised position 8. Disconnect ground cable from battery terminal.
www.JagDocs.com
9. Fit rear guide runner to glass guide.
2012-07-22
10. Fit and tighten rear guide runner adjuster securing screws.
11. Fit and tighten rear guide runner upper securing screw ensuring that a clearance of 9mm is maintained between glass and outer waist rail flange inner face. 12. Fit ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>. 13. Motor glass to fully lowered position. 14. Disconnect and remove door switchpack. 15. Fit door outer waist rail moulding. Refer to <<76.43.04>>. 16. Fit door inner waist seal. Refer to <<76.31.55>>.
2012-07-22
17. Adjust door glass as required. Refer to <<76.31.03>>. 18. Fit speaker. Refer to <<86.50.13>>. 19. Fit secondary and main water shedders. Refer to <<76.58.07>> 20. Fit door casing. Refer to <<76.34.01>>.
www.JagDocs.com
2012-07-22
Door Window Glass Weatherstrip 76.31.55

Removal 1. Remove door casing for access. Refer to <<76.34.01>>.
2. Commencing at door release button recess, carefully use a thin blade to ease inner waist seal from rear of door waist flange. 3. Working from rear, and exercising care toavoid distortion, progressively remove seal from waist flange.
Installation
1. Ensure that top edge of PVC water shedder is correctly positioned on door waist flange.
2012-07-22
www.JagDocs.com
2. Commencing at front and ensuring that end of seal aligns with front of door waist flange,fit and fully seat seal on door. 3. Fit door casing. Refer to <<76.34.01>>.
2012-07-22
Door Window Glass Weatherstrip Vehicles With: Convertible Top 76.31.55

Removal 1. Partially lower convertible top.
2. Remove two screws securing front of seal to header rail.
3. Remove seal from carrier.
2012-07-22
4. Clean carrier seal locating channel and apply a thin film of Johnson KY Jelly or equivalent.
www.JagDocs.com
Installation 1. Install seal in carrier channel ensuring it is fully seated. 2. Install two screws securing front of seal to header rail 3. Fully raise convertible top and align seal to abut frame rear seal.
2012-07-22
Door Window Regulator Motor 86.25.57

Removal 1. With door open, turn ignition key to position II. 2. Motor door glass to fully lowered position. 3. Turn ignition key to position O. 4. Remove battery cover and disconnect ground cable from battery terminal. 5. Remove door casing for access. Refer to <<76.34.01>>. 6. Remove speaker. Refer to <<86.50.13>>. 7. Remove main water shedder and position secondary shedder clear of regulator assembly. Refer to <<76.58.07>>.
8. Remove clips from nylon fixings and retain for re-use.
2012-07-22
9. Release glass regulator assembly from nylon fixings.
www.JagDocs.com
10. Manually raise glass to uppermost position and using linen or similarly strong tape, secure glass to top of door.
2012-07-22
11. Accessing via speaker aperture, disconnect harness multiplug from lift motor.
12. NOTE: The position of this stud is critical to glass alignment and must be measured accurately. Using vernier calipers, measure position of regulator channel securing stud in elongated hole and slacken and remove nut.
2012-07-22
13. Slacken and remove screws securing lift motor to door.
www.JagDocs.com
14. Lower motor/regulator assembly into bottom of door and close scissor mechanism.
2012-07-22
15. Turning it to achieve clearance, withdraw motor/regulator assembly through door aperture.
16. Place assembly on bench, slacken and remove screws securing lift motor to regulator and remove motor.
Installation 1. Position lift motor on regulator assembly and fit and tighten securing screws. 2. Close scissor mechanism and pass assembly through aperture into door. 3. Position motor/regulator assembly in door.
2012-07-22
4. Fit but do not tighten motor to door securing screws and regulator channel securing nut.
www.JagDocs.com
5. NOTE: Accurate positioning of this stud is critical to glass alignment. Position regulator channel securing stud in elongated hole as measured during removal and fit and fully tighten securing nut. 6. Fully tighten motor to door securing screws. 7. Supporting door glass, remove linen tape and lower glass onto regulator assembly. 8. Press regulator ball joints into nylon seats on lower channel and fit retaining clips. 9. Connect harness multiplug to motor.
2012-07-22
10. Position speaker in door and connect harness multiplug. 11. Align speaker and new gasket in door and fit and tighten securing screws. 12. Fit door casing. Refer to <<76.34.01>>.
2012-07-22
Driver Door Window Control Switch 86.25.03

Removal 1. Remove battery cover and disconnect ground cable from battery terminal.
www.JagDocs.com
2. Remove glass lift switch. 1. Remove glass lift switch end cover trim pad. 2. Slacken and remove the switch securing screw. 3. Disconnect the switch harness multiplug.
4. If the switch is to be renewed, remove the veneer panel from clips.
2012-07-22
Installation 1. If switch has been renewed, fit and fully seat veneer panel in retaining clips.
2. Connect harness multiplug to switch. 1. Position glass lift switch in door. 2. Fit and tighten switch securing screw. 3. Fit and fully seat switch end cover trim pad. 3. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
2012-07-22
Passenger Door Window Control Switch 86.25.06

www.JagDocs.com
2. Remove glass lift switch. 1. Remove glass lift switch end cover trim pad. 2. Slacken and remove the switch securing screw. 3. Disconnect the switch harness multiplug.
4. If the switch is to be renewed, remove the veneer panel from clips.
2012-07-22
Installation 1. If switch has been renewed, fit and fully seat veneer panel in retaining clips. 2. Connect harness multiplug to switch.
3. Fit glass lift switch. 1. Position glass lift switch in door. 2. Fit and tighten switch securing screw. 3. Fit and fully seat switch end cover trim pad. 4. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
2012-07-22
Rear Quarter Window Glass 76.31.31

Removal 1. Remove rear seat cushion and squab. Refer to <<76.70.37>> and <<76.70.38>>. 2. Remove coat hanger hook. 3. Remove rear quarter casing. Refer to <<76.13.73>>. 4. Displace door aperture seal from B post seal carrier and drip rail seal carrier. Refer to <<76.40.30>>. 5. Remove rear quarter light finisher and drip rail seal carrier. Refer to <<76.43.81>>.
www.JagDocs.com
6. Slacken and remove three screws securing B post seal carrier to B post and remove carrier.
2012-07-22
7. Apply protective masking tape around quarter light aperture. 8. Prepare cheese wire and cutting handle. Position cutting handle central tube fully upwards in handle. Cut a suitable length of cheese wire and pass one end through handle tube and locating aperture. Move cutting handle central tube fully downwards to secure cheese wire.
9. NOTE: Penetrating the seal in the wrong position can result in contact with the glass to body mounting stud. Using a suitable long bladed tool, penetrate quarter light Betaseal at B post three inches from top of glass.
2012-07-22
10. Remove tool, pass free end of cheese wire through penetration and fit second cutting handle.
www.JagDocs.com
11. With assistance, use cheese wire to cut around the glass moving downwards then rearwards and exercising care to avoid damaging paintwork at the corners.
2012-07-22
12. Fit lifting handle to glass and ease upper edge away from aperture for access.
13. Supporting the glass, use a suitable cutter to sever remaining Betaseal. 14. Remove glass from aperture and place on clean cloth on bench. 15. Remove lifting handle. 16. Remove cheese wire cutting tool from vehicle, separate handles by moving centre tubes upwards and discard cheese wire. 17. Position a protective sheet inside the vehicle.
2012-07-22
18. Ensuring that the paintwork is not damaged, use a suitable vibroknife to remove residual sealant from body flange.
www.JagDocs.com
19. If original glass is to be refitted. Use masking tape to mark finisher retaining clip positions on outside of glass then remove and retain clips. Remove residual Betaseal using a suitable scraper. Clean glass using Betawipe and refit finisher retaining clips. Remove masking tape markers.
2012-07-22
20. If 3mm thick button or spacer block become detached, retain and refit before priming. When refitting spacing block, apply suitable adhesive and fit block to glass edge maintaining a 2mm clearance between glass and bottom of block groove.
Installation 1. Thoroughly clean glass and body aperture with Betawipe spirit.
2. Apply glass primer ensuring that it is taken right up to the radiused front edge.
2012-07-22
3. Position seal carrier on B post and fit and tighten securing screws.
www.JagDocs.com
4. Cut Betaseal cartridge nozzle to achieve a triangular section bead 8mm wide by 10mm high.
2012-07-22
5. Using a suitable pneumatic application gun, apply a uniform bead of sealant to the glass edge.
6. Fit lifting handle to glass. Align glass to body, ensuring that location stud engages in body clip and press glass firmly to fully seat. 7. Remove lifting handle, remove masking tape and clean off residual sealant using Betawipe spirit. 8. Fit quarter light finisher, maintaining 4mm clearance from waist seal finisher. Refer to <<76.43.81>>.
2012-07-22
www.JagDocs.com
9. Fit drip rail seal carrier. Position drip rail seal carrier pressing it back to abut the quarter light finisher. Loosely fit carrier securing screws then tighten them commencing from the rear.
10. Apply wet sealant behind finishers butt joint between the two adjacent screw locations. 11. Fit door aperture seal. Refer to <<76.40.30>>. 12. Remove protective sheet from interior. 13. Fit rear quarter casing. Refer to <<76.13.73>>. 14. Fit rear coat hanger hook. 15. Fit rear seat cushion and squab. Refer to <<76.70.37>> and <<76.70.38>>.
9 2012-07-22
Rear Quarter Window Glass Weatherstrip Vehicles With: Convertible Top 76.40.33
Removal 1. Fully lower converible top.
2. Remove rear quarter capping. 1. Remove fastener securing rear quarter capping to 'B' post extension. 2. Slacken and remove three screws securing the capping,
3. Remove seat belt upper mounting bolt. Remove seat belt upper mounting bolt cover. Remove seat belt upper mounting bolt. 4. Lift rear quarter capping clear and remove from vehicle.
2012-07-22
5. Remove four fir tree fasteners securing front of seal.
www.JagDocs.com
6. Remove screw securing rear of seal. 7. Clean seal carrier channel.
Installation 1. Apply a thin coat of Johnson KY Jelly or equivalent to carrier channel. 2. Install seal in carrier ensuring it is fully seated in channel. 3. Install fir tree fasteners at front of seal. 4. Install screw at rear of seal.
2 2012-07-22
5. Position rear quarter capping and install screws. 6. Install seat belt upper bolt and tighten to 34-46Nm. 7. Install cover over seat belt upper bolt.
2012-07-22
Rear Quarter Window Glass Lower Weatherstrip 76.40.32

www.JagDocs.com
Installation 1. Install seal in carrier channel ensuring it is fully seated. 2. Fully raise convertible top and align seal to abut frame rear seal.
2012-07-22
Rear Quarter Window Glass Upper Weatherstrip 76.40.31

Installation 1. Install seal in carrier channel ensuring it is fully seated. 2. Fully raise convertible top and align seal to abut adjacent seals.
2012-07-22
Rear Quarter Window Regulator Motor Vehicles With: Convertible Top 86.25.11
Removal 1. Fully raise adjacent door glass and open door. 2. Remove convertible top. refer to <<76.86.15>>. 3. Remove rear quarter glass inner seal. Refer to <<76.40.33>>.
www.JagDocs.com
4. Remove inner seal carrier rear screw.
5. Remove seal carrier front screw and remove carrier from vehicle.
2012-07-22
6. Remove quarter glass outer seal. Apply protective tape to rear fender along outer edge of seal. Exercising care to avoid damaging paintwork, use a thin blade over tape to remove seal from carrier.
7. Remove quarter glass outer seal carrier. Remove screws. Remove seal carrier from vehicle.
2012-07-22
8. Disconnect lift motor link lead from rear harness multiplug. 9. If earlier PVC water shedder is installed, route glass lift motor link lead through penetration and remove water shedder from body. 10. Connect a switched 12 volt supply to motor link lead connector and power glass to fully raised position. 11. Switch off 12 volt supply and disconnect from motor connector.
www.JagDocs.com
12. Remove three nuts securing glass lift motor/regulator assembly to body.
2012-07-22
13. Feeding link lead and multiplug through water shedder (later moulded type), withdraw motor/regulator adjusters from body and remove assembly.
Installation
1. Guiding link lead through water shedder (later type), lower motor/regulator assembly through upper aperture and locate adjusters in body apertures.
2012-07-22
2. Install but do not fully tighten locking/securing nuts on motor/regulator adjusters.
www.JagDocs.com
3. Install water shedder (early PVC type), routing motor link lead through penetration and leaving access for glass installation. 4. NOTE: Do not install speakers, rear quarter casing or rear seat at this stage Install and manually raise and latch convertible top assembly. Refer to <<76.86.15>>.
2012-07-22
5. Position inner seal carrier on vehicle and install front screw.
6. Install inner seal carrier rear screw.
2012-07-22
www.JagDocs.com
7. Install quarter glass outer seal carrier. Position seal carrier on vehicle. Install carrier screws. 8. Install rear quarter glass inner seal. Refer to <<76.40.33>>.
9. Install quarter glass outer seal. Exercising care to avoid damaging seal and paintwork, use a rubber faced hammer to install seal on carrier. Remove protective tape. 10. Connect switched 12 volt supply to rear quarter glass motor harness multiplug.
2012-07-22
11. Carefully motor rear quarter glass up to just contact top seal. 12. Carefully close adjacent door ensuring glass does not contact rear quarter glass.
13. Slacken lower adjuster locknut.
2012-07-22
www.JagDocs.com
14. Move rear quarter glass to achieve a parallel 15mm gap between front edge of rear quarter glass frame and rear edge of door glass. 15. Tighten lower adjuster locknut.
16. Slacken upper adjuster locknut.
2012-07-22
17. Turn upper adjuster to achieve lateral alignment of rear quarter glass upper edge with top seal. 18. Tighten upper adjuster locknut.
19. Slacken rear adjuster locknut.
10
2012-07-22
20. Turn rear adjuster to achieve lateral alignment of rear quarter glass rear edge with top seal. 21. Tighten rear locknut. 22. Fully raise rear quarter glass, check alignment with seals and adjust as necessary. 23. Disconnect 12 volt supply from rear quarter glass link lead multiplug. 24. Connect rear quarter glass motor link lead to harness multiplug. 25. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>. 26. Turn ignition key to II, fully lower and raise convertible top, turn ignition key to position O. 27. Check rear quarter glass alignment with top seal and re-adjust as necessary. 28. Turn ignition key to II, fully lower and raise convertible top, turn ignition key to position O. 29. Finally check rear quarter glass alignment with seals. 30. Install rear speaker assembly. Refer to <<86.50.12>>. 31. Install rear quarter casing. Refer to <<76.13.73>>. 32. Install rear quarter casing capping. Refer to 76.13.76. 33. Install rear seat cushion. Refer to <<76.70.37>>. 34. Install rear seat squab. Refer to <<76.70.38>>.
www.JagDocs.com
11
2012-07-22
Rear Window Glass Vehicles Without: Convertible Top 76.81.11

2. Using masking tape, mark top and bottom central positions of finisher on BIW. 3. Remove backlight finisher. Refer to <<76.43.46>>. 4. Remove rear seat cushion and squab. Refer to <<76.70.37>> and <<76.70.38>>. 5. Remove coat hanger hook. 6. Remove rear quarter casing. Refer to <<76.13.73>>. 7. Remove rear sub-woofer speaker cover. Refer to <<86.51.05>>. 8. Remove rear parcel shelf. Refer to <<76.67.06>>..
2012-07-22
9. Disconnect backlight heater connectors.
www.JagDocs.com
10. Disconnect alarm aerial connector from centre of backlight.
2012-07-22
11. If high level stop lamp is fitted, withdraw lamp cover from two clips on base assembly.
12. Disconnect and remove high level stop lamp. Disconnect harness connector from lamp. Lift lamp assembly clear of two retainers on backlight and remove lamp from vehicle.
2012-07-22
13. Apply protective masking tape around backlight aperture.
www.JagDocs.com
14. Use masking tape to mark the positions of the eighteen finisher securing clips then remove clips from glass.
2012-07-22
15. If original backlight is to be re-fitted, mark top and bottom central positions with masking tape to aid re-positioning. 16. Prepare cheese wire and cutting handle. 1. Position cutting handle central tube fully upwards in handle. 2. Cut a suitable length of cheese wire and pass one end through handle tube and locating aperture. 3. Move cutting handle central tube fully downwards to secure cheese wire
17. Using a suitable long bladed tool, penetrate backlight Betaseal at lower central position.
2012-07-22
18. Remove tool, pass free end of cheese wire through penetration and fit second cutting handle.
www.JagDocs.com
19. With assistance, use the cheese wire to cut around the backlight glass exercising particular care at the corners to avoid damage to paint
2012-07-22
20. Fit lifting handles to glass, carefully remove backlight from vehicle and place on clean cloth on bench. 21. Remove lifting handles from backlight glass. 22. Remove cheese wire cutting tool from vehicle, separate handles by moving centre tubes upwards and discard cheese wire.
23. Apply protective tape to glass aperture flange.
2012-07-22
24. Apply protective tape to rear edge of headlining. 25. Place protective sheet over parcel tray area.
www.JagDocs.com
26. Exercising care not to damage paintwork, use vibroknife to remove residual sealant from body flange. 27. Remove protective tape from glass aperture flange.
Installation
2012-07-22
1. If original backlight is to be refitted, remove residual sealant from glass mating surface using a suitable scraper.
2. Thoroughly clean mating surface using Betawipe spirit and fit finisher securing clips at positions marked by masking tape.
2012-07-22
www.JagDocs.com
3. To prevent sealant ingress into clips causing difficulty in subsequent removal of finisher apply masking tape to back of finisher.
4. Fit and fully seat finisher onto clips.
10
2012-07-22
5. If backlight is being renewed, fit lifting handles to glass, with assistance position it correctly in aperture and using masking tape, mark top and bottom central positions on glass and BIW. 6. Remove glass from vehicle, position on bench and remove lifting handles. 7. Clean glass mating edge and body aperture flange using Betawipe spirit.
8. Apply glass primer to mating area of glass.
11
2012-07-22
9. Cut Betaseal nozzle to achieve a triangular section bead 8mmwide by 10mm high.
www.JagDocs.com
10. Using a suitable pneumatic application gun, apply a uniform bead of sealant to the glass edge commencing at bottom center and overlapping the ends approximately 100mm.
12
2012-07-22
11. Fit lifting handles and with assistance, carefully align glass with body markings and press firmly into place. 12. Remove lifting handles. 13. Remove tape markers from glass. 14. Aligning central joints with tape markers on BIW, fit finisher to backlight. Refer to <<76.43.46>>. 15. Remove tape markers from BIW. 16. Remove protective sheet from rear parcel shelf area. 17. Remove protective tape from rear edge of headlining. 18. Connect alarm aerial and backlight connectors. 19. Fit and fully seat high level stop lamp on backlight retainers. 20. Fit harness connector to high level stop lamp and fit and fully seat cover onto lamp retaining clips. 21. Fit rear parcel shelf. Refer to <<76.67.06>>. 22. Fit sub-woofer speaker and cover. Refer to <<86.51.05>>. 23. Fit rear quarter casings. Refer to <<76.13.73>>. 24. Fit rear coat hanger hook.
13
2012-07-22
25. Fit rear seat squab and cushion. Refer to <<76.70.37>> and <<76.70.38>>. 26. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>. 27. Thoroughly clean backlight and surrounding area.
www.JagDocs.com
14
2012-07-22
Rear Window Glass Vehicles With: Convertible Top 76.81.11

Removal 1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 2. Remove rear seat cushion. Refer to <<76.70.37>>. 3. Remove rear seat squab. Refer to <<76.70.38>>. 4. Remove rear quarter cappings. 5. Remove rear quarter casings. Refer to <<76.13.73>>.
6. Disconnect harness connectors from backlight heater terminals. 7. Remove carpet from convertible top stowage compartment.
2012-07-22
www.JagDocs.com
8. Slacken and remove nuts securing squab panel stiffener bracket to BIW and remove bracket from vehicle.
9. Slacken and remove headlining rear header rail clip securing nuts, remove clips and release tension cables. 10. Exercising care to avoid damage to top, use a plastic or similarly soft lever to remove backlight seal.
2012-07-22
11. Apply masking tape around backlight aperture up to glass edge to protect top and liner. 12. Prepare cheese wire and cutting handle. Position cutting handle central tube fully upwards in handle. Pass one end of a length of cheese wire through handle tube and locating aperture. Move cutting handle central tube fully downwards to secure cheese wire.
13. Using a pointed tool, penetrate backlight Betaseal at lower central position, ensuring that contact is not made with fabric or glass.
2012-07-22
14. Remove tool, pass free end of cheese wire through penetration and fit secong cutting handle.
www.JagDocs.com
15. With assistance, use cheese wire to cut around the backlight glass, exercising particular care at corners to avoid damage to fabric and glass.
2012-07-22
16. Fit lifting handles to glass and with assistance, carefully remove backlight from vehicle and place on clean cloth on bench. 17. Remove lifting handles from backlight glass. 18. Remove cheese wire cutting tool from vehicle, separate handles by moving centre tubes upwards and discard cheese wire. 19. Exercising care to avoid damaging top, use a knife to remove residual Beatseal from sealing flange. 20. If original backlight is to be fitted, use a similar tool to remove residual Betaseal. 21. Remove protective masking tape from backlight aperture.
Installation 1. Fit and fully seat new rubber seal to backlight ensuring that joint is at bottom and central on glass. 2. Fit lifting handles to glass and with assistance, position it correctly in aperture and mark position with tape. 3. Remove glass from vehicle, position on bench and remove lifting handles. 4. Using Betawipe spirit, clean glass mating edge and body aperture flange.
2012-07-22
5. Apply glass primer to mating area of glass.
www.JagDocs.com
6. Cut Betaseal nozzle to achieve a triangular section bead 8mm wide by 10mm high.
7. Using a pneumatic gun, apply a uniform bead of sealant to the glass edge, commencing at bottom center and overlapping the ends approximately 100mm.
2012-07-22
8. Fit backlight to aperture. Fit lifting handles to glass and with assistance, carefully align backlight with tape markers on aperture. Press backlight firmly into place, ensuring that rubber seal seats correctly all the way round. 9. Remove lifting handles. 10. Remove tape markers. 11. Remove protective tape from interior. 12. Connect liner tension cables to outer securing brackets. 13. Position outer brackets to liner and body studs and fit and tighten bracket securing nuts. 14. Position inner brackets on liner and body studs and fit and tighten bracket securing nuts. 15. Position stiffener bracket on rear bulkhead and fit and tighten securing bolts. 16. Fit carpet to convertible top stowage compartment. 17. Connect heater harness connectors to backlight terminals. 18. Connect security system aerial to backlight terminal. 19. Fit rear quarter casings. Refer to <<76.13.73>>. 20. Fit rear quarter cappings. 21. Fit rear seat squab. Refer to <<76.70.38>>.
2012-07-22
22. Fit rear seat cushion. Refer to <<76.70.37>>. 23. Connect ground cable to battery terminal and fit battery terminal. Refer to <<86.15.15>>. 24. Clean backlight and surrounding area.
www.JagDocs.com
2012-07-22
Windshield Glass 76.81.40

Cheese Wire Handles and Cheese Wire 42-001A and 42-001A-01 Removal 1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>> 2. Remove interior mirror. Refer to <<76.10.51>> or <<76.10.56>>. 3. Remove wiper arm and blade assembly. Refer to 84.15.44.90. 4. Remove plenum chamber cover. Refer to Section <<76.10.01>>.
5. If heated windshield is fitted: Disconnect LH power supply cable from connector located on secondary bulkhead.
2012-07-22
www.JagDocs.com
6. If heated windshield is fitted: Disconnect RH power supply cable from connector located on secondary bulkhead.
7. Slacken and remove RH water deflector securing bolt and remove deflector.
2012-07-22
8. Slacken and remove LH water deflector securing bolt and remove deflector. 9. Remove windshield finisher. Refer to <<76.43.40>>. 10. Marking the positions with masking tape, remove windshield finisher securing clips from edge of glass.
11. Remove each A post upper trim by carefully easing the three spring clips free. 12. Remove roof console. Refer to <<76.13.69>>. 13. Remove sun visors. Refer to 76.10.47.
2012-07-22
14. Apply suitable protective tape around windshield aperture to protect paintwork.
www.JagDocs.com
15. Apply suitable protective tape around leading edge of headlining. 16. Prepare cheese wire and cutting handle. Position cutting handle central tube fully upwards in handle. Cut a suitable length of cheese wire 42-001A-01 and pass one end through handle tube and locating aperture. Move cutting handle central tube downwards to secure cheese wire.
2012-07-22
17. Using a suitable long bladed tool, penetrate Betaseal approximately 6in (150mm) from top of one A post.
18. Remove tool, pass free end of cheese wire through penetration and fit second cutting handle. 19. Place a suitable protective sheet over fascia and place a protecting board over sheet.
2012-07-22
20. With assistance and exercising care at corners to avoid damaging paintwork, cut around windshield commencing downwards and along the bottom.
www.JagDocs.com
21. Fit lifting handles to glass and with assistance lift windshield clear of vehicle and place on cloth covered bench. 22. Remove lifting handles from glass. 23. Remove cheesewire cutter from windshield aperture, remove cutting handles and discard cheesewire. 24. Remove protective board from fascia, leaving protective sheet in position.
2012-07-22
25. Exercising care not to damage paintwork, use vibroknife to remove residual sealant from body flange. 26. Remove protective cloth from fascia. 27. Remove protective tape from windshield aperture flange.
Installation
1. If original windshield is to be refitted: Remove residual sealant from glass mating surface using a suitable scraper. Check installation of the two spacer buttons at bottom of glass and replace if they are damaged or missing.
2012-07-22
2. Thoroughly clean surface using Betawipe spirit, fit finisher securing clips at positions marked and remove masking tape. 3. Fit and fully seat finisher to windshield. Refer to 76.43.42.
www.JagDocs.com
4. To prevent sealant ingress into clips causing difficulty in subsequent removal of finisher, apply masking tape to back of finisher.
2012-07-22
5. Fit lifting handles to glass and with assistance, correctly position windshield in body aperture and mark position with masking tape. 6. With assistance, remove windshield from vehicle and place on cloth covered bench. 7. Remove lifting handles and position glass outer face downwards. 8. Thoroughly clean glass edge and aperture flange with Betawipe spirit.
9. Apply glass primer to mating face of windshield.
2012-07-22
10. Cut Betaseal nozzle to achieve a triangular section bead 8mm wide by 10mm high.
www.JagDocs.com
11. Using a suitable pneumatic application gun, apply a uniform bead of sealant to the glass edge commencing at bottom center and overlapping the ends approximately 100mm.
10
2012-07-22
12. Fit lifting handles and with assistance, carefully position windshield in aperture aligning glass with body markings and press firmly into place. 13. Remove lifting handles. 14. Remove tape marking windshield position. 15. Remove protective tape from leading edge of headlining. 16. Fit interior rear view mirror. Refer to <<76.10.51>>. 17. Fit sun visors. Refer to 76.10.47. 18. Fit roof console. Refer to Section <<76.13.69>>. 19. Install LH and RH water deflectors and fit and tighten securing bolts. 20. Fit plenum chamber cover. Refer to <<76.10.01>>. 21. Fit Wiper arms. Refer to 84.15.44.90.
11
2012-07-22
22. If heated windshield is fitted, connect LH power supply cable to connector on secondary bulkhead.
www.JagDocs.com
23. If heated windshield is fitted, connect RH power supply cable to connector on secondary bulkhead. 24. Thoroughly clean exterior and interior of windshield. 25. Connect ground cable to battery terminal and fit battery cover. Refer to Section <<86.15.15>>.
12
2012-07-22
Windshield Moulding 76.43.40

Removal 1. Remove wiper arm and blade assembly. Refer to 84.15.44.90. 2. Remove plenum cover. Refer to <<76.10.01>>. 3. Using a trim removal tool, carefully release windshield finisher from upper joint retaining clip.
4. Carefully release finisher from remaining retaining clips on 'A' post. 5. Clean mating surface of windshield. 6. If original finisher is to be re-fitted, clean mating surface.
Installation 1. Position finisher at 'A' post and press firmly to fully seat in retaining clips 2. Fit finisher to upper joint retaining clip. 3. Fit plenum cover. Refer to <<76.10.01>>. 4. Fit wiper arm and blade assembly. Refer to 84.15.44.90.
2012-07-22
1999 XK RANGE - Instrument Panel and Console - 501-12
Torques Component Fascia lower mounting bracket to fascia centre panel. Fascia lower mounting bracket to BIW. Airbag carrier platform to airbag support strut. Airbag support strut to BIW. Support reinforcement bracket to BIW tunnel. Fascia inner panels to support reinforcement bracket. Fascia top roll duct to BIW. Fascia end panel to BIW. Driver side lower rail. Airbag ECU to fascia. Fascia to A pillar ground connection. Driver's underscuttle to fascia. Nm 17-23 7-10 7-10 17-23 7-10 17-23 7-10 17-23 7-10 10.5-13.5 14-18 7-10
www.JagDocs.com
2012-07-22
Instrument Panel and Instrument Panel Console
Instrument Panel
The full-width, moulded PVC instrument panel is located by a dowel at each 'A' post and secured by bolts at the bulkhead and 'A' posts. Faced with maple or walnut burr veneer, the panel accepts two separate instrument clusters, one containing four major instruments, the other containing three auxiliary instruments. The major instrument cluster is situated directly ahead of driver, whilst the auxiliary cluster is located inboard from the driver, above the center console.
Center Console
2012-07-22
The center console is an injection moulded armature trimmed in matching ambla with maple or burr walnut veneer top finisher. A lined stowage tray/pen holder is incorporated forward of the 'J' gate and an illuminated smoker's compendium with press and release lid is fitted at the rear of the ' J' gate. The rear section of the console forms a deep stowage box with rear hinged lid which is padded to form a central arm rest. A hinged cup holder is incorporated in the front end of the stowage box lid. A color-keyed 'J' gate surround surmounts the veneer top finisher and the 'SPORT' mode selector switch is situated immediately to the rear of the 'J' gate. Two tongues at the front of the console locate in slots in the lower fascia, and the center and rear of the console are secured by screws to floor brackets.
www.JagDocs.com
2012-07-22
Audio Unit Housing 76.25.15

Removal 1. Remove battery cover and disconnect earth lead from terminal. Refer to <<86.15.15>>. 2. Remove 'J' gate surround. Refer to <<76.25.24>>. 3. Remove center console assembly for access. Refer to operations in this section.
4. Slacken and remove the six radio console securing screws and partially withdraw the console for access.
5. Disconnect radio assembly. Disconnect console harness multiplugs and aerial co-axial connector.
2012-07-22

Slacken and remove nut securing earth lead to radio and remove lead from stud. Disconnect radio harness multiplug and position harness clear of center console.
www.JagDocs.com
6. Remove radio. 1. Withdraw radio console, remove radio from console and remove radio retaining plate.
7. Remove air conditioning control module. Slacken and remove the three air conditioning control module securing screws and remove the module.
2012-07-22
8. Remove center console switch module. Releasing end locaters, lightly press switch module out of console. 9. Remove radio console from vehicle.
Installation 1. Connect aerial co-axial lead to radio and stow excess harness and lead lengths in radio mounting aperture. 2. Fully seat radio in console, ensuring that harnesses and leads do not obstruct. 3. Position and locate switch module in console. 4. Position the air conditioning control module in the console and fit and tighten the three securing screws. 5. Fit radio retaining plate on the console. 6. Holding radio console in position, route radio harness multiplugs into center console. 7. Connect radio harness and radio console harness multiplugs. 8. Route earth and aerial leads through radio console. 9. Finally position radio console and fit and tighten the six securing screws. 10. Fit earth lead to the radio stud and fit and tighten securing nut. 11. Connect aerial lead to radio. 12. Ensuring harness and leads do not obstruct, push radio fully home.
2012-07-22
13. Fit center console. Refer to <<76.25.01>>. 14. Fit 'J' gate surround. Refer to <<76.25.24>>. 15. Connect earth cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
www.JagDocs.com
2012-07-22
Floor Console 76.25.01

Removal 1. Position gear selector and passenger seat for access. Turn ignition key to position II. Apply footbrake and move gear selector to 'D'. Release footbrake. Power passenger seat to fully forward position and tilt squab forward. Turn ignition key to O. 2. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 3. Remove 'J' gate surround. Refer to <<76.25.24>>.
4. Slacken and remove the four center console veneer panel securing screws and remove the mounting plates.
2012-07-22
5. Position the veneer panel for access and disconnect the panel switch multiplugs.
www.JagDocs.com
6. Remove console end trim cover and slacken and remove the two rear securing bolts.
2012-07-22
7. Slacken and remove the two forward securing bolts.
8. Position console for access, disconnect cigar lighter and valet switch harness multiplugs, lift console clear of 'J' gate and remove from vehicle.
Installation 1. Install and connect center console. Position console for access. Connect valet switch and cigar lighter harness multiplugs. Finally position console. Fit and tighten forward securing bolts. Fit and tighten rear securing bolts. Fit and fully seat console rear trim cover.
2012-07-22

Position veneer panel for access and connect panel switch harness multiplugs. Reposition and seat veneer panel. Align and fit panel mounting brackets. Fit and tighten panel securing screws. Fit 'J' gate surround. Refer to <<76.25.24>>. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
www.JagDocs.com
2012-07-22
Floor Console Ashtray 76.25.25

Removal 1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 2. Remove center console for access. Refer to operations in this section. 3. Open ashtray lid and remove cigar lighter.
4. Remove cigar lighter housing. Remove tape securing harness to console underside.. Slacken and remove retaining ring from underside and remove housing complete with cable. 5. Release bulb housing tangs and withdraw bulb and housing from underside complete with flying lead.
2012-07-22
www.JagDocs.com
6. Position console for access, slacken and remove the four ashtray securing screws and remove ashtray from console.
Installation 1. Position ashtray on center console. 2. Fit and tighten the four ashtray securing screws. 3. Fit and fully seat cigar lighter housing in ashtray and fit and tighten retaining ring. 4. Fit cigar lighter housing and illumination bulb. 5. Tape cables to underside of console. 6. Fit cigar lighter in housing. 7. Close ashtray lid. 8. Fit center console assembly. Refer to 76.. 9. Connect multiplug at rear of centre console. 10. Fit centre console rear air distribution control grill. 11. Connect earth cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
2012-07-22
Floor Console Finish Panel 76.47.26

Removal 1. Apply handbrake and turn ignition key to II. 2. Depress brake pedal, move gear selector to position N and turn ignition key to O. 3. Remove battery cover and disconnect ground cable from battery terminal.
4. Remove gear selector surround finisher. Refer to <<76.25.24>>
5. Remove Sport mode and Cruise Control switches from surround finisher.
2012-07-22
www.JagDocs.com
6. Slacken and remove the four screws securing the two console veneer panel clamp plates and remove the clamp plates.
7. Withdraw veneer panel, passing switches through the aperture. On the convertible model, disconnect the roof operating switch harness multiplug.
2012-07-22
8. Remove oddments tray and remove veneer panel from console.
Installation 1. Position veneer panel on console. 2. Fit and fully seat oddments tray. 3. On convertible model, connect roof switch harness multiplug. 4. Route Sport mode and Cruise Control switches through panel aperture. 5. Fully seat veneer panel on console. 6. Position veneer panel clamp plates and fit and tighten securing screws. 7. Position gear selector surround finisher. 8. Fit and fully seat Sport mode and Cruise Control switches in finisher. 9. Finally fit gear selector surround finisher. 10. Move gear selector to position P. 11. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
2012-07-22
Floor Console Stowage Compartment 76.25.16

Removal
www.JagDocs.com
1. Remove glove box lid stay. Open glove box lid, slacken and remove the lid stay securing screw and remove lid stay.
2. Slacken and remove latch securing screws and remove latch assembly.
2012-07-22
3. Slacken and remove liner rear securing screws and remove liner.
Installation 1. Fit center console glove box. Position glove box liner in console. Fit and tighten liner rear securing screws. Position latch assembly on liner and fit and tighten securing screws. Fit lid stay, position lid to stay and fit and tighten securing screw. Close glove box lid.
2012-07-22
Floor Console Stowage Compartment Lid 76.25.18

Removal 1. Open glovebox lid.
www.JagDocs.com
2. Slacken and remove lid stay securing screw and remove stay from lid.
3. Slacken and remove glovebox latch securing screws and remove latch from glovebox.
2012-07-22
4. Slacken and remove glovebox liner rear securing screws and remove liner for access.
5. Slacken and remove remaining glovebox hinge securing screw. 6. Slacken and remove screws securing hinge to lid and remove hinge.
Installation 1. Position hinge on console lid and fit and tighten securing screws. 2. Position glovebox lid on centre console and fit and tighten securing screw. 3. Fully seat liner in centre console and fit and tighten rear securing screws. 4. Fit glovebox latch to liner and fit and tighten securing screws. 5. Position glovebox to lid stay, fit and tighten securing screw and close glovebox lid.
2012-07-22
Glove Compartment 76.52.03

Removal
www.JagDocs.com
1. Open glove box lid and slacken and remove four screws securing liner to the fascia.
2. NOTE: Do not disturb the two inner screws as these are for glovebox alignment only. Slacken and remove two outer screws securing glovebox to cross-member. Withdraw liner tangs and dowels from cross-member and separate liner. 3. Position glove box for access, disconnect footwell and glovebox lamp multiplugs and withdraw the glove box assembly.
2012-07-22
Installation 1. Position glovebox at fascia cross-member and connect footwell and glovebox lamp multiplugs. 2. Locating plastic dowels in apertures, seat glovebox on cross-member. 3. Install but do not fully tighten lower securing screws. 4. Install but do not fully tighten glovebox upper securing screws. 5. Carefully close glovebox lid and align assembly with fascia. 6. Fully tighten all glovebox securing screws.
2012-07-22
Glove Compartment Lid 76.52.02

Removal 1. Remove glovebox from fascia. Refer to <<76.52.03>>
www.JagDocs.com
2. Move the glove box lid damper cord forward to release clip from lid. 3. Remove glove box liner from lid. 4. Slacken and remove the four hinge securing nuts. 5. Carefully withdraw the lid. 6. Remove the hinges.
Installation 1. Position glove box lid and secure to hinges with four screws. 2. Fit damper cord mounting clip. 3. Position glovebox and connect footwell and glovebox lamp multiplugs. 4. Fit liner and secure top to fascia with four screws. 5. Close glove box lid. 6. Fit and tighten screws securing bottom of glovebox to lower fascia. 7. Slacken two inner screws at bottom of glovebox, adjust alignment of glovebox lid to liner and re-tighten 1 2012-07-22 screws.
Instrument Cluster Finish Panel 76.47.24

Removal 1. Remove driver side underscuttle. Refer to <<76.46.11>>. 2. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
3. Slacken and remove the two veneer panel securing screws.
4. Withdraw veneer panel from fascia upper locating slots and disconnect trip computer switch multiplug.
2012-07-22
5. Position veneer panel for access and remove trip computer switch. 6. Slacken and remove instrument panel surround securing nuts and remove surround from veneer panel.
www.JagDocs.com
Installation 1. Align instrument surround with veneer panel and fit and tighten securing nuts. 2. Fit and fully seat trip computer switch in panel. 3. Position panel at fascia and connect trip computer switch harness multiplug. 4. Engage panel lugs in fascia upper slots and fit and tighten lower securing screws. 5. Fit driver side underscuttle. Refer to <<76.46.11>>. 6. Fit ground cable onto battery terminal and fit battery cover. Refer to <<86.15.15>>.
2012-07-22
Instrument Panel 76.46.01

Removal 1. Remove battery cover and disconnect earth lead from terminal. Refer to <<86.15.15>>. 2. Remove glove box. Refer to <<76.52.02>>. 3. Remove under-scuttle. Refer to <<76.46.11>>. 4. Remove 'J' gate surround for access. Refer to <<76.25.24>>. 5. Remove center console assembly. Refer to <<76.25.01>>. 6. Remove radio console. Refer to <<76.25.15>>. 7. Remove driver's air bag module. Refer to <<76.73.39>>. 8. Remove steering wheel. Refer to <<57.60.01>>. 9. Remove steering column upper and lower cowls. Refer to <<76.46.03>>. 10. Remove front seats. Refer to 76.70.01.90.
11. Disconnect 'J' gate and gearshift interlock solenoid harness multiplugs.
2012-07-22
www.JagDocs.com
12. Detach and position 'J' gate for access. Remove four nuts securing the 'J' gate assembly to the transmission tunnel. Position 'J' gate assembly for access.
13. Remove fascia to tunnel securing nuts and bolts. 1. Remove two nuts and one bolt securing each fascia to transmission tunnel side bracket and remove brackets. 2. Remove two nuts securing fascia central bracket to transmission tunnel. 14. Remove left-hand 'A' post lower trim pad. Refer to <<76.13.30>>.
2012-07-22
15. Disconnect fascia harness multiplug connectors at left-hand 'A' post. 1. Detach three fascia harness multiplugs from mounting bracket and disconnect and position them clear of obstructions ready for fascia removal. 2. Detach spare multiplug from mounting bracket and position clear of obstructions.
16. Disconnect cables from left-hand side of fascia. 1. Remove 'A' post earth cable securing nut and remove cable eyelets from stud. 2. Remove two nuts securing hood release lever assembly to fascia studs and position lever assembly and cable clear of fascia.
2012-07-22
www.JagDocs.com
17. Remove two bolts securing fascia to left-hand 'A' post.
18. Disconnect steering column left-hand harness. 1. Detach the four harness rear multiplugs from mounting bracket and disconnect multiplugs. 2. Disconnect the front multiplug and position connector clear of bracket.
2012-07-22
19. Disconnect steering column right-hand harness. Detach the two harness multiplugs from mounting bracket and disconnect them. 20. Ensure all column to fascia multiplugs are clear of projections.
21. Remove footwell lamp mounting bracket. Remove two screws securing the footwell lamp mounting bracket to the air conditioning duct and remove bracket.
2012-07-22
www.JagDocs.com
22. Position steering column for access. 1. Remove the steering column upper mounting bracket securing nuts. Move column down from mounting bracket and reposition for access. 23. Remove right-hand 'A' post lower trim pad. Refer to <<76.13.30>>.
24. Disconnect right-hand 'A' post earth cable. At right-hand 'A' post remove the earth cable securing nut and disconnect cable from the stud.
2012-07-22
25. Disconnect multiplugs at right-hand 'A' post. Detach five fascia harness multiplugs from mounting bracket and disconnect and position them clear of projections.
26. Disconnect RH fuse box power cable. 1. Remove cover from fascia right-hand fuse box and remove nut securing power cable to fuse box. Disconnect power cable and position clear of projections on fascia.
2012-07-22
www.JagDocs.com
27. Remove two bolts securing fascia to right-hand 'A' post.
28. Remove fascia speakers and central trim cover. Remove fascia speaker covers and disconnect speaker harness multiplugs, remove speakers from fascia and place in protective area.
2012-07-22
29. Remove solar sensor from fascia. 1. Ensuring that the fascia is protected, carefully prise the sensor upwards. 2. Disconnect the sensor harness multiplug, remove sensor unit from the fascia and place in protective area.
30. Remove the three screws securing upper fascia to bulkhead.
2012-07-22
www.JagDocs.com
31. Disconnect left-hand harness at center console rear mounting bracket. 1. Detach spare central left multiplug from mounting and position clear of bracket. 2. Disconnect the three remaining left-hand harness multiplugs.
32. Disconnect right-hand harness multiplugs at center console rear mounting bracket. 1. Disconnect the three right-hand harness multiplugs and position clear of bracket. 2. Remove two rubber straps securing harnesses to tunnel.
10
2012-07-22
33. Position 'J' gate for access. Release stud and strap securing gear selector cable to tunnel and position 'J' gate for fascia removal.
34. Detach harness from left-hand side of tunnel. 1. Fold back carpet from left-hand side of tunnel for access and cut through strap securing harness to ICE cable. 2. Release two fasteners securing harness to left-hand side of tunnel.
11
2012-07-22
www.JagDocs.com
35. Detach harness from right-hand side of tunnel. Fold back carpet from right-hand side of tunnel for access and release three fasteners securing harness to side of tunnel.
36. Via glove box aperture, remove two bolts securing fascia to bulkhead mounting bracket.
12
2012-07-22
37.
CAUTION: The treadplate finishers, can easily be deformed or otherwise damaged during removal.
Remove door sill treadplates. 1. Using a suitable thin 1 inch wide scraper, carefully lift the inscribed finisher. 2. Remove the treadplate retaining screws and remove the treadplate. 3. Repeat procedure to remove opposite side treadplate.
38. Exercising care, use a thin blade to release driver footrest tangs and spigots from mounting plate.
13
2012-07-22
39. Remove footrest mounting plate securing bolts and remove mounting from vehicle.
www.JagDocs.com
40. Remove toeboard fastener.
14
2012-07-22
41. Release carpet from around kickdown switch and toeboard area.
42. Remove and discard fastener securing carpet at fascia/console area. 43. Remove handbrake lever trim and ensure that lever is left in fully upright position. Refer to <<76.13.63>>.
15
2012-07-22
44. Withdraw draught welt and release carpet retaining clips from driver door aperture flange.
www.JagDocs.com
45. Remove 1/4 turn fastener from passenger side toeboard.
16
2012-07-22
46. Remove and discard fastener on passenger side fascia/console area.
47. Withdraw draught welt and release carpet retaining clips from passenger door aperture flange. 48. At each side, lift carpet and fold to rear quarters.
17
2012-07-22
www.JagDocs.com
49. Disconnect handbrake switch harness multiplug.
50. Detach seat harness and disconnect earth cable. 1. Release fasteners securing seat harness to floor. 2. Remove nut securing the earth cable eyelet to the floor stud and remove cable from stud.
18
2012-07-22
51. At each side of tunnel, remove nut securing fascia harness earth cables and remove earth eyelets from studs.
52. Remove fascia from vehicle. 1. Withdraw harnesses from each side of tunnel and coil and strap them to the ICE console mounting bracket. 2. With assistance, carefully withdraw the fascia rearwards off the support dowels, guiding the power cable through the right-hand fuse box.
Installation 1. With assistance, align the fascia with the support dowels and position the earth cable in the right-hand fuse box.
19
2012-07-22
www.JagDocs.com
2. With assistance, ensuring multiplugs and harnesses are not trapped or obstructed, carefully press fascia forward squarely onto dowels.
3. Install three screws securing upper fascia to the bulkhead.
20
2012-07-22
4. Via glove box aperture, install two bolts securing fascia to bulkhead mounting bracket. 5. Install four bolts securing fascia to 'A' posts. 6. Install fascia harnesses on tunnel. Remove strapping temporarily securing harnesses to fascia center bracket. Route harnesses rearwards along respective sides of tunnel. Connect harness earth cable eyelets to tunnel studs and install eyelet securing nuts. 7. At left-hand side of tunnel, install new tie strap to secure ICE cable to harness. 8. Install seat harnesses. Route seat harnesses to their respective positions. Connect harness earth eyelets to floor studs and install earth securing nuts. 9. Install fasteners securing fascia and seat harnesses on tunnel and floor. 10. Connect handbrake switch harness multiplug. 11. Position and fit carpets. Roll carpets forward into position. Install handbrake trim cover. Secure trim cover fastener. Position carpet at each toeboard. Install clips securing carpet at door apertures. Install new carpet fasteners at toe-board and tunnel locations. Install driver footrest. 12. Install draught welts and treadplates. Press draught welt onto door aperture flange. Align treadplate on door sill and fit and tighten four treadplate securing screws. Ensure treadplate is clean and dry.
21
2012-07-22

If treadplate finisher is being renewed, peel protective backing from adhesive. Align finisher and press firmly into place. Repeat procedure to install opposite side draught welt and treadplate.
www.JagDocs.com
13. Position 'J' gate and fit selector cable securing strap and stud to tunnel.
14. Install fascia harness multiplugs at center console rear mounting bracket. 1. Install spare connector at center left-hand position. 2. Connect the six fascia harness multiplugs.
22
2012-07-22
15. Install solar sensor and speakers to fascia. 1. Connect solar sensor to fascia harness multiplug and carefully install sensor in fascia. 2. Connect speakers to ICE harness multiplugs and install speakers in fascia.
16. Connect power cable to fascia. 1. At right-hand fuse box, position power cable eyelet on fuse box stud and fit and install cable securing nut. Install fuse box cover. 17. Connect right-hand'A' post multiplugs and earth cable. At right-hand lower 'A' post, connect fascia harness and PI harness multiplugs and install multiplugs on mounting brackets. Position PI harness earth cable eyelet on body stud and install securing nut. 18. Install steering column. Position steering column in mounting bracket. Position yoke on bracket studs and install securing nuts.
23
2012-07-22
19. Position footwell lamp mounting bracket and secure with screws to air conditioning duct. 20. Connect steering column switch gear harness and column harness. Connect steering column switchgear harness and column harness multiplugs and install multiplugs on mounting bracket. 21. Position bonnet release lever assembly on 'A' post studs and install securing nuts. 22. Position fascia harness earth cable eyelets on 'A' post stud and fit and install securing nut. 23. Install spare harness multiplug on mounting bracket. 24. Install multiplugs at left-hand 'A' post. Connect the three fascia harness multiplugs and position on mounting bracket. Install spare multiplug on upper bracket.
www.JagDocs.com
25. Install two bolts securing fascia center bracket to the transmission tunnel.
24
2012-07-22
26. Position fascia to transmission tunnel side brackets and install retaining bolts. 27. Position 'J' gate and install four securing nuts.
28. Connect the 'J' gate harness and gearshift solenoid harness multiplugs. 29. Install center console assembly. Refer to procedures in this section. 30. Install front seats. Refer to 76.70.01.90. 31. Install 'A' post trim pads. Refer to <<76.13.30>>. 32. Install steering column cowls. Refer to <<76.46.03>>.
25
2012-07-22
33. Install steering wheel. Refer to <<57.60.01>>. 34. Install driver's air bag. Refer to <<76.73.39>>. 35. Install radio console. Refer to <<76.25.15>> 36. Install 'J' gate surround. Refer to <<76.25.24>>. 37. Install dash liner. Refer to 76.46.01.90 . 38. Install glove box. Refer to <<76.52.02>>. 39. Connect earth cable to battery terminal and install battery cover. Refer to <<86.15.15>>. 40. Remove protective film from renewed treadplate finishers.
www.JagDocs.com
26
2012-07-22
Instrument Panel Finish Panel 76.47.06

Removal 1. WARNING: FOLLOWING REMOVAL OF THE PASSENGER AIR BAG DEPLOYMENT DOOR, NEW RETAINING CLIPS MUST ALWAYS BE FITTED.
Open Glovebox lid. 2. Withdraw passenger airbag deployment door for access. Refer to <<76.73.37>>.
3. Using a thin plastic lever, carefully release centre vent veneer panel tangs from fascia clips.
4. Remove and discard centre vent veneer panel securing clips.
2012-07-22
Installation 1. Fit and fully seat new veneer panel securing clips in fascia.
2.
WARNING: NEW PASSENGER AIR BAG DEPLOYMENT DOOR, RETAINING CLIPS MUST ALWAYS BE FITTED.
Fit and fully seat veneer panel in securing clips. 3. Fit passenger air bag deployment door. Refer to <<76.73.37>>. 4. Close glovebox lid.
www.JagDocs.com
2012-07-22
Instrument Panel Lower Trim Panel 76.46.11

Removal 1. Remove battery cover and disconnect earth lead from terminal.
2. Slacken and remove the two screws securing the lower underscuttle to the fascia panel cross-member.
3. Withdraw the underscuttle upper fasteners from their locations in the fascia panel. 4. Position the underscuttle rearwards for access.
2012-07-22
www.JagDocs.com
5. Disconnect harness multiplugs and reposition underscuttle. 1. Disconnect air conditioning aspirator harness multiplug. 2. Disconnect valet switch harness multiplug.
6. Remove stowage compartment lid. 1. Position underscuttle for access. 2. Slacken and remove two screws securing the stowage compartment lid to the underscuttle and remove the lid.
2012-07-22
7. Release the valet switch securing tangs and remove the switch.
8. Remove air conditioning aspirator. 1. Slacken and remove the two nuts securing the air conditioning aspirator mounting bracket to the vent and remove the aspirator.
2012-07-22
www.JagDocs.com
9. Release the aspirator vent securing tangs and remove the vent from the underscuttle. 10. Remove the underscuttle from the vehicle.
Installation 1. Fit components to underscuttle. Fit and fully seat air conditioning aspirator vents to underscuttle. Fit and fully seat aspirator mounting bracket onto vent studs and fit and tighten bracket securing nuts. Fit stowage compartment lid and fit and tighten securing screws. 2. Fit underscuttle to vehicle. Position underscuttle below fascia. Connect valet switch, and air conditioning aspirator harness multiplugs. Position underscuttle and seat upper fasteners. Position underscuttle on lower cross-member and fit and tighten the two securing screws. 3. Connect battery earth lead and fit battery cover. Refer to <<86.15.15>>.
2012-07-22
Overhead Console 76.13.69

2. Commencing at rear and exercising care to avoid damaging headlining, use a thin plastic lever to release the three spring clips securing console to roof.
3. Disconnect roof console harness connector and remove console from vehicle.
2012-07-22
www.JagDocs.com
4. NOTE: The only serviceable item in the roof console is the garage door remote switch fitted for certain markets. Both types of console are supplied as complete assemblies. Remove three screws and release strap securing switch assembly to roof console.
5. Disconnect switch harness connector and remove switch assembly from console.
Installation 1. Position garage door remote switch on console and connect harness connector. 2. Install but do not tighten switch front securing screw. 3. Install securing strap and screws.
2012-07-22
4. Install all switch securing screws. 5. Position console at roof and connect harness connector. 6. Ensuring harness is correctly positioned, press console firmly upwards to fully seat spring clips. 7. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>
2012-07-22
Rear Cup Holder 76.25.27

Removal 1. Open centre console glove box lid.
www.JagDocs.com
2. Slacken and remove screw securing check arm to glovebox lid.
3. Slacken and remove two screws securing glove box lid to console and remove lid from console. 4. Operate latch to release the cup holder lid.
2012-07-22
5. Slacken and remove the ten screws securing inner finisher to glovebox lid. 6. Remove inner finisher and hinge from glove box lid.
7. Slacken and remove cup holder latch securing screw and remove latch assembly.
2012-07-22
8. Open cupholder, depress tang each side of latch location and withdraw cupholder assembly. from base.
www.JagDocs.com
9. Slacken and remove the five cup holder lid trim panel securing screws and remove panel from lid by releasing lower edge and withdrawing upwards.
Installation 1. Fit and fully seat trim panel to cup holder lid ensuring that panel hook engages lid and panel engages lid damper wire. 2. Fit and tighten screws securing trim panel to cup holder lid. 3. Fit and fully seat cupholder and trim panel assembly to glove box lid. 4. Position cup holder latch and fit and tighten securing screw.
2012-07-22
5. Fit hinge to glove box lid. 6. Fit and fully seat inner finisher to glove box lid and fit and tighten securing screws. 7. Close cup holder lid, position glove box lid assembly on centre console. and fit and tighten securing screws. 8. Close centre console glove box lid.
2012-07-22
Steering Column Lower Shroud 76.46.03

Removal
www.JagDocs.com
1. Move the driver's seat rearwards. 1. Open driver's door and ensure that it remains open. 2. On driver's seat switch pack, move front switch rearwards to traverse driver's seat to the rear.
2. Remove the lower cowl from the steering column. 1. Remove key from ignition switch. 2. Slacken and remove cowl securing screws. 3. Separate lower cowl from upper cowl (four tangs) and move lower cowl forward to access multiplugs. 4. Disconnect the rheostat multiplug. 5. Disconnect the column adjustment harness multiplug. Move lower cowl clear of steering column.
2012-07-22
3. Remove the rheostat from the cowl. 1. Remove adjusting knob from rheostat. 2. Slacken and remove rheostat securing screw. 3. Move retaining tangs away from the column adjustment switch and release the switch from the lower cowl. Remove lower cowl from the steering column.
Installation
1. Fit rheostat and column switch to the lower cowl. 1. Position lower cowl to front of steering column. 2. Fit and fully seat column adjustment switch to cowl ensuring that retaining tangs fully engage. 3. Position rheostat in cowl and fit and tighten securing screws. 4. Fit and fully seat rheostat adjusting knob.
2012-07-22
www.JagDocs.com
2. Connect multiplugs. 1. Position cowl to facilitate re-connection of multiplugs. 2. Connect rheostat harness multiplug. 3. Connect column adjustment harness multiplug.
3. Fit lower cowl. 1. Locating four dowels, fit lower cowl to upper cowl. 2. Fit and tighten cowl securing screws.
2012-07-22
4. Re-position driver's seat. 1. On driver's seat switch pack move front switch forward to return seat to original position. Shut driver's door.
2012-07-22
1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
Handles, Locks, Latches and Entry Systems
Central Locking System
www.JagDocs.com
The central locking system employs single key access to the driver's door, trunk lid and ignition switch/steering column lock. An additional green headed valet or parking services key permits access via the driver's door, and ignition/start-up, but denies access to the trunk and glovebox. A valet switch located in the underscuttle on the outboard side of the steering column, precludes normal internal access to the trunk. When the vehicle is not locked, each door catch can be externally released by the corresponding door handle which operates via a single rod. When unlocked, or 'single action' locked, the door catches can also be internally released by the interior handles, each of which operates via a single cable. Use of either key in the external door barrel, operates the lock via a short rod to provide locking of the door latch. These locking functions can also be achieved by use of the remote transmitter. The trunk lid can be independently unlocked via a switch located on the driver's side underscuttle. This will only operate at vehicle speeds up to 8 km/h (5 mph).
2012-07-22

External Trunk Lock
A lock barrel located between the X and K of the XK8 badge on the RH side of the trunk rear panel provides external access to the trunk via the black-headed key only.
Internal Trunk Release and Filler Flap Emergency Release
The fuel filler flap is released via a switch located on the driver's underscuttle. This switch will only operate if the engine is not running and the vehicle is unlocked, or the ignition is in position I or II. An emergency filler flap release lever is accessed by removing the LH side trunk lining below the filler.
Key Operation
To 'single action' lock or unlock the vehicle, the key is inserted in the door lock, turned towards the front or rear of the vehicle respectively, and released. Holding the key in the lock position will close all windows, and on convertible models, will also raise the top. Releasing the key stops all operations. 'Single action' locking of the vehicle locks both doors, the trunk lid and the fuel filler flap, and sets the alarm system.
2012-07-22
A 'superlocking' function deadlocks both doors, preventing door opening from the interior, and provides all of the above functions. To raise the convertible top however, the key must again be held in the 'lock' position. To 'superlock' the vehicle, the key is inserted in the door lock and turned to the unlock position, then within three seconds, turned to the lock position and released.
Remote Operation
Remote Central Locking Transmitter Unit
www.JagDocs.com
A four-button transmitter unit provides for remote controlled central locking of the vehicle. The button bearing a red closed padlock symbol locks the vehicle and arms the security system. To remote 'single action' lock, the transmitter is pointed towards the vehicle and this button is pressed and released. To 'superlock' the vehicle, the above operation is repeated within three seconds. This function can also be used to remote close any windows. Completion of 'superlocking' is indicated by an audible 'chirp' from the security system and a single flash from the direction indicators. The vehicle is unlocked and the security system disarmed by pressing the button with the open padlock symbol. The trunk lock can also be remotely released by operating the button bearing the trunk lid open symbol. The button with dipped headlamp symbol is for emergency use. When depressed three times within three seconds, it switches the headlamps on for 25 seconds and operates the vehicle alarm 5 times.
2012-07-22
Door Ajar Switch 86.65.98

Removal 1. Turn ignition key to position II. 2. Motor door glass to fully raised position. 3. Turn ignition key to position O. 4. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 5. Remove door casing for access. Refer to <<76.34.01>>. 6. Remove door primary water shedder. Refer to <<76.58.07>>. 7. Position PVC secondary water shedder for access. 8. Remove door latch assembly. Refer to <<86.65.16>>
2012-07-22
www.JagDocs.com
11. Release door ajar switch securing tangs and remove switch from latch assembly. 12. Remove and discard switch harness securing tape. 13. Remove harness multiplug pin protector and using special tool MS.1540, release switch terminal pins from multiplug.
Installation 1. Fit and fully seat terminal pins in harness multiplug and fit terminal pin protector.
2012-07-22
2. Fit door ajar switch to latch assembly, ensuring that both retaining tangs are fully seated. 3. Secure switch harness with suitable tape.
4. Fit cover to latch assembly. Position cover on latch assembly, ensuring that internal boss locates correctly in latch housing. Fit and tighten cover securing screw. 5. Fit latch assembly to door. Refer to <<86.65.16>>. 6. Reposition secondary water shedder in door. 7. Fit main water shedder to door. Refer to <<76.58.07>>. 8. Fit door casing. Refer to <<76.34.01>>. 9. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
3 2012-07-22
Door Ajar Warning Indicator Switch 86.65.96

Removal 1. Turn ignition key to position II. 2. Motor door glass to fully raised position. 3. Turn ignition key to position O. 4. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 5. Remove door casing for access. Refer to <<76.34.01>>. 6. Remove door primary water shedder. Refer to <<76.58.07>>. 7. Position PVC secondary water shedder for access. 8. Remove door latch assembly. Refer to <<86.65.16>>
www.JagDocs.com
2012-07-22
11. Release door lock/unlock switch securing tang, depress pip and remove switch from latch assembly. 12. Remove and discard switch harness securing tape. 13. Remove harness multiplug pin protector and using special tool MS.1540, release switch terminal pins from multiplug.
Installation 1. Fit and fully seat terminal pins in harness multiplug and fit terminal pin protector.
2012-07-22
2. Fit door lock/unlock switch to latch assembly, ensuring that tang and pip are correctly located. 3. Secure switch harness with suitable tape.
www.JagDocs.com
4. Fit cover to latch assembly. Position cover on latch assembly, ensuring that internal boss locates correctly in latch housing. Fit and tighten cover securing screw. 5. Fit latch assembly to door. Refer to <<86.65.16>>. 6. Reposition secondary water shedder in door. 7. Fit main water shedder to door. Refer to <<76.58.07>>. 8. Fit door casing. Refer to <<76.34.01>>. 9. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
3 2012-07-22
Door Latch 76.37.12

Removal 1. Turn ignition key to position II. 2. Motor door glass to fully raised position. 3. Turn ignition key to position O.
4.
WARNING: BEFORE COMMENCING WORK WITHIN A DOOR INTERIOR, THE GROUND CABLE MUST BE DISCONNECTED FROM THE BATTERY TERMINAL TO PREVENT INADVERTENT ACTIVATION OF THE GLOBAL GLASS CLOSING FEATURE.
Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>
5. Remove door escutcheon. 1. Holding door handle in the open position, remove the escutcheon screw cover. 2. Remove the escutcheon screw, remove escutcheon from door casing and return door handle to closed position.
2012-07-22
www.JagDocs.com
6. Remove trim mat from rear of door pocket and remove the screw.
7. Position door switch pack for access. 1. Using a suitable plasrtic hook, release plastic stud and remove trim from front of door pocket. 2. Remove switch pack to door casing screw and position switch pack for access.
2012-07-22
8. Remove casing to door bracket screw.
9. Remove door casing for access to multiplugs. 1. Release the eight casing to door studs. 2. Position the casing for access and disconnect the door switch pack and puddle lamp connectors. 10. Remove door casing from vehicle and detach switch pack. 11. Remove door water shedder. Refer to <<76.58.07>>.
2012-07-22
12. Remove the door glass rear runner lower screws.
www.JagDocs.com
13. Reposition door glass rear runner. Mark the position of the glass rear runner upper screw. Remove the upper screw and move the runner away from the glass.
2012-07-22
14. Where fitted, remove door lock security shield . Remove bolt securing lock barrel operating rod security shield. Release shield from spring clip at rear and remove shield from door.
15. Disconnect door handle and lock barrel (driver door only) operating rods from lock links.
2012-07-22
16. Remove the three screws and position lock/motor assembly for access.
www.JagDocs.com
17. Remove lock motor harness connector from mounting bracket and disconnect connector.
2012-07-22
18. Release operating cable from door handle. Move inner door handle to the locked position. Remove cable outer from support bracket. Disconnect cable inner from door inner handle. 19. Remove lock/motor assembly from door.
20. Remove lock/motor assembly cover screw.
2012-07-22
21. Releasing upper retaining boss, remove cover from lock/motor assembly.
www.JagDocs.com
22. Remove motor to lock screws.
2012-07-22
23. Release lock motor from lock operating arm. 24. Remove lock from door.
Installation
1. Connect lock motor to lock operating arm.
2012-07-22
2. Install lock motor screws.
www.JagDocs.com
3. Install cover. Position cover on lock motor ensuring upper locating boss is correctly located. Install cover screw. 4. Position lock/motor assembly in door. 5. Move inner door handle outwards to the locked position.
10
2012-07-22
6. Connect lock/motor assembly cable to door inner handle. Place lock assembly in door. Connect cable inner to door handle. Install cable outer on support bracket.
7. Connect harness to latch assembly. Working through door aperture, position latch assembly for access. Connect harness connector. Install connector on mounting bracket.
11
2012-07-22
8. Position latch assembly in door and and install screws.
www.JagDocs.com
9. Connect door handle and lock barrel (driver door only) operating rods to latch assembly.
12
2012-07-22
10. where fitted, install lock security shield. Install security shield over lock barrel operating rod and locate under spring clip at rear. Install securing bolt.
11. Install glass rear runner. Position rear runner on glass. Install but do not tighten lower screws. Install upper screw. ensure it is aligned with marker then fully tighten. Fully tighten lower screws. 12. Reposition PVC secondary water shedder. 13. Fit door main water shedder. Refer to <<76.58.07>>. 14. Install new securing studs on casing.
13
2012-07-22
15. Position but do not secure switch pack on casing. 16. Position casing at door and connect switch pack and puddle lamp connectors. 17. Align casing to door and press and fully seat securing studs into door locations. 18. Install casing securing screw at front of switch pack location. 19. Align switch pack to casing and install screw at rear. 20. Install trim to front of door pocket and fully seat plastic fastener. 21. Install casing screw at rear of door pocket. 22. Install trim mat at rear of door pocket. 23. Holding door handle in open position, install escutcheon on casing. 24. Install escutcheon screw and fit screw cover. 25. Return door handle to closed position. 26. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
www.JagDocs.com
14
2012-07-22
Door Latch Cable 76.37.67

Removal 1. Remove door latch assembly. Refer to <<86.65.16>>.
2012-07-22
www.JagDocs.com
4. Release control cable from bracket, rotate 90 degrees to align with slot in bush and withdraw cable nipple from latch assembly.
5. Release operating cable from door handle. Move inner door handle to the locked position. Remove operating cable outer abutment from support bracket. Disconnect cable inner from door inner handle and remove cable from door..
Installation 1. Fit control cable nipple to latch assembly bush, rotate 90 degrees to captive position and locate outer cable on bracket.
2012-07-22
2. Fit cover to latch assembly. Position cover on latch assembly, ensuring that internal boss locates correctly in latch housing. Fit and tighten cover securing screw. 3. Fit latch assembly and cable to door. Refer to <<86.65.16>>. 4. Reposition secondary water shedder in door. 5. Fit main water shedder to door. Refer to <<76.58.07>>. 6. Fit door casing. Refer to <<76.34.01>>. 7. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
2012-07-22
Door Lock Actuator 86.65.16

Removal 1. Turn ignition key to position II. 2. Motor door glass to fully raised position. 3. Turn ignition key to position O. 4. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>> 5. Remove door casing for access. Refer to <<76.34.01>>. 6. Remove door water shedder. Refer to <<76.58.07>>. 7. Position PVC secondary water shedder for access.
www.JagDocs.com
8. Slacken and remove the door glass rear runner lower securing screws.
2012-07-22
9. Reposition door glass rear runner. Mark the position of the glass rear runner upper securing screw. Slacken and remove the upper securing screw and move the runner away from the glass.
10. UK specification driver door only. Remove bolt securing lock barrel operating rod security shield. Release shield from spring clip at rear and remove shield from door.
2012-07-22
11. Disconnect door handle and lock barrel (driver door only) operating rods from latch links.
www.JagDocs.com
12. Slacken and remove the three latch assembly securing screws and position latch for access.
2012-07-22
13. Remove latch motor harness multiplug from mounting bracket and disconnect multiplug.
14. Release operating cable from door handle. Move inner door handle to the locked position. Remove operating csble outer abutment from support bracket. Disconnect cable inner from door inner handle. 15. Remove lock motor assembly from door.
Installation 1. Move door handle to the locked position.
2012-07-22
www.JagDocs.com
2. Connect latch assembly cable to door inner handle. Place latch assembly in door. Connect cable inner to door handle. Fit and fully seat cable outer abutment on support bracket.
3. Connect harness to latch assembly. Working through door aperture, position latch assembly for access. Connect harness multiplug. Fit multiplug onto mounting bracket.
2012-07-22
4. Position latch assembly in door and fit and tighten securing screws.
5. Connect door handle and lock barrel (driver door only) operating rods to latch assembly.
2012-07-22
www.JagDocs.com
6. UK specification driver door only. Fit security shield over lock barrel operating rod and locate under spring clip at rear. Fit and tighten securing bolt.
7. Fit glass rear runner. Position rear runner on glass. Fit but do not tighten lower securing screws. Fit upper securing screw. ensure it is aligned with marker then fully tighten. Fully tighten lower securing screws. 8. Reposition PVC secondary water shedder. 9. Fit door main water shedder. Refer to <<76.58.07>>. 10. Fit door casing. Refer to <<76.34.01>>. 11. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
7 2012-07-22
Door Lock Control Switch 86.80.32

1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.15>>. 2. Remove 'J' gate surround. Refer to <<76.25.24>>. 3. Remove centre console for access. Refer to <<76.25.01>>. 4. Remove radio console for access. Refer to <<76.25.15>>.
5. Disconnect switch module harness multiplug, release module end locaters and lightly press module out of console. Installation 1. Fit switch module to console ensuring that end locaters are fully seated. 2. Connect switch module harness multiplug. 3. Fit radio console. Refer to <<76.25.15>>. 4. Fit centre console. Refer to <<76.25.01>>. 5. Fit 'J' gate surround. Refer to <<76.25.24>>. 6. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
2012-07-22
Door Lock Cylinder 76.37.71

Removal 1. WARNING: BEFORE COMMENCING WORK WITHIN A DOOR INTERIOR, THE EARTH CABLE MUST BE DISCONNECTED FROM THE BATTERY TERMINAL TO PREVENT INADVERTENT ACTIVATION OF THE GLOBAL GLASS CLOSING FEATURE.
Remove driver's door casing. Refer to <<76.34.01>>. 2. Remove driver's door handle. Refer to <<76.58.07>>.
www.JagDocs.com
3. Remove operating arm and bias spring. 1. Remove 'C' clip securing plastic operating arm to barrel. 2. Remove operating arm and bias spring from barrel. 4. Slacken and remove screw securing barrel to housing and withdraw barrel.
Installation
2012-07-22
1. NOTE: For re-fitting of original lock barrel, refer to operations 4 to 9. Identify key cut code. 1. Hold key so that cut outs can be identified and commencing at key grip, note and record cut out sequence.
2. Fit lock discs to barrel. 1. Grease bore of lock barrel. 2. Ensure lock discs match recorded key code. 3. Grease the first seven discs and install them in the barrel in sequence with embossed spacers in between and orientated to align roller locations. 4. Fit wavy spring spacer. 5. Grease and fit final disc.
2012-07-22
www.JagDocs.com
3. Fit shutter assembly and roller to barrel. 1. Grease shutter assembly and fit to barrel. 2. Align recesses in discs and spacers to accept the steel roller. 3. Grease steel roller and fit into recesses via barrel slot. Via adjacent barrel slot, check discs for correct sequence and orientation.
4. Fit lock barrel and shutter assembly to housing. 1. Align and fit barrel into lock housing. 2. Fit plastic securing ring to barrel and rotate to engage locking tangs.
2012-07-22
5. Fit operating arm to barrel. 1. Fit bias spring to operating arm ensuring it is fully seated and tensioned, with ends positioned each side of pillar. 2. Fit operating arm and bias spring assembly to barrel and secure with 'C' clip. 6. Position lock assembly in door handle and fit and tighten securing screw. 7. Fit key and check lock function. 8. Fit driver's door handle. Refer to operations in this section. 9. Fit driver's door casing. Refer to <<76.34.01>>.
2012-07-22
Exterior Driver Door Handle 76.58.07

Removal 1. WARNING: BEFORE COMMENCING WORK WITHIN A DOOR INTERIOR, THE EARTH CABLE MUST BE DISCONNECTED FROM THE BATTERY TERMINAL TO PREVENT INADVERTENT ACTIVATION OF THE GLOBAL GLASS OPEN/CLOSE FEATURE.
Ensure that door glass is fully up. 2. Remove battery cover and disconnect earth lead from terminal. Refer to <<86.15.19>>. 3. Remove door casing. Refer to <<76.34.01>>.
www.JagDocs.com
4. Remove door casing center support bracket. 1. Slacken and remove the two casing support bracket securing bolts and remove bracket from door.
2012-07-22
5. Remove tape securing puddle lamp harness to water shedder and reposition harness for access.
6. Carefully peel back main water shedder remove from door and place adhesive face downwards on clean dry plastic sheet. 7. Position PVC secondary water shedder for access.
2012-07-22
www.JagDocs.com
8. Disconnect and remove door handle. 1. Disconnect link rod from door handle. 2. Disconnect lock barrel operating arm link rod from motor. 3. Slacken and remove the two door handle securing screws and remove door handle from vehicle. 9. Remove lock assembly from door handle. Refer to <<76.37.71>>.
Installation 1. Fit lock assembly to door handle. Refer to <<76.37.71>>.
2. Connect lock barrel link rod to operating arm. 3. Fit door handle to door.
2012-07-22

Position and fully seat door handle. Fit and tighten the two door handle securing screws. Connect lock barrel operating arm link rod to motor. Connect door handle to lock operating link rod. 4. Reposition PVC secondary water shedder. 5. Fit main water shedder to door. Ensure that adhesive face of water shedder and all door contact surfaces are clean, free of grease and oil, and absolutely dry. Commencing at the top, align and fit water shedder to door. Reposition puddle lamp harness and secure to water shedder using suitable tape. Position door casing center support bracket. and fit and tighten securing bolts. 6. Fit door casing. Refer to <<76.34.01>>. 7. Connect earth cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
2012-07-22
Exterior Passenger Door Handle 76.58.08

Removal 1. WARNING: BEFORE COMMENCING WORK WITHIN A DOOR INTERIOR, THE EARTH CABLE MUST BE DISCONNECTED FROM THE BATTERY TERMINAL TO PREVENT INADVERTENT ACTIVATION OF THE GLOBAL GLASS CLOSING FEATURE.
Ensure that door glass is fully up. 2. Remove battery cover and disconnect earth lead from terminal. Refer to <<86.15.19>>. 3. Remove door casing. Refer to <<76.34.01>>.
www.JagDocs.com
4. Remove door casing center support bracket. 1. Slacken and remove the two casing support bracket securing screws and remove bracket from door.
2012-07-22
5. Remove tape securing puddle lamp harness to water shedder and reposition harness for access.
6. Carefully peel back water shedder, remove from door and place adhesive face downwards on clean dry plastic sheet.
2012-07-22
www.JagDocs.com
7. Disconnect and remove door handle. 1. Disconnect link rod from door handle. 2. Slacken and remove the two door handle securing screws and remove door handle from vehicle.
Installation
1. Fit door handle to door. 1. Position and fully seat door handle. 2. Fit and tighten the two door handle securing screws. 3. Connect door handle to link rod. 2. Fit water shedder to door. Ensure that adhesive face of water shedder and all door contact surfaces are clean, free of grease and oil, and absolutely dry. Commencing at the top, align and fit water shedder to door. Reposition puddle lamp harness and secure to water shedder using suitable tape.
2012-07-22

Position door casing center support bracket. and fit and tighten securing bolts. 3. Fit door casing. Refer to <<76.34.01>>. 4. Connect earth cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
2012-07-22
Glove Compartment Lid Lock Cylinder 76.52.23

Removal 1. Remove glovebox lid. Refer to <<76.52.02>>.
www.JagDocs.com
2. Remove the glove box handle and lock barrel. 1. Holding the handle in the open position, remove it from the mounting bracket by carefully prising the RH support outwards. 2. Remove the handle return spring. 3. Releasing the retaining tangs, remove the lock barrel.
Installation
1. Fit glove box handle and lock barrel to lid. 1. Fit handle return spring ensuring that it engages in the lid mounting slot.
2012-07-22

2. Position lock rods inwards and fit and fully seat handle in right-hand mounting bracket. 3. Fit lock barrel to lid. 2. Fit glovebox lid. Refer to <<76.52.02>>.
2012-07-22
Hood Ajar Switch 86.65.99

Removal 1. Open hood and fit cover to RH side fender.
www.JagDocs.com
2. Release hood open microswitch harness multiplug from body tang and disconnect multiplug.
3. Remove three bolts securing RH bonnet latch/microswitch assembly to body.
2012-07-22
4. Withdraw hood release outer cable from latch mounting bracket.
5. Disconnect hood release cable hook from latch lever. 6. Remove latch/microswitch assembly from vehicle.
Installation 1. Position latch/microswitch assembly at body. 2. Connect release cable hook to latch lever. 3. Locate and fully seat release outer cable in latch mounting bracket. 4. Position latch/microswitch assembly on body apertures and install securing bolts.
2 2012-07-22
5. Connect hood open microswitch harness multiplug and fit and fully seat multiplug on body tang. 6. Remove fender cover, shut hood and check that latch and microswitch function correctly.
www.JagDocs.com
2012-07-22
Ignition Lock Cylinder 57.40.29

Removal
1. Remove the ignition key from the steering column lock. 2. Remove the steering column lower cowl; refer to Section <<501-05>>.
3. Insert the ignition key into the steering column lock. 1. Turn the key to the AUXILIARY position.
2012-07-22
www.JagDocs.com
4. Remove the lock barrel from the steering column lock. 1. Press the lock barrel retaining peg to release the barrel. 2. Withdraw the lock barrel from the steering lock. 5. Remove the ignition key.
Installation 1. Insert the ignition key into the lock barrel.
2. Align the lock barrel to the steering column lock. 1. Rotate the ignition key until alignment of the lock barrel is attained.
2012-07-22
3. Install the lock barrel to the steering column lock. 1. Fully seat the lock barrel to the steering column lock. 2. Ensure that the retaining peg has engaged.
4. Turn the ignition key to the OFF position. 1. Withdraw the ignition key from the lock. 5. Install the steering column lower cowl; refer to Section <<501-05>>. 6. Insert the ignition key into the steering lock.
2012-07-22
Luggage Compartment Lid and Fuel Filler Door Release Switch 86.65.95
Removal 1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 2. Remove driver side underscuttle for access to lower fascia. Refer to <<76.46.11>>.
www.JagDocs.com
3. Release retaining tangs and withdraw switch assembly from driver side lower fascia.
4. Disconnect harness multiplug from fuel filler flap/trunk lid release switch assembly.
Installation 1. Install fuel filler flap/trunk lid release switch assembly to driver side lower fascia, ensuring that retaining tangs
2012-07-22

are fully seated. 2. Connect harness multiplug to switch assembly. 3. Install driver side underscuttle. Refer to <<76.46.11>> 4. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
2012-07-22
Luggage Compartment Lid Latch 76.19.25

Removal 1. Remove trunk floor carpet. 2. Remove trunk rear finisher. Refer to <<76.19.44>>.
www.JagDocs.com
3. Remove tape securing lock mechanism harness and disconnect harness multiplug.
4. Slacken and remove lock mechanism securing bolts.
2012-07-22
5. Position lock mechanism for access and disconnect lock barrel operating cable.
6. Disconnect trunk lock actuator operating cable 7. Remove lock mechanism from trunk lid.
Installation 1. Position lock mechanism in trunk lid.
2012-07-22
2. Connect trunk lock actuator operating cable.
www.JagDocs.com
3. Connect trunk lock barrel operating cable.
2012-07-22
4. Position and fully seat lock mechanism and fit but do not tighten securing bolts.
5. Connect trunk lock harness multiplug. 6. Close trunk lid, and check lock for satisfactory operation. 7. Open trunk lid adjust lock position as necessary and fully tighten securing bolts. 8. Secure harness to trunk lid with linen adhesive tape. 9. Fit trunk rear finisher. Refer to <<76.19.44>>. 10. Fit trunk floor carpet.
2012-07-22
Luggage Compartment Lid Latch Actuator 76.19.25

Removal 1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 2. Remove trunk floor carpet. 3. Remove trunk rear finisher. Refer to <<76.19.44>>.
www.JagDocs.com
4. Remove the two trunk lid lock motor mounting bracket securing screws and position bracket/motor assembly for access.
5. Free motor release cable outer from bracket abutment.
2012-07-22
6. Disconnect release cable hook from motor rod and withdraw motor/bracket assembly from trunk.
7. Remove two screws securing motor to mounting bracket and remove motor from bracket.
Installation 1. Position trunk lid lock motor on mounting bracket. 2. Install motor to mounting bracket securing screws. 3. Fit release cable hook onto motor rod. 4. Position motor release cable outer on bracket abutment. 5. Position and fully seat lock motor/ mounting bracket assembly.
2012-07-22
6. Install bracket securing screws. 7. Install trunk rear finisher. Refer to <<76.19.44>>. 8. Install trunk floor carpet. 9. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
www.JagDocs.com
2012-07-22
Luggage Compartment Lid Lock Cylinder 76.19.19

Removal 1. Remove trunk floor carpet. 2. Remove battery cover. Refer to <<86.15.19>>. 3. Remove trunk rear finisher. Refer to <<76.19.44>>. 4. Remove adhesive tape from trunk access aperture
5. Slacken and remove lock barrel housing securing nuts and release housing from operating cable abutment bracket.
2012-07-22

6. Disconnect cable from lock barrel operating arm and remove barrel and housing from trunk.
7. Remove circlip securing operating arm to lock barrel and remove operating arm and bias spring from barrel.
www.JagDocs.com
8. Remove barrel from housing. Release detent plunger and spring from housing and withdraw barrel assembly. Remove spring clip from housing groove.
2012-07-22
9. Using a flat-bladed screwdriver, ease barrel cover free and discard cover and plastic tension ring.
10. Remove: 1. Closing plate. 2. Shutter flap, tension spring and pivot pin. 3. Retaining key. 4. Shutter housing.
2012-07-22
www.JagDocs.com
11. NOTE: If original discs and spacers are to be fitted, record sequence during removal. Remove discs and spacer washers from barrel.
Installation
1. Fit and fully seat plastic sealing ring on barrel flange. 2. If original discs are to be fitted, proceed to step 3 noting positions recorded during removal.
2012-07-22
3. Identify key cut code. Hold key so that cut outs can be identified and commencing at key grip, note and record cut out sequence.
4. Fit lock discs to barrel. 1. Apply grease supplied to bore of lock barrel. 2. Ensure lock discs match recorded key code. 3. Grease the first seven discs and install them in the barrel in sequence with embossed spacers in between and orientated to align roller locations. 4. Fit wavy spring spacer. 5. Grease and fit final disc. 6. Through barrel slot, check discs for correct sequence and orientation.
2012-07-22
5. Align discs and spacers to accept the steel rollers grease rollers and fit into disc recesses via barrel slot.
www.JagDocs.com
6. Grease and fit shutter pivot and spring ensuring that spring is correctly tensioned.
2012-07-22
7. Grease and fit detent plunger and spring to lock barrel recess.
8. Grease and fit spring clip into groove in bore of barrel housing.
2012-07-22
www.JagDocs.com
9. Aligning detent plunger with groove in housing, push barrel assembly home until plunger engages in rear recess. 10. Turn key to locate plunger in housing detent, check for satisfactory lock operation and remove key.
11. Fit operating arm and bias spring to barrel. Fit bias spring to barrel, locating lower tang on lock housing pillar. Position operating arm at housing, locate bias spring upper tang on arm pillar and seat arm with spring tensioned.
2012-07-22
12. Fit and fully seat arm securing circlip.
13. Position lock barrel and housing at cable abutment bracket and connect operating cable.
2012-07-22
14. Position barrel and housing assembly on cable abutment bracket studs and fit and tighten securing nuts. 15. Fit new adhesive tape to panel aperture. 16. Fit trunk rear finisher. Refer to <<76.19.44>>. 17. Fit trunk floor carpet. 18. Fit battery cover. Refer to <<86.15.19>>.
www.JagDocs.com
10
2012-07-22
Luggage Compartment Lid Warning Indicator Switch 86.65.93

Removal 1. Remove trunk floor carpet. 2. Remove trunk lock mechanism for access. Refer to <<76.19.25>>.
3. Carefully ease warning switch tangs from trunk lock mechanism. 4. Remove warning switch assembly from lock mechanism.
Installation 1. Position warning switch on lock mechanism and fit and fully seat tangs. 2. Install trunk lock mechanism. Refer to <<76.19.25>> 3. Install trunk floor carpet.
2012-07-22
1999 XK RANGE - Wipers and Washers - 501-16
Torques Component Nut securing wiper arm to spindle Nm 15,5 - 20,5
www.JagDocs.com
2012-07-22
Wipers and Washers

Windshield Wipers
The conventional twin wiper system is driven by a single motor controlled from the right hand column stalk switch. The motor which has 'microswitch overload protection,' is mounted on a bracket below the plenum cover on the driver's side. Available only as a complete assembly including motor, the wiper system is handed to suit market requirements. The wiper arms are dedicated to either driver or passenger side installation and incorporate blade carriers that enable wipers to be parked in lowest possible position on the windshield. The wiper blades are of synthetic rubber. Windshield washer jet assemblies are mounted on the wiper arms. Operating modes selected by a column mounted wiper control stalk switch, are normal, high speed, flick wipe, and six settings of intermittent operation with delays ranging from 2 to 20 seconds. On vehicles with rain sensing installed, the first intermittent setting is replaced by an AUTO position.
Windshield Washers
The windshield washers are of wiper arm mounted, running jet configuration, with each jet assembly incorporating a conventional nozzle plus three nozzles of silicone rubber 'duckbill' design. If the system is initially operated at low ambient temperatures, the 'duckbill' nozzles permit any frozen residual washer fluid to be ejected under pump
1 2012-07-22

pressure. The windshield wash feed tubes supplied assembled in the associated wiper arms fit at their lower ends onto connectors in the plenum cover. Located on the rear face of the washer fluid reservoir the windshield wash pump is connected by feed tubes to the plenum cover. The seven liter washer fluid reservoir is situated in a cavity formed by the front bumper, LH front valance and the front wing liner. The windshield washers are operated by pressing the button at the end of the wiper control stalk switch. Pressing and releasing the button operates the washers for 1 - 1.4 seconds and the wipers complete three sweeps. An optional drip wipe function adds a further sweep of the wipers after a 4 second delay, to clear residual fluid from the windshield. If the button is held depressed, the washers and wipers will operate continuously for up to 20 seconds.
Headlamp Powerwash System Headlamp Powerwash Jet Assembly (Retracted and Extended)
www.JagDocs.com
The headlamp powerwash system incorporates a telescopic nozzle unit mounted in the lower section of each headlamp. Each nozzle is connected via snap fittings to a powerwash pump mounted above the windshield wash pump on the rear face of the washer fluid reservoir. The powerwash system operates in conjunction with the windshield washers when the ignition switch is in position II and the headlamp switch is in the dip or main beam position. When the powerwash pump is activated, the nozzle units under fluid pressure, extend forward approximately 72 mm and commence the wash cycle. The wash cycle consists of two 800 ms pulses separated by a six second delay. To conserve washer fluid, headlamp powerwash will only function on every sixth operation of the windshield wash switch. When the 'WASHER FLUID LOW' message is illuminated, the windshield washers will continue to operate for a limited period but the headlamp powerwash will not function until the fluid level is restored.
Rain Sensing System

The rain sensing system installed for some markets, provides automatic wiper operation when rain is detected on the windshield. The system detects differing levels of rainfall and varies wiper operation ranging from intermittent to maximum continuous, to suit prevailing requirements. The system which is brought into operation by selecting AUTO on the wiper control switch bezel, does not preclude normal manual control of wiper operation. The system consists of a rain sensor, an electronic control module and a dedicated wiper control switch.
2012-07-22
The rain sensor is an optical transducer that is sensitive to changes in infra-red light penetration of the windshield created by the refractive effects of water droplets. The sensor elements consist of two groups of light emitting diodes which alternately project infra-red light onto the windshield and a photo-diode that receives resulting reflections from the glass. All of the infra-red light is reflected back from a moisture-free windshield, resulting in a constant 5V output signal from the sensor and no wiper activation. Rain falling on the light sensing area of the windshield results in refraction and diffusion of a proportion of the projected light with a corresponding imbalance of light received by the photodiode. This results in pulsed outputs from the sensor, the frequency and duration of which are directly proportional to the number and size of water droplets respectively. These pulses together with wiper switch position signals are received by the sensor control module and processed to mimic column switchgear operation. In this recognisable form, signals are input to the body processor module (BPM) where they are interpreted as normal wiper operation requests.
The rain sensor unit is installed on the inside of the windshield within the rear view mirror stem cover. The unit is secured to the glass by a special adhesive that facilitates service removal. When installing a rain sensor unit, it must be positioned in the clear circle within the obscuration band.
2012-07-22
The rain sensor control module is a non-serviceable unit installed on the passenger side dash panel and connected to the rain sensor unit and the body processor module.
www.JagDocs.com
The column mounted wiper control stalk switch on vehicles with rain sensing installed, has an AUTO position (this replaces the first intermittent setting on non rain-sensing wiper controls), five intermittent settings, and normal, high speed and flick wipe positions.
2012-07-22
Headlamp Washer Jet 84.20.08

Removal 1. Turn steering wheel to full lock position that provides access to appropriate wheel arch liner.
2. Remove wheel arch liner access panel. Rotate liner access cover fastener 1/4 turn and remove cover from vehicle. Ensure that fastener is retained.
3. Remove clips securing front of wheel arch liner to fender. 4. Position front of wheel arch liner for access. 5. Remove headlamp rear trim cover and water deflector.
2012-07-22
www.JagDocs.com
6. Remove headlamp fixings. 1. Disconnect headlamp harness multiplug. 2. Slacken and remove headlamp upper and lower securing bolts. 3. Slacken headlamp securing nut.
7. Remove powerwash jet assembly from headlamp. Carefully withdraw and position headlamp for access to underside, release washer jet tangs and remove assembly from headlamp.
Installation 1. Fit powerwash jet assembly to headlamp, ensuring tangs fully seat. 2. Fit headlamp assembly to BIW. 3. Fit but do not fully tighten headlamp upper and lower securing bolts.
2012-07-22
4. Align headlamp with vehicle profile as detailed in <<501-18>>. 5. Tighten headlamp securing nut. 6. Fully tighten headlamp securing bolts. 7. Connect feed hose to powerwash jet assembly. 8. Connect harness multiplug to headlamp. 9. Fit headlamp rear trim panel and water deflector. 10. Fit and fully seat front of wheelarch liner and secure with new fasteners. 11. Fit and fully seat access panel to wheelarch liner and rotate fastener 1/4 turn to secure. 12. Return steering to straight ahead position. 13. Carry out headlamp beam alignment.
2012-07-22
Rain Sensor 86.56.62

www.JagDocs.com
2. Remove cover from rear view mirror base.
3. Disconnect flying lead from sensor unit connector.
2012-07-22
4. Using a thin plastic blade, carefully remove sensor unit from windshield. 5. Using an approved solvent, remove residual adhesive from windshield. 6. If sensor is to be re-used, remove adhesive pad and clean base of unit using an approved solvent.
Installation 1. Install new adhesive pad. Peel backing paper from one side of new adhesive pad. Position pad correctly in clear area of obscuration band and press firmly to fully seat. Peel remaining backing paper from adhesive pad.
2. Ensuring sensor is correctly orientated, press firmly into position on adhesive pad.
2012-07-22
3. Connect flying lead connector to sensor unit.
www.JagDocs.com
4. Install cover over sensor and mirror base ensuring tangs fully engage. 5. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
2012-07-22
Rain Sensor Module 86.56.60

Removal 1. Remove battery cover and disconnect ground cable from battery terminal. Refer to 86.15 19. 2. Remove glove box for access. Refer to <<76.52.03>>.
3. Remove two bolts securing module to passenger side dash panel.
4. Disconnect harness connector from module and remove module from vehicle.
Installation 1. Position module at dash panel and connect harness connector.
2012-07-22
2. Install module bolts. 3. Install glove box. 4. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
www.JagDocs.com
2012-07-22
Windshield Washer Pump and Headlamp Washer Pump 84.10.21

Removal 1. Raise front of vehicle and support on stands. 2. Remove LH front wheel. 3. Remove LH front wheel arch liner. Refer to <<76.10.90>>. 4. Position a suitable drain receptacle under fluid reservoir.
5. Supporting reservoir, carefully release pump from connectors and seals.
6. Disconnect pump hoses and harness multiplug.
2012-07-22
7. Remove and discard pump to reservoir sealing washers and clean surrounding area of reservoir. 8. Remove drain receptacle.
Installation 1. Fit and fully seat new sealing washers to reservoir. 2. Apply suitable lubricant to outer face of sealing washers. 3. Positioning pump at reservoir, press and firmly seat connectors firmly in sealing washers. 4. Connect hoses to pump and reservoir. 5. Open hood and fill reservoir with correct fluid. 6. Check that all connections are free from leakage. 7. Close hood. 8. Connect harness multiplug to pump 9. Fit LH wheel arch liner. Refer to <<76.10.90>>. 10. Fit LH front road wheel. 11. Raise vehicle, remove stands and lower vehicle onto wheels.
www.JagDocs.com
2012-07-22
Windshield Washer Reservoir 84.10.01

Removal 1. Fit LH fender cover and open hood. 2. Raise front of vehicle and support on stands. 3. Remove LH front wheel. 4. Remove LH front wheel arch liner. Refer to <<76.10.90>>. 5. Remove windshield washer and headlamp powerwash pumps from reservoir. Refer to <<84.10.21>>.
6. Remove elbow from reservoir filler neck.
2012-07-22
www.JagDocs.com
7. Remove filler neck. Carefully pull lower end of filler neck from reservoir and discard sealing ring. Remove and discard 'O' ring seal from filler neck upper end.
8. Slacken and remove the three reservoir to BIW securing bolts and remove reservoir from vehicle.
Installation 1. Position reservoir in wheelarch, align with BIW holes and fit and tighten the three securing bolts. 2. Clean pump seal and filler neck seal locations. 3. Fit and fully seat new windshield washer and powerwash pump sealing washers to reservoir apertures. 4. Fit and fully seat new filler neck lower sealing ring to reservoir aperture.
2012-07-22
5. Apply suitable lubricant to sealing washers and filler neck seal.
6. Position filler neck upper end in BIW aperture and fully seat lower end in sealing ring. 7. Fit windshield washer and powerwash pumps to reservoir. Refer to <<84.10.21>>. 8. Fit new 'O' ring seal to upper end of filler neck. and apply suitable lubricant. 9. Fit and firmly seat filler elbow to upper end of filler neck. 10. Fill reservoir with correct fluid. 11. Check that all connections are free from leakage. 12. Connect harness multiplugs to pumps. 13. Fit LH wheel arch liner. Refer to <<76.10.90>>. 14. Fit LH front road wheel. 15. Raise vehicle, remove stands and lower vehicle onto wheels. 16. Remove fender cover and close hood.
2012-07-22
Windshield Wiper Motor 84.15.13

Removal 1. Remove battery cover and disconnect earth cable from battery terminal. Refer to <<86.15.19>>. 2. Remove wiper arm and blade assemblies. Refer to operations in this section. 3. Remove plenum chamber cover. Refer to Section <<501-02>>.
www.JagDocs.com
4. Slacken and remove the bolt securing the driver side water deflector to the plenum chamber and remove the deflector.
5. Remove convertible model bulkhead brace. 1. Slacken and remove the driver side bulkhead brace rear securing bolt. 2. Slacken and remove the bulkhead brace front securing nut and remove brace from vehicle.
1 2012-07-22
6. Sever the strap securing the wiper motor multiplug to the securing bracket and disconnect the multiplug.
7. Slacken and remove the three wiper motor/linkage securing bolts and withdraw the motor and linkage from the plenum chamber. 8. Remove the wiper motor/linkage mounting rubbers and spacers.
Installation 1. Fit mounting rubbers and treat the bores with a suitable lubricant. 2. Fit spacers to mounting rubbers.
2012-07-22
3. Position wiper motor/linkage assembly in the plenum chamber and fit and tighten securing bolts. 4. Connect wiper motor harness multiplug and secure to bracket with new retaining strap. 5. Fit convertible model bulkhead brace. Position driver side bulkhead brace, locating front on suspension turret stud and fit and tighten rear securing bolt. Fit and tighten nut securing front of brace to suspension turret. 6. Position driver side water deflector in plenum chamber and fit and tighten securing bolt. 7. Fit plenum chamber cover. Refer to Section <<501-02>>. 8. Fit wiper arm assemblies. Refer to operations in this section. 9. Connect earth cable to battery terminal and fit battery cover. Refer to Section <<414-01>>.
www.JagDocs.com
2012-07-22
Wiper Pivot Arm 84.15.03

Windshield wiper arm extractor 18G2 Removal
1. Disconnect windshield washer tubing. 1. Open the hood. 2. Disconnect wiper arm windshield washer tubing from plenum cover connector. 3. Note position of wiper blade on windshield.
2012-07-22
www.JagDocs.com
2. Withdraw wiper arms from spindles. 1. Remove plastic cover from wiper arm securing nut. 2. Slacken but do not remove wiper arm securing nut. 3. Fit extractor 18G2 and ensuring that wiper and plenum cover are not damaged, release wiper arm from tapered spindle. Remove extractor, remove wiper arm securing nut and lift wiper arm off spindle.
Installation 1. Fit wiper arm and blade. Fit wiper arm and blade assembly onto spindle splines aligning blade to original position on windshield. Fit wiper arm securing nut. Supporting the wiper arm, carefully tighten the securing nut to press arm on to tapered splines. 2. Fit plastic cover over securing nut. Connect washer tubing to plenum cover. Close hood.
2012-07-22
1999 XK RANGE - Convertible Top - 501-18
Convertible Top
Description
The convertible top has a fully lined and padded interior, and is mounted on an aluminum frame with steel linkages providing lightness with good structural strength. When lowered, the top folds to a low stack height in the body and is concealed by a matching soft cover. A front seal shot moulded to the windshield header and 'A' posts, achieves highly efficient weatherproofing, reduced noise levels and improved aerodynamics. The green tinted glass backlight is bonded to the top to achieve a semi-flush finish.
Power Operation
Convertible Top Hydraulic Power Pack
Powered actuation and latching is provided by an electrically driven hydraulic pump installed in RH side of trunk. With the ignition switch in position I or II, both the convertible top and rear quarter glass are operated by a single switch located forward of the 'J' gate and marked 'ROOF. The top is lowered by pressing and holding the rear of the switch until top movement ceases.When the top unlatches, an audible alarm sounds for 0.7 seconds , the rear quarters fully open and any fully closed door glass lowers 12 mm. The audible alarm operates again when the top starts to move. If the door glass is closed, the rear quarters close, then all glass lowers 12 mm. When the top is fully lowered, the audible alarm operates and the door glass returns to the fully closed position. The top is raised by pressing and holding the front of the switch until the top is fully erected and latched.When the top is fully raised and latched, the audible alarm operates again and all glass closes. Operation of the convertible top is inhibited at vehicle speeds in excess of 16 km/h (10 mile/h). If the vehicle exceeds this speed when the top is moving to the lowered position, it will continue to the fully down position. Should the vehicle exceed this speed when the top is being raised, further movement will be inhibited until the speed is reduced.
2012-07-22

Emergency Manual Raising of Top Manual Latching of Top Using Key Provided
www.JagDocs.com
In the event of latch failure when the top is raised, a visual warning will illuminate on instrument panel. In such an emergency, the top must be manually positioned using a center pull down facility, then latched using a key stowed alongside the top operating pump. To manually operate the latch, the key is inserted in the recess in the windscreen header, turned clockwise to ensure the latch is fully released, then turned counter-clockwise to lock. The top can also be manually raised in the event of failure to power operate. In such a situation, the pump isolating valve must first be turned fully counter-clockwise to the manual operation position. Manual latching is then achieved as described above. When manually raising the top, the linkages from the frame to the wheel arches must be moved to the over-center position.
Emergency Manual Lowering of Top

In the event of failure of powered lowering of the top, the following procedure must be adopted. Failure to follow this procedure when manually lowering the top can result in damage to the frame and operating linkages. 1. Lower the rear quarter glass by pressing the rear of the 'ROOF' button once. 2. Rotate the pump valve (located in the RH side-well of the trunk) counter-clockwise to the manual operation position. 3. Remove the blanking plug from the header trim, insert the Allen key provided (stowed alongside the top pump) and unlatch the top by turning the key clockwise.
2012-07-22

Direction of Manual Thrust During Emergency lowering of Top
4. Reaching behind the top rear quarter curtains, pull the rams and linkages at both sides firmly downwards as far as possible. 5. Manually lower top to stowed position, if necessary repeating step 4 above.
2012-07-22
Convertible Top Assembly 76.86.15

Removal 1. Remove carpet from convertible top stowage compartment.
www.JagDocs.com
2. Disconnect backlight heater harness connectors. 3. Ensuring that backlight heater harness is clear, power top to fully lowered position. 4. Remove rear seat cushion. Refer to <<76.70.37>>. 5. Remove rear seat squab. Refer to <<76.70.38>>. 6. Remove LH and RH rear quarter trim cappings. 7. Remove LH and RH rear quarter trim panels. Refer to <<76.13.73>>. 8. Remove rear speaker assembly (premium ICE only). Refer to 86.51.06.
2012-07-22
9. Slacken and remove nuts securing squab panel stiffener bracket to BIW and remove bracket from vehicle. 10. Remove heated backlight. Refer to <<76.81.11>>.
11. Slacken and remove bolt securing ground cable to frame and position cable clear of frame.
2012-07-22
12. Slacken and remove security aerial retaining clip securing bolt.
www.JagDocs.com
13. Slacken and remove security aerial mounting bracket securing screws and position aerial clear of top. 14. NOTE: Do not allow top to latch. Power top to 3/4 closed position. 15. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
2012-07-22
16. Position trunk RH liner for access and turn hydraulic pump valve fully counter- clockwise to the manual operation position.
17. Remove backlight link lever securing clips and position link levers for access.
2012-07-22
www.JagDocs.com
18. Remove mounting bracket cover plate securing screws Slacken and remove mounting bracket cover plate lower securing screw, position headlining for access and remove the two remaining screws.
19. Release headlining rear securing rods from securing clips.
2012-07-22
20. Slacken and remove nuts securing rear tack strip to BIW.
21. Withdraw tack strip from vehicle and remove end covers from tack strip.
2012-07-22
22. Remove over-centre link lever retaining clips, remove nylon spacers and position link levers for access.
www.JagDocs.com
23. Disconnect hydraulic cylinder actuating rods from convertible top frame. Remove spring clip/pin securing each hydraulic cylinder rod to frame. Partially retract cylinder rod and withdraw from frame.
2012-07-22
24. Move each hydraulic cylinder clear of outer half pivot, position cylinder to facilitate top removal and remove and retain wavy washer from pivot. 25. Tape plastic sheet over trunk lid, rear panel and fenders to protect paint
26. Slacken and remove upper bolts securing mounting brackets to BIW.
2012-07-22
27. Slacken but do not remove mounting bracket lower securing bolts. 28. Manually lower convertible top.
www.JagDocs.com
29. Slacken and remove rear quarter glass inner seal rear securing screws.
2012-07-22
30. Release and discard rear quarter glass inner seal front fir tree fasteners and remove seals from carriers.
31. Slacken the front bolt securing each seal carrier to BIW.
10
2012-07-22
32. Slacken and remove the rear bolts securing each seal carrier to BIW and remove seal carriers.
www.JagDocs.com
33. Ensure that mounting bracket lower bolts are sufficiently slackened, then with assistance, carefully lift and remove convertible top assembly from vehicle.
Installation 1. With assistance, carefully lift convertible top assembly and position in vehicle, locating lower slot in each mounting bracket on BIW bolt. 2. Fit mounting bracket upper securing bolts.
11
2012-07-22
3. Position rear quarter glass inner seal carriers and fit but do not tighten rear securing bolts.
4. Fully tighten seal carrier front securing bolts.
12
2012-07-22
5. Fit and fully seat inner seals in carriers and fit and tighten rear securing screws.
www.JagDocs.com
6. Secure front of inner seals with new fir tree fasteners. 7. Manually raise convertible top.
13
2012-07-22
8. Fit wavy washers onto half pivots and fit and fully seat hydraulic cylinders.
9. Fit hydraulic cylinder actuating rod ends to frame. Align and extend cylinder rods to convertible top frame. Position end of each rod on linkage and secure with clip/pin assemblies.
14
2012-07-22
10. Position over-centre link levers, fit nylon spacers and fit link rod securing clips. 11. Position tack strip on BIW and fit end covers.
www.JagDocs.com
12. Commencing in centre, fit and tighten tack strip securing bolts.
15
2012-07-22
13. Fit and fully seat headlining rear securing rods.
14. Fit mounting bracket cover plates. Fit and fully seat mounting bracket cover plates, ensuring that half pivots locate correctly in ram recesses. Fit and tighten upper securing screws.
16
2012-07-22
15. Position headlining rear quarters over mounting bracket cover plates and fit and tighten lower securing screws.
www.JagDocs.com
16. Position backlight link levers and fit and fully seat securing clips.
17
2012-07-22
17. Turn hydraulic pump valve fully clockwise to power operation position. 18. Position and fully seat trunk RH liner. 19. Connect ground cable to battery terminal. Refer to <<86.15.15>>. 20. Manually guiding latch striker into header mechanism, power convertible top to fully raised position 21. Accessing through cover plate apertures, tighten mounting bracket securing bolts. 22. Tighten rear quarter inner seal carrier rear securing bolts. 23. Remove protective sheet from rear bodywork. 24. Power convertible top to fully lowered position and back to fully raised position, checking for satisfactory operation and ensuring thar cover is correctly tensioned and fre from ripples or sagging 25. Position security aerial and fit and tighten mounting bracket securing screws. 26. Fit and tighten security aerial 'P' clip securing bolt. 27. Position ground cable eyelet and fit and tighten securing bolt. 28. Position squab panel stiffener bracket and fit and tighten securing bolts. 29. Fit heated backlight. Refer to <<76.81.11>>. 30. Fit carpet to convertible top stowage compartment. 31. Fit rear speaker assembly (premium ICE only). Refer to 86.51.06
18 2012-07-22
32. Fit rear quarter trim panels. Refer to <<76.13.73>>. 33. Fit rear quarter panel cappings. 34. Fit rear seat squab. Refer to <<76.70.38>>. 35. Fit rear seat cushion. Refer to <<76.70.37>>. 36. Connect backlight heater.harness connectors. 37. Fit battery cover.
www.JagDocs.com
19
2012-07-22
Convertible Top Headliner 76.86.16

Removal 1. Remove carpet from convertible top stowage compartment.
2. Disconnect heated backlight harness connectors and position harness clear of top. 3. Power top to fully down position. 4. Remove rear seat cushion. Refer to <<76.70.37>>. 5. Remove rear seat squab. Refer to <<76.70.38>>. 6. Remove rear quarter casing cappings Refer to <<76.13.73>>. 7. Remove rear quarter casings. Refer to <<76.13.73>>. 8. Remove rear speaker -Premium ICE only. Refer to 86.51.06.
2012-07-22
www.JagDocs.com
9. Slacken and remove squab panel stiffener bracket to body securing nuts and remove bracket. 10. NOTE: Do not allow top to latch. Power top to 3/4 closed position. 11. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
12. Position trunk RH liner for access and turn hydraulic pump valve fully counter-clockwise to manual operation position.
2012-07-22
13. Remove LH cantrail seal and carrier. Slacken and remove screws securing LH cantrail seal to frame and withdraw seal. Slacken and remove screws securing LH cantrail seal carrier and remove seal carrier from vehicle. 14. Slacken and remove screws securing RH cantrail seal to frame and remove seal. 15. Slacken and remove screws securing RH cantrail seal carrier and remove seal carrier.
16. Remove LH main column seal and carrier. Withdraw LH main column seal from carrier. Slacken and remove screws securing seal carrier and remove carrier from vehicle. 17. Release and remove RH main column seal from carrier. 18. Slacken and remove screws securing RH main column seal carrier and remove carrier.
2012-07-22
www.JagDocs.com
19. Remove latch striker and guide pins. Slacken and remove latch striker securing screws and remove striker from header plate. Slacken and remove screws securing latch plate guide pins to frame and remove guide pins.
20. Slacken and remove screws securing latch plate to frame and remove latch plate. 21. Noting positions for installation, release bonded sections of cover from frame.
2012-07-22
22. Disconnect roof side tension cables from frame.
23. Release cover front retaining rod from retaining clips in frame and remove rod from cover.
2012-07-22
www.JagDocs.com
24. Noting the positions for installation, release bonded areas of padding bag from frame and withdraw bag from front of frame.
25. Slacken and remove eight screws and outer clips securing padding bag to frame. 26. Manually move top to fully raised position.
2012-07-22
27. Position top cover and padding bag rearwards and release both headlining rear tension rods.
28. Slacken and remove screws securing headlining to main column bracket covers.
2012-07-22
www.JagDocs.com
29. Drill out the two rivets each side, securing rear of headlining.
30. Release section of headlining secured by velcro strips to frame around pull-down handle aperture (bonded on early vehicles).
2012-07-22
31. Exercising care to avoid damaging cords, drill out the two pop rivets securing tension cords to frame. 32. Position tension cords for access.
33. Drill out the seven pop rivets securing front bow rail to top frame and remove rail.
2012-07-22
www.JagDocs.com
34. Withdraw the front bow rail from the headlining piping, tension cords and straps. 35. Position tension cords for access.
36. Drill out pop rivets securing centre bow rail to top frame and remove rail from headlining piping.
10
2012-07-22
37. Withdraw headlining rear edge flange from retaining slot in rear bow rail and position rear tension cables for disconnection.
38. Release and remove tension cable retaining bushes, and disconnect cables from frame.
11
2012-07-22
www.JagDocs.com
39. Release headlining fir tree or press stud fasteners from cantrails. Refer to Note in Step 42.
40. Release front of headlining from double-sided tape on frame. 41. Release the side tension cords and rear tension cables and remove headlining from vehicle. 42. NOTE: On certain early model year vehicles, press-stud fixings securing the the headlining to the frame must be removed and replaced by fir-tree fixings. The procedure for this modification is detailed in Technical Bulletin Number <<501-14>>. Clean rivet swarf from convertible top area and remove double-sided tape from front of frame.
12
2012-07-22
Installation
1. Place headlining in vehicle, positioning and seating rear of lining in rear bow rail slot. 2. Move padding bag forward for access and check that lining is fully seated on rear bow rail.
3. Route rear tension cables through the headlining piping.
13
2012-07-22
www.JagDocs.com
4. Connect rear tension cables onto frame and fit and fully seat retaining bushes. 5. Move padding bag rearward for access. 6. To prevent damage to headlining during fitting, apply protective tape to leading end of centre bow rail.
7. Ensuring correct orientation, feed centre bow rail into the headlining. 8. Manually lower top to halfway position.
14
2012-07-22
9. Align bow rail to frame and secure with pop rivets. 10. To prevent damage to headlining during fitting, apply protective tape to leading end of front bow rail.
11. Fit tension cords and straps to front bow rail. Cut slits in front bow rail piping to accommodate the tension cords and straps. Ensuring that tension cords and straps are not twisted, position them in the appropriate slits in the bow rail piping.
15
2012-07-22
www.JagDocs.com
12. Ensuring correct orientation, feed the front bow rail into the headlining, simultaneously threading tension cords and straps through the piping slits onto the bow rail.
13. Align front bow rail to frame and secure with pop rivets.
16
2012-07-22
14. Using a piece of welding rod or similar draw wire, pull the outer tension cords through the headlining piping.
15. Position the outer tension cords to the frame and secure with pop rivets. 16. Manually move top to fully raised position.
17
2012-07-22
www.JagDocs.com
17. Align rear of headlining, pierce it through existing holes at riveting points in the retaining brackets and pop rivet headlining to retaining brackets.
18. Secure headlining at pull-down handle aperture. Remove backing from Velcro strips and position and firmly seat at pull-down handle aperture. Feed headlining trim material through frame to pull-down handle aperture and secure on Velcro strips.
18
2012-07-22
19. Fit and fully seat new fir tree fasteners securing headlining to frame.
20. Remove backing from double-sided tape on front of headlining and position and firmly seat lining on frame.
19
2012-07-22
www.JagDocs.com
21. Align padding bag to frame and secure with 'P' clips and retaining screws.
22. Apply adhesive to front edge of padding bag and position and fully seat on frame. 23. Manually move top to half down position.
20
2012-07-22
24. Using a piece of welding rod or similar draw wire, pull side tension cables through outer cover and secure them to frame.
25. Apply adhesive to adjacent front positions of cover and frame and fully seat cover on frame.
21
2012-07-22
26. Fit front retaining rod to cover and seat rod in securing clips.
www.JagDocs.com
27. Position latch plate and fit and tighten securing screws.
22
2012-07-22
28. Position guide pins and latch striker and fit and tighten securing screws.
29. Fit cantrail seal carriers. Position cantrail seal carriers and fit but do not securing screws. Ensuring that seal carriers are positioned towards outboard end of elongated holes, tighten securing screws. 30. Fit and fully seat cantrail seals in carriers and fit and tighten securing screws.. 31. Connect ground cable to battery terminal. Refer to <<86.15.15>>.
23
2012-07-22
www.JagDocs.com
32. Turn hydraulic pump valve fully clockwise to power operation position and return trunk RH liner to correct position. 33. Ensuring that rear quarter lights are fully lowered, power top to fully up and latched position. 34. Apply adhesive to adjacent areas of cover and frame at main column and fully seat cover on frame. 35. Power top to half down position.
36. Fit main column seal carriers. Position main column seal carriers and fit but do not tighten securing screws. Ensuring that carriers are positioned towards outboard end of elongated holes, tighten securing screws. 37. Fit and fully seat main column seals in carriers.
24
2012-07-22
38. Power top to fully up and latched position.
39. Position headlining and fit and fully seat rear securing rods.
40. Position headlining over cover plates and fit and tighten securing screws. 41. Remove protective tape from BIW. 42. Power top from fully down to fully up positions, checking for satisfactory operation and ensuring that cover is correctly tensioned and free from rippling.
25
2012-07-22
www.JagDocs.com
43. Position squab panel stiffener bracket and fit and tighten securing nuts. 44. Fit carpet to convertible top stowage compartment. 45. Fit rear speaker assemblies. Refer to 86.51.06. 46. Fit rear quarter trim panels. Refer to <<76.13.73>>. 47. Fit rear quarter panel cappings. Refer to <<76.13.73>>. 48. Fit rear seat squab. Refer to <<76.70.38>>. 49. Fit rear seat cushion. Refer to <<76.70.37>>. 50. Connect backlight heater harness multiplugs. 51. Fit battery cover.
26
2012-07-22
Convertible Top Hydraulic Lift Cylinder 76.86.17

Removal 1. Power convertible top to fully lowered position. 2. Power adjacent front seat to fully forward position. 3. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 4. Remove rear seat cushion. Refer to <<76.70.37>>. 5. Remove rear seat squab. Refer ti <<76.70.38>>. 6. Remove rear quarter casing cappings. Refer to <<76.13.73>>. 7. Remove rear quarter casings. Refer to <<76.13.73>>. 8. Remove rear speaker (premium ICE only). Refer to 86.51.06.
9. Position trunk RH liner for access and turn hydraulic pump valve fully counter-clockwise to manual operation position. 10. Manually move convertible top to fully raised position.
2012-07-22
www.JagDocs.com
11. Remove clip/pin assembly securing hydraulic cylinder to frame linkage.
12. Disconnect hydraulic cylinder harness multiplug (RH hydraulic cylinder only).
2012-07-22
13. Free headlining rear quarter for access. Slacken and remove mounting bracket cover plate lower securing screw, position headlining for access and remove two remaining screws.
14. Move hydraulic cylinder clear of half pivot and remove and retain wavy washer from pivot. 15. Position a piece of absorbent cloth below hydraulic cylinder to protect paintwork from any fluid spillage.
2012-07-22
16. Identify and mark position of hoses relative to hydraulic cylinder connectors, disconnect hoses and remove and discard 'O' ring seals. 17. Fit blanking plugs to hydraulic cylinder and hose connectors. 18. Remove hydraulic cylinder from vehicle.
www.JagDocs.com
Installation 1. Remove blanking plugs from hose and pump connectors. 2. Install new 'O' ring seals in hose connectors. 3. Position hydraulic cylinder in vehicle and ensuring correct orientation as marked during removal, fit and tighten hose connectors to cylinder.
2012-07-22
4. Fit wavy washer to mounting bracket pivot and install and fully seat hydraulic cylinder on pivot.
5. Fit mounting bracket cover plate, ensuring that inner half pivot locates in cylinder recess and fit and tighten upper securing screws.
2012-07-22
6. Position headlining rear quarters over mounting bracket cover plates and fit and tighten lower securing screws.
www.JagDocs.com
7. Connect hydraulic cylinder harness multiplug (RH hydraulic cylinder only).
2012-07-22
8. Fit hydraulic cylinder to frame. Align and extend cylinder actuating rod to convertible top frame location. Fit and fully seat clip/pin assembly to secure cylinder rod end on frame. 9. Manually move convertible top to fully lowered position.
10. Turn hydraulic pump valve fully clockwise to power operation position. 11. Connect ground cable to battery terminal. Refer to <<86.15.15>>. 12. Check hydraulic system for satisfactory operation and freedom from leaks. 1. Power top to fully raise position. 2. Power top to fully lowered position. 3. Power top to fully raised position. 4. Check all connections for leakage.
2012-07-22
13. Remove protective cloth positioned below ram. 14. Remove trunk floor carpet. 15. Remove trunk front liner. Refer to <<76.19.31>>. 16. Remove trunk rear finisher. Refer to <<76.19.44>>. 17. Remove trunk RH liner. 18. Position a piece of absorbent cloth on trunk floor to protect paintwork from any fluid spillage.
19.
CAUTION: Two fluid levels are marked on the pump reservoir body. The upper mark denotes the fluid level when the top is fully lowered and the lower mark denotes the level when the top is fully raised. NOTE: The convertible top hydraulic system is 'self-bleeding' and does not require further action to expel entrapped air.
www.JagDocs.com
Slacken and remove reservoir filler plug and remove and discard 'O' ring seal. 20. Check fluid level and top up .as necessary. 21. Fit new 'O' ring seal to filler plug. 22. Fit and fully tighten filler plug on reservoir. 23. Remove protective cloth from trunk floor. 24. Fit RH liner to trunk. 25. Fit trunk rear finisher. Refer to <<76.19.44>>. 26. Fit trunk front liner. Refer to <<76.19.31>>. 27. Fit trunk floor carpet. 28. Fit battery cover. 29. Fit rear speaker assemblies. Refer to 86.51.06. 30. Fit rear quarter casings. Refer to <<76.13.73>>. 31. Fit rear quarter casing cappings.
2012-07-22
32. Fit rear seat squab. Refer to <<76.70.38>>. 33. Fit rear seat cushion. Refer to <<76.70.37>>. 34. Power adjacent front seat to original position.
2012-07-22
Convertible Top Hydraulic Lift Cylinder Hoses 76.86.24

Removal 1. Power convertible top to fully lowered position. 2. Power adjacent seat to fully forward position. 3. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 4. Remove trunk floor carpet. 5. Remove trunk front liner. Refer to <<76.19.31>>. 6. Remove trunk rear finisher. Refer to <<76.19.44>>. 7. Remove trunk RH liner. 8. Position a piece of absorbent cloth on trunk floor to protect paintwork from any fluid spillage.
www.JagDocs.com
9. Turn hydraulic pump valve fully counter-clockwise to manual operation position. 10. Remove rear seat cushion. Refer to <<76.70.37>>. 11. Remove rear seat squab. Refer to <<76.70.38>>. 12. Remove rear quarter casing cappings. Refer to <<76.13.73>>. 13. Remove rear quarter casings. Refer to <<76.13.73>>.
2012-07-22
14. Remove rear speaker (premium ICE only). Refer to 86.51.06. 15. Manually move top to fully raised position. 16. Position a piece of absorbent cloth below hydraulic cylinder to protect paintwork from any fluid spillage.
17. Disconnect hoses from hydraulic cylinder. Identify and mark position of hoses relative to hydraulic cylinder connectors. Slacken and remove hoses from hydraulic cylinder and fit blanking plugs to cylinder and hose connectors. 18. Remove carpet from convertible top stowage compartment.
19. Route free end of each hose under headlining and rear harnesses and around seat squab support panel to RH side of vehicle (LH hydraulic cylinder hoses only).
2012-07-22
20. Sever, remove and discard tie straps securing hoses and rear harness to BIW.
www.JagDocs.com
21. Slacken and remove the two pump assembly securing bolts, release pump from outboard grommet locations and position for access to outboard hoses.
22. Identify and mark pump outboard hose connections. 1. LH cylinder: Pump rear connectors - hydraulic cylinder bottom hose to lower connector. NOTE: Pump inboard connectors are for latch operating hoses only. 2. RH cylinder: Pump front connectors - hydraulic cylinder top hose to lower connector. 23. Disconnect appropriate hoses from pump, remove and discard 'O' ring seals and fit blanking plugs to hoses and pump connectors.
2012-07-22
24. Carefully withdraw hoses through BIW aperture into vehicle interior and remove hoses from vehicle.
Installation 1. Place hydraulic hoses in convertible top stowage compartment. 2. LH hydraulic cylinder only: Route pump connecting ends of hoses across top stowage compartment to RH side of vehicle.
3. Pass pump connecting ends of hoses through BIW RH aperture and into trunk.
2012-07-22
www.JagDocs.com
4. LH cylinder only: Route hydraulic cylinder end of hoses around LH end of seat squab support panel and under rear harnesses and headlining to cylinder location. 5. Remove blanking plugs from hydraulic cylinder and corresponding hose connectors, fit new 'O' ring seals to hose connectors.
6. Noting identifying marks applied during removal, connect and tighten hoses onto cylinder. 7. Remove blanking plugs from hydraulic pump and corresponding hose connectors and fit new 'O' ring seals to hose connectors.
2012-07-22
8. Connect and tighten hoses on pump outboard connectors ensuring corrct orientation as follows: 1. LH cylinder: Pump rear connectors - cylinder bottom hose to lower connector. NOTE: Pump inboard connectors are for latch operating hoses only. 2. RH cylinder: Pump front connectors - cylinder top hose to lower connector. 9. Fit new tie straps to BIW, position harness and hoses in straps and tighten straps to secure. 10. Fit carpet to convertible top stowage compartment. 11. Position pump on platform and fully seat rubber mounting grommets. 12. Fit and tighten pump securing bolts. 13. Manually move convertible top to fully lowered position.
2012-07-22
14. Turn hydraulic pump valve fully clockwise to power operation position. 15. Connect ground cable to battery terminal. Refer to <<86.15.15>>. 16. Check hydraulic system for satisfactory operation and all connections for freedom from leaks. 1. Power top to fully raise position. 2. Power top to fully lowered position. 3. Power top to fully raised position. 4. Check hose connections for leakage.
www.JagDocs.com
17.
Slacken and remove reservoir filler plug and remove and discard 'O' ring seal. 18. Check fluid level and top up .as necessary. 19. Fit new 'O' ring seal to filler plug. 20. Fit and fully tighten filler plug on reservoir. 21. Remove protective cloth from trunk floor. 22. Fit RH liner to trunk. 23. Fit trunk rear finisher. Refer to <<76.19.44>>.
2012-07-22
24. Fit trunk front liner. Refer to <<76.19.31>>. 25. Fit trunk floor carpet. 26. Fit battery cover. 27. Fit rear speaker assemblies. Refer to 86.51.06. 28. Fit rear quarter casings. Refer to <<76.13.73>>. 29. Fit rear quarter casing cappings. 30. Fit rear seat squab. Refer to <<76.70.38>>. 31. Fit rear seat cushion. Refer to <<76.70.37>>. 32. Power adjacent front seat to original position.
2012-07-22
Convertible Top Hydraulic Pump 76.86.06

Removal 1. Power convertible top to fully lowered position. 2. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 3. Remove trunk floor carpet. 4. Remove trunk front liner. Refer to <<76.19.31>>. 5. Remove trunk rear finisher. Refer to <<76.19.44>>. 6. Remove trunk RH liner.
www.JagDocs.com
7. Sever and remove tie strap securing pump harness multiplug to pump hose and disconnect multiplug from pump motor.
2012-07-22
8. Disconnect harness multiplugs from raise and lower solenoid control valves. 9. Position a piece of absorbent cloth on trunk floor to protect paintwork from any fluid spillage.
10. Identify and mark position of inboard hoses relative to pump, disconnect hoses, remove and discard 'O' ring seals and fit blanks to pump and hose connectors.
2012-07-22
www.JagDocs.com
11. Slacken and remove the two pump assembly securing bolts.
12. Remove pump from mounting. Release pump from outboard grommet locations and position pump for access to outboard hoses. Identify and mark position of outboard hoses relative to pump, disconnect hoses, remove and discard 'O' ring seals and fit blanks to hose and pump connectors. 13. Remove pump from trunk. 14. If pump is to be renewed: 1. Remove and retain mounting rubbers from pump. 2. Remove connector blanks. 3. Slacken and remove pump reservoir filler ,plug 4. Invert pump over a suitable receptacle and allow fluid to completely drain. 5. Fit and tighten reservoir filler plug and connector blanks.
3 2012-07-22
Installation 1. Ensure that convertible top is in fully lowered position.
2.
CAUTION: Two fluid levels are marked on the pump reservoir body. The upper mark denotes the fluid level when the top is fully lowered and the lower mark denotes the level when the top is fully raised.
Slacken and remove the filler plug, fill the reservoir with correct fluid to the upper mark on the reservoir body and fit and tighten filler plug. 3. Fit and fully seat rubber mounting grommets to base of pump assembly. 4. Remove blanks from pump outboard connectors. 5. Remove blanks and fit new 'O' ring seals to outboard hoses. 6. Position pump on trunk platform for access to outboard connectors. 7. Noting positional marks made during removal, connect and fully tighten outboard hoses on pump. 8. Position pump on platform and fully seat mounting grommets. 9. Fit and tighten pump securing bolts. 10. Remove blanks from inboard connectors and associated hoses. 11. Fit new 'O' ring seals to inboard hoses and noting positional marks, connect and fully tighten hoses on pump connectors
2012-07-22
12. Position pump harness correctly and connect multiplugs to solenoid control valves. 13. Connect harness multiplug to pump motor. 14. Secure pump motor harness to hoses using new tie strap. 15. Connect ground cable to battery terminal. Refer to <<86.15.15>>. 16. Check hydraulic system for satisfactory operation and freedom from leaks: 1. Power top to fully raised position. 2. Power top to fully lowered position. 3. Power top to fully raised position.
17.
www.JagDocs.com
Slacken and remove pump reservoir filler plug. 18. Check fluid level and top up as necessary to lower mark on reservoir. 19. Fit and tighten reservoir filler plug. 20. Remove protective cloth from trunk floor. 21. Fit RH liner to trunk. 22. Fit trunk rear finisher. Refer to <<76.19.44>>. 23. Fit trunk front liner. Refer to <<76.19.31>>. 24. Fit trunk floor carpet. 25. Fit battery cover.
2012-07-22
Convertible Top Latch 76.86.19

Removal 1. Power convertible top to fully lowered position. 2. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 3. Remove roof console. Refer to <<76.13.69>>.
4. Where fitted, disconnect microphone harness multiplug. 5. Remove the sun visors. Refer to <<76.10.48>> 6. Remove the sun visor retaining clips. Refer to <<76.10.58>> 7. Remove 'A' post upper trim finishers. Refer to <<76.13.31>>.
2012-07-22

8. Carefully remove and discard fir tree fastener retaining trim finisher on header rail and remove finisher from header rail.
www.JagDocs.com
9. Remove and discard retaining stud from LH end of header seal.
10. Lift rear edge of seal for access and slacken and remove latch cover LH end securing screw. 11. Remove retaining stud from RH end of header seal, lift rear edge of seal for access and slacken and remove latch cover RH end securing screw.
2012-07-22
12. Slacken and remove two remaining latch cover securing screws and remove latch cover from header rail.
13. Disconnect convertible top harness multiplug.
2012-07-22
14. Release hydraulic hose retaining clips from LH upper 'A' post.
www.JagDocs.com
15. Release sun visor harness multiplugs from retainers on latch assembly bracket.
2012-07-22
16. Slacken and remove the seven latch assembly to BIW header lower securing screws.
17. Slacken and remove the latch assembly to BIW header upper securing screws.
2012-07-22
18. NOTE: When carrying out the following operation, do not disturb securing bolts installed in the open-ended slots. Slacken and remove the latch assembly to BIW header rear securing screws.
www.JagDocs.com
19. Supporting latch assembly, slacken but do not remove securing bolts installed in the rear inner open-ended slots.
2012-07-22
20. Withdraw latch assembly and sever and remove tie straps securing hydraulic hoses to assembly.
21. Remove spring clip from latch actuator clevis pin and withdraw pin.
2012-07-22
22. Pull retaining lever away from latch hydraulic cylinder.
www.JagDocs.com
23. Lift hydraulic cylinder to vertical position and separate from latch assembly. 24. Remove latch assembly from vehicle.
Installation
2012-07-22
1. Position hydraulic cylinder vertically in latch assembly slots and lower to engage lugs.
2. Retain hydraulic cylinder in latch assembly. Move locking lever across to secure actuator. Fit and fully seat clevis pin. Fit retaining clip to clevis pin. 3. Using new tie strap, secure hydraulic hoses to latch assembly.
2012-07-22
4. Ensuring that hydraulic hoses are not trapped, position open-ended slots in rear face of latch assembly under the undisturbed rear screws.
www.JagDocs.com
5. Supporting the latch assembly, fit but do not tighten the two top securing screws. 6. Fit but do not tighten the remaining securing screws. 7. Tighten the two top securing screws. 8. Tighten all remaining securing screws. 9. Install sun visor harness multiplugs on latch assembly bracket retainers. 10. Connect latch assembly harness multiplug. 11. Fit and fully seat hydraulic hose retaining clips on upper 'A' post
10
2012-07-22
12. Fit latch assembly cover panel. Refer to <<76.86.20>>. 13. Position trim finisher on header rail and secure with new fir tree fastener, exercising care to avoid damaging finisher. 14. Fit upper 'A' post trim finisher. Refer to <<76.13.31>>. 15. Fit the sun visor retaining clips. Refer to <<76.10.58>> 16. Fit the sun visors. Refer to <<76.10.48>> 17. Where applicable, connect microphone harness multiplug. 18. Fit roof console. Refer to <<76.13.69>>. 19. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>. 20. Check hydraulic system for satisfactory operation and all connections for freedom from leaks. 1. Power top to fully raised position. 2. Power top to fully lowered position. 3. Power top to fully raised position.
11
2012-07-22
Convertible Top Latch Hydraulic Cylinder 76.86.21

Removal 1. Remove convertible top latch assembly for access. Refer to <<76.86.19>>. 2. Sever and remove tie straps securing hydraulic hoses to latch assembly. 3. Identify and mark position of hydraulic hoses relative to hydraulic cylinder. 4. To protect the vehicle interior from any fluid spillage, position a plastic sheet immediately below the hydraulic cylinder.
www.JagDocs.com
5. Disconnect hydraulic hoses from hydraulic cylinder, remove and discard 'O' ring seals from hose connectors and fit blanking plugs to hydraulic cylinder and hoses. 6. Place latch assembly on a clean work surface.
2012-07-22
7. Remove spring clip from hydraulic cylinder clevis pin and withdraw pin.
8. Pull retaining lever away from latch hydraulic cylinder.
2012-07-22
9. Lift hydraulic cylinder to vertical position and separate from latch assembly.
www.JagDocs.com
Installation
1. Position hydraulic cylinder in latch assembly slots and lower to engage lugs.
2012-07-22
2. Move locking lever across to secure hydraulic cylinder.
3. Fit and fully seat clevis pin and fit retaining cip.
2012-07-22
www.JagDocs.com
4. Connect hoses to hydraulic cylinder. Position latch assembly in vehicle, remove blanking plugs from hoses and cylinder connectors and fit new 'O' ring seals to hose connectors. Noting marked positions, fit and tighten hoses to actuator, ensuring that hoses are not twisted or distorted. 5. Remove plastic protective sheet from vehicle interior. 6. Using a new tie strap, secure hydraulic hoses to the latch assembly. 7. Fit latch assembly to BIW header. Refer to <<76.86.19>>. 8. Fit latch assembly cover panel. Refer to <<76.86.20>>. 9. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>. 10. Check hydraulic system for satisfactory operation and freedom from leaks. 1. Power top to fully raised position. 2. Power top to fully lowered position. 3. Power top to fully raised position. 4. Check that hose connections are free from leakage. 11. Position trim finisher on header rail and secure with new fir tree fastener, exercising care to avoid damaging finisher. 12. Fit upper 'A' post trim finisher. Refer to <<76.13.31>>. 13. Fit sun visors and retention bezels. Refer to 76.10.47. 14. Where applicable, connect microphone harness multiplug. 15. Fit roof console. Refer to <<76.13.69>>.
2012-07-22
Convertible Top Latch Hydraulic Cylinder Hoses 76.86.22

Removal 1. Power convertible top to fully lowered position. 2. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 3. Remove trunk floor carpet. 4. Remove trunk front liner. Refer to <<76.19.31>>. 5. Remove trunk rear finisher. Refer to <<76.19.44>>. 6. Remove trunk RH liner. 7. Position a piece of absorbent cloth on trunk floor to protect paintwork from any fluid spillage.
8. Sever and remove tie strap securing hydraulic pump hose to pump harness.
2012-07-22
www.JagDocs.com
9. Mark with location and slacken and disconnect hydraulic hoses from pump. 10. Remove and discard 'O' ring seals from hose connectors and fit blanking plugs to hoses and pump connectors. 11. Remove rear seat cushion. Refer to <<76.70.37>>. 12. Remove rear seat squab. Refer to <<76.70.38>>. 13. Remove LH rear quarter casing capping. Refer to <<76.13.73>>. 14. Remove LH rear quarter casing. Refer to <<76.13.73>>. 15. Remove LH rear speaker (premium ICE only). Refer to 86.51.06. 16. Remove front LH seat. Refer to 76.70.01.90. 17. Remove 'J' gate surround. Refer to <<76.25.24>>. 18. Remove centre console. Refer to <<76.25.01>>. 19. Remove LH sill treadplate. Refer to 76.76.01. 20. Remove glovebox. Refer to <<76.52.03>>. 21. Remove fascia LH end fusebox. Refer to <<86.70.57>>. 22. Remove roof console. Refer to <<76.13.69>>.
2012-07-22
23. Remove the sun visors. Refer to <<76.10.48>> 24. Remove the sun visor retaining clips. Refer to <<76.10.58>> 25. Remove 'A' post upper trim finishers. Refer to <<76.13.31>>.
26. Where applicable disconnect microphone harness multiplug. 27. Carefully remove and discard fir tree fastener retaining trim finisher on header rail and remove finisher from header rail. 28. Remove convertible top latch assembly cover panel. Refer to <<76.86.20>>.
29. Disconnect convertible top harness multiplug.
2012-07-22
30. Release hydraulic hose retaining clips from LH upper 'A' post.
www.JagDocs.com
31. Release sun visor multiplugs from retainers on latch assembly bracket. 32. Position a piece of absorbent cloth in LH footwell to protect vehicle interior from any fluid spillage.
2012-07-22
33. Slacken and remove the latch assembly to BIW header lower securing screws.
34. Slacken and remove the latch assembly to BIW header upper securing screws.
2012-07-22
35. NOTE: When carrying out the following operation, do not disturb securing bolts installed in the open-ended slots. Slacken and remove the latch assembly to BIW header rear securing screws.
www.JagDocs.com
36. Supporting latch assembly, slacken but do not remove securing screws installed in rear open-ended slots. 37. Withdraw latch assembly, position in LH footwell and sever and remove tie straps securing hoses to latch hydraulic cylinder and harness.
2012-07-22
38. Mark latch hydraulic cylinder hoses with locations and disconnect hoses from cylinder assembly. 39. Remove and discard 'O' ring seals from hoses and fit blanking plugs to hoses and hydraulic cylinder connectors. 40. Remove and discard tape securing hoses to 'A' post adjacent to top of fascia.
41. Withdraw hoses from retaining clips in fascia LH end fusebox aperture. 42. Route hoses from behind fascia to lower 'A' post. 43. Remove tape securing hoses to front of inner sill.
2012-07-22
www.JagDocs.com
44. Lift edge of LH carpet for access, sever and remove tie straps securing hoses and release hoses from BIW clips.
45. Release hoses from spring clip at transmission tunnel and draw hoses under carpet to tunnel.
2012-07-22
46. Lift LH carpet at transmission tunnel and heel board and release hoses from retaining clips. 47. withdraw hoses from under transmission tunnel insulation, harness and carpet.
48. Rotate hydraulic pump valve fully counter-clockwise to the manual operation position. 49. Manually move convertible top to fully up position. 50. Sever and remove tie straps securing hoses to power cable and rear harness.
2012-07-22
www.JagDocs.com
51. Carefully withdraw hoses through BIW aperture into vehicle interior and remove from vehicle.
Installation 1. Position hoses in convertible top stowage compartment. 2. Route hydraulic pump end of hoses through BIW aperture into trunk. 3. Remove blanking plugs from hoses and pump connectors. 4. Fit new 'O' ring seals to hoses and fit and tighten hoses onto pump. 5. Mark free end of each hose with position of corresponding connector on latch hydraulic cylinder as identified on removal. 6. Secure pump harness to hoses with new tie strap. 7. Route hydraulic hoses along rear harness and power cable and using new tie straps secure hoses to BIW at rear quarter above wheel arch. 8. Using new tie straps, secure rear harness and hydraulic hoses to BIW. 9. Using new tie straps, secure hydraulic hoses to power cable. 10. Manually move convertible top to fully lowered position. 11. Route hydraulic hoses under carpet, transmission tunnel insulation and harness. 12. Fit and fully seat hoses in retaining clips on carpet underside.
10
2012-07-22
13. Fit and secure hoses in new BIW tie straps. 14. Route hoses under carpet across rear of footwell to 'A' post.
15. Install hoses in spring clip at transmission tunnel. 16. Under front section of carpet, fit new tie straps to BIW and secure hydraulic hoses.
17. Route hoses up LH 'A' post, and accessing through fascia end fuse box aperture, fit and fully seat in retaining clips. 18. Using linen tape, secure hydraulic hoses to front of inner sill and top and bottom of upper 'A' post. 19. Remove blanking plugs from hose connectors and fit new 'O' ring seals.
11
2012-07-22
20. Noting positions marked on hose connectors, fit and tighten hoses on hydraulic cylinder. 21. Using new tie strap, secure hoses to hydraulic cylinder. 22. Fit and fully seat hydraulic hose retaining clips on upper 'A' post. 23. Fit fascia LH end fusebox. Refer to <<86.70.57>>. 24. Fit latch assembly to header rail. Refer to <<76.86.19>>. 25. Fit glovebox. Refer to <<76.52.03>>. 26. Fit sill tread plate. Refer to 76.76.01. 27. Fit centre console. Refer to <<76.25.01>>. 28. Fit 'J' gate surround. Refer to <<76.25.24>>. 29. Fit rear speaker assemblies. Refer to 86.51.06. 30. Connect ground cable to battery terminal. Refer to <<86.15.15>>. 31. Rotate hydraulic pump valve fully clockwise to power operation position. 32. Check hydraulic system for satisfactory operation. 1. Power top to fully raised position. 2. Power top to fully lowered position. 3. Power top to fully raised position. 4. Check that all hose connections are free from leakage.
www.JagDocs.com
12
2012-07-22
33. Remove protective cloth from LH footwell. 34. Fit LH rear quarter trim panel. Refer to <<76.13.73>>. 35. Fit LH rear quarter panel capping. 36. Fit rear seat cushion. Refer to <<76.70.37>>. 37. Fit rear seat squab. Refer to <<76.70.38>>. 38. Fit front seat. Refer to 76.70.01.90.
39.
CAUTION: Two fluid levels are marked on the pump reservoir body. The upper mark denotes fluid level when the top is fully lowered and the lower mark denotes the level when the top is fully raised. NOTE: The convertible top hydraulic system is 'self-bleeding' and does not require any further action to dispel entrapped air.
Slacken and remove reservoir filler plug and remove and discard 'O' ring seal. 40. Check fluid level and top up as necessary to low mark on reservoir. 41. Fit new 'O' ring seal to filler plug and fit and fully tighten on reservoir.. 42. Remove protective cloth from trunk floor. 43. Fit RH liner to trunk. 44. Fit trunk rear finisher. Refer to <<76.19.44>>. 45. Fit trunk front liner. Refer to <<76.19.31>>. 46. Fit trunk floor carpet. 47. Fit battery cover.
13
2012-07-22
Convertible Top Material 76.86.12

Removal 1. Remove carpet from top stowage compartment.
www.JagDocs.com
2. Disconnect backlight heater harness multiplugs. 3. Ensuring that backlight heater harness is clear, power top to fully lowered position. 4. Remove rear seat cushion. Refer to <<76.70.37>>. 5. Remove rear seat squab. Refer to <<76.70.38>>. 6. Remove LH and RH rear quarter trim cappings. Refer to <<76.13.73>>. 7. Remove LH and RH rear quarter trim panels. Refer to <<76.13.73>>. 8. Remove rear speaker assemblies. Refer to 86.51.06.
2012-07-22
9. Slacken and remove nuts securing squab panel stiffener bracket to BIW and remove bracket from vehicle. 10. Remove heated backlight from roof. Refer to <<76.81.11>>.
11. Noting their positions, remove staples securing cover to backlight frame and release cover from frame. 12. NOTE: Do not allow top to latch. Power top to 3/4 closed position. 13. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
2012-07-22
www.JagDocs.com
14. Position trunk RH liner for access and turn hydraulic pump valve fully counter-clockwise to manual operation position.
15. Remove LH cantrail seal and carrier. Slacken and remove screws securing LH cantrail seal to frame and withdraw seal. Slacken and remove screws securing LH cantrail seal carrier and remove seal carrier from vehicle. 16. Slacken and remove screws securing RH cantrail seal to frame and remove seal. 17. Slacken and remove screws securing RH cantrail seal carrier and remove seal carrier.
2012-07-22
18. Remove LH main column seal and carrier. Withdraw LH main column seal from carrier. Slacken and remove screws securing seal carrier and remove carrier from vehicle. 19. Release and remove RH main column seal from carrier. 20. Slacken and remove screws securing RH main column seal carrier and remove carrier.
21. Remove latch striker and guide pins. Slacken and remove latch striker securing screws and remove striker from header plate. Slacken and remove screws securing latch plate guide pins to frame and remove guide pins.
2012-07-22
22. Slacken and remove screws securing latch plate to frame and remove latch plate. 23. Noting positions for installation, release bonded sections of cover from frame.
www.JagDocs.com
24. Disconnect convertible top side tension cables from frame.
2012-07-22
25. Release cover front retaining rod from retaining clips in frame and remove rod from cover. 26. Manually close but do not latch top.
27. Slacken and remove screws securing headlining rear quarters to main column bracket cover plates.
2012-07-22
28. Release and remove headlining rear securing rods.
www.JagDocs.com
29. Slacken and remove bolts securing rear tack strip to BIW.
2012-07-22
30. Withdraw tack strip from vehicle and remove end covers from tack strip. 31. Apply protective tape to adjacent painted areas of BIW.
32. Position tack strip clear of BIW and drill out pop rivets securing tack strip to cover.
2012-07-22
33. Release cover from tack strip and withdraw side tension cables through cover piping. 34. Remove cover from vehicle. 35. Remove sealing strip from backlight frame and clean off any residual sealant. 36. Noting positions for installation, clean residual adhesive from frame. 37. Using white spirit, ensure that frame is grease free and dry.
www.JagDocs.com
Installation
1. Apply new sealant strip to backlight frame.
2012-07-22
2. Place cover on clean work surface, fold in half to determine centre and mark centreline with tape at rear edge. 3. Measure and mark centreline of tack strip.
4. Position cover on frame, aligning tape with tack strip centreline.
5. NOTE: It may be necessary to use a suitably soft drift and mallet to fully seat cover in tack strip. Fit and fully seat rear edge of cover in tack strip retaining flange. 6. Using a suitable pointed tool pierce cover through existing holes in tack strip, drill through penetrations and pop rivet cover to tack strip. 7. Fit end covers to tack strip.
10
2012-07-22
8. Position tack strip on BIW and commencing in centre fit and tighten securing bolts.
www.JagDocs.com
9. Using a piece of welding rod or similar material, draw side tension cables through cover piping 10. Ensure that cover is correctly positioned on frame. 11. Manually lower top to halfway position.
11
2012-07-22
12. Connect side tension cables to frame.
13. Apply adhesive to adjacent front positions of cover and frame and fully seat cover on frame.
12
2012-07-22
14. Fit front retaining rod to cover and seat rod in retaining clips.
www.JagDocs.com
15. Position latch plate and fit and tighten securing screws.
13
2012-07-22
16. Fit guide pins and latch striker. Position guide pins and fit and tighten securing screws. Position latch striker and fit and tighten securing screws.
17. Fit cantrail seal carriers. Position cantrail seal carriers and fit but do not securing screws. Ensuring that seal carriers are positioned towards outboard end of elongated holes, tighten securing screws. 18. Fit and fully seat cantrail seals in carriers and fit and tighten securing screws.. 19. Connect ground cable to battery terminal. Refer to <<86.15.15>>.
14
2012-07-22
20. Turn hydraulic pump valve fully clockwise to power operation position. 21. Ensuring that rear quarter lights are fully lowered, power top to fully up and latched position.
www.JagDocs.com
22. Apply adhesive to adjacent areas of cover and frame at main column and fully seat cover on frame. 23. Power top to half down position.
15
2012-07-22
24. Fit main column seal carriers. Position main column seal carriers and fit but do not tighten securing screws. Ensuring that carriers are positioned towards outboard end of elongated holes, tighten securing screws. 25. Fit and fully seat main column seals in carriers. 26. Power top to fully up and latched position.
27. Staple cover to backlight frame. Commencing at bottom centre and working to position half-way up one side, staple cover to backlight frame. If necessary, slit cover within backlight frame to relieve tension. Repeat stapling operation along opposite side.
16
2012-07-22
www.JagDocs.com
28. Commencing at top centre, staple cover along top and down sides to meet previous stapling, if necessary, gradually slitting cover within frame to relieve tension in fabric. At each corner, add a further outer row of staples for reinforcement.
29. Trim off excess fabric to facilitate backlight fitment.
17
2012-07-22
30. Position headlining and fit and fully seat rear securing rods.
31. Position headlining over cover plates and fit and tighten securing screws. 32. Remove protective tape from BIW. 33. Power top from fully down to fully up positions, checking for satisfactory operation and ensuring that cover is correctly tensioned and free from rippling.
18
2012-07-22
www.JagDocs.com
34. Position squab panel stiffener bracket and fit and tighten securing nuts. 35. Fit heated backlight. Refer to <<76.81.11>>. 36. Fit carpet to convertible top stowage compartment. 37. Fit rear speaker assemblies. Refer to 86.51.06. 38. Fit rear quarter trim panels. Refer to <<76.13.73>>. 39. Fit rear quarter panel cappings. Refer to <<76.13.73>>. 40. Fit rear seat squab. Refer to <<76.70.38>>. 41. Fit rear seat cushion. Refer to <<76.70.37>>. 42. Connect backlight heater harness multiplugs. 43. Fit battery cover.
19
2012-07-22
Header Rail Lower Trim Panel 76.64.16.70

1. Remove roof console. Refer to <<76.13.69>>. 2. Remove interior mirror. Refer to <<76.10.56>>. 3. Remove the sun visors. Refer to <<76.10.48>> 4. Remove the sun visor retaining clips. Refer to <<76.10.58>> 5. Remove both 'A' post upper finishers. Refer to <<76.13.31>>.
6. Withdraw finisher from header rail. Installation
1. Position and fully seat finisher on header rail. 2. Install 'A' post upper finishers. Refer to <<76.13.31>>.
2012-07-22
3. Install the sun visor retaining clips. Refer to <<76.10.58>> 4. Install the sun visors. Refer to <<76.10.48>> 5. Install roof console. Refer to <<76.13.69>>. 6. Install interior mirror. Refer to <<76.10.56>>.
www.JagDocs.com
2012-07-22
Header Rail Upper Trim Panel 76.86.20

Removal 1. Power convertible top to fully lowered position. 2. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 3. Remove roof console. Refer to <<76.13.69>>.
4. Where fitted, disconnect microphone harness multiplug. 5. Remove the sun visors. Refer to <<76.10.48>> 6. Remove sun visor retaining clips. Refer to <<76.10.58>> 7. Remove 'A' post upper trim finishers. Refer to <<76.13.31>>.
2012-07-22

8. Carefully remove and discard fir tree fastener retaining trim finisher on header rail and remove finisher from header rail.
www.JagDocs.com
9. Carefully remove and discard retaining stud from LH end of header seal.
10. Lift rear edge of seal for access and slacken and remove latch cover LH securing screw. 11. Remove and discard retaining stud from RH end of header seal, lift rear edge of seal and slacken and remove latch cover RH securing screw.
2012-07-22
12. Slacken and remove the latch cover centre securing screws and remove latch cover from header rail.
Installation 1. Position latch cover on header rail and fit and tighten centre securing screws. 2. Lift RH edge of header seal for access and fit and tighten the latch cover RH securing screw. 3. Fit and fully seat new retaining stud to RH end of header seal. 4. Lift LH edge of header seal for access and fit and tighten the latch cover LH securing screw. 5. Fit and fully seat new retaining stud to LH end of header seal. 6. Ensuring that microphone flying lead is routed towards harness multiplug, position trim finisher on header rail and secure with new fir tree fastener. 7. Fit 'A' post upper trim finishers. refer to <<76.13.31>>. 8. Fit the sun visor retaining clips. Refer to <<76.10.58>> 9. Fit the sun visors. Refer to <<76.10.48>> 10. Connect microphone flying lead to harness. 11. Fit roof console. Refer to <<76.13.69>>. 12. Fit ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>. 13. Power convertible top to fully raised position
3 2012-07-22
Header Rail Weatherstrip

Removal 1. Power the convertible top to the fully lowered position.
www.JagDocs.com
2. Remove the header rail weatherstrip right-hand retaining screw.
3. Detach the header rail weatherstrip right-hand upper retaining clip.
2012-07-22
4. Detach the header rail weatherstrip right-hand lower retaining clips.
5. Detach the header rail weatherstrip from the right-hand locating channel.
2012-07-22
6. Remove the header rail weatherstrip right-hand locating channel.
www.JagDocs.com
7. NOTE: Note the position of the header rail weatherstrip right-hand insulator. Remove and discard the header rail weatherstrip right-hand insulator.
2012-07-22
8. NOTE: Note the position of the header rail weatherstrip right-hand locating channel insulator. Remove and discard the header rail weatherstrip right-hand locating channel insulator.
9. Remove the header rail weatherstrip left-hand retaining screw.
2012-07-22
10. Detach the header rail weatherstrip left-hand upper retaining clip.
www.JagDocs.com
11. Detach the header rail weatherstrip left-hand lower retaining clips.
2012-07-22
12. Detach the header rail weatherstrip from the left-hand locating channel.
13. Remove the header rail weatherstrip left-hand locating channel.
2012-07-22
www.JagDocs.com
14. NOTE: Note the position of the header rail weatherstrip left-hand insulator. Remove and discard the header rail weatherstrip left-hand insulator.
15. NOTE: Note the position of the header rail weatherstrip left-hand locating channel insulator. Remove and discard the header rail weatherstrip left-hand locating channel insulator. 16. NOTE: Note the position of the header rail weatherstrip. Remove the header rail weatherstrip from the header rail.
2012-07-22

Installation 1. CAUTION: Make sure all adhesive has been removed from the insulator mating surfaces. NOTE: Install the header rail weatherstrip to the position noted during removal. NOTE: Install new header rail weatherstrip locating channel insulators to the positions noted during removal. NOTE: Install new header rail weatherstrip insulators to the positions noted during removal. To install, reverse the removal procedure.
2012-07-22
1999 XK RANGE - Bumpers - 501-19
Torques Component Bolts securing bumper beam to strut Bolts securing bumper guide to body Bolts securing energy absorbing strut to body Bolts securing non-energy absorbing strut to body Nm 39 - 51 15,5 - 20,5 22 - 28 15,5 - 20,5
www.JagDocs.com
2012-07-22
Bumpers
Front Bumper
The front bumper is part of a fully integrated 'soft front end' that satisfies bumper impact requirements. The bumper has a polyurethane cover color-matched to the body and moulded to form an elliptical air intake. The cover is secured to the body via fixings to the fenders and the BIW upper crossmember. The lower section of the cover The cover lower extremity is attached to a GMT undertray fitted to assist air flow through the cooling pack and is supported in the center by clips integral with the overrider covers.
2012-07-22

Front Bumper Beam , Mounting Struts and Splitter Vane
www.JagDocs.com
Glass mat thermoplastic (GMT) bumper beams are secured by a single bolt and nut to each of two GMT mounting brackets, each of which is in turn attached to the BIW by three bolts and nuts. Aluminum bumper beams installed for certain markets are similarly mounted, but employ menasco energy absorbing struts instead of GMT mounting brackets. A chromed splitter vane, located centrally in the air intake, is secured to the bumper beam lower face by three rivets. Two polycarbonate overrider covers that fit over the splitter vane and overriders are secured by scrivets to the upper face of the bumper beam. A plastic air deflector is attached to the undertray in each wheelarch area to improve airflow in the front wheel area. Left- and right-handed twin circular fog lamps installed in recesses in the lower section of the cover are accessed by removal of the undertray. Side marker lamps fitted to the bumper cover for some markets, serve only as side reflectors for other markets. Side marker lamps/reflectors are pressed in from the outside and unclipped from inside.
2012-07-22

Rear Bumper Assembly and Mountings
The rear bumper has a color matched, moulded polyurethane cover mounted on a GMT or aluminum beam dependent upon the market. The beams are respectively mounted on two brackets or energy absorbing menasco struts, each of which is located and secured to the BIW by three bolts. The bumper cover incorporates integral LH and RH support armatures which engage in guide blocks secured to the body by a captive bolt and a nut. Under low speed impact, this configuration enables the bumper to move forward on the guide blocks, preventing rear body damage. Rear side marker lamps/reflectors are fitted and removed in the same manner as those at the front.
2012-07-22
Bumper Bracket 76.22.87

1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>> 2. Remove bumper cover. Refer to 76.22.28.
www.JagDocs.com
3. Remove and discard rivets securing both overrider covers to beam and remove covers.
4. Remove and discard rivets securing splitter vane to underside of bumper beam. Installation 1. Position splitter vane on bumper beam and secure to underside with new rivets. 2. Fit overrider covers and secure with new rivets.
2012-07-22
3. Fit bumper cover. Refer to 76.22.28. 4. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
2012-07-22
Bumper Isolator 76.22.88

1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>> 2. Remove bumper cover. Refer to 76.22.28.
www.JagDocs.com
3. Remove and discard rivets securing covers to bumper beam and remove covers from vehicle. Installation 1. Fit covers onto overriders and secure to bumper beam with new rivets. 2. Fit bumper cover. Refer to 76.22.28. 3. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
2012-07-22
Front Bumper 76.22.08

Removal 1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 2. Raise front of vehicle to working height and support on stands. 3. Remove bumper beam cover. Refer to 76.22.28. 4. Remove bumper splitter vane. Refer to <<76.22.87>>.
5. Disconnect harness spade connectors from horns.
6. Release ambient air temoerature sensor from RH horn mounting bracket tang.
2012-07-22
7. Slacken and remove bolts securing power steering cooler mounting clips to beam.
www.JagDocs.com
8. Release clips from powerwash hose and position hose clear of beam.
2012-07-22
9. Remove and discard two scrivets securing harness conduit to bumper beam.
10. Slacken and remove the two bolts securing bumper beam to mounting struts, withdraw beam from vehicle and place on bench.
2012-07-22
www.JagDocs.com
11. Remove horns and mounting brackets. Slacken and remove horn securing nuts and remove horns from mounting brackets. Slacken and remove horn mounting bracket securing bolts and remove brackets from beam.
Installation
1. Fit horns and mounting brackets. Position horn mounting brackets on bumper beam ensuring that bracket lugs locate in holes. Fit and tighten bracket securing bolts. Position horns on mounting brackets and fit and tighten securing nuts.
2012-07-22
2. Ensuring that oil cooler and harness conduit are clear, position bumper beam on struts and fit and tighten securing bolts.
3. Position harness conduit on beam and secure with new scrivets.
2012-07-22
4. Position power wash hose in clips and close clips to secure.
www.JagDocs.com
5. Position power steering oil cooler and clips on beam and fit and tighten securing bolts ensuring cooler is correctly located in clips. 6. Fit ambient temperature sensor onto horn mounting bracket tang. 7. Connect harness spade connectors to horns. 8. Fit bumper splitter vane. Refer to <<76.22.87>>. 9. Fit bumper beam cover. Refer to 76.22.28. 10. Raise front of vehicle, remove stands and lower vehicle onto wheels. 11. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
2012-07-22
Front Bumper Cover 76.22.78

Removal 1. Position vehicle on 4-post ramp. 2. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 3. Raise vehicle to working height. 4. Remove and discard fasteners from both wheelarch liners and remove liners for access. Refer to <<76.10.90>>. 5. Remove wheelarch spoilers. 6. Using a thin plastic lever, carefully release front number plate from plinth.. 7. Slacken and remove screws securing number plate plinth to overriders.
8. Remove and discard the eight rivets securing undertray to the bumper cover.
2012-07-22
9. Remove and discard three fasteners securing undertray to lower crossmember and remove undertray.
www.JagDocs.com
10. At each side of vehicle: Disconnect fog lamp harness multiplug and where fitted, disconnect sidemarker lamp. Slacken and remove three bolts securing bumper cover to the fender lower flange. 11. Lower 4-post ramp.
2012-07-22
12. Remove bumper cover from vehicle. Remove and discard the three fir tree fasteners securing bumper cover to BIW front upper cross-member. Remove six bolts securing bumper cover to front upper cross-member and remove cover from vehicle.
13. Slacken and remove three bolts securing each fog lamp to bumper cover and remove both lamps from vehicle.
2012-07-22
14. Release sidemarker lamp/reflector clips and remove both lamps/reflectors from bumper cover.
www.JagDocs.com
Installation
1. Position fog lamps in bumper cover and fit and tighten securing bolts.
2012-07-22
2. Fit and fully seat sidemarker lamps/reflectors in bumper cover.
3. Position and secure bumper cover to front upper cross-member. Position bumper cover over bumper beam and locate on upper cross-member using three new fir tree fasteners. Fit and tighten six cover to upper cross-member securing bolts. 4. Raise vehicle to working height.
2012-07-22
www.JagDocs.com
5. At each side of vehicle: Fit and tighten three bolts securing bumper cover to fender lower flange. Connect harness multiplugs to fog lamps and where fitted, side marker lamps.
6. Fit undertray. Position undertray on vehicle and secure to lower cross-member with three new fasteners Secure undertray to bumper cover using eight new rivets. 7. At each side of vehicle, reposition and secure wheelarch spoiler and wheelarch liner using new fasteners. Refer to <<76.10.90>>. 8. Lower 4-post ramp. 9. Position front number plate plinth on overriders, fit and tighten securing screws and fit number plate to plinth. 10. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
2012-07-22
Front Bumper Isolator 76.22.31

Removal 1. Remove battery cover and disconnect ground cable from battery terminal. 2. Raise front of vehicle to working height and support on stands. 3. Remove bumper cover. Refer to 76.22.28 4. Remove bumper splitter vane. Refer to <<76.22.87>>. 5. Remove bumper beam. Refer to 76.22.26.
6. Slacken and remove three bolts securing strut to front lower cross-member and remove strut from vehicle.
Installation 1. Position strut on cross-member and fit and tighten securing bolts. 2. Fit bumper beam. Refer to 76.22.26. 3. Fit Splitter vane assembly. Refer to <<76.22.87>>. 4. Fit bumper cover. Refer to 76.22.28 5. Check bumper to BIW clearances and adjust as necessary. Refer to Section 18. 6. Raise front of vehicle, remove stands and lower vehicle onto wheels.
2012-07-22
Rear Bumper 76.22.27

Removal 1. WARNING: THE REAR BUMPER IS CLOSE TO THE EXHAUST PIPES WHICH MAY BE HOT. CARE MUST THEREFORE BE EXERCISED WHEN WORKING IN THIS VICINITY.
Position vehicle on a 4-post ramp with parking brake on and raise ramp to working height.
www.JagDocs.com
2. Remove rear wheel arch liners and side marker bulb holders. 1. Slacken and remove rear wheel arch liner plastic nut and remove liner from wheel arch. On N. American vehicles, rotate side marker bulb holder 1/4 turn, withdraw from lamp and ensure that leads are free from bumper. Repeat operations on opposite side of vehicle.
2012-07-22

3. Reposition the telephone antenna. Remove and discard the retaining rivet. Remove and discard the wiring harness tie wraps.
4. Disconnect the reversing aid electrical connectors. One connector shown, remaining connectors similar.
5. Separate bumper from supports. 1. Slacken and remove bolts securing beam to support brackets (menasco struts on N. American market vehicles).
2012-07-22
www.JagDocs.com
6. Remove rear bumper from vehicle. With assistance, slide bumper assembly rearwards off guide blocks, holding it clear of the exhaust trims.
7. Remove bumper cover from beam. 1. Position bumper for access to the nine cover to beam fasteners, remove center pin from each fastener and remove and discard all fasteners.
Installation 1. Fit cover to bumper beam. With assistance, position bumper beam in cover, aligning fastener locating holes. Fit nine new fasteners and center pins.
2012-07-22
2. Position bumper on vehicle. 1. With assistance, align bumper cover side armatures with guide blocks. 2. Slide bumper assembly forward holding it clear of the exhaust trims.
3. Fit and hand tighten beam securing bolts.
2012-07-22
www.JagDocs.com
4. Adjust bumper to body clearance. 1. Rotate adjuster spacers to achieve required clearance between bumper and body rear upper panel. 2. Tighten beam securing bolts.
5. Check and adjust fender to bumper clearance. 1. Check clearance between lower rear fenders and bumper cover, and adjust to 4 to 6mm as necessary by slackening guide block securing nuts, positioning bumper and re-tightening nuts. 6. Fit wheel arch liners and side marker bulb holders. Position rear wheel arch liner, fit securing nut and tighten. Fit bulb holder to side marker lamp and rotate 1/4 turn. Repeat on opposite side of vehicle.
2012-07-22
7. Fit the telephone antenna. Fit new the retaining rivet. Fit new wiring harness tie wraps.
8. Connect the reversing aid electrical connectors. One connector shown, remaining connectors similar. 9. Lower the 4-post ramp.
2012-07-22
Rear Bumper Isolator 76.22.70

Removal 1. WARNING: THE REAR BUMPER IS CLOSE TO THE EXHAUST PIPES WHICH MAY BE HOT. CARE MUST THEREFORE BE EXERCISED WHEN WORKING IN THIS VICINITY.
Remove rear bumper cover and beam. Refer to <<76.22.77>> and <<76.22.27>>.
www.JagDocs.com
2. Remove rear strut. 1. Slacken and remove rear strut securing bolts. 2. Remove strut from body rear panel. 3. Remove and discard strut gasket. 4. Remove height adjuster spacer.
Installation
1. Fit rear strut. 1. Fit and align new strut gasket.
2012-07-22

2. Position rear strut. 3. Fit and tighten strut securing bolts 4. Fit height adjuster spacer. 2. Fit rear bumper beam and cover. Refer to <<76.22.27>> and <<76.22.77>>.
2012-07-22
1999 XK RANGE - Safety Belt System - 501-20A
Torques Component Front seat buckle Rear seat buckle Coupe pillar loop nut Pre-tensioner arming pin Webbing guide bracket Pre-tensioner top mounting Seat belt pretensioner to B post lower securing bolt. Seat belt pretensioner to B post upper securing bolt. Front seat belt inertia reel securing bolt Rear seat belt inertia reel securing bolt. Seat belt guide bracket securing bolts. Front seat belt height adjuster securing bolts. Front seat belt slider bar securing bolt. Nm 34 - 46 60 - 80 30 - 40 7 - 10 7 - 10 7 - 10 34-46 7-10 36-46 34-46 7-10 17-23 34-46
www.JagDocs.com
2012-07-22
Safety Belt System
Front Seat Belts
Each front seat belt is in color-keyed webbing with plastic moulding on the running loop and tongue and has three anchorage points. The front seat belts are common to both coupe and convertible models. Differing top fittings are selected and fitted as appropriate on installation. The coupe also has a manual, four position, belt shoulder height adjuster installed in each 'B' post. On each model, the front belts are also left- and right-handed. Rear passenger entry and exit is aided by slider bar outboard lower mountings and each belt buckle is secured to a moving inboard seat rail by a strap that enables the seat to be moved without adjustment or removal of the belt. Visual and audible warnings operate if the driver's seat belt is not worn when the driving seat is occupied and the ignition is switched to position I or II.
Rear Seat Belts
2012-07-22
Two rear seat belts are dedicated to installation in the coupe or convertible, each has three anchorage points with emergency, and where applicable, automatic locking retractors. The belt buckles, common to both models, are each mounted on twin cables and share a single central floor anchorage. The buckle cables exit the rear seat cushion via a tailored penetration concealed by a matching gaiter. Coupe belt retractors are mounted on the outboard sides of the parcel shelf, with belt webbing exiting via color keyed escutcheons in the quarter casings. Convertible belt retractors are mounted on rear seat pan behind the seat squab. Belt webbing is routed upwards inside the seat belt tower and exits via color keyed escutcheons surmounting the rear seat squab. The lower anchorage points, located on outboard sides of the seat pan, are common to both models. All seat belt retractors incorporate emergency locking (ELR), which locks the retractor unit under rapid deceleration of the vehicle. At all other times the wearer is free to move the upper torso. Automatic locking retractor (ALR) fitted for certain markets, enables a child seat to be secured by any passenger seat belt. When adjusted with all slack removed, the ALR locks, preventing further belt extraction. Unclipping of the buckle allows the belt to return to the normal stowed position and revert to ELR operation. For some markets, child seat anchorage points are located on the body. Only complete seat belt assemblies are available as serviceable items.
Pyrotechnic Seat Belt Pre-tensioners
www.JagDocs.com
Each front seat belt has a pyrotechnic device with independent mechanical sensing and pre-tensioning retractor unit, installed at the base of the 'B' post. In the event of severe frontal impact, this provides additional occupant protection by removing any excess slack from the seat belt. Seat belt pre-tensioning activates when a frontal impact of sufficient force occurs within 30 degrees of vehicle center line. Under such an impact, mechanical sensors in the retractor unit fire, igniting the pre-tensioner gas generator. The gas generator initiates a chemical reaction, producing gases under pressure. Gas pressure drives the piston/cable up a tube, rotating the retractor spindle and removing excess slack from the seat belt. The mechanical sensor is made live by screwing the arming pin in to fully depress the red arming button. The pre-tensioning system can only be activated if a safety lever is re-set by fitting the associated belt to an occupant or child seat. When the pre-tensioner unit has been activated, the seat belt will lock and cannot be retracted or pulled from the reel. No attempt must be made to dismantle a retractor unit as unactivated pre-tensioning components contain a solid, flammable material. There are no serviceable parts. If a pre-tensioning unit is inadvertently ruptured and ingestion or inhalation of the propellant occurs, first aid must be applied and medical advice sought.
2012-07-22
When handling the piston housing, the piston must be pointed downwards and away from one's self and other personnel. Fingers must be kept away from the take-up spool mechanism. Any unit dropped from a height greater than 0.3 m (12 inches) must not be fitted to a vehicle. If a seat belt pre-tensioner activates, a small quantity (less than 1 liter) of gas is produced containing nitrogen, oxygen and water vapor.
2012-07-22
Front Safety Belt Retractor LH 76.73.10

Removal 1. Remove rear seat cushion and squab. Refer to <<76.70.37>> and <<76.70.38>>. 2. Remove coat hanger hook.
www.JagDocs.com
4. Remove front seat belt escutcheon.
2012-07-22

1. On coupe model, slacken and remove securing screw from front seat belt upper escutcheon and remove escutcheon from rear quarter casing.
5. Detach front seat belt lower anchor bar. 1. Slacken and remove front seat belt lower anchor bar securing bolt. 2. Remove anchor bar from body grommet and seat belt loop. 3. Retain anchor bar spacer and card washer. 6. On coupe model release rear quarter casing fasteners and position casing for access. Refer to <<76.13.73>>.
2012-07-22
8. Slacken and remove two bolts securing seat belt guide to B post and position belt guide along seat belt.
www.JagDocs.com
9. Slacken and remove seat belt pretensioner arming bolt located immediately below upper securing bolt.
2012-07-22
10. Slacken and remove two bolts securing seat belt pretensioner assembly to B post, withdraw assembly from B post and remove from vehicle.
Installation
1. Fit pretensioner in B post. Position pretensioner in B post ensuring alignment with fixing holes. Fit and fully tighten pretensioner to B post securing bolts.
2012-07-22
2. Fit and fully tighten pretensioner arming bolt.
www.JagDocs.com
3. Position seat belt guide on B post and fit and fully tighten the two securing bolts. 4. Position quarter casing in vehicle and pass seat belt anchor plate and tongue through aperture. 5. Fit rear quarter casing. Refer to <<76.13.73>>. 6. Fit coat hanger hook. 7. Fit front seat belt anchor bar. Pass front seat belt anchor bar through seat belt loop and body grommet. Fit securing bolt to seat belt anchor bar. Fit spacer and card washer and locate and fully tighten securing bolt.
2012-07-22
8. Fit front seat belt upper anchor plate. Fit plastic cover to front seat belt upper anchor plate securing stud. Position upper anchor plate on securing stud and fit and tighten securing nut. Fasten upper anchor plastic cover. 9. On coupe model: Fit rear seat belt anchor plate. Fit securing bolt to rear seat belt anchor plate. Fit card washer to securing bolt. Position anchor plate over bolt location and engage and fully tighten securing bolt. Position and seat rear seat belt escutcheon to casing aperture. Fit coat hanger hook. 10. On convertible model, position rear quarter capping, secure to 'B' post extension with fastener and fit and tighten three securing screws. 11. Fit rear seat squab and cushion. Refer to <<76.70.38>> and <<76.70.37>>.
2012-07-22
Front Safety Belt Retractor RH 76.73.21

Removal 1. Remove rear seat cushion and squab. Refer to <<76.70.37>> and <<76.70.38>>. 2. Remove coat hanger hook.
www.JagDocs.com
4. Remove front seat belt escutcheon.
2012-07-22

1. On coupe model, slacken and remove securing screw from front seat belt upper escutcheon and remove escutcheon from rear quarter casing.
5. Detach front seat belt lower anchor bar. 1. Slacken and remove front seat belt lower anchor bar securing bolt. 2. Remove anchor bar from body grommet and seat belt loop. 3. Retain anchor bar spacer and card washer. 6. On coupe model release rear quarter casing fasteners and position casing for access. Refer to <<76.13.73>>.
2012-07-22
8. Slacken and remove two bolts securing seat belt guide to B post and position belt guide along seat belt.
www.JagDocs.com
9. Slacken and remove seat belt pretensioner arming bolt located immediately below upper securing bolt.
2012-07-22
10. Slacken and remove two bolts securing seat belt pretensioner assembly to B post, withdraw assembly from B post and remove from vehicle.
Installation
1. Fit pretensioner in B post. Position pretensioner in B post ensuring alignment with fixing holes. Fit and fully tighten pretensioner to B post securing bolts.
2012-07-22
2. Fit and fully tighten pretensioner arming bolt.
www.JagDocs.com
3. Position seat belt guide on B post and fit and fully tighten the two securing bolts. 4. Position quarter casing in vehicle and pass seat belt anchor plate and tongue through aperture. 5. Fit rear quarter casing. Refer to <<76.13.73>>. 6. Fit coat hanger hook. 7. Fit front seat belt anchor bar. Pass front seat belt anchor bar through seat belt loop and body grommet. Fit securing bolt to seat belt anchor bar. Fit spacer and card washer and locate and fully tighten securing bolt.
2012-07-22
8. Fit front seat belt upper anchor plate. Fit plastic cover to front seat belt upper anchor plate securing stud. Position upper anchor plate on securing stud and fit and tighten securing nut. Fasten upper anchor plastic cover. 9. On coupe model: Fit rear seat belt anchor plate. Fit securing bolt to rear seat belt anchor plate. Fit card washer to securing bolt. Position anchor plate over bolt location and engage and fully tighten securing bolt. Position and seat rear seat belt escutcheon to casing aperture. Fit coat hanger hook. 10. On convertible model, position rear quarter capping, secure to 'B' post extension with fastener and fit and tighten three securing screws. 11. Fit rear seat squab and cushion. Refer to <<76.70.38>> and <<76.70.37>>.
2012-07-22
Rear Safety Belt Retractor Vehicles Without: Convertible Top 76.73.18

Removal 1. Remove rear seat cushion and squab. Refer to <<76.70.37>> and <<76.70.38>>. 2. Remove coat hanger hook. 3. Remove and position rear quarter casing for access. Refer to <<76.13.73>>. 4. Remove rear parcel shelf. Refer to <<76.67.06>>.
www.JagDocs.com
5. Slacken and remove seat belt lower anchor plate to seatpan securing bolt.
6. Remove escutcheon from rear quarter casing and pass belt through gap in lower half.
2012-07-22
7. Slacken and remove inertia reel to parcel shelf panel securing bolt and remove belt and inertia reel assembly from vehicle.
Installation
1. Fit inertia reel assembly. Position inertia reel on parcel shelf panel ensuring that dowel locates correctly in reel housing. Fit and tighten inertia reel to panel securing bolt.
2012-07-22
www.JagDocs.com
2. Secure belt lower anchor plate. Moving rear quarter casing for access, position belt lower anchor plate at seatpan location. Fit securing bolt to anchor plate, place card washer and spacer on bolt. Fit and tighten bolt securing belt anchor plate in seatpan location ensuring dowel locates in slot. 3. Fit parcel shelf. Refer to <<76.67.06>>. 4. Fit rear quarter casing. Refer to <<76.13.73>>. 5. Fit escutcheon over belt and press firmly into casing aperture. 6. Fit coat hanger hook. 7. Fit rear seat cushion and squab. Refer to <<76.70.37>> and <<76.70.38>>.
2012-07-22
Rear Safety Belt Retractor Vehicles With: Convertible Top 76.73.18

Removal 1. Remove rear seat cushion. Refer to <<76.70.37>>.
2. Release belt from seat squab. Slacken and remove two screws securing seat belt escutcheon to top of seat squab. Pass belt through gap in escutcheon and retain escutcheon. 3. Remove rear seat squab for access. Refer to <<76.70.38>>.
4. Slacken and remove seat belt lower anchor plate to seatpan securing bolt.
2012-07-22
5. Slacken and remove seat belt inertia reel to squab panel securing bolt.
www.JagDocs.com
6. Pass seat belt lower anchor plate and tongue over belt guide on squab panel and remove belt and inertia reel from vehicle.
Installation 1. Position inertia reel at seat squab panel anchorage point, ensuring that dowel correctly locates in reel housing. 2. Fit and tighten inertia reel to seat squab panel securing bolt. 3. Route seat belt lower anchor plate and tongue up belt tower and over guide. 4. Fit rear seat squab. Refer to <<76.70.38>>.
2012-07-22
5. Fit escutcheon over belt, position at top of squab and fit and tighten two securing screws. 6. Fit seat belt lower anchor. Fit securing bolt to seat belt lower anchor plate and fit card washer and spacer to bolt. Ensuring belt is not twisted, fit and tighten belt anchor plate to seatpan securing bolt ensuring dowel locates in slot. 7. Fit rear seat cushion. Refer to <<76.70.37>>.
2012-07-22
1999 XK RANGE - Supplemental Restraint System - 501-20B
Torques Component Front seat buckle Rear seat buckle Coupe pillar loop nut Pre-tensioner arming pin Webbing guide bracket Pre-tensioner top mounting Seat belt pretensioner to B post lower securing bolt. Seat belt pretensioner to B post upper securing bolt. Front seat belt inertia reel securing bolt Rear seat belt inertia reel securing bolt. Seat belt guide bracket securing bolts. Front seat belt height adjuster securing bolts. Front seat belt slider bar securing bolt. Nm 34 - 46 60 - 80 30 - 40 7 - 10 7 - 10 7 - 10 34-46 7-10 36-46 34-46 7-10 17-23 34-46
www.JagDocs.com
2012-07-22
Air Bag Supplemental Restraint System (SRS)
Airbag Module Locations
Airbag/SRS units provided for driver and front seat passenger, are installed in the center of the steering wheel and the passenger side fascia respectively. The control module(ECU) with integral safing sensor and diagnostic capability is installed by the RH 'A' post. The ECU also incorporates independent back-up battery power supplies to ensure airbag deployment in the event of loss of main battery power in a crash. Two primary crash sensors hardwired to the airbags, are fitted forward of the radiator, inboard of the headlamps. Electronic extension of the primary sensors (dwell enhancement) incorporated in the ECU, maintains deployment circuitry in the event of loss of primary sensor signals. A disarm feature also incorporated in the ECU, isolates deployment power from the airbag system until a primary sensor closes. The airbag system will only be activated when the ignition switch is in position II or III and the air bags will only deploy if at least one primary sensor and the safing sensor are made. Before any airbag/SRS service is performed, at least one minute must elapse after disconnection of the battery positive cable, to allow dissipation of back-up power supply energy. The airbag/SRS system ECU continuously monitors all system components and wiring connections for faults. If a fault occurs in the airbag/SRS readiness indication line, a code written into the non-volatile memory of the ECU is transmitted to the system cluster to display a continuous LED warning. In the event of a further fault being detected during this condition, an audible tone comprising five sets of five bleeps will sound. The readiness indicator line fault must be corrected before fault codes can be determined. If a fault creates a risk of spurious airbag/SRS deployment, the ECU will attempt to remove deployment power by rupturing the 10A battery fuse via a solid state switch. To aid fault diagnosis, the ECU will not rupture the fuse again until the fault is rectified and cleared. The 10A battery fuse must not be renewed until the airbag/SRS system has been de-activated. The fuse (F4) is located in the fuse-box at the driver's end of the fascia.
2012-07-22
Air Bag Control Module LHD 76.73.41

Removal WARNING: BEFORE ANY AIRBAG/SRS SERVICE IS PERFORMED, AT LEAST ONE MINUTE MUST ELAPSE AFTER DISCONNECTION OF THE BATTERY POSITIVE CABLE, TO ALLOW DISSIPATION OF BACK-UP POWER SUPPLY ENERGY. WARNING: IN THE EVENT OF A FAULT RUPTURING THE 10A BATTERY SUPPLY FUSE(F4 LOCATED IN THE FUSE-BOX AT THE DRIVER'S END OF THE FASCIA), THE FUSE MUST NOT BE RENEWED UNTIL THE AIRBAG/SRS SYSTEM HAS BEEN DE-ACTIVATED. FUSES OF ANY OTHER VALUE MUST NEVER BE USED, AS THIS CAN CAUSE DISARM FAILURE. 1. Turn ignition key to position II, power passenger's seat fully rearwards and turn ignition key to position O. 2. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 3. Remove glove box. Refer to <<76.52.03>>. 4. Remove body processor module. Refer to <<86.80.31>>.
www.JagDocs.com
5. Remove footwell lamp and mounting bracket. 1. Slacken and remove screw securing footwell lamp mounting bracket to the air conditioning duct. 2. Disconnect footwell lamp multiplug. 3. Remove footwell lamp and bracket.
2012-07-22
6. Detach fascia harness fasteners from fascia RH end panel and reposition harness for access.
7. Disconnect air bag control module harness multiplugs.
2012-07-22
8. Remove fascia harness to cabin harness multiplugs from mounting bracket and reposition for access. 9. Remove air bag control module from fascia. Slacken and remove the two air bag module mounting bracket to fascia outer securing bolts. Slacken and remove module/fascia securing bolt. Slacken and remove air bag control module upper securing bolt. Remove air bag control module from vehicle.
www.JagDocs.com
Installation 1. Fit air bag control module. Position air bag module at fascia. Fit but do not tighten the two module mounting bracket outer securing bolts. Fit but do not tighten the module/fascia securing bolt. Fit and tighten module upper securing bolt. Tighten all module securing bolts. 2. Connect air bag control module. Connect module harness multiplugs. Position and fit fascia to cabin harness multiplugs to mounting bracket. 3. Fit footwell lamp. Align and fit footwell outlet duct. Position footwell lamp mounting bracket and fit and tighten securing screws. Connect footwell lamp harness multiplug. 4. Fit body processor module. Refer to <<86.80.31>>. 5. Fit glove box. Refer to <<76.52.03>>. 6. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
2012-07-22
Air Bag Control Module RHD 76.73.41

Removal 1. Turn ignition key to position II, power driver's seat to fully rearward position and turn ignition key to O.
2.
WARNING: BEFORE ANY AIRBAG/SRS SERVICE IS PERFORMED, AT LEAST ONE MINUTE MUST ELAPSE AFTER DISCONNECTION OF THE BATTERY POSITIVE CABLE, TO ALLOW DISSIPATION OF BACK-UP POWER SUPPLY ENERGY. WARNING: IN THE EVENT OF A FAULT RUPTURING THE 10A BATTERY SUPPLY FUSE(F4 LOCATED IN THE FUSE-BOX AT THE DRIVER'S END OF THE FASCIA), THE FUSE MUST NOT BE RENEWED UNTIL THE AIRBAG/SRS SYSTEM HAS BEEN DE-ACTIVATED. FUSES OF ANY OTHER VALUE MUST NEVER BE USED, AS THIS CAN CAUSE DISARM FAILURE.
Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 3. Remove driver's side underscuttle. Refer to <<76.46.11>>.
4. Remove footwell lamp and mounting bracket. 1. Slacken and remove the two screws securing the footwell lamp mounting bracket to the fascia frame. 2. Disconnect footwell lamp multiplug and remove footwell lamp and bracket.
2012-07-22
www.JagDocs.com
5. Detach fascia harness fasteners from fascia end panel and reposition harness for access.
6. Disconnect air bag control module harness multiplugs.
2012-07-22
7. Remove fascia harness to forward harness multiplugs from mounting bracket and reposition for access.
8. Remove air bag control module from fascia. 1. Slacken and remove the two air bag control module mounting bracket to fascia outer securing bolts. 2. Slacken and remove module/fascia securing bolt. 3. Slacken and remove module upper securing bolt and remove air bag control module.
Installation 1. Fit air bag control module. Position air bag control module at fascia. Fit but do not tighten the two module bracket outer securing bolts. Fit but do not tighten the module/fascia securing bolt. Fit and tighten module upper securing bolt. Tighten all module securing bolts. 2. Connect air bag control module.
2012-07-22

Connect module harness multiplugs. Position and fit fascia to forward harness multiplugs to mounting bracket. 3. Fit footwell lamp. Align and fit footwell outlet duct. Position footwell lamp mounting bracket and fit and tighten securing screws. Connect footwell lamp harness multiplug. 4. Fit driver's side underscuttle. Refer to <<76.46.11>>. 5. Connect ground cable to battery terminal. Refer to <<86.15.15>>. 6. Power driver's seat forward to original position.
www.JagDocs.com
2012-07-22
Crash Sensor 76.73.55

Removal WARNING: BEFORE ANY AIRBAG/SRS SERVICE IS PERFORMED, AT LEAST ONE MINUTE MUST ELAPSE AFTER DISCONNECTION OF THE BATTERY POSITIVE CABLE, TO ALLOW DISSIPATION OF BACK-UP POWER SUPPLY ENERGY. WARNING: IN THE EVENT OF A FAULT RUPTURING THE 10A BATTERY SUPPLY FUSE(F4 LOCATED IN THE FUSE-BOX AT THE DRIVER'S END OF THE FASCIA), THE FUSE MUST NOT BE RENEWED UNTIL THE AIRBAG/SRS SYSTEM HAS BEEN DE-ACTIVATED. FUSES OF ANY OTHER VALUE MUST NEVER BE USED, AS THIS CAN CAUSE DISARM FAILURE. 1. Open hood. 2. Open trunk lid. 3. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
4. Remove air bag sensor harness from mounting bracket and disconnect multiplug.
2012-07-22
www.JagDocs.com
5. Slacken and remove three bolts securing the sensor to the BIW front cross member and remove the sensor from the vehicle.
Installation 1. Position sensor on BIW cross member and fit and tighten the three securing bolts. 2. Connect sensor harness multiplug and fit multiplug in mounting bracket. 3. Close hood. 4. Connect ground cable to battery terminal and fit cover to battery. Refer to <<86.15.15>>. 5. Close trunk lid.
2012-07-22
Driver Air Bag Module 76.73.39

Removal 1. WARNING: BEFORE ANY AIRBAG/SRS SERVICE IS PERFORMED, AT LEAST ONE MINUTE MUST ELAPSE AFTER DISCONNECTION OF THE BATTERY POSITIVE CABLE, TO ALLOW DISSIPATION OF BACK-UP POWER SUPPLY ENERGY. WARNING: IN THE EVENT OF A FAULT RUPTURING THE 10A BATTERY SUPPLY FUSE (F4 LOCATED IN THE FUSE-BOX AT THE DRIVER'S END OF THE FASCIA), THE FUSE MUST NOT BE RENEWED UNTIL THE AIRBAG/SRS SYSTEM HAS BEEN DE-ACTIVATED. FUSES OF ANY OTHER VALUE MUST NEVER BE USED, AS THIS CAN CAUSE DISARM FAILURE. WARNING: FOLLOWING TEN YEARS IN SERVICE, AN AIR BAG ASSEMBLY MUST BE REMOVED AND DISPOSED OF IN THE APPROVED MANNER AND A NEW AIR BAG MUST BE INSTALLED Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
2. Remove air bag module securing bolts. 1. Turn steering wheel 90 degrees to the left to provide access to module LH securing bolt. 2. Fully slacken captive securing bolt Turn steering wheel 90 degrees to the right to provide access to module RH securing bolt. Fully slacken captive securing bolt.
2012-07-22
3.
www.JagDocs.com
WARNING: AIR BAGS CONTAIN A CHEMICAL IRRITANT. IF AN AIR BAG MODULE IS BEING RENEWED, THE ORIGINAL UNIT MUST BE DISPOSED OF IN ACCORDANCE WITH CURRENT SAFETY PROCEDURES.
Remove air bag module from steering wheel. 1. Carefully withdraw airbag module from steering wheel and position for access. 2. Disconnect air bag module harness multiplug and remove air bag module from vehicle.
Installation 1. Position air bag module and connect harness multiplug. 2. Carefully install airbag module in steering wheel. 3. Turn steering wheel 90 degrees to right and partially tighten module RH securing bolt. 4. Turn steering wheel 90 degrees to left and partially tighten module LH securing bolt. 5. Repeat steps 3 and 4 to fully tighten securing bolts and return steering wheel to central position. 6. Fit ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
2012-07-22
Passenger Air Bag Module 76.73.37

Removal 1. WARNING: BEFORE ANY AIRBAG/SRS SERVICE IS PERFORMED, AT LEAST ONE MINUTE MUST ELAPSE AFTER DISCONNECTION OF THE BATTERY POSITIVE CABLE, TO ALLOW DISSIPATION OF BACK-UP POWER SUPPLY ENERGY. WARNING: IN THE EVENT OF A FAULT RUPTURING THE 10A BATTERY SUPPLY FUSE(F4 LOCATED IN THE FUSE-BOX AT THE DRIVER'S END OF THE FASCIA), THE FUSE MUST NOT BE RENEWED UNTIL THE AIRBAG/SRS SYSTEM HAS BEEN DE-ACTIVATED. FUSES OF ANY OTHER VALUE MUST NEVER BE USED, AS THIS CAN CAUSE DISARM FAILURE. WARNING: FOLLOWING TEN YEARS IN SERVICE, AN AIR BAG ASSEMBLY MUST BE REMOVED AND DISPOSED OF AND A NEW AIR BAG MUST BE INSTALLED. WARNING: AIR BAGS CONTAIN A CHEMICAL IRRITANT. IF AN AIR BAG MODULE IS BEING RENEWED, THE ORIGINAL UNIT MUST BE DISPOSED OF IN ACCORDANCE WITH CURRENT SAFETY PROCEDURES. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>. 2. Remove glove box. Refer to <<76.52.03>>.
3. Remove deployment door from mounting clips and position for access.
2012-07-22
4. Slacken, remove and discard two bolts securing air bag module to fascia.
www.JagDocs.com
5. Slacken and remove the four deployment door mounting bracket securing bolts and partially withdraw bracket for access.
2012-07-22
6. Remove air bag module multiplug from mounting bracket and disconnect multiplug.
7. Slacken, remove and discard two lower bolts securing air bag module tether bracket to fascia.
2012-07-22
8.
www.JagDocs.com
WARNING: AIR BAGS CONTAIN A CHEMICAL IRRITANT. IF AN AIR BAG MODULE IS BEING RENEWED, THE ORIGINAL UNIT MUST BE DISPOSED OF IN ACCORDANCE WITH CURRENT SAFETY PROCEDURES.
Withdraw air bag module and remove from vehicle.
9. Slacken, remove and discard two bolts securing air bag tether bracket to air bag module.
2012-07-22

Installation
1. Position air bag module on tether bracket and fit and tighten two new securing bolts. 2. Position air bag module and deployment door mounting bracket in fascia.
3. Fit and tighten two new bolts securing air bag module and tether bracket to lower fascia, connect multiplug and fit to bracket.
2012-07-22
4. Fit and tighten four bolts securing door mounting bracket to fascia.
www.JagDocs.com
5. Fit and tighten two new bolts securing air bag module to fascia. 6. Fit air bag deployment door into mounting clips. 7. Fit glove box. Refer to <<76.52.03>>. 8. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
2012-07-22
1999 XK RANGE - Body Repairs - General Information - 501-25
Body Repairs
Body Pre-treatment, Painting and Sealing
PVC Coated Underside
The body is pre-treated to ensure high resistance to corrosion and stone chip damage. Prior to the first major pre-treatment process, the body shell is high-pressure washed to remove any metal dust and residual oil. The first major pre-treatment process consists of phosphate and electro-paint deposition, which together with zinc coating, forms the basis of the corrosion protection. This process includes high pressure knock-off, alkali de-greasing, zinc phosphate conversion of body steel (dissolving iron and coating with zinc phosphate crystals), trivalent chrome rinsing and demineralized water rinsing, sealing all chemicals and impurities. Both dip and spray techniques are employed and the bodies are submerged to the waistline during the first and third rinses of the main phosphate clean. Chemical strengths and solution temperatures are continuously monitored and accurately controlled throughout the process. An 80% water primer is then cathodic electro-deposition applied to the thoroughly cleansed bodies in a uniform 'sag-free' film 18 to 32 micron thick. Optimum durability of the electroprimer is achieved by finally curing in a stoving oven at 165 C for a period of 20 minutes. All underbody seams of the fully primed bodies are then manually sealed, to prevent water and dust ingress into the vehicle and to enhance corrosion protection. A semi-automatic airless spray application of a PVC coating 800 to 1000 g/m2, is applied to the underside of the main floor panels, trunk floor and rear wheel arches (ref. illustration above). The upper panels of primed and externally sealed bodyshells are next lightly scuffed to remove imperfections and a PVC coating is applied to all internal seams by an airless spray technique. A PVC bead seal is also applied to the doors, hood and trunk clinch joints. Following anti-corrosion, sealing and priming treatment, the bodies enter the first stage of 'cosmetic' painting. This consists of the application of two coats of a highly chip resistant polyester surfacer, employing high voltage electrostatic 'spinning bells', to achieve a final film thickness of 35 to 50 micron. Between surfacer coats, a polyurethane coat is automatically applied to the sills to impart even greater resistance to stone chipping.
2012-07-22
Wax Injected Box Sections
www.JagDocs.com
All interior panels are then painted using a color keyed sealer, wet-on-wet with a surfacer material, after which the bodyshells are stoved at 160 C for a period of 20 minutes. Further protection against corrosion is provided by a medium solids black pigmented wax which is airless spray applied to vehicle undersides. Critical body box-sections are similarly protected by spray injecting a high solids wax. This is then re-flowed at 70 to 90 C to achieve optimum seam/joint penetration and form a resilient and durable internal coating (ref. illustration above). After full wet sanding, rinsing and drying to provide a good substrate, a color-keyed semi-matt sealer coat is applied using electrostatic bells to achieve a film build of 25 to 35 micron. The bodies are then stoved for a further 20 minutes at a temperature of 145 C and subjected to a local 'seek-and-find' de-nib operation prior to the final two coat process. The final top coat finish is achieved by using polyester base coat colors and an acrylic sag resistant clear coat. This clear over base (COB) process produces a high gloss, durable paint finish with a film thickness of 50 to 65 micron, which is finally cured at a temperature of 135 C for 20 minutes. The Munsell three dimensional system of color management is employed to achieve highly accurate control of vehicle colors. This system ensures that paint pigmentations are accurately maintained and facilitates vigorous final checking of finished vehicles for color match. The hue of individual panels such as trunk lids, doors and hoods is in some instances adjusted to offset the effects of differing light angles. Where applicable, coachlines are manually applied and radiant heat cured on the completed and valeted vehicle prior to hand spray application of a protective wax coat.
Introduction
All repairs, whether structural or cosmetic must return the vehicle to the original manufactured condition with regard to occupant safety, dimensional accuracy, finish and corrosion protection, and ensure continuation of the Paint Surface and Corrosion warranty where applicable.
2012-07-22
Similarly, repaired vehicles must be fully checked, and where appropriate reset, with regard to steering, suspension, braking, and occupant restraint systems.
Health and Safety

It is the duty of both employer and employee to ensure safe working conditions and practices. Correct safety procedures and equipment must be applied to any potential hazards that are notified, or identified by an operator. Employees must observe local legislation governing working conditions and practices at all times and must always act in a responsible manner in the workplace. In the event of personal injury resulting from any workshop activity, medical help should be obtained as soon as possible. Self-treatment other than by first aid, should not be attempted. WARNING: READ AND UNDERSTAND WORKING PRACTICES CONCERNING CLIMATE CONTROL SYSTEMS, SECTION 412, WITH SPECIAL REGARD TO: REFRIGERANT MUST NEVER BE DIRECTLY VENTED TO ATMOSPHERE. ALWAYS USE JAGUAR APPROVED RECOVERY / RECYCLE / RECHARGE EQUIPMENT, WEAR SUITABLE EYE AND SKIN PROTECTION AND OBSERVE ALL APPLICABLE SAFETY REQUIREMENTS. With the constant introduction of new materials in the manufacture of vehicles, an awareness of the potential risks and appropriate precautions is important.
Notification of Hazards
Symbols, which convey important information, will be positioned at the beginning of any specific operation or text. Standard symbols will be used where repairs or service procedures are detailed. All symbols will conform to standard ANSI Z535.3 (American National Standards Institute). The surround shape of the symbol will indicate the basis of the message to be conveyed (see top three elements of ?) The icon depicting the message will be within the surrounding shape. Once nominated the icon will retain its meaning.
POTENTIAL RISKS Paint

Organic solvents, found in paints, may cause damage or severe irritation to liver, kidneys, digestive tracts and respiratory system if inhaled over long periods of time. Prolonged exposure to isocyanates can cause lung sensitization with asthma-like symptoms developing on subsequent exposure to even low concentrations of isocyanates. Solvent inhalation can cause dizziness or loss of consciousness and inhalation of spray dust and sanding debris may cause lung damage. Spillage or splashes of solvents, paint activators and additives can cause dermatitis or eye injury. Contact with peroxide or acid catalysts can cause serious burns.
Applied Heat (Welding)

There is considerable risk of damage to eyes and skin if welding or flame cutting is attempted without using the correct protective equipment. Many materials or fluids within vehicles are highly flammable and toxic and dangerous fumes may also be liberated if heat is applied to expanded foam, corrosion protection, trim and seat materials, paints containing isocyanates, and adhesive and sealing compounds. When heated to a temperature of 300C, polyurethane based compounds may liberate small quantities of isocyanate. Many types of nitrogen containing chemicals may be liberated as breakdown products which can contain isocyanates, oxides of nitrogen and hydrogen cyanide. Potentially toxic or asphyxiant fumes and gases produced when welding include zinc oxide from zinc coated panels, and ozone gas from the MIG process.
2012-07-22
Metal Repair
There is considerable risk of damage to eyes, ears and skin when cutting, forming, or dressing metal. Soldering operations can also be hazardous due to heat generated fumes and the risk of skin contact with hot materials.
PRECAUTIONS Paint
The inhalation of sprays, fumes, or dust during paint application or sanding processes should always be avoided. Ensure 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 employed in any process involving the use of isocyanates. Operators working in a spray booth where isocyanate material is present must use air-fed breathing equipment with air supplied to the visor at the recommended pressure and filtered to remove oil, water, and fumes. Operators involved in handling mixing or spraying should wear protective clothing including gloves and goggles, to avoid skin and eye contact. Particle masks or canister type respiratosr should be worn when sanding.
Applied Heat
When welding, flame cutting, brazing etc, the operator should use as appropriate, goggles, mask / fume extractor and flameproof protective clothing. It is especially important when working with polyurethane compounds to use air-fed breathing equipment. Appropriate fire fighting equipment and personnel trained in its use must always be available.
www.JagDocs.com
Metal Repair
Appropriate eye and hand protection should be worn when sanding, drilling, cutting, chiselling, flatting or welding. Face masks or air-fed visors should also be worn when sanding or flatting either body solder or fillers. On completion of a soldering operation, swarf must be removed from the work area and the operator must wash his hands thoroughly.
GENERAL REPAIR NOTES The following advice should be noted before any repair work is carried out.
Disconnect the vehicle battery ground lead (disconnect the alternator where electric welding is used) and take note of the reconnection procedures as detailed in <<86.15.15>>. Where structural parts are straightened or renewed, a body alignment / straightening jig must be used. The application of heat, especially excessive heat, reduces the strength of steels, where appropriate therefore, structural sections should be straightened by cold processes. Repairs may only be carried out successfully, and any warranties protected, if genuine Jaguar replacement parts and Jaguar approved materials are used. The correct tools, procedures and facilities must always be used. The quality of the work must not be compromised by using inappropriate methods or equipment. All trim and electrical components in the locality of the repair must be removed or disconnected prior to panel removal / replacement; this is especially important where hollow sections may contain harnesses, tubes or foam, see section A4.3.5. WARNING: DO NOT WORK IN THE VICINITY OF A LIVE AIR BAG. ALWAYS DISCONNECT THE GROUND CABLE FROM THE BATTERY TERMINAL FIRST. NOTE WORKING PRACTICES FOR AIR BAGS IN SECTION 20. ANY SEAT BELT WHICH HAS BEEN WORN IN AN ACCIDENT MUST BE RENEWED.
2012-07-22
CAUTION: Electric arc welding should not be used on Jaguar vehicles. The high voltages produced by this process will cause irreparable damage to the electrical control and microprocessor systems. The following welding and gas processes are the only ones recommended by Jaguar Cars Ltd.
Welding and Gas Processes

Resistance spot welding, MIG welding and all gas processes may only be carried out on bare, unpainted or unplated metal. The flanges of panels to be welded together, must be clean, corrosion free and treated as appropriate, with either weld-through primer or inter-weld sealer. Only materials and processes specified in the 'Body Sealing and Preservation Manual' should be used in the relevant application areas detailed in this section. Refer to 'Zinc Coated Panels' Section Generally, resistance spot welding equipment used in the motor vehicle repair industry does not produce welds of equivalent strength to those achieved during manufacture. The expression 'single row of resistance spot welds' indicates that the spots should be spaced on a pitch of 19mm to 25mm, which normally results in more spot welds than those produced in the original factory joint. Resistance spot welds should be removed using a resistance spot weld cutter. If the new joint is to be MIG plug welded, old resistance spot welds should be cut from the panel to be retained and the resulting 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 sections.
PLASTICS-EXPLANATORY NOTES Plastic component and trim materials.

This table, in conjunction with the illustrations on the following pages will enable rapid identification of the particular material of any major plastic part. NOTE: Only those components suitable for economic reclamation are identified. Term abs abs / pa abs / pc ABS / PBT pa pc pe pmma pom pp ppo pur pvc SMA Material Name Acrylonitrile Butadiene Styrene Acrylonitrile Butadiene Styrene and Polyamide (nylon) blend Acrylonitrile Butadiene Styrene and Polycarbonate blend Acrylonitrile Styrene Acrylate and Polybutylene Terephthalate Polyamide (nylon) Polycarbonate Polyethylene Polymethyl Methacrylate Polyoxymethylene (acetal) Polypropylene Modified Polyphenylene Oxide Polyurethane Polyvinylchloride Styrene Maleic Anhydride
2012-07-22
Plastics - Handling Notes

The exterior panel temperature of a vehicle must not exceed 95C at any time and may only be held at this level for a maximum of two hours. Similarly, interior vehicle temperature must be limited to 86C for a maximum duration of two hours. Exposure to temperatures above those specified may result in distorted or permanently damaged components. If there is doubt concerning temperature limitations, components that may be adversely affected by exposure to heat should be removed from the vehicle. Plastic components that become greasy may be cleaned with an 'SBP 3' spirit wipe, or equivalent.
Recycled Materials
Any of the materials listed in this section, may be recycled provided that they are not contaminated by other incompatible plastics or metals. For instance, the air conditioning unit case, manufactured from PP (polypropylene), must be separated from the heater matrix, evaporator, control devices (electronic and mechanical) and all fixings before it can be considered for recycling. After removal, the case must only be placed for disposal with materials of the same generic type. Bumper cover assemblies similarly have side armatures of dissimilar materials rivetted to them, these together with their fixings must be removed prior to recycling. Components manufactured from 'blended' materials must not be recycled with pure materials. For example do not mix PC/ABS (wheel trim) with ABS ('B' pillar upper trim).
www.JagDocs.com
Body Structure Introduction

The Jaguar XK8 has a unit construction monocoque body structure with bolt-on front fenders and welded rear fenders. The door and rear quarter glass are of frameless drop-glass design.
Constructional Steel Classification

Material High strength low alloy (HLSA). Double sided zinc plated mild steel. Boron steel. Mild steel. Bake-hardened steel. Application Impact prone areas, ie. seat frame and bumper mountings. Exterior body panels subject to severe conditions such as stone chipping and weather exposure (excluding roof panel). Door intrusion beams Internal brackets, fillets and strengtheners. For increased panel stiffness. e.g. front longitudinals.
BODY ALIGNMENT
The Body Dimensions Plan and Side, Front and Rear views, provide specified body dimensions to facilitate damage assessment and location of replacement parts. These dimensions must be strictly applied when used for damage assessment, component location or post repair verification. NOTE: The right-hand side is always looking towards the front, from the rear of the vehicle. The nominated plan view master datums are on the right-hand side of the body with the left-hand datums dimensioned from them. Right-hand datums must therefore be known to be correct before any other cross-car dimensions are checked.
2012-07-22
Datum location, Example

The Front Master Datum (hole in front RH longitudinal to right of crossbeam front mounting) is nominally 440,07mm to the right-hand side of the body center line. The LH side front datum is measured 879,14/ 881,14mm from the RH. Refer to the Body Dimensions Plan. Expressed as a true position in three planes, the centre line of the front master body location is: Location Centre line of the master body location hole (31mm dia). Position X 636,58 Y 440,07 Z 1,6
Body Dimensions-Plan and Side Views
2012-07-22
Key to Plan and Side Views

Key 1 2 3 4 5 6 Location Transit skid Jacking plate centres Master body location hole Master jig location rear To LH location For reference
www.JagDocs.com
2012-07-22

Body Dimensions- Front and Rear Views
2012-07-22
Key to Front and Rear Views

Key 1 2 Location Jacking plates Reference
ZINC COATED PANELS Description

Approximately 70% of the 'body in white' (body) mass is made up of zinc coated panels. NOTE: To maintain the protective qualities of the zinc treatment, repairs to any damaged coated area must be made as soon as possible after the damage has occurred. All exterior skin panels, with the exception of the roof, are double side zinc plated and this coating (nominally 7,5 microns) provides two way corrosion protection. Should the outer layer of paint become chipped with the zinc coating remain intact, the zinc will oxidize on contact with air and being impermeable, this coat of oxidation will prevent corrosion damage of the base metal. If the outer layer of paint and the zinc coating become damaged, the zinc rather than the base metal will react with the air and 'sacrifice' itself to corrosion as a 'sacrificial anode'.
www.JagDocs.com
Welding Preparation
Contamination of the weld with resultant reduction in joint strength increase and increased electrode tip dressing frequency will occur zinc coating is not removed. In exceptional cases where the zinc coating must remain intact, the tip pressure and welding current should be increased by 10 to 20%. Where 'resistance spot welding' is employed, the zinc coating should be lightly abraded away on the mating surfaces and those in contact with the electrode tips. Do not remove more zinc coating than is absolutely necessary. Before welding, a weld-through primer or inter-weld sealer should be applied, as detailed in the Body Sealing and Preservation manual. Where MIG welding is used as an alternative to resistance spot welding for plug and butt welds or due to limited access, the problems caused by the presence of zinc coating are much the same, with the added complication of increased weld spatter and nozzle contamination.
Body Fillers
Conventional polyester fillers do not adhere satisfactorily to zinc plated panels, it is therefore important that only those products specifically designed for this application are used and the manufacturer's recommendations are followed.
Refinishing
Only use products approved by Jaguar Cars Ltd and exercise special care on zinc coated panels. Replacement panels are supplied ready primed and only those areas to be welded etc should have bare metal exposed as decribed in 'Welding Preparation. Where any part of a panel is dressed back to the bare surface, it should be treated with a zinc rich primer compatible with the paint application system.
10
2012-07-22

GENERAL PREPARATION OF PANELS Removal of Panels and Welds
NOTE: Where other components must be removed for access, refer to the relevant manual section for guidance. This is particularly important where steering, braking, suspension, electrical and safety systems are affected. Expose all resistance spot welds, using a rotary wire brush fitted to an air drill or a hand held wire brush on those that are not clearly visible (1). WARNING: DO NOT BURN UNDERSEAL OFF. USE A 'HOT KNIFE' OR SUITABLE SOLVENT. Cut out spot welds using a Zipcutter or Roto-Bor (2). At this point it may be necessary to cut out the bulk of the panel using a pneumatic saw (3). NOTE: On some panels, before removing the bulk with a pneumatic saw, it may be necessary to remove brazed areas and MIG welded seams. Separate spot welded joints and remove the panel remnants.
Removal of Panels and Welds
PREPARATION OF PANEL SURFACES

WARNING: DO NOT BURN UNDERSEAL OFF. USE A 'HOT KNIFE' OR SUITABLE SOLVENT. NOTE:
11
2012-07-22

Observe all appropriate safety procedures. Remove weld nuggets with a sander and 36 grit disc and clean all flanges to a bright smooth finish (1). Straighten existing panel joint edges as required. Mark off the area of new panel and cut to size leaving approximately two inches overlap on the existing panel. Offer up new panel or section, align with associated parts, i.e. new rear fender aligned with door / luggage compartment lid / backlight aperture and clamp the panel into position.Where necessary, cut the new and original panels to form a butt joint. Release all clamps and remove the new panel. If required, apply inner panel protection and or sound insulation. Prepare the new panel joint edges, including interior and exterior, for welding by cleaning to bright metal (1). Apply weld-through primer or interweld sealer(2) to all surfaces to be resistance spot welded. Where appropriate, apply metal-to-metal adhesive or sealer (3) in accordance with the manufacturer's instructions.
Panel Surface Preparation
www.JagDocs.com
ALIGNING AND WELDING PANELS
NOTE: Observe all appropriate safety procedures. Apply appropriate sealer or joint preparation. Align the replacement panel with adjacent panels, secure with clamps, MIG tack welds or self tapping screws. Finally check panel alignment and contours and re-adjust as necessary.
12
2012-07-22
Select the correct 'arms' for resistance spot welding and ensure that tips are correctly trimmed. NOTE: It is recommended that 'arms' of not more than 300 mm (12 in.) long are used and the equipment is tested for satisfactory operation by producing test samples (2). In the absence of test equipment, a satisfactory weld can be verified by pulling the test samples apart and viewing the weld condition. Prepare zinc coated panels as detailed in this section and resistance spot weld where required (3). Dress back all tack welds, then MIG seam-weld the butt joints (4). Finally dress all welds as necessary and final braze and fill prior to paint preparation.
Aligning and Welding Panels
13
2012-07-22

Cutting andWelding Symbols
www.JagDocs.com
CAUTION: Reference should always be made to the welding tables and illustrations in the relevant procedures. Observe all safety precautions with respect to yourself, other people, your equipment and the workplace. 1. 2. 3. 4. 5. 6. 7. 8. 9. Saw Cut Chisel Cut Cut out Spot Weld Resistance Spot Weld MIG Tack Weld MIG Seam/Butt Weld Braze Gas Weld MIG Plug Weld
CAVITY WAX INJECTION - APPROVED ADHESIVES, SEALERS AND BODY PROTECTION SYSTEMS
NOTE: Cavity wax processes should only be applied on completion of all other refinishing and protection procedures.
14
2012-07-22

Hood Front Cavity Wax Injection Points
15
2012-07-22
Front Longitudinal and Lower Fender Wax Injection Points
www.JagDocs.com
Door Wax Injection Points
16
2012-07-22
Forward Sill Wax Injection Point
17
2012-07-22
Floor Wax Injection Areas
www.JagDocs.com
18
2012-07-22
Rear Wheel Arch and Trunk Lid Wax Injection Points
19
2012-07-22

Rear Fender Inner Wax Injection Points
www.JagDocs.com
20
2012-07-22

Rear Quarter and Seat Pan Wax Injection Points
21
2012-07-22

Rear Longitudinal Wax Injection Points
www.JagDocs.com
22
2012-07-22

BODY UNDERSEAL Underseal Application
CAUTION: Do not apply underseal to hot or rotating components. Underseal should be applied as indicated by the hatching and omitted from areas indicated in solid black.
23 2012-07-22
APPROVED PAINT SYSTEMS

The manufacturer's paint systems listed below are currently approved for refinishing Jaguar vehicles. NOTE: * Not available in certain markets but alternatives may be used, provided that they comply with the following company standards. Manufacturer Akzo Sikkens Dupont Glasurit Wash Etch+ Bare metal etch primer Washprimer Primer surfacer Autocryl / Autonova Base color coat Autobase Centari 600* System 54 (solid/metallic) System 56 (micatallic) System 59 and 69 (pearl) Herberts ICI PPG Galvaprep D840 Wash primer D831 Hi-build primer D855 Epoxy surfacer DP40 Deltron / non Isocyanate Primer D828 R-M Eurofill R-M Prof / Maxfill Diamont Basecoat Diamont Clearcoat Deltron HS 2 Metal pre-treatment and rust remover 301.2595 Standox Basislak Standox Clearlak Autocolor Deltron Concept 2001 HS clear D880 Clear lacquer Autoclear 1000 3000 Automat Centari 600* Clear lacquer 923-85
www.JagDocs.com
CAUTION: To avoid damage to the vehicle interior, trim and plastic items, effective panel temperature must not exceed 95C during paint cure process.
Product type Bare metal etch primer Primer surfacer Base color and clear lacquer
Applicable Standard JMS 20.29.06 JMS 20.29.11 JMS 20.29.09
OBSCURATION BANDS
NOTE: This process is not required on dark colored vehicles. Unsightly areas visible between panels, through gaps and under bonded glass are masked by applying matt black paint with heat resistance of 40 to 120C.
24
2012-07-22
ANTI-THEFT LABELS Original Components

On North American specification vehicles, the VIN is marked on all major external panels, certain structural members and power / transmission units. The labels carrying this information are known as 'Label-Anti-theft VIN (USA body panel only)' or 'Label-Anti-theft-Engine and Gearbox (U.S.A. only),' drawing reference A .
Replacement Components
Only genuine Jaguar replacement parts must be used in the repair of a vehicle. Furthermore, any new parts replacing items carrying a VIN label must have either 'Label-Anti-theft Replacement Part (USA body panel only)' or 'Label-Anti-theft Replacement Part-Engine and Gearbox (U.S.A. only),' drawing reference B , fitted in a different location to the previous label. A protective mask used to prevent the replacement part label from being damaged or obscured during the refinishing / protection processes, must be removed prior to customer hand-over.
Procurement
Anti-theft labels may only be ordered from Jaguar Cars through : Product Compliance Dept., Jaguar Inc., 555 MacArthur Blvd., Mahwah NJ 07430
Label Fitting Process

CAUTION: It is a requirement of United States of America federal law that the protective mask is removed from all anti-theft labels after performing painting and rustproofing operations. Failure to comply with this requirement may render both the manufacturer and the dealer in violation of the law. NOTE: Any attempt to remove an anti-theft label will destroy that label. Ensure correct location before affixing. Using a suitable solvent clean the area where the anti-theft label is to be affixed. Peel the backing from the label and position on the panel. Carry out all refinishing / protection processes. Remove the anti-theft label protective mask prior to vehicle handover to the customer.
25
2012-07-22
APPLICATION OF STONE CHIP PROTECTION

Apply approved material to the areas indicated by hatching.
GLAZING
In order that the design condition of the vehicle is preserved when direct glazing repairs are carried out, it is essential that only approved materials and processes are employed.
Glass and Body Preparation

Betaseal HV3 System methods and materials, are used on all Jaguar vehicles. Ease of working and extended process time can however be gained by ensuring that the vehicle body and replacement glass are at a minimum room temperature of 20C prior to adhesive application and fitting. In the event of damage to the body flange finish, rectify as appropriate with the full paint refinishing process as described in the Paint Refinishing Manual.
Adhesive Application Temperature

The specified adhesive has a high viscosity and is not easily applied at 'room temperature' using conventional methods. When the adhesive is applied it chills rapidly on contact with the body and reverts to the hard condition, providing retention strength within minutes. Raising the temperature of the adhesive will reduce viscosity and speed up the flow. It is recommended that the adhesive is pre-warmed in a heated cabinet for a minimum of twenty minutes and applied with an extrusion gun incorporating integral heating elements. Temperature Effect Optimum Maximum Minimum Temperature Range 60C - 70C 75C 35C Application time - including positioning 4 minutes 4 minutes Will not bond
www.JagDocs.com
Adhesive Application
CAUTION: The glass will not bond to the body if the time taken to apply the adhesive and position the glass, exceeds the stated limit. NOTE: The depth of the glass and thus the thickness of the adhesive, is controlled by the screen rubber contacting the body flange. It is recommended that the bead of adhesive conforms to the shape and dimensions shown in the Adhesive Application illustration and is positioned along the edge of the rubber.
26
2012-07-22

Adhesive Application
Key to Adhesive Application Drawing

1 2 Fitted condition Bead application
Adhesive Curing
The specified adhesive cures by exposure to moisture (not by heat). Cure times may vary considerably dependent upon ambient humidity levels. Initial 'chill off' will occur within 1 to 4 minutes ( dependent upon the application temperature and rate of cooling), after which the screen must not be moved.
BUMPER REPAIR\RENEWAL Bumper Description

Each bumper comprises a beam mounted to the body via two strut assemblies and a moulded polypropylene cover incorporating side armatures and chrome plated plastic upper trims. The front bumper cover which is moulded to form a lower air intake for the cooling pack, also incorporates twin fog lamps, and side marker lamps or reflectors (dependent upon market). A plastic undertray secured to the lower edge of the front bumper and the body improves airflow and minimises the ingress of road grime in that area. Standard bumpers have glass mat thermoplastic (GMT) beams mounted on GMT struts. For certain markets, aluminium bumper beams are installed on menasco energy absorbing struts.
27
2012-07-22

Bumper Cover Repair
Prior to commencing any work, bumper damage should be assessed for repairability and categorized in accordance with the following guidelines. Bumper covers that are torn or holed are not repairable and must be discarded. CAUTION: Cosmetic appearance must not jeopardise safety. No attempt must be made to repair bumper covers damaged beyond category three. Damage of this extent will compromise the protective performance of the cover and it must be renewed. The thermo-setting nature of the cover material, precludes the repair of splits by heat or welding techniques.
Category Cosmetic Substrate surface Substrate penetration
Damage Abrasion to surface paint finish only Deep scratches, gouges or localized radial stress cracks. Splits not exceeding 100mm. Splits radiating from a gouge and accompanied by localized stress cracks.
Repair Materials
Repair of accepted damage for categories 2 and 3 may be carried out using 3M '5900 FPRM' (Flexible part repair material) or Kent Industries 'Urepatch'. Repair product manufacturers' recommendations and procedures must always be strictly followed.
www.JagDocs.com
Bumper Cover Refinishing

The paint refinishing system must be approved by Jaguar Cars Ltd., and be appropriate for polyurethane substrate application. It is essential that the finishing clear lacquer includes a plasticising ingredient (mixed to the manufacturer's recommendation) that will achieve the 'semi-flex' condition of the factory finished item.
Bumper Cover Support

CAUTION: During heat cure, the effective panel temperature must not exceed 95C. Exposure to heat decreases bumper cover rigidity. Covers removed for repair must therefore be supported to prevent distortion and sagging during the paint curing process. Where the original bumper cover has been repaired, the beam will provide sufficient support for the centre section. It is recommended that the side armatures are supported as they would be on the vehicle. If a new cover is required, the beam may be temporarily fitted to provide the necessary support during refinishing.
28
2012-07-22
Simple Jig Construction for Bumper Cover Support
Replacement Bumper Covers

Replacement covers are supplied in a primed condition and must be finished to match the vehicle in accordance with the procedures included in this section..
Bumper to body Alignments and Clearances

New bumper covers and beams and replacement fixings such as bumper beam adjusters and guide blocks must be fitted and adjusted to achieve the following alignments and clearances:
29
2012-07-22

Front Bumper to Hood Clearance
www.JagDocs.com
Front Bumper to Headlamp Clearance
30
2012-07-22
Front Bumper to Fender Alignment
Front Bumper to Splitter Vane Clearance and Alignment
31
2012-07-22
www.JagDocs.com
32
2012-07-22
Rear Bumper to body Clearance
33
2012-07-22

Rear Bumper to Wheel Arch Alignment
www.JagDocs.com
Recycling of Bumper Materials

The aluminium bumper beams fitted for some markets, should not be over-looked as components suitable for recycling. Replacement bumper cover assemblies includer side armatures, which should be removed from discarded bumper assemblies and routed for recycling.
General Clearances and Alignments

When any panel, closure or body component is renewed, refitted or reset, the specified clearances and alignments must be restored. This ensures that vehicle appearance and operation fully satisfy design intent and the customer.
Clearances
Gaps should be uniform around body panel contours and must be parallel to within 1mm in a 400mm linear measurement. Panels centered between two adjacent panels must have equal gaps on either side. For exceptions to this, refer to the appropriate specification. Gaps between adjacent panels or components must not expose harnesses, labels, brackets or visually poor joint or assembly conditions. NOTE: Sliding roof panel clearances are specified without the edge seal installed. Areas of particular concern are, fuel filler flap, trunk lid to fenders and saddle panels, hood to fenders, grill and headlamps, sliding roof to main roof panel, door gaps at fenders, B\C posts, roof drip rail and rocker panel, and bumper cover to fenders and cross car assemblies
34 2012-07-22

Alignment
Panels must be correctly profiled to maintain cosmetic appearance, and ensure correct seating of seals with minimal wind noise. Areas of particular concern are hood to fenders , trunk lid to fenders and saddle panels, doors to apertures, doors to fenders and adjacent doors and relationship of the sliding roof panel leading and trailing edges to the main roof panel.
Exterior Fitments
Bezels, trims and lamps must be concentric with apertures and have equal clearances with adjacent panels. Areas of particular concern are headlamp to hood, fender and trim panel, exhaust tailpipe trim to bumper cover cut-out, rear lamp assembly to trunk lid, fender and bumper cover trim, and side feature lines including body side mouldings, fender to door and door to door.
35
2012-07-22
1999 XK RANGE - Uni-Body, Subframe and Mounting System - 502-00
Front Axle Crossmember

Tie-Rod-End Taper Separator 211-098 (JD 100)
www.JagDocs.com
Engine Support Beam 303-021 (MS 53D)
CAUTION: Do not attempt to weld or repair the aluminum crossbeam. If it is damaged, a new one must be installed.
1. Position vehicle on a four-post lift. 2. Disconnect battery ground cable. Refer to section <<414-01>>. 3. Open engine compartment to service position, and fit paintwork protection covers to fenders.
2012-07-22
4. Remove both engine covers (normally aspirated vehicles only). Release pegs. Remove covers.
5. Support weight of engine. 1. Position special tool in RH and LH fender channels and tighten beam fixings. 2. Engage hooks into the engine front lifting eyes. 3. Tighten hook adjustment nuts until weight of engine is supported.
2012-07-22
www.JagDocs.com
6. Remove generator front cooling duct. Remove bolt. Move duct rearwards to release tang from undertray. Release front duct from rear vertical duct.
7. Remove undertray. 1. Remove and discard eight scrivets. 2. Remove three screws. 3. Remove undertray.
2012-07-22
8. Remove cruciform strut (convertible vehicles only). Remove four bolts. Remove cruciform strut. 9. Raise front of vehicle and support on stands. Refer to section <<100-02>>. 10. Remove front wheels. Refer to section <<204-04>>.
11. Drain brake fluid from both front brakes. 1. Remove dust cap. 2. Connect pipe to bleed nipple, and insert pipe into a fluid container. 3. Undo bleed nipple sufficiently, to allow brake fluid to drain. Pump brake pedal until brake fluid stops draining. Tighten bleed nipple, remove pipe, and fit dust cover. Repeat procedure on opposite-side brake caliper.
2012-07-22
www.JagDocs.com
12. Disconnect both front brake hoses from brake tubes. 1. Undo union nut connecting brake tube to brake hose. 2. Remove locknut securing brake hose to bracket and release brake hose. Fit blanking plugs to brake hose and tube. Repeat procedure to disconnect opposite-side brake hose.
13. Disconnect connectors from both front ABS sensors. 1. Remove tie straps securing ABS harness to upper wishbone. 2. Disconnect connector. Repeat procedure to disconnect opposite-side ABS sensor.
2012-07-22
14. Disconnect electrical connector from steering rack transducer.
2012-07-22
www.JagDocs.com
16. Release hose retaining plate from pinion housing. 1. Remove bolt. Move retaining plate along hose.
17. Drain power steering fluid. Position drain pan under pinion housing. Disconnect hoses and allow fluid to drain. Remove and discard 'O'-ring seals from hoses. Fit blanking plugs to hoses and pinion housing ports.
2012-07-22
18. NOTE: Make sure steering is in the central position. Release steering column from pinion shaft. 1. Remove bolt. Move column upwards to release it from pinion shaft.
19.
CAUTION: To prevent damage to the crossbeam, place a piece of wood between the jack and crossbeam.
Using a suitable jack, support weight of crossbeam.
20. Remove both front mounting brackets from the crossbeam. 1. Remove front bolts (one bolt on convertible vehicles). 2. Remove rear bolt. 3. Remove bracket. Repeat procedure to remove opposite-side bracket.
2012-07-22
www.JagDocs.com
21. Release both front engine mountings from crossbeam. Remove bolt. Repeat procedure to release opposite-side mounting.
22.
CAUTION: Do not allow the weight of the hub assembly to hang on the ball-joints. Support the weight of the hubs before releasing the shock absorbers.
Release both front shock absorbers from the lower mountings. Remove nut and bolt. Repeat procedure to release opposite-side shock absorber.
2012-07-22
23. Release crossbeam rear mountings from chassis. Remove mounting center bolt. Repeat procedure to release opposite-side mounting. 24. With assistance, lower crossbeam, and place it on a workbench.
25. Release both links from stabilizer bar. Remove nut, use an open-ended spanner on the ball-pin flats to prevent the rubber cover from twisting. Release link. Repeat procedure to release opposite-side link.
10
2012-07-22
www.JagDocs.com
26. Remove stabilizer bar from crossbeam. 1. Remove bolts. 2. Remove mounting brackets. 3. Remove stabilizer bar.
27. Remove nuts from both tie-rod-ends. Remove nut. Remove opposite-side, tie-rod-end nut.
11
2012-07-22
28. Release both tie-rod-ends from steering arms. 1. Fit special tool to tie-rod-end. 2. Tighten tool bolt to release tie-rod-end, taper-pin. 3. Remove tool and disengage tie-rod-end. Repeat procedure to release opposite-side tie-rod-end.
29. Remove steering rack from crossbeam. 1. Remove bolts. 2. Remove steering rack.
12
2012-07-22
www.JagDocs.com
30.
CAUTION: Note the position of the fulcrum bolts, as some vehicles are fitted with an eccentric bolt to the rear wishbone arm. See General Procedures section <<204-01>> for information.
Release both lower wishbones from crossbeam. 1. Remove nut and bolt from front arm of wishbone. 2. Remove nut and bolt from rear arm of wishbone. 3. Release wishbone from crossbeam. Repeat procedure to release opposite-side lower wishbone: collect fulcrum tie.
31.
CAUTION: For installation reference, note position of washers and shims before removing fulcrum bolt.
With assistance remove both vertical link and wishbone assemblies from crossbeam. 1. Remove nut. 2. Remove fulcrum bolt: collect washers and shims. 3. Remove vertical link and wishbone assembly.
13 2012-07-22

Repeat procedure to remove opposite-side vertical link and wishbone assembly.
Installation 1. Fit front mounting bushes to crossbeam. Refer to operation <<60.35.24>>.
2.
CAUTION: Support the hub assembly. Do not allow the weight of the hub assembly to hang on the ball-joints.
With assistance, fit the vertical link and wishbone assembly to the crossbeam. 1. Align lower wishbone to crossbeam. 2. Fit nut and bolt to wishbone rear arm: DO NOT tighten at this stage. 3. Align fulcrum tie to front arm of wishbone. 4. Fit front bolt to wishbone.
3. Fit upper wishbone to crossbeam. 1. Position wishbone to crossbeam.

14 2012-07-22

2. Fit fulcrum bolt, also fit shims and washers in positions noted in removal.
www.JagDocs.com
4. Fit and tighten upper wishbone fulcrum-shaft nut.
5.
CAUTION: Make sure the fulcrum bolts are fitted in their original positions as noted in removal.
Tighten lower wishbone nuts and bolts. Raise wishbone to the horizontal position. Fit nut, and tighten front-arm fulcrum bolt. Tighten rear-arm fulcrum bolt. 6. Repeat four previous pictorial procedures to fit opposite-side wishbone and vertical link assembly.
15
2012-07-22
7. NOTE: Make sure mounting rubbers are fully seated in stabilizer bar retaining bosses and crossbeam recesses. Fit stabilizer bar to crossbeam. 1. Position stabilizer bar to crossbeam. 2. Position mounting brackets. 3. Fit and tighten bolts.
8. Fit links to stabilizer bar. 1. Position link to stabilizer bar. 2. Fit and tighten nut: use an open-ended spanner on the ball-pin flats to prevent the rubber cover from twisting. Repeat procedure to fit opposite-side link.
16
2012-07-22
www.JagDocs.com
9. Fit steering rack to crossbeam. 1. Align steering rack to crossbeam. 2. Fit and tighten bolts.
10. Fit both tie-rod-ends to steering arms. Insert tie-rod-end taper pin into steering arm. Fit and tighten nut. Repeat procedure to fit opposite-side, tie-rod-end.
11.
CAUTION: To prevent damage to the crossbeam, place a piece of wood between the transmission jack and crossbeam.
With assistance, position crossbeam on jack, and align crossbeam to vehicle.
17
2012-07-22
12. Secure crossbeam rear mountings to chassis. Fit and tighten mounting center bolt Repeat procedure to secure opposite-side rear mounting.
13. Fit shock absorbers to lower mountings. 1. Align shock absorber to mounting and fit bolt. 2. Fit and tighten nut. Repeat procedure to fit opposite-side shock absorber.
18
2012-07-22
www.JagDocs.com
15. Fit crossbeam front mounting-brackets. 1. Align mounting bracket to crossbeam. 2. Fit front bolts: do not tighten at this stage, (one bolt on convertible vehicles). 3. Fit and tighten rear bolt. 4. Tighten front bolts. Repeat procedure to fit opposite-side mounting bracket. 16. Lower and remove jack from underneath crossbeam.
19
2012-07-22
17. NOTE: Make sure steering wheel and wheels are in the central position before fitting steering column. Fit steering column to pinion shaft. Move column downwards onto pinion shaft. 1. Fit and tighten bolt. 18. Remove blanking plugs from PAS hoses and pinion housing ports.
19. Connect return hose to pinion shaft housing. Apply clean PAS fluid to a new O-ring and fit to hose. Connect and fully seat hose.
20
2012-07-22
www.JagDocs.com
20. Connect feed hose to pinion shaft housing. Apply clean PAS fluid to a new O-ring and fit to hose. Connect and fully seat hose.
21. Fit retaining plate to pinion housing. 1. Align retaining plate and hoses. 2. Fit and tighten bolt.
21
2012-07-22
22. Secure PAS hose to steering rack. 1. Fit insulation rubbers. 2. Secure hose to steering rack with tie straps.
22
2012-07-22
www.JagDocs.com
24. Connect ABS sensor connectors. 1. Connect ABS sensor connector. 2. Secure ABS harness to upper wishbone with tie-straps. Repeat procedure to connect opposite side ABS sensor.
25. Connect brake hoses to brake tubes. Remove blanking plugs. 1. Position hose to bracket and tighten locking nut. 2. Connect brake tube to hose and tighten union nut. Repeat procedure to connect opposite-side brake hose.
23
2012-07-22
26. Fit cruciform strut (convertible vehicles only). Position cruciform strut. Fit and tighten bolts.
27. Fit generator cooling duct deflector. Position deflector over rear vertical duct. Slide deflector forward to engage center tang over undertray. Fit bolt and tighten to 17-23Nm.
24
2012-07-22
www.JagDocs.com
28. Fit undertray. 1. Position undertray. 2. Fit three screws fasteners. 3. Fit eight new scrivets. 29. Fit front wheels. Refer to section <<204-04>>. 30. Remove stands and lower vehicle. 31. Lower four-post lift.
32. Remove engine support tool. 1. Release hook adjustment nuts. 2. Release hooks from brackets. 3. Remove special tool.
25
2012-07-22
33. Secure front engine mountings to crossbeam. Tighten bolt. Repeat procedure to secure opposite-side mounting.
34. Fit engine covers (normally aspirated vehicles only). Secure pegs. 35. Connect battery ground cable. Refer to section <<414-01>>: Battery Reconnection Procedure. 36. Bleed brake system. Refer to section <<206-06>>. 37. Fill power-steering system. Refer to section <<211-02>>. 38. Remove paintwork protection covers.
26
2012-07-22
Front Axle Crossmember Front Bushing 60.35.24

www.JagDocs.com
Crossbeam Bush Replacer 204-212 (JD 242)
Crossbeam Bush Remover 204-213 (JD 243) Removal 1. CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used. See
2012-07-22

section <<100-00>> for information. Remove crossbeam. Refer to operation 76.10.05.
2. Using a hydraulic press, remove front mounting bush from the crossbeam. 1. Place special tool on the press-bed, with the tool cut-outs upper most. 2. Position crossbeam on press-bed, with special tool aligned underneath bush. 3. Align special tool on top of bush. Operate press to remove bush from crossbeam.
Installation
1. NOTE: The bush must be in the position shown when it is fitted to the crossbeam - viewed from the top of the crossbeam. Invert the crossbeam and place it, onto the bed of the hydraulic press.
2012-07-22
www.JagDocs.com
2. With assistance partially press the mounting bush into the crossbeam. 1. Align bush to crossbeam. 2. Align a suitable mandrel on top of bush. 3. Operate press and partially fit bush into crossbeam. Make sure bush is aligned correctly as shown in illustration above.
3. Press mounting bush, fully into crossbeam. 1. Position special tool under crossbeam, and align to bush aperture. 2. Align special tool to bush. 3. Operate press to fit bush into position. 4. Fit crossbeam. Refer to operation 76.10.05.
2012-07-22
Front Axle Crossmember Rear Bushing 60.35.26

Engine Support Beam 303-021 (MS 53D) Removal 1. CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used. See section <<100-00>> for information.
Position vehicle on a four-post lift. 2. Open the engine compartment to the service position. 3. Fit paintwork protection covers to fenders. 4. Disconnect battery ground cable. Refer to section <<414-01>>.
2012-07-22
www.JagDocs.com
5. Remove both engine covers. Release retaining pegs. Remove covers.
6. Support weight of engine. 1. Position tool in RH and LH fender channels and tighten beam fixings. 2. Engage hooks into engine front lifting eyes. 3. Tighten hook adjustment nuts until the weight of engine is supported. 7. Position steering in the central position and remove ignition keys to lock steering.
2012-07-22
8. Release both front shock absorber upper mountings from body. 1. Remove covers. 2. Vehicles fitted with adaptive damping : disconnect connector. 3. Remove nuts. Repeat procedure to release opposite-side shock absorber. 9. NOTE: Guide shock absorber upper mounting studs through body when raising front of vehicle. Raise front of vehicle and support on stands. Refer to section <<100-02>>.
10. Release lower steering column from pinion shaft. 1. Remove bolt. Disconnect steering column.
2012-07-22
www.JagDocs.com
12. Release front engine-mountings from crossbeam. Remove bolt. Repeat procedure to release opposite-side mounting.
13.
CAUTION: To prevent damage to the crossbeam, use a wooden block between the jack and crossbeam.
Using a suitable jack support weight of front crossbeam.
2012-07-22
14. NOTE: The bolt situated directly above the wishbone will remain captive. Release rear mounting from crossbeam. Remove bolts.
15. Release crossbeam rear mountings from body. Remove center bolt. Repeat procedure to release opposite-side mounting from body.
16.
CAUTION: Take care not to damage power steering hydraulic-pipes when lowering crossbeam.
Lower crossbeam sufficiently to remove rear mounting. 17. Remove rear mounting.
2012-07-22
18. Clean relevant parts.
Installation 1. Apply Loctite 270 or 243 to the rear-mounting captive bolt. 2. Position rear mounting to crossbeam.
www.JagDocs.com
3. Secure rear mounting to crossbeam. Align mounting. Fit and tighten bolts. 4. Raise crossbeam.
5. Secure crossbeam rear mountings to body.
2012-07-22

Fit and tighten bolt. Repeat procedure to secure opposite-side mounting to body. 6. Lower and remove jack from beneath crossbeam.
8. Connect connector to steering rack transducer.
2012-07-22
www.JagDocs.com
9. NOTE: Make sure steering wheel and road wheels are in the central position. Connect steering column to pinion shaft. Align steering column to pinion shaft. 1. Fit and tighten bolt. 10. NOTE: Guide shock absorber upper mountings into body apertures when lowering vehicle. Remove stands and lower front of vehicle.
11. Secure shock absorber upper mountings to body. Fit and tighten nuts. Vehicles fitted with adaptive damping: connect connector. Fit covers. Repeat procedure to secure opposite-side shock absorber.
2012-07-22
12. Release weight of engine. 1. Loosen hook adjustment nuts. 2. Remove hooks from lifting eyes. 3. Remove special tool.
13. Secure engine mountings to crossbeam. Tighten bolt. Repeat procedure to secure opposite-side mounting.
2012-07-22
www.JagDocs.com
14. Fit both engine covers. Position covers to engine. Fit retaining pegs. 15. Connect battery ground cable. Refer to section <<414-01>>, Battery Connection Procedure. 16. Remove paintwork protection covers.
10
2012-07-22
Rear Axle Crossmember 64.25.16

2. Remove both rear struts (convertible vehicles only). Remove ratchet straps securing drain tube. Remove four bolts. Remove struts.
2012-07-22
www.JagDocs.com
3. Remove bolts shown, from suspension subframe. 1. Remove bolts. 2. Remove nuts and bolts. 3. Remove nuts and bolts.
4.
CAUTION: Position a piece of wood between the jack and the differential drive coupling.
Position a jack under the differential drive coupling and support the weight of axle assembly.
2012-07-22
5. Remove both mounting brackets from the suspension subframe. 1. Remove bush center bolt from bracket. 2. Remove bolts securing bracket to body. Remove bracket. Repeat procedure to remove opposite-side bracket. 6. To allow for access, lower jack approximately 25 mm.
7. Remove and retain spacer from top of each bush.
2012-07-22
www.JagDocs.com
8. Remove bolts securing link assemblies to suspension subframe. 1. Remove bolt. 2. Make sure spacer remains captive in bracket. Repeat procedure to remove bolt from opposite-side of subframe.
9. With assistance remove suspension subframe from the vehicle. Using hand pressure, support weight of subframe. Remove bolts. Remove subframe. 10. Clean relevant components and mating faces.
2012-07-22

Installation
1.
CAUTION: Make sure the fuel pump electrical lead does not become trapped when fitting the suspension subframe.
With assistance fit suspension subframe to vehicle. Position subframe to vehicle. Fit bolts shown, DO NOT tighten at this stage.
2. Fit bolts securing link assemblies to suspension subframe. 1. Make sure spacer is in position. 2. Fit bolt, DO NOT tighten at this stage. Repeat procedure to fit bolt to opposite-side of subframe.
2012-07-22
www.JagDocs.com
3. Fit bolts shown, to suspension subframe. 1. Fit bolts, DO NOT tighten at this stage. 2. Fit nuts and bolts, DO NOT tighten at this stage. 3. Fit nuts and bolts, DO NOT tighten at this stage.
4. Tighten subframe bolts shown.
2012-07-22
5. Tighten subframe bolts shown. Repeat procedure to tighten bolt on opposite-side of subframe.
6. Tighten subframe nuts and bolts shown. 1. Tighten nuts. 2. Tighten nuts.
2012-07-22
7. Tighten subframe bolts shown.
www.JagDocs.com
8. Position spacer into the recess of each subframe bush.
2012-07-22
9. Locate subframe bushes onto the tapered body locations. Raise jack.
2012-07-22
www.JagDocs.com
12. Tighten mounting-bracket, bush center-bolts. Repeat procedure on opposite-side mounting bracket.
10
2012-07-22
13. Fit rear struts (convertible vehicles only). Align struts and fit and tighten bolts. Secure drain tube to struts with tie straps. 14. Lower and remove jack. 15. Lower four-post lift.
11
2012-07-22
Rear Axle Crossmember Bushing 64.25.02

Remover/Replacer Suspension Bushes 204-116/02 (JD 143-2)
www.JagDocs.com
Remover/Replacer Adaptor 204-116/06 (JD143-6B)
1. Remove suspension subframe from vehicle. Refer to 64.25.20.
2012-07-22
2. Position special tool 204-116-02 on press-bed with the recesses uppermost.
3. Remove nut and washer from tool. Position special tool 204-116-06 on bush with recesses accommodating the bush rebound stops. Install washer and nut on tool, but do not tighten nut at this stage.
2012-07-22
4. Invert subframe and position assembly on special tool 204-116-02, with subframe located in the recess.
www.JagDocs.com
5.
CAUTION: Ensure special tool 204-116-06 is correctly aligned and does not contact the bush housing bore.
Remove bush from subframe. 1. Align assembly with the press-ram. 2. Operate press to remove bush. 6. Remove bush from special tool and discard bush. 7. Thoroughly clean the bush-housing bore.
2012-07-22

Installation 1. Use a coarse grade emery cloth to roughen the bush-housing bore, and mating surface of the bush. 2. Using an air line, remove residual dust from bush and housing mating surfaces. 3. Clean the bush-housing bore and bush with cleaning solvent (SPB3 Solvent 30) or equivalent. 4. Invert suspension subframe.
5. Mark bush position on sub-frame. 1. Stretch a length of thin cord across the center line of each bush location. 2. Below the string, place two pieces of masking tape diametrically opposite on the bore periphery. 3. Mark string position on the masking tape.
6. NOTE: New bushes are bonded in position using a rapid drying adhesive Application of this adhesive and fitting of the bush must be completed within 3 minutes. It is therefore strongly recommended that the procedure is rehearsed to ensure it can be completed within that period.
2012-07-22
Position subframe on a hydraulic-press. Position special tool 204-116-02 on press-bed, with recesses uppermost. Position subframe on top of tool.
www.JagDocs.com
7. Apply 'Alphabond Rapid 101' epoxy adhesive to the shaded area of the bush (as shown), and corresponding area of the bush-housing bore.
8.
CAUTION: Bush alignment error must not exceed 5 degrees.
Aligning bush with subframe. Position bush with large single void facing forward. Align small void centers with masking tape markers.
2012-07-22
9. Install bush in housing. Position a steel plate over the bush, ensuring the plate is large enough to cover the rubber flange. Operate the press to install the bush.
10. Ensure bush is fully seated in subframe. The clearance between the bush flange and subframe must not exceed 1.5 mm. 11. Ensure bush is aligned correctly in subframe as detailed in Step 8 or 9 as appropriate. 12. Wipe off excess adhesive from subframe and bush, and remove masking tape. 13. NOTE: Allow adhesive at least 30 minutes to cure, before installing subframe on vehicle. Install suspension subframe on vehicle. Refer to 64.25.20.
2012-07-22

Workshop Manual 1999 - 3000pp

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Workshop Manual 1999 - 3000pp

Uploaded by

Copyright:

Available Formats

Workshop Manual

41300:InstrumentClusterandPanelIllumination DescriptionandOperation InstrumentClusterandPanelIllumination RemovalandInstallation HighBeamIndicatorBulb(86.45.65) InstrumentClusterBulb(86.46.22) InstrumentPanelConsoleInstrumentClusterBulb(86.46.21)

1999 XK RANGE - General Information - 100-00

General Service Information

Notes, Cautions and Warnings

Workshop Manual Organization

1999 XK RANGE - General Information - 100-00

Repairs and Replacements

1999 XK RANGE - General Information - 100-00

Service Repair Operation Numbering

References to Left- and Right-Hand

1999 XK RANGE - General Information - 100-00

References to Engine Banks

Disconnecting/Connecting the Battery

Use of Control Modules

Protecting the Vehicle

1999 XK RANGE - General Information - 100-00

1999 XK RANGE - General Information - 100-00

1999 XK RANGE - General Information - 100-00

On-Board Diagnostics (OBD)

1999 XK RANGE - General Information - 100-00

Fault Identification (DTC)

1999 XK RANGE - General Information - 100-00

BARO B+ BBDC BTDC BLR BPM BDC bhp BMEP BOO

1999 XK RANGE - General Information - 100-00

Standard specification issued by the British Standards Institution

1999 XK RANGE - General Information - 100-00

Diagnostic Test Mode

DPFE dc DLS EGRT EVR EVP EEPROM

EAIR ECM EOD ECL ECT ECTS

Referring to a vehicle fascia, eg EOD air vent

Engine speed Environmental Protection Agency Evaporative Emission

1999 XK RANGE - General Information - 100-00

FC FMVSS Fig. FEEPROM

Engine cooling fan control

CKFS FI FPRC FP FPM FPR

FSD GEN gcm gf g GND

1999 XK RANGE - General Information - 100-00

MIL MAP MAPS MST

1999 XK RANGE - General Information - 100-00

MAF MAFS max. m M MFD mm mmHg ms min. minute MY M MD MIA

Unit of electrical capacitance, one millionth of a farad

1999 XK RANGE - General Information - 100-00

RAM ROM RES RTN RPM RH RHD

AIRB AIRC AIRD AIRPC

1999 XK RANGE - General Information - 100-00

AIRP AIRR AIRS SLCM S

Service Repair Operation (number)

SD SS SIG RTN SRCM SAE SCCM cm2 std SCP

Module controlling Speed Control System

1999 XK RANGE - General Information - 100-00

1999 XK RANGE - Identification Codes - 100-01

Automatic Transmission Number

Date of Manufacture (Certain markets only)

Item GVWR GAWR F GAWR R Paint Trim

1999 XK RANGE - Identification Codes - 100-01

1999 XK RANGE - Jacking and Lifting - 100-02

Using the Vehicle Jack

WARNING: ENSURE THAT THE VEHICLE IS STANDING ON FIRM, LEVEL GROUND.

1999 XK RANGE - Jacking and Lifting - 100-02

1999 XK RANGE - Jacking and Lifting - 100-02

1999 XK RANGE - Jacking and Lifting - 100-02

Transporter or Trailer Recovery