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2001-2009 Jaguar X-TYPE Sedan & Estate Workshop Service Repair Manual PDF

Original price was: $49.95.Current price is: $29.95.

Comprehensive Jaguar X-TYPE Workshop Manual covering Sedan and Estate (Wagon) models from 2001 to 2009. Includes 2.0L, 2.5L and 3.0L gasoline applications plus 2.0L and 2.2L diesel applications, with detailed diagnosis, specifications, removal and installation procedures, component repair, special-tool information, tightening data, illustrations and system testing across chassis, powertrain, electrical, body and vehicle systems.

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Description

2001-2009 Jaguar X-TYPE Sedan & Estate Workshop Service Repair Manual PDF

The 2001-2009 Jaguar X-TYPE Sedan & Estate Workshop Service Repair Manual PDF is an extensive workshop reference for X-TYPE Sedan and Estate (Wagon) vehicles covering the 2001 to 2009 range. At 2810 pages, it brings together descriptive information, diagnosis and testing, specifications, general procedures, in-vehicle repairs, removal and installation instructions, and component disassembly and assembly across the major vehicle systems.

Coverage extends across the gasoline and diesel powertrains identified in the manual, including the 2.0L NA V6 – AJV6, 2.5L NA V6 – AJV6, 3.0L NA V6 – AJ27, 2.0L Duratorq-TDCi and 2.2L Duratorq-TDCi (110kW/150PS) – Puma applications. Transmission material includes the 5-speed automatic JATCO, 6-speed automatic AWF21, 5-speed manual MT75 and 6-speed manual MMT6 systems where applicable.

File Details

  • Manual type: Workshop Manual
  • Brand: Jaguar
  • Model: X-TYPE Sedan and Estate (Wagon)
  • Coverage: 2001 to 2009
  • Language: English
  • Page count: 2810 pages
  • File format: PDF
  • Published: 11-May-2011

Vehicle and Powertrain Coverage

This Jaguar X-TYPE workshop manual is structured to cover a range of vehicles rather than one single specification. Individual procedures identify the applicable engine, transmission, body style, equipment configuration or VIN range when those distinctions matter. That makes it useful for checking the procedure that corresponds to the particular X-TYPE being serviced instead of treating every Sedan, Estate, gasoline and diesel version as mechanically identical.

  • Body styles: Sedan and Estate (Wagon)
  • Gasoline engines: 2.0L NA V6 – AJV6, 2.5L NA V6 – AJV6, 3.0L NA V6 – AJ27
  • Diesel engines: 2.0L Duratorq-TDCi, 2.2L Duratorq-TDCi (110kW/150PS) – Puma
  • Automatic transmissions: 5-Speed Automatic Transaxle – JATCO and 6-Speed Automatic Transaxle – AWF21
  • Manual transmissions: 5-Speed Manual Transmission – MT75 and 6-Speed Manual Transaxle – MMT6

Diagnosis, Testing and Repair Information

The manual is much more than a sequence of component replacement instructions. Diagnosis and Testing sections are used throughout the vehicle systems to help isolate faults before parts are removed. The manual describes On-Board Diagnostics coverage for engine management, automatic transmission and anti-lock braking systems, and diagnostic material can include symptom charts, Diagnostic Trouble Codes, possible causes and structured pinpoint tests. Electrical troubleshooting information also refers to circuit identification, connectors, splices, fuses, wire gauge and colors where applicable.

Removal and Installation sections provide the recommended work sequence and frequently identify special tools, cautions, warnings and tightening requirements. Major assemblies receive deeper treatment where required. Examples visible throughout the manual include engine removal and installation, engine disassembly and assembly, cylinder-head and piston work, transmission servicing, suspension component replacement, wheel bearing work, brake servicing, steering repairs, fuel-system procedures, cooling-system service and numerous electrical or body-component operations.

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2001-2009 Jaguar X-TYPE Sedan & Estate Workshop Service Repair Manual PDF — PDF page 1 preview
2001-2009 Jaguar X-TYPE Sedan & Estate Workshop Service Repair Manual PDF — PDF page 101 preview
2001-2009 Jaguar X-TYPE Sedan & Estate Workshop Service Repair Manual PDF — PDF page 142 preview

Specifications are placed within the relevant sections rather than separated from the repair information. This lets a technician move from diagnosis to inspection, adjustment and reassembly while consulting the corresponding service values. The manual contains examples such as wheel-alignment values, ride-height data, tire pressures, wheel specifications and detailed tightening specifications for suspension and other assemblies.

Chapters Covered

  • 1: General Information
    • Service Information – general service information, identification codes, jacking and lifting, noise, vibration and harshness
  • 2: Chassis
    • Suspension – general information, front suspension, rear suspension, wheels and tires
    • Driveline – driveline system, driveshaft, rear drive axle/differential, front and rear drive halfshafts
    • Brake System – general information, front and rear disc brakes, parking brake, hydraulic and power brake actuation, anti-lock control and stability assist
    • Steering System – general information, power steering, steering linkage, steering column and steering column switches
  • 3: Powertrain
    • Engine System – general engine information and mechanical inspection procedures
    • Gasoline Engines – 2.0L NA V6 – AJV6, 2.5L NA V6 – AJV6 and 3.0L NA V6 – AJ27
    • Diesel Engines – 2.0L Duratorq-TDCi and 2.2L Duratorq-TDCi (110kW/150PS) – Puma
    • Engine Cooling – gasoline and diesel cooling-system procedures
    • Fuel Charging and Controls – gasoline, diesel and turbocharger systems
    • Accessory Drive, Starting System, Engine Ignition and Glow Plug System
    • Engine Emission Control, Intake Air Distribution and Filtering, Evaporative Emissions and Electronic Engine Controls
    • Automatic Transmission/Transaxle – 5-Speed JATCO and 6-Speed AWF21, cooling and external controls
    • Manual Transmission/Transaxle and Clutch – general information, clutch, clutch controls, MT75/MMT6 transmission and external controls
    • Transfer Case
    • Exhaust System – gasoline and diesel configurations including diesel particulate filter-related components where fitted
    • Fuel System – general information, fuel tank and lines, acceleration control and speed control
  • 4: Electrical
    • Climate Control System – general information, air distribution, heating and ventilation, auxiliary heating, air conditioning and controls
    • Instrumentation and Warning Systems – instrument cluster, horn, message center, warning devices and parking aid
    • Battery and Charging System – battery, cables, generator and regulator
    • Information and Entertainment Systems – audio unit, antenna and speakers
    • Lighting – exterior lighting, interior lighting and daytime running lamps
    • Electrical Distribution – module communications, module configuration and wiring harnesses
    • Electronic Feature Group – active and passive anti-theft, remote convenience, navigation, cellular phone and multifunction electronic modules
  • 5: Body and Paint
    • Front End Body Panels and Body Closures
    • Interior Trim and Ornamentation
    • Exterior Trim and Ornamentation
    • Rear View Mirrors and Seating
    • Glass, Frames and Mechanisms
    • Instrument Panel and Console
    • Handles, Locks, Latches and Entry Systems
    • Wipers and Washers
    • Roof Opening Panel and Bumpers
    • Safety Belt System and Supplemental Restraint System
    • Uni-Body, Subframe and Mounting System

Taken as a whole, the manual follows the vehicle from basic identification and workshop practices through chassis, driveline, engine, transmission, electrical and body systems. Its organization allows a technician to identify how a system operates, inspect or diagnose a reported concern, consult the relevant specifications and then move into the applicable repair procedure.

Detailed Mechanical Procedures

The chassis sections provide substantial hands-on repair coverage. Suspension information includes wheel alignment, front and rear toe adjustment, wheel-bearing inspection, lower arms, shock absorbers and springs, stabilizer bars, wheel hubs, wheel knuckles and bushings. The driveline sections cover driveshafts, rear differential components and front and rear halfshafts. Brake chapters address bleeding, discs, pads, calipers, parking-brake components, hydraulic actuation, brake booster components, ABS sensors, hydraulic control units and stability-assist equipment.

Complete PDF Bookmark Tree

Complete Bookmarks

The complete bookmarks in the “2001-2009 Jaguar X-TYPE Sedan & Estate Workshop Service Repair Manual PDF” 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
Jackingp. 78
Liftingp. 79
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
Suspension Systemp. 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
Front Suspensionp. 101
Diagnosis and Testingp. 103
Front Suspensionp. 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
Rear Suspensionp. 142
Diagnosis and Testingp. 144
Rear Suspensionp. 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
Wheels and Tiresp. 178
Diagnosis and Testingp. 184
Wheels and Tiresp. 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
Driveline Systemp. 196
Diagnosis and Testingp. 197
Driveline Systemp. 197
205-01: Driveshaftp. 199
Specificationp. 199
Description and Operationp. 200
Driveshaftp. 200
Diagnosis and Testingp. 201
Driveshaftp. 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
Brake Systemp. 261
Diagnosis and Testingp. 262
Brake Systemp. 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
Front Disc Brakep. 274
Diagnosis and Testingp. 275
Front Disc Brakep. 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
Rear Disc Brakep. 282
Diagnosis and Testingp. 283
Rear Disc Brakep. 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
Parking Brakep. 293
Diagnosis and Testingp. 294
Parking Brakep. 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
Brake Boosterp. 348
Diagnosis and Testingp. 349
Power Brake Systemp. 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
Steering Systemp. 410
Diagnosis and Testingp. 411
Steering Systemp. 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
Power Steeringp. 428
Diagnosis and Testingp. 429
Power Steeringp. 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
Steering Linkagep. 464
Diagnosis and Testingp. 465
Steering Linkagep. 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
Steering Columnp. 470
Diagnosis and Testingp. 471
Steering Columnp. 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
Enginep. 486
Diagnosis and Testingp. 487
Enginep. 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
Enginep. 522
Diagnosis and Testingp. 525
Enginep. 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
Enginep. 668
Disassembly and Assembly of Subassembliesp. 688
Cylinder Head (12.29.22)p. 688
Piston (12.17.02)p. 691
Assemblyp. 694
Enginep. 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
Enginep. 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
Enginep. 860
Assemblyp. 888
Enginep. 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
Engine Coolingp. 969
Diagnosis and Testingp. 973
Engine Coolingp. 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
Engine Coolingp. 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
Turbochargerp. 1127
Diagnosis and Testingp. 1131
Turbochargerp. 1131
Removal and Installationp. 1137
Turbochargerp. 1137
303-05: Accessory Drivep. 1150
Specificationp. 1150
Description and Operationp. 1151
Accessory Drivep. 1151
Diagnosis and Testingp. 1154
Accessory Drivep. 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
Starting Systemp. 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
Engine Ignitionp. 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
Glow Plug Systemp. 1207
Diagnosis and Testingp. 1209
Glow Plug Systemp. 1209
Removal and Installationp. 1213
Glow Plugsp. 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
External Controlsp. 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
External Controlsp. 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
Clutchp. 1605
Diagnosis and Testingp. 1606
Clutchp. 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
Clutch Controlsp. 1610
Diagnosis and Testingp. 1613
Clutch Controlsp. 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
Manual Transaxlep. 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
External Controlsp. 1718
Diagnosis and Testingp. 1720
External Controlsp. 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
Transfer Casep. 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
Exhaust Systemp. 1773
Diagnosis and Testingp. 1780
Exhaust Systemp. 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
Fuel Systemp. 1817
Diagnosis and Testingp. 1821
Fuel Systemp. 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
Speed Controlp. 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
Air Conditioningp. 2007
Diagnosis and Testingp. 2009
Air Conditioningp. 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
Warning Devicesp. 2058
Diagnosis and Testingp. 2061
Warning Devicesp. 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
Parking Aidp. 2064
Diagnosis and Testingp. 2066
Parking Aidp. 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
Battery Chargingp. 2104
414-01: Battery, Mounting and Cablesp. 2105
Specificationp. 2105
Description and Operationp. 2106
Battery and Cablesp. 2106
Diagnosis and Testingp. 2108
Batteryp. 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
Generatorp. 2124
Diagnosis and Testingp. 2126
Generatorp. 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
Audio Systemp. 2135
415-01: Audio Unitp. 2139
Description and Operationp. 2139
Audio Systemp. 2139
Diagnosis and Testingp. 2143
Audio Systemp. 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
Antennap. 2160
Diagnosis and Testingp. 2163
Antennap. 2163
Removal and Installationp. 2164
Antenna (86.51.17.60) – Wagonp. 2164
Modulep. 2168
415-03: Speakersp. 2169
Description and Operationp. 2169
Speakersp. 2169
Diagnosis and Testingp. 2170
Speakersp. 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
Exterior Lightingp. 2177
Diagnosis and Testingp. 2178
Headlampsp. 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
Interior Lightingp. 2194
Diagnosis and Testingp. 2195
Interior Lightingp. 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
Wiring Harnessp. 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
Navigation Systemp. 2307
Diagnosis and Testingp. 2309
Navigation Systemp. 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
Cellular Phonep. 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
Body Closuresp. 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
Weatherstripp. 2385
501-05: Interior Trim and Ornamentationp. 2388
Specificationp. 2388
Description and Operationp. 2389
Interior Trimp. 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
Exterior Trimp. 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
Rear View Mirrorsp. 2440
Diagnosis and Testingp. 2441
Rear View Mirrorsp. 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
Seatsp. 2451
Diagnosis and Testingp. 2459
Seatsp. 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
Instrument Panelp. 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
Bumpersp. 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
Air Bag Disposalp. 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
Frame Assemblyp. 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

Powertrain coverage reaches into both routine component service and larger mechanical operations. The gasoline V6 section contains engine specifications, diagnosis, valve-clearance work, camshafts, crankshaft seals, cylinder heads, manifolds, oil-system components, timing-drive components and engine removal, disassembly, assembly and installation. Diesel coverage includes crankshaft seals, front cover, engine mounts, intake manifold, oil pan, timing chain, valve cover and complete engine removal and assembly procedures. Supporting chapters cover cooling, injection, turbocharger, accessory drives, starting, ignition or glow-plug systems, emissions and electronic engine controls.

Electrical, Diagnostic and Body-System Coverage

The 2001-2009 Jaguar X-TYPE Sedan & Estate Workshop Service Repair Manual PDF also reaches well beyond the engine bay. Climate-control chapters cover system testing, refrigerant-related service operations, blower and heater components, air-conditioning compressor and control components. Electrical chapters deal with charging, instrumentation, lighting, communications networks, wiring harness repair, anti-theft functions, key programming using diagnostic equipment, navigation and other electronic modules.

Body-related material includes trim removal, seats, window regulators, glass, instrument panel and console, locks and latches, wipers, roof opening panel, bumpers, safety belts, Supplemental Restraint System components and subframe-related procedures. Separate Sedan and Wagon procedures are identified where the body configuration changes the work, including rear suspension, parking aid, audio equipment, trim, seating, lighting and body closures.

Workshop Information for Accurate Service and Repair

Correct repair work depends on more than knowing which component to remove. This manual repeatedly combines procedural steps with safety notices, component orientation, tightening values, special-tool references and configuration-specific notes. Identification material explains VIN locations and coding, while workshop-practice sections address safe lifting, vehicle protection, component inspection and other preparation needed before repair work begins.

For owners carrying out advanced maintenance, independent workshops and technicians working on X-TYPE vehicles, the breadth of the Jaguar X-TYPE 2001-2009 workshop manual makes it possible to trace a problem through the relevant system instead of relying on isolated instructions. It is especially valuable when a task requires model-specific disassembly sequences, diagnostic logic, torque data or a distinction between gasoline, diesel, automatic, manual, Sedan and Estate configurations.

Get the Complete Jaguar X-TYPE Workshop Manual

Use this 2001-2009 Jaguar X-TYPE Sedan & Estate Workshop Service Repair Manual PDF for detailed support with diagnosis, mechanical repair, component removal and installation, engine and transmission work, suspension and brake service, steering repairs, electrical troubleshooting, climate-control work and body-system servicing. Following the applicable procedure and specification helps avoid guesswork when component orientation, tightening values, adjustment data, safety precautions or special tools matter.

Your manual is delivered as an instant PDF after purchase, with no physical book and no shipping delay. Open it on a computer, tablet or other PDF-compatible device and print the pages needed for workshop use.

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