Description
2001-2009 Jaguar X-Type Sedan & Estate Workshop Manual – Gasoline & Diesel
This 2001-2009 Jaguar X-Type Sedan & Estate Workshop Manual – Gasoline & Diesel is a comprehensive workshop reference for X-TYPE Sedan and Estate (Wagon) vehicles across the 2001 to 2009 coverage shown in the manual. It covers the 2.0 L, 2.5 L and 3.0 L gasoline applications together with the 2.0 L and 2.2 L diesel applications, with model- and powertrain-specific procedures identified throughout the sections. The manual is arranged around five major groups – General Information, Chassis, Powertrain, Electrical, and Body and Paint – and combines system descriptions, specifications, diagnosis and testing, general procedures, removal and installation, in-vehicle repair, and disassembly and assembly where applicable.
File Details
- Manual type: Workshop Manual
- Brand / model: Jaguar X-TYPE
- Body styles: Sedan and Estate (Wagon)
- Vehicle coverage: 2001 to 2009
- Engines shown: 2.0 L, 2.5 L and 3.0 L gasoline; 2.0 L and 2.2 L diesel
- Language: English
- Pages: 2810
- File format: PDF
- Published: 11-May-2011
What This Jaguar X-Type Workshop Manual Helps You Do
The manual is designed around practical service work rather than a brief owner’s overview. Its procedures move from system description and specifications into diagnosis, testing and repair, giving the technician a structured path from identifying a fault to carrying out the required mechanical or electrical work. The general information section explains workshop practices, safety, lifting, identification codes and road testing, while the diagnostic material includes symptom-based testing and, where applicable, OBD information, Diagnostic Trouble Code guidance and pinpoint-test logic. Relevant repair procedures identify special tools and include tightening information and cautions directly alongside the work.
Engine coverage is particularly broad. The contents identify 2.0L NA V6 – AJV6, 2.5L NA V6 – AJV6 and 3.0L NA V6 – AJ27 gasoline applications, plus 2.0L Duratorq-TDCi and 2.2L Duratorq-TDCi (110kW/150PS) – Puma diesel applications. Beyond routine component replacement, the engine sections include checks for bearing and journal clearances, camshaft end play and lobe lift, crankshaft measurements, cylinder block and cylinder head distortion, piston and ring measurements, valve-related inspections and other service-limit work. Separate sections cover engine cooling, fuel charging and controls, turbocharger service, accessory drives, starting, ignition or glow-plug systems, emissions, intake-air systems and electronic engine controls.
Transmission and driveline work is also split by the fitted equipment. The manual includes the 5-speed automatic transaxle – JATCO and 6-speed automatic transaxle – AWF21, along with manual transmission coverage for the MT75 and MMT6. Procedures include fluid service, control and selector components, seals, valve-body or electronic-control work where listed, transmission removal and installation, clutch systems, transfer case service, driveshafts, differentials and halfshafts. This makes the Jaguar X-Type 2001-2009 workshop manual useful for both fault diagnosis and major component-level repair planning.
Chapters Covered
- General Information
- Service information, workshop practices, safety precautions, solvents, sealants and adhesives
- Identification codes and VIN information
- Jacking, lifting and vehicle recovery
- Noise, Vibration and Harshness diagnosis and testing
- Suspension, Wheels and Tires
- Suspension system specifications and wheel alignment
- Front suspension removal, installation and component overhaul
- Rear suspension, arms, springs, dampers, hubs and knuckles
- Wheels, tires and Tire Pressure Monitoring System
- Driveline
- Driveline system diagnosis
- Driveshaft service and balancing
- Rear drive axle and differential
- Front and rear drive halfshafts and CV joint boots
- Brake System
- Brake system specifications, diagnosis and bleeding
- Front and rear disc brakes
- Parking brake and hydraulic brake actuation
- Power brake actuation
- Anti-Lock Control and Stability Assist
- Steering System
- Steering system diagnosis and fluid procedures
- Power steering
- Steering linkage
- Steering column and steering-column switches
- Engine
- Engine system specifications, inspection measurements and diagnostic procedures
- 2.0L / 2.5L / 3.0L gasoline V6 engine repair
- 2.0L / 2.2L diesel engine repair
- Engine cooling systems
- Fuel charging and controls
- Turbocharger, accessory drive, starting, ignition and glow-plug systems
- Emission control, intake-air systems and electronic engine controls
- Automatic Transmission / Transaxle
- 5-speed JATCO automatic transaxle
- 6-speed AWF21 automatic transaxle
- Transmission cooling and external controls
- Manual Transmission, Clutch and Transfer Case
- Manual transmission and clutch general information
- Clutch and clutch controls
- MT75 and MMT6 manual transaxles
- External shift controls
- Transfer case service
- Exhaust and Fuel Systems
- Exhaust system, catalytic converters and diesel particulate filter coverage
- Fuel system diagnosis and pressure procedures
- Fuel tank, lines, filters, pumps and level-sensing components
- Acceleration and speed control
- Climate Control
- Climate-control system diagnosis
- Air distribution and filtering
- Heating, ventilation and auxiliary heating
- Air-conditioning service, recovery, evacuation, charging and component replacement
- Climate-control sensors and actuators
- Instrumentation and Warning Systems
- Instrument cluster and panel illumination
- Information and message center
- Warning devices and oil-change indicator reset
- Parking aid system
- Battery, Charging and Starting-Related Electrical Systems
- Battery care, cables and mounting
- Generator and regulator
- Charging-system diagnosis
- Information and Entertainment
- Audio unit and amplifier
- Antenna systems
- Speakers and steering-wheel audio controls
- Lighting
- Exterior lighting and headlamp adjustment
- High Intensity Discharge headlamp components
- Interior lighting
- Daytime Running Lamps
- Electrical Distribution and Electronic Features
- Module communications network
- Module configuration
- Wiring harness repair
- Active and passive anti-theft systems
- Key programming and security access
- Remote convenience
- Navigation, cellular phone / Bluetooth and multifunction electronic modules
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “2001-2009 Jaguar X-Type Sedan & Estate Workshop Manual – Gasoline & Diesel” are as follows:
Front Pagep. 1
TABLE OF CONTENTSp. 2
+1: General Informationp. 46
+100: Service Informationp. 48
+100-00: General Informationp. 48
+Description and Operationp. 48
About This Manualp. 46
Application and Use of Specificationsp. 47
General Service Informationp. 48
Health and Safety Precautionsp. 56
How To Use This Manualp. 66
Important Safety Instructionsp. 67
Road/Roller Testingp. 68
Solvents, Sealants and Adhesivesp. 70
Standard Workshop Practicesp. 71
+100-01: Identification Codesp. 72
+Description and Operationp. 72
Identification Codesp. 72
+100-02: Jacking and Liftingp. 78
+Description and Operationp. 78
+100-04: Noise, Vibration and Harshnessp. 82
+Description and Operationp. 82
Noise, Vibration and Harshness (NVH)p. 82
+Diagnosis and Testingp. 83
Noise, Vibration and Harshness (NVH)p. 83
+General Proceduresp. 88
Exhaust System Neutralizingp. 88
+2: Chassisp. 89
+204: Suspensionp. 89
+204-00: Suspension System – General Informationp. 89
Specificationp. 89
+Description and Operationp. 90
Wheel Alignment Anglesp. 90
+Diagnosis and Testingp. 93
+General Proceduresp. 95
Front Toe Adjustment (57.65.01)p. 95
Rear Toe Adjustment (57.65.08)p. 97
Wheel Bearing Inspectionp. 99
+204-01: Front Suspensionp. 100
Specificationp. 100
+Description and Operationp. 101
+Diagnosis and Testingp. 103
+Removal and Installationp. 104
Lower Arm (60.35.02)p. 104
Shock Absorber and Spring Assembly (60.30.02)p. 113
Front Stabilizer Bar (60.10.01)p. 122
Front Stabilizer Bar Bushing (60.10.04)p. 124
Front Wheel Bearing and Wheel Hub (60.25.03)p. 130
Wheel Knuckle (60.25.23)p. 133
+Disassembly and Assemblyp. 139
Shock Absorber and Spring Assembly (60.30.21)p. 139
+204-02: Rear Suspensionp. 141
Specificationp. 141
+Description and Operationp. 142
+Diagnosis and Testingp. 144
+Removal and Installationp. 145
Damperp. 145
Front Lower Arm (64.35.51) – 4-Doorp. 147
Front Lower Arm (64.35.51) – Wagonp. 149
Rear Lower Arm (64.35.52)p. 154
Spring (64.20.01)p. 157
Rear Stabilizer Bar (64.35.08)p. 160
Rear Stabilizer Bar Link (64.35.24)p. 161
Upper Arm (64.25.31)p. 162
Wheel Hub (64.15.14)p. 164
Wheel Knuckle (64.15.22)p. 167
Wheel Knuckle Front Bushing (64.15.28)p. 173
Wheel Knuckle Rear Bushing (64.15.30)p. 174
+204-04: Wheels and Tiresp. 177
Specificationp. 177
+Description and Operationp. 178
+Safety Precautionsp. 178
+Diagnosis and Testingp. 184
+Removal and Installationp. 187
Tire Low Pressure Sensor – VIN Range: J28493->V99999p. 187
Tire Pressure Monitoring System (TPMS) Front Antenna – VIN Range: J28493->V99999p. 189
Tire Pressure Monitoring System (TPMS) Main Antenna – VIN Range: J28493->V99999p. 190
Tire Pressure Monitoring System (TPMS) Module – VIN Range: J28493->V99999p. 192
Tire Pressure Monitoring System (TPMS) Rear Antenna – VIN Range: J28493->V99999p. 194
Wheel and Tire (74.20.05)p. 195
+205: Drivelinep. 196
+205-00: Driveline System – General Informationp. 196
+Description and Operationp. 196
+Diagnosis and Testingp. 197
+205-01: Driveshaftp. 199
Specificationp. 199
+Description and Operationp. 200
+Diagnosis and Testingp. 201
+General Proceduresp. 202
Driveshaft Runout and Balancingp. 202
+Removal and Installationp. 203
Driveshaft (47.15.01)p. 203
+205-02: Rear Drive Axle/Differentialp. 205
Specificationp. 205
+Description and Operationp. 206
Rear Drive Axle and Differentialp. 206
+Diagnosis and Testingp. 207
Rear Drive Axle and Differentialp. 207
+In-Vehicle Repairp. 208
Axle Shaft Seal (51.20.04) (51.20.36)p. 208
Drive Pinion Flangep. 209
Drive Pinion Seal (51.20.01)p. 214
+Removal and Installationp. 219
Axle Assembly (51.25.13)p. 219
+205-04: Front Drive Halfshaftsp. 224
Specificationp. 224
+Description and Operationp. 225
Front Drive Halfshaftsp. 225
+Diagnosis and Testingp. 226
Front Drive Halfshaftsp. 226
+Removal and Installationp. 227
Front Halfshaft LH (47.10.15)p. 227
Front Halfshaft RH (47.10.16) – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NAV6 – AJ27p. 233
Front Halfshaft RH (47.10.16) – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) – Pumap. 241
Inner Constant Velocity (CV) Joint Boot (47.10.18)p. 246
Intermediate Shaftp. 249
Outer Constant Velocity (CV) Joint Boot (47.10.19)p. 251
+205-05: Rear Drive Halfshaftsp. 253
Specificationp. 253
+Description and Operationp. 254
Rear Drive Halfshaftsp. 254
+Diagnosis and Testingp. 255
Rear Drive Halfshaftsp. 255
+Removal and Installationp. 256
Rear Halfshaft (47.10.13)p. 256
Outer Constant Velocity (CV) Joint Boot (47.10.32)p. 258
+206: Brake Systemp. 260
+206-00: Brake System – General Informationp. 260
Specificationp. 260
+Description and Operationp. 261
+Diagnosis and Testingp. 262
+General Proceduresp. 270
Brake Disc Runout Checkp. 270
Brake System Bleeding (70.25.03)p. 271
+206-03: Front Disc Brakep. 273
Specificationp. 273
+Description and Operationp. 274
+Diagnosis and Testingp. 275
+Removal and Installationp. 276
Brake Caliper (70.55.02)p. 276
Brake Disc (70.10.10)p. 278
Brake Pads (70.40.02)p. 279
+206-04: Rear Disc Brakep. 281
Specificationp. 281
+Description and Operationp. 282
+Diagnosis and Testingp. 283
+Removal and Installationp. 284
Brake Caliper (70.55.03) (70.55.25)p. 284
Brake Disc (70.10.11)p. 287
Brake Disc Shield (70.10.19)p. 288
Brake Pads (70.40.03)p. 289
+206-05: Parking Brake and Actuationp. 292
Specificationp. 292
+Description and Operationp. 293
+Diagnosis and Testingp. 294
+Removal and Installationp. 296
Parking Brake Cable (70.35.29) – Vehicles With: Manually Adjusted Parking Brakep. 296
Parking Brake Cable (70.35.29) – Vehicles With: Self-Adjusting Parking Brakep. 298
Parking Brake Control (70.35.08) – Vehicles With: Manually Adjusted ParkingBrakep. 300
Parking Brake Control (70.35.08) – Vehicles With: Self-Adjusting Parking Brakep. 302
+206-06: Hydraulic Brake Actuationp. 305
Specificationp. 305
+Description and Operationp. 306
Hydraulic Brake Actuationp. 306
+Diagnosis and Testingp. 307
Hydraulic Brake Actuationp. 307
+Removal and Installationp. 308
Brake Fluid Reservoir (70.30.16)p. 308
Brake Master Cylinder (70.30.08)p. 311
Brake Pedal and Bracket (70.35.03)p. 316
Brake Pedal Cross-Shaftp. 326
+206-07: Power Brake Actuationp. 347
Specificationp. 347
+Description and Operationp. 348
+Diagnosis and Testingp. 349
+Removal and Installationp. 350
Brake Booster (70.50.17) – LHD AWD/LHD FWDp. 350
Brake Booster (70.50.17) – RHD AWD/RHD FWDp. 360
Brake Vacuum Pump – 2.0L NA V6 – AJV6p. 371
Brake Vacuum Pump – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS)– Pumap. 372
+206-09: Anti-Lock Control – Stability Assistp. 375
Specificationp. 375
+Description and Operationp. 376
Anti-Lock Control – Stability Assistp. 376
+Diagnosis and Testingp. 378
Anti-Lock Control – Stability Assist – VIN Range: C00344->J12991p. 378
Anti-Lock Control – Stability Assist – VIN Range: J12992->V99999p. 387
+Removal and Installationp. 396
Anti-Lock Brake System (ABS) Module (70.60.02) – VIN Range: C00001->J12991p. 396
Front Wheel Speed Sensor (70.60.03)p. 397
Hydraulic Control Unit (HCU) (70.60.18) (70.60.19) – VIN Range: C00001->J12991p. 398
Hydraulic Control Unit (HCU) (70.60.18) (70.60.19) – VIN Range: J12992->V99999p. 400
Rear Wheel Speed Sensor (70.60.04)p. 402
Stability Assist Modulep. 404
Steering Wheel Rotation Sensor (86.56.58)p. 405
Yaw Rate Sensor (86.56.57) – 2.0L Duratorq-TDCi/2.0L NA V6 – AJV6/2.5L NA V6 –AJV6/3.0L NA V6 – AJ27p. 406
Yaw Rate Sensor (86.56.57) – 2.2L Duratorq-TDCi (110kW/150PS) – Pumap. 407
+211: Steering Systemp. 409
+211-00: Steering System – General Informationp. 409
Specificationp. 409
+Description and Operationp. 410
+Diagnosis and Testingp. 411
+General Proceduresp. 423
Power Steering System Fillingp. 423
Power Steering System Flushing (57.15.08)p. 424
+211-02: Power Steeringp. 427
Specificationp. 427
+Description and Operationp. 428
+Diagnosis and Testingp. 429
+General Proceduresp. 430
Start Up Procedure After Power Steering Pump/Gear Overhaulp. 430
+Removal and Installationp. 431
Power Steering Control Valve Actuator (57.10.32) – 2.5L NA V6 – AJV6/3.0L NAV6 – AJ27p. 431
Power Steering Fluid Cooler (57.15.11) – 2.0L Duratorq-TDCip. 433
Power Steering Fluid Cooler (57.15.11) – 2.2L Duratorq-TDCi (110kW/150PS) –Pumap. 434
Power Steering Fluid Reservoir (57.15.08)p. 436
Power Steering Pump (57.20.14) – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NAV6 – AJ27p. 437
Power Steering Pump (57.20.14) – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) – Pumap. 439
Steering Gear (57.10.01) – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) – Pumap. 446
Steering Gear (57.10.01) – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 –AJ27p. 451
+211-03: Steering Linkagep. 463
Specificationp. 463
+Description and Operationp. 464
+Diagnosis and Testingp. 465
+Removal and Installationp. 466
Steering Gear Boot (57.10.29)p. 466
Tie Rod End (57.55.02)p. 467
+211-04: Steering Columnp. 469
Specificationp. 469
+Description and Operationp. 470
+Diagnosis and Testingp. 471
+Removal and Installationp. 472
Ignition Switch Lock Cylinder (57.40.29)p. 472
Steering Column (57.40.01)p. 473
Steering Column Couplingp. 476
Steering Wheel (57.60.01)p. 477
+211-05: Steering Column Switchesp. 478
+Description and Operationp. 478
Steering Column Switchesp. 478
+Diagnosis and Testingp. 479
Steering Column Switchesp. 479
+Removal and Installationp. 480
Steering Column Multifunction Switch LH (86.65.78)p. 480
Steering Column Multifunction Switch RH (86.65.41)p. 482
+3: Powertrainp. 483
+303: Enginep. 483
+303-00: Engine System – General Informationp. 483
Specificationp. 483
+Description and Operationp. 486
+Diagnosis and Testingp. 487
+General Proceduresp. 492
Bearing Inspectionp. 492
Camshaft Bearing Journal Clearancep. 493
Camshaft Bearing Journal Diameterp. 494
Camshaft End Playp. 495
Camshaft Lobe Liftp. 496
Camshaft Surface Inspectionp. 497
Connecting Rod Cleaningp. 498
Connecting Rod Large End Borep. 499
Crankshaft End Playp. 500
Crankshaft Main Bearing Journal Clearancep. 501
Crankshaft Main Bearing Journal Diameterp. 503
Cylinder Block Distortionp. 504
Cylinder Bore Out-of-Roundp. 505
Cylinder Head Distortionp. 506
Exhaust Manifold Cleaning and Inspectionp. 507
Flywheel Inspectionp. 508
Piston Diameterp. 509
Piston Inspectionp. 510
Piston Pin Diameterp. 511
Piston Pin to Bore Diameterp. 512
Piston Ring End Gapp. 513
Piston Ring-to-Groove Clearancep. 514
Valve Seat Inspectionp. 515
Valve Spring Free Lengthp. 516
Valve Stem Diameterp. 517
Leakage Test Using Smoke Test Equipmentp. 518
+303-01A: Engine – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27p. 520
Specificationp. 520
+Description and Operationp. 522
+Diagnosis and Testingp. 525
+General Proceduresp. 526
Valve Clearance Adjustment (12.29.48)p. 526
Valve Clearance Check (12.29.47)p. 527
+In-Vehicle Repairp. 528
Camshafts LH (12.13.19)p. 528
Crankshaft Front Seal (12.21.14)p. 529
Crankshaft Pulley (12.21.09)p. 530
Crankshaft Rear Seal (12.21.20)p. 534
Cylinder Head LH (12.29.02)p. 536
Engine Front Cover (12.65.01)p. 542
Engine Front Mount (12.45.01)p. 564
Exhaust Manifold LH (30.15.55)p. 568
Flexplate (12.53.13)p. 575
Exhaust Manifold RH (30.15.56)p. 576
Flywheel (12.53.07)p. 578
Intake Manifold (30.15.01)p. 579
Lower Intake Manifold (30.15.61)p. 591
Oil Cooler (12.60.68)p. 595
Oil Pan (12.60.44)p. 596
Oil Pressure Senderp. 602
Oil Pump (12.60.26)p. 603
Timing Drive Components (12.65.13)p. 605
Valve Cover LH (12.29.43)p. 614
Valve Cover RH (12.29.44)p. 617
+Removalp. 619
Engine (12.41.01) – Vehicles With: 5-Speed Manual Transmission – MT75/6-Speed Manual Transaxle – MMT6p. 619
Engine (12.41.01) – Vehicles With: 5-Speed Automatic Transaxle – JATCO/6-SpeedAutomatic Transaxle – AWF21p. 643
+Disassemblyp. 668
+Disassembly and Assembly of Subassembliesp. 688
Cylinder Head (12.29.22)p. 688
Piston (12.17.02)p. 691
+Assemblyp. 694
+Installationp. 720
Vehicles With: 5-Speed Manual Transmission – MT75/6-Speed Manual Transaxle – MMT6p. 720
EngineVehiclesWith: 5-Speed Automatic Transaxle – JATCO/6-Speed Automatic Transaxle – AWF21p. 743
+303-01B: Engine – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) – Pumap. 766
Specificationp. 766
+Description and Operationp. 767
+In-Vehicle Repairp. 773
Crankshaft Front Seal (12.21.14)p. 773
Crankshaft Rear Seal (12.21.20)p. 776
Engine Front Cover (12.65.01)p. 778
Engine Front Mount (12.45.01)p. 787
Flexplate (12.53.13)p. 794
Flywheel (12.53.07)p. 795
Intake Manifold (30.15.01)p. 796
Oil Pan (12.60.44)p. 798
Timing Chainp. 800
Valve Coverp. 806
+Removalp. 817
Engine (12.41.01) – 2.0L Duratorq-TDCip. 817
Engine (12.41.01) – 2.2L Duratorq-TDCi (110kW/150PS) – Pumap. 838
+Disassemblyp. 860
+Assemblyp. 888
+Installationp. 928
Engine (12.41.01) – 2.0L Duratorq-TDCip. 928
Engine (12.41.01) – 2.2L Duratorq-TDCi (110kW/150PS) – Pumap. 947
+303-03A: Engine Cooling – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27p. 968
Specificationp. 968
+Description and Operationp. 969
+Diagnosis and Testingp. 973
+General Proceduresp. 979
Cooling System Backflushingp. 979
Cooling System Draining, Filling and Bleedingp. 980
Cooling System Flushingp. 983
+Removal and Installationp. 984
Block Heater (86.62.18)p. 984
Coolant Expansion Tank (26.15.01)p. 985
Cooling Fan Module (26.25.38)p. 987
Cooling Fan Motor (26.25.24)p. 989
Cooling Fan Motor and Shroud (26.25.25)p. 990
Cooling Module (26.40.16)p. 993
Radiator (26.40.01)p. 1004
Thermostat (26.45.07)p. 1005
Water Pump (26.50.01)p. 1006
Water Pump Housing (26.50.07)p. 1007
+303-03B: Engine Cooling – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) –Pumap. 1010
Specificationp. 1010
+Description and Operationp. 1011
+General Proceduresp. 1014
Cooling System Draining, Filling and Bleedingp. 1014
Cooling System Draining and Vacuum Fillingp. 1017
+Removal and Installationp. 1021
Cooling Fan Motor and Shroud (26.25.25)p. 1021
Cooling Module (26.40.16)p. 1022
Radiator (26.40.01)p. 1026
Water Pump (26.50.01)p. 1027
+303-04A: Fuel Charging and Controls – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NAV6 – AJ27p. 1034
Specificationp. 1034
+Description and Operationp. 1035
Fuel Charging and Controlsp. 1035
+Diagnosis and Testingp. 1037
Fuel Charging and Controls – 2.0L NA V6 – AJV6p. 1037
Fuel Charging and Controls – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27, VIN Range:E96603->J28492p. 1038
Fuel Charging and Controls – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27, VIN Range:J28493->V99999p. 1045
+Removal and Installationp. 1052
Fuel Charging Wiring Harness (86.70.22)p. 1052
Fuel Injection Supply Manifold (19.60.13)p. 1055
Fuel Injectors (18.10.02)p. 1058
Fuel Pulse Damper (18.30.98) – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27p. 1060
Throttle Body (19.70.04)p. 1061
+303-04B: Fuel Charging and Controls – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) – Pumap. 1065
Specificationp. 1065
+Description and Operationp. 1066
Fuel Charging and Controlsp. 1066
+Diagnosis and Testingp. 1069
Fuel Charging and Controlsp. 1069
+General Proceduresp. 1073
Fuel Injection Component Cleaningp. 1073
+Removal and Installationp. 1074
Fuel Injection Pumpp. 1074
Fuel Injection Supply Manifold (19.60.13)p. 1099
Fuel Injector (18.10.01)p. 1110
Fuel Metering Valvep. 1119
Fuel Return Line Venturip. 1122
+303-04C: Fuel Charging and Controls – Turbochargerp. 1126
Specificationp. 1126
+Description and Operationp. 1127
+Diagnosis and Testingp. 1131
+Removal and Installationp. 1137
+303-05: Accessory Drivep. 1150
Specificationp. 1150
+Description and Operationp. 1151
+Diagnosis and Testingp. 1154
+Removal and Installationp. 1155
Accessory Drive Belt (12.10.40) – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) – Pumap. 1155
Accessory Drive Belt (12.10.40) – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NAV6 – AJ27p. 1159
Accessory Drive Belt Tensioner (12.10.41) – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) – Pumap. 1161
Accessory Drive Belt Tensioner (12.10.41) – 2.0L NA V6 – AJV6/2.5L NA V6 –AJV6/3.0L NA V6 – AJ27p. 1166
Power Steering Pump Belt – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) – Pumap. 1167
Power Steering Pump Belt Tensioner – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) – Pumap. 1171
Water Pump Belt (12.10.44) – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 –AJ27p. 1173
Water Pump Belt Tensioner (12.10.45) – 2.0L NA V6 – AJV6/2.5L NA V6 –AJV6/3.0L NA V6 – AJ27p. 1174
+303-06: Starting Systemp. 1175
Specificationp. 1175
+Description and Operationp. 1176
+Diagnosis and Testingp. 1179
Starting System – 2.0L NA V6 – AJV6p. 1179
Starting System – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27p. 1180
+Removal and Installationp. 1184
Starter Motor (86.60.01) – 2.0L Duratorq-TDCip. 1184
Starter Motor (86.60.01) – 2.2L Duratorq-TDCi (110kW/150PS) – Pumap. 1188
Starter Motor (86.60.01) – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 –AJ27p. 1192
+303-07A: Engine Ignition – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27p. 1197
Specificationp. 1197
+Description and Operationp. 1198
+Diagnosis and Testingp. 1199
Engine Ignition – 2.0L NA V6 – AJV6p. 1199
Engine Ignition – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27p. 1200
+Removal and Installationp. 1204
Ignition Coil-On-Plug LH (18.20.44)p. 1204
Ignition Coil-On-Plug RH (18.20.43)p. 1205
+303-07B: Glow Plug Systemp. 1206
Specificationp. 1206
+Description and Operationp. 1207
+Diagnosis and Testingp. 1209
+Removal and Installationp. 1213
+303-08: Engine Emission Control – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) – Pumap. 1215
Specificationp. 1215
+Description and Operationp. 1216
Engine Emission Controlp. 1216
+Diagnosis and Testingp. 1217
Engine Emission Controlp. 1217
+Removal and Installationp. 1218
Exhaust Gas Recirculation (EGR) Coolerp. 1218
Exhaust Gas Recirculation (EGR) Cooler to EGR Valve Tubep. 1222
Exhaust Gas Recirculation (EGR) Valve (17.45.01)p. 1226
+303-12A: Intake Air Distribution and Filtering – 2.0L NA V6 – AJV6/2.5L NA V6 –AJV6/3.0L NA V6 – AJ27p. 1230
+Description and Operationp. 1230
Intake Air Distribution and Filteringp. 1230
+Diagnosis and Testingp. 1231
Intake Air Distribution and Filteringp. 1231
+Removal and Installationp. 1232
Air Cleaner (19.10.05)p. 1232
Air Cleaner Element (19.10.08)p. 1233
Air Cleaner Outlet Pipe (19.10.31)p. 1235
+303-12B: Intake Air Distribution and Filtering – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) – Pumap. 1236
Specificationp. 1236
+Description and Operationp. 1237
Intake Air Distribution and Filteringp. 1237
+Diagnosis and Testingp. 1239
Intake Air Distribution and Filteringp. 1239
+Removal and Installationp. 1240
Air Cleaner (19.10.05)p. 1240
Air Cleaner Element (19.10.08)p. 1243
Air Cleaner Outlet Pipe (19.10.31)p. 1245
Charge Air Cooler – 2.0L Duratorq-TDCip. 1248
Charge Air Cooler – 2.2L Duratorq-TDCi (110kW/150PS) – Pumap. 1251
+303-13: Evaporative Emissionsp. 1253
Specificationp. 1253
+Description and Operationp. 1254
Evaporative Emissionsp. 1254
+Diagnosis and Testingp. 1255
Evaporative Emissions – 2.0L NA V6 – AJV6p. 1255
Evaporative Emissions – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27p. 1256
+Removal and Installationp. 1263
Evaporative Emission Canister (17.15.13) – 2.0L NA V6 – AJV6p. 1263
Evaporative Emission Canister (17.15.13) – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27p. 1265
Evaporative Emission Canister Purge Valve (17.15.30)p. 1273
+303-14A: Electronic Engine Controls – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NAV6 – AJ27p. 1275
Specificationp. 1275
+Description and Operationp. 1276
Electronic Engine Controlsp. 1276
+Diagnosis and Testingp. 1282
Electronic Engine Controls – 2.0L NA V6 – AJV6p. 1282
Electronic Engine Controls – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27, VIN Range:E96603->J28492p. 1286
Electronic Engine Controls – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27, VIN Range:J28493->V99999p. 1316
+General Proceduresp. 1347
Powertrain Control Module (PCM) Long Drive Cycle Self-Testp. 1347
Powertrain Control Module (PCM) Short Drive Cycle Self-Testp. 1348
+Removal and Installationp. 1349
Camshaft Position (CMP) Sensor (18.30.63)p. 1349
Catalyst Monitor Sensor LH (18.30.81)p. 1350
Catalyst Monitor Sensor RH (18.30.80)p. 1352
Crankshaft Position (CKP) Sensor (18.30.12)p. 1354
Engine Control Module (ECM) (18.30.01)p. 1355
Fuel Temperature Sensor (18.30.99) – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27p. 1357
Heated Oxygen Sensor (HO2S) LH (18.30.79)p. 1359
Heated Oxygen Sensor (HO2S) RH (18.30.78)p. 1360
Knock Sensor (KS) (18.30.69)p. 1361
Mass Air Flow (MAF) Sensor (18.30.15)p. 1365
Oil Temperature Sensor (18.31.01)p. 1366
Throttle Position (TP) Sensor (18.30.17)p. 1367
Variable Camshaft Timing (VCT) Oil Control Solenoid (18.30.90)p. 1369
+303-14B: Electronic Engine Controls – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) – Pumap. 1370
Specificationp. 1370
+Description and Operationp. 1371
Electronic Engine Controlsp. 1371
+Diagnosis and Testingp. 1373
Electronic Engine Controlsp. 1373
+Removal and Installationp. 1386
Camshaft Position (CMP) Sensor (18.30.63)p. 1386
Catalytic Converter Temperature Sensorp. 1387
Crankshaft Position (CKP) Sensor (18.30.12)p. 1391
Cylinder Head Temperature (CHT) Sensor (18.30.97)p. 1393
Diesel Particulate Filter (DPF) Temperature Sensorp. 1396
Engine Control Module (ECM) (18.30.01)p. 1397
Engine Oil Pressure (EOP) Sensorp. 1399
Fuel Temperature Sensor (18.30.99)p. 1400
Knock Sensor (KS) (18.30.69)p. 1402
Manifold Absolute Pressure and Temperature (MAPT) Sensorp. 1404
Manifold Absolute Pressure (MAP) Sensor (18.30.86)p. 1408
Mass Air Flow (MAF) Sensor (18.30.15)p. 1410
+307: Automatic Transmission/Transaxlep. 1412
+307-01A: Automatic Transmission/Transaxle – Vehicles With: 5-Speed AutomaticTransaxle – JATCOp. 1412
Specificationp. 1412
+Description and Operationp. 1413
Transmission Description – Vehicles With: 5-Speed Automatic Transaxle – JATCOp. 1413
+Diagnosis and Testingp. 1428
Diagnostic Strategy – Vehicles With: 5-Speed Automatic Transaxle – JATCOp. 1428
+General Proceduresp. 1441
Transmission Fluid Drain and Refill (44.24.02)p. 1441
Transmission Fluid Level Checkp. 1442
Transmission Range (TR) Sensor Adjustment (44.15.37)p. 1444
+In-Vehicle Repairp. 1445
Halfshaft Seal LH (37.23.10)p. 1445
Halfshaft Seal RHp. 1446
Main Control Valve Body (44.40.01)p. 1447
Shift Solenoids (SS) (44.15.50)p. 1451
Transaxle Support Insulator (37.16.42)p. 1452
Transmission Control Module (TCM) (44.15.32)p. 1456
Transmission Range (TR) Sensorp. 1459
+Removalp. 1460
Transaxle (44.20.01)p. 1460
+Disassembly and Assembly of Subassembliesp. 1471
Input Shaft Seal (44.32.07)p. 1471
+Installationp. 1473
Transaxle (44.20.01)p. 1473
+307-01B: Automatic Transmission/Transaxle – Vehicles With: 6-Speed AutomaticTransaxle – AWF21p. 1484
Specificationp. 1484
+Description and Operationp. 1485
Transmission Description – Vehicles With: 6-Speed Automatic Transaxle – AWF21p. 1485
Transmission Electronic Control System – Vehicles With: 6-Speed Automaticp. 1497
+Diagnosis and Testingp. 1501
Diagnostic Strategy – Vehicles With: 6-Speed Automatic Transaxle – AWF21p. 1501
+General Proceduresp. 1513
Transmission Fluid Drain and Refill (44.24.02)p. 1513
Transmission Fluid Level Checkp. 1516
+In-Vehicle Repairp. 1518
Main Control Valve Body (44.40.01)p. 1518
Selector Shaft Sealp. 1522
Transmission Control Module (TCM) (44.15.32)p. 1523
Transmission Internal Wiring Harness (44.15.35)p. 1525
Transmission Fluid Pan (44.24.04)p. 1527
+Removal and Installationp. 1529
Torque Converterp. 1529
Torque Converter Sealp. 1530
Turbine Shaft Speed (TSS) Sensorp. 1531
+Removalp. 1532
Transmission (44.20.01)p. 1532
+Installationp. 1539
Transmission (44.20.01)p. 1539
+307-02A: Transmission/Transaxle Cooling – Vehicles With: 5-Speed AutomaticTransaxle – JATCOp. 1546
Specificationp. 1546
+Description and Operationp. 1547
Transmission Cooling – Vehicles With: 5-Speed Automatic Transaxle – JATCOp. 1547
+Diagnosis and Testingp. 1548
Transmission Coolingp. 1548
+Removal and Installationp. 1549
Transmission Fluid Cooler (44.24.10)p. 1549
Transmission Fluid Cooler Tubes (44.24.19)p. 1551
+307-02B: Transmission/Transaxle Cooling – Vehicles With: 6-Speed AutomaticTransaxle – AWF21p. 1552
Specificationp. 1552
+Description and Operationp. 1553
Transmission Cooling – Vehicles With: 6-Speed Automatic Transaxle – AWF21p. 1553
+Diagnosis and Testingp. 1554
Transmission Coolingp. 1554
+Removal and Installationp. 1555
Transmission Fluid Cooler (44.24.10)p. 1555
Transmission Fluid Cooler Return Tube (44.24.13) (44.24.29)p. 1556
Transmission Fluid Cooler Supply Tube (44.24.14) (44.24.28)p. 1558
+307-05A: Automatic Transmission/Transaxle External Controlsp. 1560
Specificationp. 1560
+Description and Operationp. 1561
External Controls – Vehicles With: 5-Speed Automatic Transaxle – JATCOp. 1561
+Diagnosis and Testingp. 1563
+General Proceduresp. 1566
Selector Lever Cable Adjustment (44.15.07)p. 1566
+Removal and Installationp. 1568
Selector Lever Cable and Bracket (44.15.08)p. 1568
Selector Lever Assembly (44.15.04)p. 1572
+307-05B: Automatic Transmission/Transaxle External Controls – Vehicles With:6-Speed Automatic Transaxle – AWF21p. 1577
Specificationp. 1577
+Description and Operationp. 1578
External Controls – Vehicles With: 6-Speed Automatic Transaxle – AWF21p. 1578
+Diagnosis and Testingp. 1582
+General Proceduresp. 1585
Selector Lever Cable Adjustment (44.15.07)p. 1585
+Removal and Installationp. 1587
Selector Lever Assembly (44.15.04)p. 1587
Selector Lever Knob (44.15.06)p. 1590
+308: Manual Transmission/Transaxle, Clutch and Transfer Casep. 1591
+308-00: Manual Transmission/Transaxle and Clutch – General Informationp. 1591
Specificationp. 1591
+Description and Operationp. 1592
Manual Transmission and Clutchp. 1592
+Diagnosis and Testingp. 1593
Manual Transmission and Clutchp. 1593
+General Proceduresp. 1598
Clutch System Bleeding (33.15.01) – Vehicles With: 5-Speed ManualTransmission – MT75p. 1598
Clutch System Bleeding (33.15.01) – Vehicles With: 6-Speed Manual Transaxle –MMT6p. 1599
Gearshift Cable Adjustment (37.16.47)p. 1600
Release Hub and Bearing Checkp. 1603
+308-01: Clutchp. 1604
Specificationp. 1604
+Description and Operationp. 1605
+Diagnosis and Testingp. 1606
+Removal and Installationp. 1607
Clutch Disc and Pressure Plate (12.53.13) (33.10.01)p. 1607
+308-02: Clutch Controlsp. 1609
Specificationp. 1609
+Description and Operationp. 1610
+Diagnosis and Testingp. 1613
+Removal and Installationp. 1614
Clutch Master Cylinder (33.20.01)p. 1614
Clutch Slave Cylinder (33.35.01) – Vehicles With: 5-Speed Manual Transmission –MT75p. 1619
Clutch Slave Cylinder (33.35.01) – Vehicles With: 6-Speed Manual Transaxle –MMT6p. 1620
+308-03: Manual Transmission/Transaxlep. 1622
Specificationp. 1622
+Description and Operationp. 1623
Manual Transaxle – Vehicles With: 5-Speed Manual Transmission – MT75p. 1623
Manual Transaxle – Vehicles With: 6-Speed Manual Transaxle – MMT6p. 1624
+Diagnosis and Testingp. 1634
+General Proceduresp. 1635
Transaxle Draining and Filling (44.24.02) – Vehicles With: 5-Speed ManualTransmission – MT75p. 1635
Transaxle Draining and Filling (44.24.02) – Vehicles With: 6-Speed ManualTransaxle – MMT6p. 1636
+In-Vehicle Repairp. 1637
Halfshaft Seal LHp. 1637
Halfshaft Seal RHp. 1638
Input Shaft Seal (37.23.09)p. 1639
Selector Mechanism – Vehicles With: 5-Speed Manual Transmission – MT75p. 1640
Selector Mechanism – Vehicles With: 6-Speed Manual Transaxle – MMT6p. 1657
Support Insulator (37.16.42)p. 1661
+Removalp. 1666
Transaxle (37.20.01) – 2.0L Duratorq-TDCip. 1666
Transaxle (37.20.01) – 2.2L Duratorq-TDCi (110kW/150PS) – Pumap. 1675
Transaxle (37.20.01) – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27p. 1682
+Installationp. 1692
Transaxle (37.20.01) – 2.0L Duratorq-TDCip. 1692
Transaxle (37.20.01) – 2.2L Duratorq-TDCi (110kW/150PS) – Pumap. 1700
Transaxle (37.20.01) – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27p. 1707
+308-06: Manual Transmission/Transaxle External Controlsp. 1717
Specificationp. 1717
+Description and Operationp. 1718
+Diagnosis and Testingp. 1720
+Removal and Installationp. 1721
Gearshift Cables (37.16.45) – Vehicles With: 5-Speed Manual Transmission –MT75p. 1721
Gearshift Cables (37.16.45) – Vehicles With: 6-Speed Manual Transaxle – MMT6p. 1725
Gearshift Lever (37.16.04) – Vehicles With: 5-Speed Manual Transmission – MT75p. 1728
Gearshift Lever (37.16.04) – Vehicles With: 6-Speed Manual Transaxle – MMT6p. 1730
+308-07: Transfer Casep. 1732
Specificationp. 1732
+Description and Operationp. 1733
+General Proceduresp. 1734
Transfer Case Draining and Fillingp. 1734
+In-Vehicle Repairp. 1742
Halfshaft Seal RH (46.10.03)p. 1742
Transfer Case Rear Output Shaft Seal (46.10.04)p. 1743
+Removalp. 1751
Transfer Case (46.10.01)p. 1751
+Installationp. 1761
Transfer Case (46.10.01)p. 1761
+309: Exhaust Systemp. 1772
+309-00: Exhaust Systemp. 1772
Specificationp. 1772
+Description and Operationp. 1773
+Diagnosis and Testingp. 1780
+Removal and Installationp. 1782
Catalytic Converter (17.50.05) – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) – Pumap. 1782
Catalytic Converter LH (17.50.15) – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NAV6 – AJ27p. 1787
Catalytic Converter RH (17.50.16) – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NAV6 – AJ27p. 1793
Diesel Particulate Filter (DPF)p. 1796
Diesel Particulate Filter (DPF) Differential Pressure Sensorp. 1799
Exhaust Flexible Pipe (30.10.57) – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) – Pumap. 1801
Front Muffler (30.10.18) – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) – Pumap. 1803
Front Muffler (30.10.18) – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27p. 1805
Muffler and Tailpipe (30.10.52) – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) – Puma, 2.0Lp. 1808
Muffler and Tailpipe (30.10.52) – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27p. 1809
Muffler Inlet Pipe (30.10.06) – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 –AJ27p. 1810
Muffler Inlet Pipe (30.10.06) – Vehicles With: Diesel Particulate Filter (DPF)p. 1814
+310: Fuel Systemp. 1816
+310-00: Fuel System – General Informationp. 1816
Specificationp. 1816
+Description and Operationp. 1817
+Diagnosis and Testingp. 1821
+General Proceduresp. 1825
Fuel System Pressure Checkp. 1825
Fuel System Pressure Release (19.50.02)p. 1827
Fuel Tank Draining – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) –Pumap. 1828
Fuel Tank Draining – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27p. 1829
Quick Release Coupling – Push Connectp. 1833
Spring Lock Couplingsp. 1838
+310-01: Fuel Tank and Linesp. 1841
Specificationp. 1841
+Description and Operationp. 1842
Fuel Tank and Linesp. 1842
+Diagnosis and Testingp. 1846
Fuel Tank and Linesp. 1846
+Removal and Installationp. 1855
Fuel Filter (19.25.02) – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) –Pumap. 1855
Fuel Filter (19.25.02) – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27p. 1858
Fuel Level Sender – 2.0L NA V6 – AJV6p. 1860
Fuel Level Sender – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) –Pumap. 1862
Fuel Level Sender LH – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27p. 1864
Fuel Level Sender RH – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27p. 1866
Fuel Level Sensor (88.25.32) – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) – Pumap. 1867
Fuel Pump Module (19.45.08) – 2.0L NA V6 – AJV6p. 1869
Fuel Pump Module (19.45.08) – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27p. 1871
Fuel Tank (19.55.01) – 2.0L NA V6 – AJV6p. 1877
Fuel Tank (19.55.01) – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) –Pumap. 1882
Fuel Tank (19.55.01) – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27p. 1886
Fuel Tank Filler Pipe (19.55.33)p. 1899
Gas Fuel Tank Pressure Sensor (19.55.31)p. 1901
Fuel Transfer Pump (19.45.21)p. 1902
Inertia Fuel Shutoff (IFS) Switch (18.30.35)p. 1906
Fuel Tank Filler Pipe Hosep. 1907
+310-02: Acceleration Controlp. 1909
Specificationp. 1909
+Description and Operationp. 1910
Acceleration Controlp. 1910
+Diagnosis and Testingp. 1911
Acceleration Controlp. 1911
+General Proceduresp. 1916
Accelerator Cable Adjustment (12.20.05) – 2.0L NA V6 – AJV6p. 1916
+Removal and Installationp. 1917
Accelerator Cable (19.20.06) – 2.0L NA V6 – AJV6p. 1917
Accelerator Pedal (19.20.01)p. 1919
+310-03: Speed Controlp. 1921
Specificationp. 1921
+Description and Operationp. 1922
+Diagnosis and Testingp. 1925
Speed Control – 2.0L NA V6 – AJV6p. 1925
Speed Control – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27p. 1926
+Removal and Installationp. 1932
Speed Control Deactivator Switch (19.75.20)p. 1932
Speed Control Module (19.75.26)p. 1933
Speed Control Switch (19.75.25)p. 1936
+4: Electricalp. 1937
+412: Climate Control Systemp. 1937
+412-00: Climate Control System – General Informationp. 1937
Specificationp. 1937
+Description and Operationp. 1938
Climate Control Systemp. 1938
+Diagnosis and Testingp. 1939
Climate Control Systemp. 1939
+General Proceduresp. 1943
Air Conditioning (A/C) Compressor Leak Detectionp. 1943
Air Conditioning (A/C) System Flushingp. 1944
Air Conditioning (A/C) System Recovery, Evacuation and Charging (82.30.30)p. 1946
Contaminated Refrigerant Handlingp. 1947
Discharging and Recovery (82.30.30)p. 1948
Electronic Leak Detectionp. 1949
Inspection and Assembly Requirementsp. 1950
Leak Detectionp. 1951
Refrigerant Oil Addingp. 1952
Refrigerant System Testsp. 1953
+412-01: Air Distribution and Filteringp. 1954
+Description and Operationp. 1954
Air Distribution and Filteringp. 1954
+Diagnosis and Testingp. 1955
Air Distribution and Filteringp. 1955
+Removal and Installationp. 1956
Center Registers (82.20.38)p. 1956
Driver Side Register (82.20.39)p. 1957
Front Footwell Duct LH (82.20.91)p. 1958
Front Footwell Duct RH (82.20.92)p. 1959
Passenger Side Register (82.20.40)p. 1960
Pollen Filter (76.10.09)p. 1961
+412-02A: Heating and Ventilationp. 1962
Specificationp. 1962
+Description and Operationp. 1963
Heating and Ventilationp. 1963
+Diagnosis and Testingp. 1964
Heating and Ventilationp. 1964
+Removal and Installationp. 1965
Blower Motor (82.25.66)p. 1965
Evaporator Core Housing (80.20.01)p. 1966
Heater Core (80.20.29)p. 1972
+Disassembly and Assemblyp. 1975
Evaporator Core Housingp. 1975
+412-02B: Auxiliary Heatingp. 1980
Specificationp. 1980
+Description and Operationp. 1981
Electric Booster Heaterp. 1981
Fuel Fired Booster Heaterp. 1983
+Diagnosis and Testingp. 1986
Auxiliary Heaterp. 1986
Fuel Fired Booster Heaterp. 1996
+Removal and Installationp. 2000
Electric Booster Heaterp. 2000
Fuel Fired Booster Heaterp. 2002
+412-03: Air Conditioningp. 2006
Specificationp. 2006
+Description and Operationp. 2007
+Diagnosis and Testingp. 2009
+Removal and Installationp. 2010
Air Conditioning (A/C) Compressor (82.10.20) – 2.0L NA V6 – AJV6/2.5L NA V6 –AJV6/3.0L NA V6 – AJ27p. 2010
Air Conditioning (A/C) Compressor (82.10.20) – 2.0L Duratorq-TDCi/2.2LDuratorq-TDCi (110kW/150PS) – Pumap. 2012
Air Conditioning (A/C) Pressure Transducer (82.10.47)p. 2016
Clutch and Clutch Field Coil (82.10.25) – 2.0L NA V6 – AJV6/2.5L NA V6 –AJV6/3.0L NA V6 – AJ27p. 2017
Condenser Core (82.15.07)p. 2022
Evaporator Core (82.25.20)p. 2024
Evaporator Core Orifice (82.25.67)p. 2026
Suction Accumulator (82.17.02)p. 2027
+412-04: Control Componentsp. 2029
+Description and Operationp. 2029
Control Componentsp. 2029
+Diagnosis and Testingp. 2032
Control Componentsp. 2032
+Removal and Installationp. 2033
Air Discharge Temperature Sensor (82.20.64)p. 2033
Ambient Air Temperature Sensor (82.20.02)p. 2034
Climate Control Assembly (82.20.07)p. 2035
Defrost Vent/Register Blend Door Actuator (82.20.84)p. 2038
Footwell Vent/Duct Blend Door Actuator (80.20.20 or 82.20.85)p. 2039
Sunload Sensor (82.20.70)p. 2040
Temperature Blend Door Actuator (82.20.86)p. 2042
+413: Instrumentation and Warning Systemsp. 2043
+413-00: Instrument Cluster and Panel Illuminationp. 2043
+Diagnosis and Testingp. 2043
Instrument Cluster and Panel Illuminationp. 2043
+413-01: Instrument Clusterp. 2044
+Description and Operationp. 2044
Instrument Clusterp. 2044
+Diagnosis and Testingp. 2047
Instrument Clusterp. 2047
+Removal and Installationp. 2048
Instrument Cluster (88.20.01)p. 2048
+413-06: Hornp. 2049
Description and Operationp. 2049
Diagnosis and Testingp. 2051
+Removal and Installationp. 2052
Horn (86.30.02) (86.30.10)p. 2052
Horn Switch (86.30.01)p. 2053
+413-08: Information and Message Centerp. 2054
+Description and Operationp. 2054
Information and Message Centerp. 2054
+Diagnosis and Testingp. 2055
Information and Message Centerp. 2055
+Removal and Installationp. 2056
Message Centerp. 2056
Message Center Switch (86.66.11)p. 2057
+413-09: Warning Devicesp. 2058
+Description and Operationp. 2058
+Diagnosis and Testingp. 2061
+General Proceduresp. 2062
Oil Change Indicator Resetp. 2062
+Removal and Installationp. 2063
Low Washer Fluid Warning Indicator Switch (84.10.17)p. 2063
+413-13: Parking Aidp. 2064
+Description and Operationp. 2064
+Diagnosis and Testingp. 2066
+Removal and Installationp. 2068
Front Parking Aid Sensor (86.62.33)p. 2068
Front Parking Aid Speaker (86.54.18) (86.62.34)p. 2069
Parking Aid Module (86.80.39) – 4-Doorp. 2072
Parking Aid Module (86.80.39) – Wagonp. 2073
Rear Parking Aid Sensor (86.54.14) (86.62.01)p. 2075
Rear Parking Aid Speaker (86.54.19) (86.62.02) – 4-Doorp. 2076
Rear Parking Aid Speaker (86.54.19) (86.62.02) – Wagon, VIN Range: D86655->E43419p. 2077
Rear Parking Aid Speaker (86.54.19) (86.62.02) – Wagon, VIN Range: E43420->V99999p. 2079
+414: Battery and Charging Systemp. 2081
+414-00: Battery and Charging System – General Informationp. 2081
+Description and Operationp. 2081
Charging Systemp. 2081
Battery Carep. 2082
Quiescent Drainp. 2091
+Diagnosis and Testingp. 2092
Charging System – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27p. 2092
Charging System – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) –Pumap. 2099
+General Proceduresp. 2104
+414-01: Battery, Mounting and Cablesp. 2105
Specificationp. 2105
+Description and Operationp. 2106
Battery and Cablesp. 2106
+Diagnosis and Testingp. 2108
+General Proceduresp. 2109
Battery Connect (86.15.15)p. 2109
Battery Disconnect and Connectp. 2110
+Removal and Installationp. 2111
Battery (86.15.01)p. 2111
Battery Cables (86.15.32) – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 –AJ27p. 2113
Battery Cables (86.15.32) – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) – Pumap. 2117
Battery Tray (86.15.11)p. 2122
+414-02: Generator and Regulatorp. 2123
Specificationp. 2123
+Description and Operationp. 2124
+Diagnosis and Testingp. 2126
+Removal and Installationp. 2127
Generator (86.10.02) – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27p. 2127
Generator (86.10.02) – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) –Pumap. 2129
+415: Information and Entertainment Systemsp. 2135
+415-00: Information and Entertainment System – General Informationp. 2135
+Diagnosis and Testingp. 2135
+415-01: Audio Unitp. 2139
+Description and Operationp. 2139
+Diagnosis and Testingp. 2143
+Removal and Installationp. 2144
Audio Unit (86.50.03)p. 2144
Audio Unit Amplifier (86.50.10) (86.50.36) – 4-Doorp. 2145
Audio Unit Amplifier (86.50.10) (86.50.36) – Wagonp. 2147
Compact Disc (CD) Changer (86.50.06) – 4-Doorp. 2150
Compact Disc (CD) Changer (86.50.06) – Wagonp. 2153
Steering Wheel Audio Controls (86.50.42)p. 2158
+415-02: Antennap. 2159
Specificationp. 2159
+Description and Operationp. 2160
+Diagnosis and Testingp. 2163
+Removal and Installationp. 2164
Antenna (86.51.17.60) – Wagonp. 2164
Modulep. 2168
+415-03: Speakersp. 2169
+Description and Operationp. 2169
+Diagnosis and Testingp. 2170
+Removal and Installationp. 2171
Front Door Speaker (86.50.13)p. 2171
Front Door Tweeter Speaker (86.50.63)p. 2172
Parcel Shelf Speaker (86.51.06)p. 2173
Rear Door Speaker (86.50.14)p. 2174
Rear Door Tweeter Speaker (86.50.62)p. 2175
+417: Lightingp. 2176
+417-01: Exterior Lightingp. 2176
Specificationp. 2176
+Description and Operationp. 2177
+Diagnosis and Testingp. 2178
+General Proceduresp. 2180
Headlamp Adjustment (86.40.18)p. 2180
+Removal and Installationp. 2181
Ballast (86.41.52)p. 2181
Front Fog Lamp (86.40.96)p. 2182
Headlamp Assembly (86.41.33)p. 2183
Headlamp Bulb (86.42.14) – Vehicles With: High Intensity Discharge Headlampsp. 2185
Headlamp Leveling Modulep. 2186
Headlamp Leveling Sensor (86.42.15)p. 2187
Headlamp Switch (86.65.26)p. 2189
High Mounted Stoplamp (86.41.01) (86.41.32) – 4-Doorp. 2190
High Mounted Stoplamp (86.41.01) (86.41.32) – Wagonp. 2191
Rear Lamp Assembly (86.40.70) – 4-Doorp. 2192
Rear Lamp Assembly (86.40.70) – Wagonp. 2193
+417-02: Interior Lightingp. 2194
+Description and Operationp. 2194
+Diagnosis and Testingp. 2195
+Removal and Installationp. 2196
Front Interior Lamp (86.45.12)p. 2196
Rear Interior Lamp (86.46.03)p. 2197
+417-04: Daytime Running Lamps (DRL)p. 2198
+Description and Operationp. 2198
Daytime Running Lamps (DRL)p. 2198
+Diagnosis and Testingp. 2199
Daytime Running Lamps (DRL)p. 2199
+418: Electrical Distributionp. 2200
+418-00: Module Communications Networkp. 2200
+Description and Operationp. 2200
Communications Networkp. 2200
+Diagnosis and Testingp. 2201
Communications Network – VIN Range: E96603->J28492p. 2201
Communications Network – VIN Range: J28493->V99999p. 2239
+418-01: Module Configurationp. 2280
+Diagnosis and Testingp. 2280
Module Configurationp. 2280
+General Proceduresp. 2281
Module Configurationp. 2281
+418-02: Wiring Harnessesp. 2282
+Description and Operationp. 2282
+General Proceduresp. 2293
Wiring Harness Repairp. 2293
+419: Electronic Feature Groupp. 2294
+419-01A: Anti-Theft – Activep. 2294
+Description and Operationp. 2294
Anti-Theft – Activep. 2294
+Diagnosis and Testingp. 2296
Anti-Theft – Activep. 2296
+Removal and Installationp. 2297
Anti-Theft Alarm Horn (86.52.03)p. 2297
+419-01B: Anti-Theft – Passivep. 2298
+Description and Operationp. 2298
Anti-Theft – Passivep. 2298
+Diagnosis and Testingp. 2299
Anti-Theft – Passivep. 2299
+General Proceduresp. 2300
Anti-Theft Security Accessp. 2300
Key Programming Using Diagnostic Equipmentp. 2301
+Removal and Installationp. 2302
Passive Anti-Theft System (PATS) Transceiver (86.52.30)p. 2302
+419-02: Remote Conveniencep. 2303
+Description and Operationp. 2303
Universal Transmitterp. 2303
+Diagnosis and Testingp. 2304
Universal Transmitterp. 2304
+General Proceduresp. 2305
Universal Transmitter Programmingp. 2305
+419-07: Navigation Systemp. 2307
+Description and Operationp. 2307
+Diagnosis and Testingp. 2309
+Removal and Installationp. 2311
Navigation System Antenna (86.62.06) – 4-Door, VIN Range: E96603->J39905p. 2311
Navigation System Antenna (86.62.06) – 4-Door, VIN Range: J39906->V99999p. 2313
Navigation System Antenna (86.62.06) – Wagonp. 2315
Navigation System Display Module (86.62.07)p. 2316
Navigation System Module (86.62.05) – 4-Doorp. 2319
Navigation System Module (86.62.05) – Wagonp. 2322
+419-08: Cellular Phonep. 2327
Specificationp. 2327
+Description and Operationp. 2328
+Diagnosis and Testingp. 2331
Cellular Phonep. 2331
Cellular Phone – Vehicles With: Bluetoothp. 2333
+Removal and Installationp. 2350
Bluetooth Modulep. 2350
Handset Holder (86.51.12)p. 2351
Module – 4-Doorp. 2355
Module – Wagonp. 2356
+419-10: Multifunction Electronic Modulesp. 2357
Specificationp. 2357
+Description and Operationp. 2358
Module Controlled Functionsp. 2358
+Diagnosis and Testingp. 2360
Multifunction Electronic Modulep. 2360
+Removal and Installationp. 2363
Generic Electronic Module (GEM) (86.55.75) (86.80.38)p. 2363
Multifunction Voice Activated Module (86.53.13) (86.80.40) – 4-Doorp. 2364
Multifunction Voice Activated Module (86.53.13) (86.80.40) – Wagonp. 2366
+5: Body and Paintp. 2367
+501: Body and Paintp. 2367
+501-02: Front End Body Panelsp. 2367
+Description and Operationp. 2367
Front End Body Panelsp. 2367
+Removal and Installationp. 2368
Air Deflector (76.11.41) – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS)- Pumap. 2368
Cowl Vent Screen (76.10.01)p. 2369
Fender Splash Shield (76.10.90)p. 2370
Radiator Splash Shield (76.22.90)p. 2371
+501-03: Body Closuresp. 2372
Specificationp. 2372
+Description and Operationp. 2373
+General Proceduresp. 2374
Door Alignmentp. 2374
Hood Alignment (76.16.02)p. 2376
Liftgate Alignment (76.19.54.60)p. 2378
Luggage Compartment Lid Alignment (76.19.03)p. 2382
+Removal and Installationp. 2385
+501-05: Interior Trim and Ornamentationp. 2388
Specificationp. 2388
+Description and Operationp. 2389
+Removal and Installationp. 2390
A-Pillar Trim Panel (76.13.31)p. 2390
B-Pillar Lower Trim Panel (76.13.29)p. 2391
B-Pillar Upper Trim Panel (76.13.28)p. 2392
Cowl Side Trim Panel (76.13.30)p. 2394
C-Pillar Trim Panel (76.13.73) – 4-Doorp. 2395
C-Pillar Trim Panel (76.13.73) – Wagonp. 2396
D-Pillar Trim Panel (76.13.73.60)p. 2398
Front Door Trim Panel (76.34.01)p. 2400
Front Scuff Plate Trim Panel (76.13.81)p. 2402
Headliner (76.64.01) – 4-Doorp. 2403
Headliner (76.64.01) – Wagonp. 2406
Liftgate Trim Panel (76.19.65.60)p. 2411
Loadspace Scuff Plate Trim Panel (76.19.90.60)p. 2413
Loadspace Trim Panel (76.13.73.60)p. 2415
Parcel Shelf (76.67.06)p. 2418
Rear Door Trim Panel (76.34.04)p. 2420
Rear Scuff Plate Trim Panel (76.13.82)p. 2422
Rear Window Blind (76.14.04)p. 2423
Sun Visor (76.10.48)p. 2425
+501-08: Exterior Trim and Ornamentationp. 2426
Specificationp. 2426
+Description and Operationp. 2427
+Removal and Installationp. 2429
Door Moulding (76.43.72)p. 2429
Liftgate Moulding (76.43.79)p. 2430
Radiator Grille (76.55.03)p. 2432
Rear Spoiler (76.19.86.60) – Wagonp. 2433
Rocker Panel Moulding (76.11.36)p. 2435
Roof Rail (76.43.86.60)p. 2436
Window Moulding (76.43.20)p. 2438
+501-09: Rear View Mirrorsp. 2439
Specificationp. 2439
+Description and Operationp. 2440
+Diagnosis and Testingp. 2441
+Removal and Installationp. 2442
Auto-Dimming Interior Mirror (76.10.56)p. 2442
Exterior Mirror (76.10.52)p. 2443
Exterior Mirror Control Switch (86.65.75)p. 2445
Exterior Mirror Cover (76.10.55)p. 2446
Exterior Mirror Glass (76.10.53)p. 2447
Exterior Mirror Motor (76.10.57) (76.11.09)p. 2448
Interior Mirror (76.10.51)p. 2449
+501-10: Seatingp. 2450
Specificationp. 2450
+Description and Operationp. 2451
+Diagnosis and Testingp. 2459
+Removal and Installationp. 2468
Front Seat (76.70.01)p. 2468
Front Seat Backrest (76.70.06)p. 2471
Front Seat Cushion (76.70.11)p. 2475
Front Seat Front Height Adjustment Motor (86.75.31)p. 2476
Front Seat Rear Height Adjustment Motor (86.75.32)p. 2478
Front Seat Recliner Motor (86.75.04)p. 2480
Front Seat Track Motor (86.75.33)p. 2482
Lumbar Assembly (86.75.12)p. 2484
Rear Seat Backrest (76.70.38) – 4-Doorp. 2487
Rear Seat Backrest (76.70.38) – 4-Door, Vehicles With: 70/30 Split Seatp. 2488
Rear Seat Backrest (76.70.38) – Wagon, Vehicles With: 70/30 Split Seatp. 2489
Rear Seat Backrest Latch (76.70.62.60) – Wagonp. 2491
Rear Seat Bolster (76.70.67) – 4-Doorp. 2492
Rear Seat Bolster (76.70.67) – Wagonp. 2493
Rear Seat Cushion (76.70.37)p. 2494
Seat Base (76.70.08)p. 2495
Seat Control Switch (86.75.23)p. 2497
+Disassembly and Assemblyp. 2499
Front Seat Backrest (76.70.23)p. 2499
Front Seat Cushion (76.70.34)p. 2502
Rear Seat Backrest (76.70.48) – 4-Door, Vehicles With: 70/30 Split Seatp. 2503
Rear Seat Backrest (76.70.48) – Wagon, Vehicles With: 70/30 Split Seatp. 2505
Rear Seat Backrest (76.70.48)p. 2509
Rear Seat Bolsterp. 2511
Rear Seat Cushion (76.70.47)p. 2512
+501-11: Glass, Frames and Mechanismsp. 2514
Specificationp. 2514
+Description and Operationp. 2515
Glass, Frames and Mechanismsp. 2515
+Diagnosis and Testingp. 2516
Glass, Frames and Mechanismsp. 2516
+General Proceduresp. 2517
Door Window Motor Initializationp. 2517
Liftgate Window Glass Adjustmentp. 2518
+Removal and Installationp. 2520
Front Door Window Glass (76.31.01)p. 2520
Front Door Window Regulator and Motor (76.31.45)p. 2522
Liftgate Window Glass (76.31.22) (76.81.11.60)p. 2523
Rear Door Fixed Window Glassp. 2529
Rear Door Window Glass (76.31.02)p. 2532
Rear Door Window Regulator (76.31.46)p. 2534
Rear Door Window Regulator and Motor (86.25.09)p. 2537
Rear Quarter Window Glass (76.31.31)p. 2538
Rear Window Glass Using Cheese Wire (76.81.41)p. 2543
Rear Window Glass Using Cutting Toolp. 2551
Window Control Switch (86.25.08)p. 2559
Windshield Glass Using Cheese Wire (76.81.40)p. 2560
Windshield Glass Using Cutting Tool (76.81.01)p. 2565
+501-12: Instrument Panel and Consolep. 2572
+Description and Operationp. 2572
+Removal and Installationp. 2573
Floor Console (76.25.01)p. 2573
Instrument Panel (76.46.01)p. 2577
Overhead Console (76.13.69)p. 2582
Overhead Console Switch Mouldingp. 2583
+501-14: Handles, Locks, Latches and Entry Systemsp. 2587
Specificationp. 2587
+Description and Operationp. 2588
Handles, Locks, Latches and Entry Systemsp. 2588
+Diagnosis and Testingp. 2591
Locks, Latches and Entry Systemsp. 2591
+General Proceduresp. 2594
Remote Transmitter Programmingp. 2594
+Removal and Installationp. 2595
Exterior Front Door Handle (76.58.01)p. 2595
Front Door Lock Actuator (76.37.74)p. 2597
Front Door Lock Cylinder (76.37.71)p. 2599
Fuel Filler Door Release Handle and Cable (76.11.39) – 4-Doorp. 2600
Fuel Filler Door Release Handle and Cable (76.11.39) – Wagonp. 2604
Liftgate Latch Actuator (86.25.65.60)p. 2608
Liftgate Window Glass Release Switch (76.19.59.60)p. 2609
Luggage Compartment Lid Latch Actuator (76.19.25)p. 2614
Rear Door Lock Actuator (76.37.09)p. 2615
+501-16: Wipers and Washersp. 2617
Specificationp. 2617
+Description and Operationp. 2618
Wipers and Washersp. 2618
+Diagnosis and Testingp. 2620
Wipers and Washersp. 2620
+Removal and Installationp. 2621
Headlamp Washer Pump (84.20.21)p. 2621
Rain Sensor (84.12.10) (86.56.62)p. 2622
Rain Sensor Module (86.56.60)p. 2623
Rear Window Wiper Motor (84.15.48.60) (84.35.12)p. 2624
Windshield and Rear Window Washer Pump (84.10.21.60)p. 2627
Windshield Washer Pump (84.10.21)p. 2628
Windshield Washer Reservoir (84.10.01) (84.10.03)p. 2629
Windshield Wiper Motor (84.15.13)p. 2631
Wiper Mounting Arm and Pivot Shaft (84.15.24)p. 2632
Wiper Pivot Arm (84.15.03)p. 2633
+501-17: Roof Opening Panelp. 2635
Specificationp. 2635
+Description and Operationp. 2636
Roof Opening Panelp. 2636
+Diagnosis and Testingp. 2638
Roof Opening Panelp. 2638
+General Proceduresp. 2641
Motor Synchronization (76.82.48)p. 2641
Roof Opening Panel Alignmentp. 2642
+Removal and Installationp. 2643
Air Deflector (76.82.07)p. 2643
Lifter Arms (76.82.57)p. 2644
Roof Opening Panel Control Switch (86.76.05)p. 2645
Roof Opening Panel Drain Hose (76.82.26)p. 2646
Roof Opening Panel Frame (76.82.01)p. 2648
Roof Opening Panel Glass (76.82.05)p. 2653
Roof Opening Panel Motor (86.76.01)p. 2654
Roof Opening Panel Shield (76.82.06)p. 2655
Roof Opening Panel Weatherstrip (76.82.15)p. 2656
+501-19: Bumpersp. 2657
Specificationp. 2657
+Description and Operationp. 2658
+Removal and Installationp. 2659
Front Bumper Cover (76.22.78)p. 2659
Front Bumper Cover Insert (76.22.73)p. 2662
Rear Bumper (76.22.27) (76.22.52) – 4-Doorp. 2663
Rear Bumper (76.22.27) (76.22.52) – Wagonp. 2664
Rear Bumper Cover (76.22.74) (76.22.77) – 4-Doorp. 2665
Rear Bumper Cover (76.22.74) (76.22.77) – Wagonp. 2669
Rear Bumper Cover Insert (76.22.75) – 4-Doorp. 2676
Rear Bumper Cover Insert (76.22.75) – Wagonp. 2677
+501-20A: Safety Belt Systemp. 2678
Specificationp. 2678
+Description and Operationp. 2679
Safety Belt Systemp. 2679
+Diagnosis and Testingp. 2681
Safety Belt Systemp. 2681
+Removal and Installationp. 2691
Front Safety Belt Retractor (76.73.10)p. 2691
Front Safety Belt Shoulder Height Adjuster (76.73.12)p. 2693
Rear Center Safety Belt Retractor (76.73.20) – 4-Doorp. 2694
Rear Center Safety Belt Retractor (76.73.20) – Wagonp. 2696
Rear Safety Belt Buckle (76.73.50)p. 2697
Rear Safety Belt Retractor (76.73.18) – 4-Doorp. 2698
Rear Safety Belt Retractor (76.73.18) – Wagonp. 2700
Safety Belt Buckle and Pretensioner (76.73.49)p. 2702
+501-20B: Supplemental Restraint Systemp. 2704
Specificationp. 2704
+Description and Operationp. 2705
Air Bag Supplemental Restraint System (SRS)p. 2705
+Diagnosis and Testingp. 2708
Air Bag Supplemental Restraint System (SRS)p. 2708
+General Proceduresp. 2722
+Removal and Installationp. 2725
Clockspring (86.65.92)p. 2725
Crash Sensor (76.73.55)p. 2728
Driver Air Bag Module (76.73.39)p. 2730
Driver Lower Air Bag Module (76.73.75)p. 2733
Occupant Classification Sensor (76.73.60)p. 2736
Passenger Air Bag Deactivation (PAD) Indicator (76.73.58)p. 2739
Passenger Air Bag Module (76.73.37)p. 2741
Restraints Control Module (RCM) (76.73.48)p. 2745
Seat Position Sensor (76.73.62)p. 2746
Side Air Curtain Module (76.73.64) – 4-Doorp. 2748
Side Air Curtain Module (76.73.64) – Wagonp. 2752
Side Impact Sensor (76.73.53)p. 2758
+502: Frame and Mountingp. 2759
+502-00: Uni-Body, Subframe and Mounting Systemp. 2759
Specificationp. 2759
+Description and Operationp. 2760
+General Proceduresp. 2761
Underbody Misalignment Check (57.65.20)p. 2761
+Removal and Installationp. 2766
Front Subframe (76.10.05) – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 –AJ27p. 2766
Front Subframe (76.10.05) – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) – Pumap. 2781
Front Subframe Front Bushing (60.35.51)p. 2793
Front Subframe Rear Bushing (60.35.26)p. 2796
Rear Axle Crossmember Bushing (64.25.02)p. 2799
Rear Subframe (64.25.01)p. 2802
Rear Subframe Bushing (64.25.04)p. 2808
- Body and Paint
- Front-end body panels and body closures
- Interior and exterior trim
- Rear-view mirrors and seating
- Glass, window mechanisms, instrument panel and console
- Handles, locks, latches and entry systems
- Wipers and washers
- Roof opening panel and bumpers
- Safety belts and Supplemental Restraint System
- Uni-body, front and rear subframes and mounting systems
Across these chapters, the X-TYPE workshop information follows the vehicle system rather than treating the car as a single generic configuration. Variant notes identify body style, engine, transmission, drivetrain, VIN range or equipment differences when they matter to a procedure. That is especially important on a manual covering both Sedan and Estate (Wagon) vehicles and multiple gasoline and diesel powertrains.
Diagnosis, Specifications and Illustrated Repair Procedures
The diagnostic sections are intended to help isolate the cause of a concern before parts are removed. The manual’s general service information describes OBD coverage for engine management, automatic transmission and anti-lock braking, with symptom charts, DTC-related guidance and pinpoint tests used where applicable. Other sections use inspection charts and system-specific diagnosis, such as Noise, Vibration and Harshness, suspension, wheels and tires, steering, brakes, climate control and electronic systems.
Specifications are placed with the relevant systems, including torque charts at the front of applicable sections. The manual also contains practical service data such as wheel alignment values, tire pressures, component tightening torques and system-specific measurements. Procedures show the recommended sequence for removal and installation and identify special tools when required. Illustrated pages cover assemblies such as front and rear suspension, component locations, identification points and step-by-step repair work, helping the technician follow how parts are arranged before dismantling them.
For Mechanical, Electrical and Body-System Work
The scope extends well beyond engine work. A technician can use this Jaguar X-Type Sedan and Estate workshop manual for brake and ABS service, suspension and wheel-bearing work, steering repairs, driveline components, transmission service, air-conditioning, charging and electrical diagnosis, wiring-harness repairs, security and convenience electronics, lighting, interior equipment, glass and door mechanisms, restraint systems and subframe work. Procedures also address vehicle lifting, safe workshop practice, road testing and functional checks after repair, which supports a more complete service workflow.
Get the Complete Jaguar X-Type Workshop Reference
The 2001-2009 Jaguar X-Type Sedan & Estate Workshop Manual – Gasoline & Diesel gives you the procedures, diagnostic paths, specifications, tightening information and component-level repair coverage needed to approach X-TYPE service work methodically. It can support jobs ranging from routine adjustments and component replacement to engine, transmission, driveline, electrical, climate-control, suspension, braking and body-system repairs. Using the specified sequence, measurements and tightening data matters when parts must be removed, inspected, adjusted and installed correctly. Your purchase is delivered as an instant PDF download – there is no shipping wait, the file can be viewed on compatible phones, tablets and computers, and pages can be printed for workshop use when needed.
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