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2003-09 Jaguar XJ Workshop Manual – PDF DOWNLOAD
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Description
2003-09 Jaguar XJ Workshop Manual – PDF DOWNLOAD
DESCRIPTION:
2003-09 Jaguar XJ Workshop Manual – PDF DOWNLOAD
About This Manual
Notes, Cautions and Warnings
Throughout this manual, important information is highlighted by the use of notes, cautions and warnings. NOTES give additional information on a topic or procedure, CAUTIONS are given to prevent damage to the vehicle, and WARNINGS are given to prevent personal injury.
General Service Information
Repairs and Replacements
- When service parts are required, it is essential that only genuine Jaguar/Daimler replacements are used. Attention is drawn to the following points concerning repairs and the fitting of replacement parts and accessories:
- · Safety features embodied in the vehicle may be impaired if other than genuine parts are fitted. In certain territories, legislation prohibits the fitting of parts which are not produced to the vehicle manufacturer’s specification.
- · Torque wrench setting figures given in this manual must be strictly adhered to. Locking devices, where specified, must be fitted. If the efficiency of a locking device is impaired during removal it must be renewed.
- · Owners purchasing accessories while travelling abroad should make sure that the accessory and its fitted location on the vehicle conform to mandatory requirements existing in their country of origin.
- · The vehicle warranty may be invalidated by the fitting of other than genuine Jaguar/Daimler parts. All Jaguar/Daimler replacements have the full backing of the factory warranty. · Jaguar/Daimler dealers are obliged to supply only genuine service parts
Vehicle Specifications
- Purchasers are advised that the specification details set out in this manual apply to a range of vehicles and not to any specific one. For the specification of a particular vehicle, purchasers should consult their dealer.
- The Manufacturer reserves the right to vary the specifications, with or without notice, and at such times and in such manner as the Manufacturer thinks fit. Major as well as minor changes may be involved, in accordance with the Manufacturer’s policy of continuous improvement.
- Whilst every effort is made to make sure the accuracy of the particulars contained in this manual, neither the Manufacturer nor the Dealer, by whom the manual is supplied, shall in any circumstances be held liable for any inaccuracy or the consequences thereof
Service Repair Operation Numbering
A master index of numbered operations has been compiled for universal application to all vehicles manufactured by Jaguar Cars Ltd. Each operation is allocated a number from the master index and cross-refers with an identical number in the Repair Operation Times schedule. The number consists of six digits arranged in three pairs.
TABLE OF CONTENTS:
2003-09 Jaguar XJ Workshop Manual – PDF DOWNLOAD
www.JagDocs.com ...................................................................................................................................... 1 X350 Workshop Manual.................................................................................................................................. 1 TABLE OF CONTENTS..................................................................................................................................... 2 1. GENERAL INFORMATION............................................................................................................................ 58 100 : Service Information..................................................................................................................... 58 100-00 : General Information.................................................................................................................. 58 About This Manual......................................................................................................................... 58 Application and Use of Specifications..................................................................................................... 59 General Service Information............................................................................................................... 60 Health and Safety Precautions............................................................................................................. 87 How To Use This Manual.................................................................................................................... 107 Important Safety Instructions............................................................................................................. 108 Road/Roller Testing....................................................................................................................... 109 Solvents, Sealants and Adhesives.......................................................................................................... 112 Standard Workshop Practices............................................................................................................... 114 100-01 : Identification Codes................................................................................................................. 115 Identification Codes - VIN Range: G00442->G45703.......................................................................................... 115 Identification Codes - VIN Range: G45704->G99999.......................................................................................... 123 100-02 : Jacking and Lifting.................................................................................................................. 135 Jacking................................................................................................................................... 135 Jacking – Armoured Vehicles............................................................................................................... 136 Lifting................................................................................................................................... 137 100-04 : Noise, Vibration and Harshness....................................................................................................... 141 General Procedures........................................................................................................................ 141 Exhaust System Neutralizing........................................................................................................... 141 Description and Operation................................................................................................................. 142 Noise, Vibration and Harshness (NVH).................................................................................................. 142 Diagnosis and Testing..................................................................................................................... 144 Noise, Vibration and Harshness (NVH).................................................................................................. 144 2. CHASSIS........................................................................................................................................ 157 204 : Suspension.............................................................................................................................. 157 204-00 : Suspension System - General Information.......................................................................................... 157 Specifications – Armoured Vehicles ................................................................................................... 159 General Procedures.................................................................................................................... 161 Camber and Caster Adjustment...................................................................................................... 161 Front Toe Adjustment.............................................................................................................. 166 Rear Toe Adjustment............................................................................................................... 168 Wheel Bearing Inspection ......................................................................................................... 169 Description and Operation............................................................................................................. 170 Wheel Alignment Angles............................................................................................................ 170 Suspension Design Height Setting – Armoured Vehicles.............................................................................. 176 Diagnosis and Testing ................................................................................................................ 178 204-01 : Front Suspension................................................................................................................. 183 Description and Operation............................................................................................................. 184 Front Suspension...................................................................................................................... 184 Front Suspension – Armoured Vehicles.................................................................................................. 186 Diagnosis and Testing................................................................................................................. 187 Removal and Installation ............................................................................................................. 188 Front Lower Arm (60.35.53) ....................................................................................................... 188 Rear Lower Arm (60.35.54)......................................................................................................... 191 Rear Lower Arm Bushing (60.35.56)................................................................................................. 201 Shock Absorber Bushing (60.30.16)................................................................................................. 205 Front Stabilizer Bar - 3.0L NA V6 - AJ27 (60.10.01)............................................................................... 208 Front Stabilizer Bar - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L NA V8 -AJV8 (60.10.01)............................................ 230 Front Stabilizer Bar - 2.7L V6 - TdV6 (60.10.01).................................................................................. 249 Front Stabilizer Bar Link (60.10.02).............................................................................................. 250 Stabilizer Bar Link Bushing (60.10.03)............................................................................................ 252 Upper Arm LH (60.35.41)........................................................................................................... 254 Upper Arm RH (60.35.42)........................................................................................................... 258 Front Wheel Bearing and Wheel Hub (60.25.03)...................................................................................... 264 Wheel Knuckle (60.25.23).......................................................................................................... 266 Shock Absorber and Spring Assembly (60.30.02) – Armoured Vehicles................................................................. 274 204-02 : Rear Suspension.................................................................................................................. 277 Description and Operation............................................................................................................. 278 Rear Suspension................................................................................................................... 278 Rear Suspension – Armoured Vehicles............................................................................................... 280 Diagnosis and Testing................................................................................................................. 281 Removal and Installation ............................................................................................................. 282 Lower Arm......................................................................................................................... 282 Rear Stabilizer Bar............................................................................................................... 290 Rear Stabilizer Bar Link.......................................................................................................... 303 Upper Arm......................................................................................................................... 305 Rear Wheel Bearing................................................................................................................ 309 204-04 : Wheels and Tires................................................................................................................. 323 Description and Operation............................................................................................................. 332 Wheels and Tires - VIN Range: G00442->G45703...................................................................................... 332 Wheels and Tires - VIN Range: G45704->H18679...................................................................................... 337 Wheels and Tires - VIN Range: H18680->H99999...................................................................................... 349 Wheels and Tires – Armoured Vehicles.............................................................................................. 361 Diagnosis and Testing................................................................................................................. 364 Wheels and Tires - VIN Range: G00442->G45703...................................................................................... 364 Wheels and Tires - VIN Range: G45704->G99999...................................................................................... 349 Removal and Installation ............................................................................................................. 408 Tire Low Pressure Sensor.......................................................................................................... 408 Tire Pressure Monitoring System (TPMS) Front Antenna.............................................................................. 412 Tire Pressure Monitoring System (TPMS) Module..................................................................................... 413 Tire Pressure Monitoring System (TPMS) Rear Antenna............................................................................... 415 Wheel and Tire.................................................................................................................... 417 Wheel and Tire (74.20.05) – Armoured Vehicles..................................................................................... 419 204-05 : Vehicle Dynamic Suspension....................................................................................................... 426 General Procedures.................................................................................................................... 427 Ride Height Adjustments........................................................................................................... 429 Description and Operation............................................................................................................. 430 Diagnosis and Testing................................................................................................................. 435 Removal and Installation.............................................................................................................. 480 Air Suspension Compressor......................................................................................................... 480 Air Suspension Control Module..................................................................................................... 486 Air Suspension Reservoir.......................................................................................................... 490 Air Suspension Solenoid Valve Block............................................................................................... 495 Front Air Spring.................................................................................................................. 499 Front Vertical Accelerometer...................................................................................................... 505 Rear Air Spring - VIN Range: G00442->G45703....................................................................................... 507 Rear Air Spring - VIN Range: G45704->G99999....................................................................................... 517 Rear Air Spring Lower Bushing..................................................................................................... 525 Rear Vertical Accelerometer....................................................................................................... 530 Suspension Height Sensor.......................................................................................................... 532 205 : Driveline............................................................................................................................... 536 205-00 : Driveline System - General Information........................................................................................... 536 General Procedures.................................................................................................................... 536 Driveline Angle Inspection........................................................................................................ 536 Description and Operation............................................................................................................. 539 Diagnosis and Testing................................................................................................................. 542 205-01 : Driveshaft................................................................................................................... 550 General Procedures................................................................................................................ 551 Driveshaft Runout and Balancing............................................................................................... 551 Description and Operation......................................................................................................... 552 Diagnosis and Testing............................................................................................................. 554 Removal and Installation.......................................................................................................... 555 Driveshaft (47.15.01)......................................................................................................... 555 205-02 : Rear Drive Axle/Differential................................................................................................. 560 Description and Operation......................................................................................................... 561 Diagnosis and Testing............................................................................................................. 563 Removal and Installation.......................................................................................................... 564 Axle Assembly - Vehicles Without: Differential Drain Plug (51.25.13).......................................................... 564 Axle Assembly - Vehicles With: Differential Drain Plug (51.25.13)............................................................. 569 Axle Housing Bushing (64.25.30)............................................................................................... 570 In Vehicle Repair................................................................................................................. 573 Drive Pinion Seal (51.20.01).................................................................................................. 573 205-05 : Rear Drive Halfshafts........................................................................................................ 578 Description and Operation......................................................................................................... 579 Diagnosis and Testing............................................................................................................. 581 Removal and Installation.......................................................................................................... 582 Rear Halfshaft (47.10.13)..................................................................................................... 582 Inner Constant Velocity (CV) Joint Boot (47.10.33)............................................................................ 593 Outer Constant Velocity (CV) Joint Boot (47.10.32)............................................................................ 598 General Procedures........................................................................................................................ 536 Driveline Angle Inspection............................................................................................................ 536 Description and Operation................................................................................................................. 539 Diagnosis and Testing..................................................................................................................... 542 205-01 : Driveshaft....................................................................................................................... 550 General Procedures.................................................................................................................... 551 Driveshaft Runout and Balancing................................................................................................... 551 Description and Operation............................................................................................................. 552 Diagnosis and Testing................................................................................................................. 554 Removal and Installation.............................................................................................................. 555 Driveshaft (47.15.01)............................................................................................................. 555 205-02 : Rear Drive Axle/Differential..................................................................................................... 560 Description and Operation............................................................................................................. 561 Diagnosis and Testing................................................................................................................. 563 Removal and Installation.............................................................................................................. 564 Axle Assembly - Vehicles Without: Differential Drain Plug (51.25.13).............................................................. 564 Axle Assembly - Vehicles With: Differential Drain Plug (51.25.13)................................................................. 569 Axle Housing Bushing (64.25.30)................................................................................................... 570 In Vehicle Repair..................................................................................................................... 573 Drive Pinion Seal (51.20.01)...................................................................................................... 573 205-05 : Rear Drive Halfshafts............................................................................................................ 578 Description and Operation............................................................................................................. 579 Diagnosis and Testing................................................................................................................. 581 Removal and Installation.............................................................................................................. 582 Rear Halfshaft (47.10.13)......................................................................................................... 582 Inner Constant Velocity (CV) Joint Boot (47.10.33)................................................................................ 593 Outer Constant Velocity (CV) Joint Boot (47.10.32)................................................................................ 598 206 : Brake System............................................................................................................................ 603 206-00 : Brake System - General Information............................................................................................... 603 Brake Lining and Disc Specifications – Armoured XJ.................................................................................... 606 General Procedures.................................................................................................................... 8 Brake Disc Runout Check........................................................................................................... 607 Brake System Bleeding - VIN Range: G00442->G45703................................................................................. 609 Brake System Bleeding - VIN Range: G45704->H99999................................................................................. 616 Brake System Bleeding (70.25.03) – Armoured XJ.................................................................................... 624 Description and Operation............................................................................................................. 628 Brake System - VIN Range: G00442->G45703.......................................................................................... 628 Brake System - VIN Range: G45704->G99999.......................................................................................... 630 Diagnosis and Testing................................................................................................................. 632 206-03 : Front Disc Brake................................................................................................................. 654 Description and Operation............................................................................................................. 656 Front Disc Brake - VIN Range: G00442->G45703...................................................................................... 656 Front Disc Brake - VIN Range: G45704->G99999...................................................................................... 659 Front Disc Brake.................................................................................................................. 662 Front Disc Brake – Armoured Vehicles.............................................................................................. 667 Diagnosis and Testing................................................................................................................. 669 Removal and Installation.............................................................................................................. 670 Brake Caliper - Vehicles With: Standard Brakes, VIN Range: G00442->G45703......................................................... 670 Brake Caliper - Vehicles With: Standard Brakes, VIN Range: G45704->G99999......................................................... 673 Brake Caliper - Vehicles With: High Performance Brakes, VIN Range:G00442->G45704.................................................. 681 Brake Caliper - Vehicles With: High Performance Brakes, VIN Range:G45704->G99999.................................................. 684 Brake Caliper (70.55.02) – Armoured Vehicles...................................................................................... 690 Brake Disc - Vehicles With: Standard Brakes, VIN Range: G00442->G45703............................................................ 693 Brake Disc - Vehicles With: Standard Brakes, VIN Range: G45704->G99999............................................................ 695 Brake Disc - Vehicles With: High Performance Brakes, VIN Range: G00442->G45703.................................................... 697 Brake Disc - Vehicles With: High Performance Brakes, VIN Range: G45704->G99999.................................................... 699 Brake Disc (70.10.10) – Armoured Vehicles......................................................................................... 701 Brake Disc Shield - Vehicles With: StandardBrakes................................................................................. 702 Brake Disc Shield - Vehicles With: High Performance Brakes........................................................................ 703 Brake Pads - Vehicles With: Standard Brakes, VIN Range: G00442->G45703............................................................ 704 Brake Pads - Vehicles With: Standard Brakes, VIN Range: G45704->G99999............................................................ 707 Brake Pads - Vehicles With: High Performance Brakes, VIN Range: G00442->G45703.................................................... 711 Brake Pads - Vehicles With: High Performance Brakes, VIN Range: G45704->G99999.................................................... 716 Brake Pads (70.40.02) – Armoured Vehicles......................................................................................... 720 206-04 : Rear Disc Brake.................................................................................................................. 723 Description and Operation............................................................................................................. 725 Rear Disc Brake - VIN Range: G00442->G45703....................................................................................... 725 Rear Disc Brake - VIN Range: G45704->G99999....................................................................................... 728 Rear Disc Brake................................................................................................................... 730 Rear Disc Brake – Armoured XJ..................................................................................................... 733 Diagnosis and Testing................................................................................................................. 735 Removal and Installation.............................................................................................................. 736 Brake Caliper - Vehicles With: Standard Brakes, VIN Range: G00442->G45703 (70.55.03).............................................. 736 Brake Caliper - Vehicles With: High Performance Brakes, VIN Range:G00442->G45703 (70.55.03)....................................... 741 Brake Caliper - VIN Range: G45704->G99999 (70.55.03).............................................................................. 744 Brake Caliper (70.55.03) – Armoured Vehicles...................................................................................... 754 Brake Disc - Vehicles With: Standard Brakes, VIN Range: G00442->G45703(70.10.11).................................................. 757 Brake Disc - Vehicles With: High Performance Brakes, VIN Range: G00442->G45703 (70.10.11)......................................... 759 Brake Disc - VIN Range: G45704->G99999 (70.10.11)................................................................................. 762 Brake Pads - Vehicles With: Standard Brakes, VIN Range: G00442->G45703(70.40.03).................................................. 766 Brake Disc (70.10.11) – Armoured Vehicles......................................................................................... 765 Brake Pads - Vehicles With: High Performance Brakes, VIN Range: G00442->G45703 (70.40.03)......................................... 771 Brake Pads - VIN Range: G45704->G99999 (70.40.03)................................................................................. 777 Brake Pads (70.40.03) – Armoured Vehicles......................................................................................... 783 206-05 : Parking Brake and Actuation...................................................................................................... 786 General Procedures.................................................................................................................... 788 Parking Brake Cable Tension Release - VIN Range: G00442->G45703................................................................... 788 Parking Brake Cable Tension Release - VIN Range: G45704->G99999................................................................... 792 Description and Operation............................................................................................................. 797 Parking Brake - VIN Range: G00442->G45703......................................................................................... 797 Parking Brake - VIN Range: G45704->G99999......................................................................................... 799 Diagnosis and Testing................................................................................................................. 802 Parking Brake - VIN Range: G00442->G45170......................................................................................... 802 Parking Brake - VIN Range: G45171->G99999......................................................................................... 814 Removal and Installation.............................................................................................................. 882 Parking Brake Module - VIN Range: G00442->G45703.................................................................................. 882 Parking Brake Module - VIN Range: G45704->G99999.................................................................................. 884 Parking Brake Pads - Vehicles With: High Performance Brakes....................................................................... 887 Parking Brake Rear Cables......................................................................................................... 890 Parking Brake Release Actuator - VIN Range: G00001->G03445........................................................................ 893 Parking Brake Release Actuator - VIN Range: G03446->H99999........................................................................ 896 Parking Brake Switch.............................................................................................................. 907 206-06 : Hydraulic Brake Actuation........................................................................................................ 908 Description and Operation............................................................................................................. 909 Hydraulic Brake Actuation......................................................................................................... 909 Hydraulic Brake Actuation - Component Location.................................................................................... 11 Diagnosis and Testing................................................................................................................. 913 Hydraulic Brake Actuation......................................................................................................... 913 Removal and Installation.............................................................................................................. 914 Brake Fluid Reservoir............................................................................................................. 914 Brake Master Cylinder - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -AJ27/3.5L NA V8 - AJV8.................................... 917 Brake Master Cylinder - 2.7L V6 - TdV6............................................................................................ 920 206-07 : Power Brake Actuation............................................................................................................ 922 Description and Operation............................................................................................................. 923 Diagnosis and Testing................................................................................................................. 926 Removal and Installation.............................................................................................................. 927 Brake Booster..................................................................................................................... 927 Brake Vacuum Pump................................................................................................................. 930 206-09 : Anti-Lock Control -.............................................................................................................. 940 Description and Operation............................................................................................................. 941 Anti-Lock Control - Stability Assist - VIN Range: G00442->G45703.................................................................. 941 Anti-Lock Control - Stability Assist - VIN Range: G45704->G99999.................................................................. 944 Anti-Lock Control - Stability Assist.............................................................................................. 948 Diagnosis and Testing................................................................................................................. 952 Anti-Lock Control - Stability Assist - VIN Range: G00442->G45703.................................................................. 952 Anti-Lock Control - Stability Assist - VIN Range: G45704->G99999.................................................................. 986 Removal and Installation..............................................................................................................1051 Anti-Lock Brake System (ABS) Module...............................................................................................1051 Brake Master Cylinder Pressure Transducer.........................................................................................1052 Brake Pedal Travel Sensor - VIN Range: G00442->G49700.............................................................................1054 Front Wheel Speed Sensor..........................................................................................................1055 Hydraulic Control Unit (HCU) - VIN Range: G00442->G45703..........................................................................1057 Hydraulic Control Unit (HCU) - VIN Range: G45704->G99999..........................................................................1060 Rear Wheel Speed Sensor...........................................................................................................1066 Steering Wheel Rotation Sensor....................................................................................................1068 Yaw Rate Sensor and Accelerometer.................................................................................................1070 211 : Steering System.........................................................................................................................1072 211-00 : Steering System - General Information............................................................................................1072 General Procedures....................................................................................................................1073 Power Steering System Bleeding....................................................................................................1073 Steering Column Lower Shaft Setting...............................................................................................1074 Power Steering System Flushing....................................................................................................1076 Description and Operation.............................................................................................................1081 Diagnosis and Testing.................................................................................................................1082 211-02 : Power Steering...................................................................................................................1107 Description and Operation.............................................................................................................1108 Diagnosis and Testing.................................................................................................................1110 Removal and Installation..............................................................................................................1111 Power Steering Control Valve Actuator.............................................................................................1111 Power Steering Fluid Cooler.......................................................................................................1113 Power Steering Fluid Reservoir - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0LNA V6 - AJ27/3.5L NA V8 - AJV8...........................1116 Power Steering Fluid Reservoir - 2.7L V6 - TdV6...................................................................................1118 Power Steering Pump - 3.0L NA V6 - AJ27...........................................................................................1120 Power Steering Pump - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L NA V8 -AJV8........................................................1124 Power Steering Pump - 2.7L V6 - TdV6..............................................................................................1130 Steering Gear Bushing.............................................................................................................1134 211-03 : Steering Linkage.................................................................................................................1139 Description and Operation.............................................................................................................1140 Diagnosis and Testing.................................................................................................................1142 Removal and Installation..............................................................................................................1143 Steering Gear Boot................................................................................................................1143 Tie Rod End.......................................................................................................................1145 211-04 : Steering Column..................................................................................................................1148 Description and Operation.............................................................................................................1149 Diagnosis and Testing.................................................................................................................1152 Removal and Installation..............................................................................................................1153 Ignition Switch Lock Cylinder.....................................................................................................1153 Steering Column...................................................................................................................1157 Steering Column Lower Shaft.......................................................................................................1164 Steering Wheel....................................................................................................................1167 Assembly & Disassembly................................................................................................................1170 211-05 : Steering Column Switches.........................................................................................................1176 Diagnosis and Testing.................................................................................................................1180 Removal and Installation..............................................................................................................1183 Steering Column Lock Actuator.....................................................................................................1183 Steering Column Multifunction Switch LH...........................................................................................1185 Steering Column Multifunction Switch RH...........................................................................................1187 3. POWERTRAIN.....................................................................................................................................1189 303 : Engine..................................................................................................................................1189 303-00 : Engine System - General Information..............................................................................................1189 General Procedures....................................................................................................................1194 Bearing Inspection................................................................................................................1194 Camshaft Bearing Journal Clearance................................................................................................1195 Camshaft Bearing Journal Diameter.................................................................................................1197 Camshaft End Play.................................................................................................................1198 Camshaft Lobe Lift................................................................................................................1199 Camshaft Surface Inspection.......................................................................................................1200 Connecting Rod Cleaning...........................................................................................................1201 Connecting Rod Large End Bore.....................................................................................................1202 Crankshaft End Play...............................................................................................................1203 Crankshaft Main Bearing Journal Clearance - 3.0L NA V6 - AJ27.....................................................................1204 Crankshaft Main Bearing Journal Clearance - 4.2L NA V8 - AJV8/4.2L SC V8- AJV8/3.5L NA V8 - AJV8..................................1205 Cylinder Bore Out-of-Round........................................................................................................1209 Cylinder Head Distortion..........................................................................................................1210 Exhaust Manifold Cleaning and Inspection..........................................................................................1211 Piston Inspection.................................................................................................................1212 Piston Pin Diameter...............................................................................................................1213 Piston Pin to Bore Diameter.......................................................................................................1214 Piston Ring End Gap...............................................................................................................1215 Piston Ring-to-Groove Clearance...................................................................................................1216 Valve Spring Free Length..........................................................................................................1217 Valve Stem Diameter...............................................................................................................1218 Description and Operation.............................................................................................................1219 Diagnosis and Testing.................................................................................................................1221 Engine - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 - AJ27/3.5L NAV8 - AJV8...................................................1221 Engine - 2.7L V6 - TdV6..........................................................................................................1239 303-01A : Engine - 3.0L NA V6 - AJ27......................................................................................................1240 General Procedures....................................................................................................................1242 Valve Clearance Adjustment........................................................................................................1242 Valve Clearance Check.............................................................................................................1244 Description and Operation.............................................................................................................1245 Diagnosis and Testing.................................................................................................................1247 Removal...............................................................................................................................1248 Installation..........................................................................................................................1261 In Vehicle Repair.....................................................................................................................1273 Camshafts LH......................................................................................................................1273 Crankshaft Front Seal.............................................................................................................1275 Crankshaft Pulley.................................................................................................................1277 Crankshaft Rear Seal..............................................................................................................1284 Cylinder Head.....................................................................................................................1287 Engine Front Cover................................................................................................................1293 Engine Mount......................................................................................................................1310 Exhaust Manifold LH - VIN Range: G004442->G45703..................................................................................1324 Exhaust Manifold LH - VIN Range: G45704->G99999...................................................................................1328 Flexplate.........................................................................................................................1332 Intake Manifold...................................................................................................................1335 Lower Intake Manifold.............................................................................................................1351 Oil Cooler........................................................................................................................1353 Oil Pan...........................................................................................................................1358 Oil Pump..........................................................................................................................1380 Timing Drive Components...........................................................................................................1383 Valve Cover LH....................................................................................................................1399 Valve Cover RH....................................................................................................................1402 Disassembly...........................................................................................................................1404 Disassembly/Assembly of subassemblies.................................................................................................1409 Cylinder Head.....................................................................................................................1409 Piston............................................................................................................................1414 Assembly..............................................................................................................................1411 303-01B : Engine - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L NA V8 - AJV8..................................................................1465 General Procedures....................................................................................................................1468 Valve Clearance Adjustment........................................................................................................1468 Valve Clearance Check.............................................................................................................1473 Description and Operation.............................................................................................................1474 Diagnosis and Testing.................................................................................................................1483 Removal and Installation..............................................................................................................1484 Crankshaft Main Bearing Carrier...................................................................................................1484 Removal...............................................................................................................................1558 Installation..........................................................................................................................1570 In Vehicle Repair.....................................................................................................................1582 Camshafts RH - VIN Range: G00442->G45703..........................................................................................1582 Camshafts RH - VIN Range: G45704->G99999..........................................................................................1599 Crankshaft Front Seal - VIN Range: G00442->G45703.................................................................................1615 Crankshaft Front Seal - VIN Range: G45704->G99999.................................................................................1617 Crankshaft Pulley.................................................................................................................1619 Crankshaft Rear Seal..............................................................................................................1626 Cylinder Head LH - VIN Range: G00442->G45703......................................................................................1630 Cylinder Head LH - VIN Range: G45704->G99999......................................................................................1659 Engine Front Cover - VIN Range: G00442->G45703....................................................................................1687 Engine Front Cover - VIN Range: G45704->G99999....................................................................................1697 Engine Mount LH...................................................................................................................1717 Engine Mount RH...................................................................................................................1725 Exhaust Manifold RH - VIN Range: G00442->G45703...................................................................................1731 Exhaust Manifold RH - VIN Range: G45704->G99999...................................................................................1735 Flexplate.........................................................................................................................1742 Intake Manifold - VIN Range: G00442->G45703.......................................................................................1745 Intake Manifold - VIN Range: G45704->G99999.......................................................................................1763 Oil Cooler - Vehicles With: Supercharger..........................................................................................1780 Oil Cooler - Vehicles Without: Supercharger.......................................................................................1783 Oil Pan...........................................................................................................................1787 Oil Pan Extension.................................................................................................................1790 Oil Pump - VIN Range: G00442->G45703..............................................................................................1802 Oil Pump - VIN Range: G45704->G99999..............................................................................................1820 Secondary Timing Chain Tensioner..................................................................................................1838 Timing Drive Components - VIN Range: G00442->G45703...............................................................................1845 Timing Drive Components - VIN Range: G45704->G99999...............................................................................1867 Valve Cover LH - VIN Range: G00442->G45703........................................................................................1889 Valve Cover LH - VIN Range: G45704->G99999........................................................................................1898 Valve Cover RH - VIN Range: G00442->G45703........................................................................................1907 Valve Cover RH - VIN Range: G45704->G99999........................................................................................1916 Disassembly...........................................................................................................................1924 Disassembly/Assembly of subassemblies.................................................................................................1977 Cylinder Head.....................................................................................................................1977 Assembly..........................................................................................................................1983 303-01C : Engine - 2.7L V6 - TdV6.........................................................................................................2056 Description and Operation.............................................................................................................2059 Diagnosis and Testing.................................................................................................................2078 Removal...............................................................................................................................2086 Installation..........................................................................................................................2099 In Vehicle Repair.....................................................................................................................2114 Camshaft Front Seal...............................................................................................................2114 Camshaft Rear Seal................................................................................................................2120 Camshafts LH......................................................................................................................2124 Crankshaft Front Seal.............................................................................................................2165 Crankshaft Rear Seal..............................................................................................................2172 Crankshaft Vibration Damper.......................................................................................................2174 Cylinder Head LH..................................................................................................................2176 Engine Mount LH...................................................................................................................2182 Engine Mount RH...................................................................................................................2189 Exhaust Manifold LH...............................................................................................................2201 Exhaust Manifold RH...............................................................................................................2205 Flexplate.........................................................................................................................2208 Oil Filter Element................................................................................................................2210 Oil Pan...........................................................................................................................2214 Oil Pan Extension.................................................................................................................2228 Oil Pump..........................................................................................................................2238 Timing Belt.......................................................................................................................2247 Timing Belt Cover.................................................................................................................2261 Valve Cover LH....................................................................................................................2281 Valve Cover RH....................................................................................................................2316 303-03A : Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6.................................................................2335 General Procedures....................................................................................................................2337 Cooling System Backflushing.......................................................................................................2337 Cooling System Draining, Filling and Bleeding.....................................................................................2340 Cooling System Draining and Vacuum Filling........................................................................................2344 Cooling System Flushing........................................................................................................... 19 Description and Operation.............................................................................................................2356 Diagnosis and Testing.................................................................................................................2367 Removal and Installation..............................................................................................................2374 Coolant Expansion Tank............................................................................................................2374 Cooling Fan Motor and Shroud......................................................................................................2377 Radiator..........................................................................................................................2383 Thermostat - 3.0L NA V6 - AJ27....................................................................................................2390 Thermostat - 4.2L NA V8 - AJV8/3.5L NA V8 - AJV8..................................................................................2392 Thermostat - 4.2L SC V8 - AJV8....................................................................................................2397 Water Pump - 3.0L NA V6 - AJ27, VIN Range: G00442->G45703.........................................................................2402 Water Pump - 3.0L NA V6 - AJ27, VIN Range: G45704->G99999.........................................................................2406 Water Pump - 4.2L NA V8 - AJV8/3.5L NA V8 - AJV8..................................................................................2410 Water Pump - 4.2L SC V8 - AJV8....................................................................................................2413 303-03B : Supercharger Cooling............................................................................................................2417 General Procedures....................................................................................................................2418 Supercharger Cooling System Draining, Filling and Bleeding........................................................................2418 Description and Operation.............................................................................................................2424 Diagnosis and Testing.................................................................................................................2424 Removal and Installation..............................................................................................................2425 Radiator..........................................................................................................................2425 Water Pump........................................................................................................................2429 303-03C : Engine Cooling - 2.7L V6 - TdV6.................................................................................................2432 General Procedures....................................................................................................................2433 Cooling System Draining, Filling and Bleeding.....................................................................................2433 Cooling System Draining and Vacuum Filling........................................................................................2438 Description and Operation.............................................................................................................2439 Diagnosis and Testing.................................................................................................................2444 Removal and Installation..............................................................................................................2448 Coolant Expansion Tank............................................................................................................2448 Cooling Fan Motor and Shroud......................................................................................................2451 Radiator..........................................................................................................................2456 Thermostat........................................................................................................................2466 Water Pump........................................................................................................................2471 303-04A : Fuel Charging and Controls - 3.0L NA V6 - AJ27..................................................................................2476 Description and Operation.............................................................................................................2477 Diagnosis and Testing.................................................................................................................2479 Fuel Charging and Controls - VIN Range: G00442->G45703............................................................................2479 Fuel Charging and Controls - VIN Range: G45704->G99999............................................................................2503 Removal and Installation..............................................................................................................2521 Fuel Charging Wiring Harness......................................................................................................2521 Fuel Injectors....................................................................................................................2525 Fuel Injection Supply Manifold....................................................................................................2527 Throttle Body - VIN Range: G00442->G45703.........................................................................................2528 Throttle Body - VIN Range: G45704->G99999.........................................................................................2531 303-04B : Fuel Charging and Controls - 4.2L NA V8 - AJV8/4.2L SC V8 -.....................................................................2534 Description and Operation.............................................................................................................2535 Diagnosis and Testing.................................................................................................................2538 Fuel Charging and Controls - VIN Range: G00442->G45703............................................................................2538 Fuel Charging and Controls - VIN Range: G45704->G99999............................................................................2563 Removal and Installation..............................................................................................................2590 Fuel Injection Supply Manifold....................................................................................................2590 Fuel Injectors....................................................................................................................2592 Throttle Body - 4.2L SC V8 - AJV8, VIN Range: G00442->G45703......................................................................2597 Throttle Body - 4.2L SC V8 - AJV8, VIN Range: G45704->G99999......................................................................2600 Throttle Body - 4.2L NA V8 - AJV8/3.5L NA V8 - AJV8, VIN Range: G00442->G45703....................................................2605 Throttle Body - 4.2L NA V8 - AJV8/3.5L NA V8 - AJV8, VIN Range: G45704->G99999....................................................2608 303-04C : Fuel Charging and Controls - 2.7L V6 - TdV6.....................................................................................2611 General Procedures....................................................................................................................2612 Fuel Injection Component Cleaning.................................................................................................2612 Description and Operation.............................................................................................................2614 Diagnosis and Testing.................................................................................................................2619 Removal and Installation..............................................................................................................2759 Fuel Diverter Rail................................................................................................................2759 Fuel Injection Pump...............................................................................................................2772 Fuel Injector.....................................................................................................................2801 Fuel Rail.........................................................................................................................2816 Intake Air Shutoff Throttle.......................................................................................................2827 Swirl Plate Actuator Diaphragm....................................................................................................2835 303-04D : Fuel Charging and Controls - Turbocharger - 2.7L V6 - TdV6......................................................................2847 Description and Operation.............................................................................................................2848 Diagnosis and Testing.................................................................................................................2851 Removal and Installation..............................................................................................................2878 Turbocharger LH...................................................................................................................2878 Turbocharger RH...................................................................................................................2887 303-05 : Accessory Drive..................................................................................................................2894 Description and Operation.............................................................................................................2895 Diagnosis and Testing.................................................................................................................2901 Accessory Drive - 3.0L/3.5L/4.2L..................................................................................................2901 Accessory Drive - 2.7L Diesel.....................................................................................................2902 Removal and Installation..............................................................................................................2905 Accessory Drive Belt - 3.0L NA V6 - AJ27, VIN Range: G00442->G45703...............................................................2905 Accessory Drive Belt - 3.0L NA V6 - AJ27, VIN Range: G45704->G99999...............................................................2906 ccessory Drive Belt - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L NA V8 -AJV8........................................................2908 Accessory Drive Belt - 2.7L V6 - TdV6.............................................................................................2910 Accessory Drive Belt Idler Pulley - 3.0L NA V6 - AJ27, VIN Range: G00442->G45703..................................................2912 Accessory Drive Belt Idler Pulley - 3.0L NA V6 - AJ27, VIN Range: G45704->G99999..................................................2913 Accessory Drive Belt Idler Pulley - 4.2L NA V8 - AJV8/4.2L SC V8 -AJV8/3.5L NA V8 - AJV8, VIN Range: G00442->G45703...............2915 Accessory Drive Belt Idler Pulley - 4.2L NA V8 - AJV8/4.2L SC V8 -AJV8/3.5L NA V8 - AJV8, VIN Range: G45704->G99999...............2917 Accessory Drive Belt Idler Pulley - 2.7L V6 - TdV6................................................................................2921 Accessory Drive Belt Tensioner - 3.0L NA V6 - AJ27, VIN Range: G00442->G45703.....................................................2923 Accessory Drive Belt Tensioner - 3.0L NA V6 - AJ27, VIN Range: G45704->G99999.....................................................2924 Accessory Drive Belt Tensioner - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5LNA V8 - AJV8.............................................2926 Accessory Drive Belt Tensioner - 2.7L V6 - TdV6...................................................................................2928 Fuel Injection Pump Belt..........................................................................................................2930 Fuel Injection Pump Pulley........................................................................................................2935 Supercharger Belt - VIN Range: G00442->G45703.....................................................................................2937 Supercharger Belt - VIN Range: G45704->G99999.....................................................................................2939 Supercharger Belt Idler Pulley - VIN Range: G04422->G45703........................................................................2940 Supercharger Belt Idler Pulley - VIN Range: G45704->G99999........................................................................2942 Supercharger Belt Tensioner - VIN Range: G00442->G45703...........................................................................2946 Supercharger Belt Tensioner - VIN Range: G45704->G99999........................................................................... 0 303-06 : Starting System..................................................................................................................2948 Description and Operation.............................................................................................................2949 Diagnosis and Testing.................................................................................................................2950 Removal and Installation..............................................................................................................2961 Starter Motor - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -AJ27/3.5L NA V8 - AJV8............................................2961 Starter Motor - 2.7L V6 - TdV6....................................................................................................2966 303-07A : Engine Ignition - 3.0L NA V6 - AJ27.............................................................................................2972 Description and Operation.............................................................................................................2973 Diagnosis and Testing.................................................................................................................2974 Engine Ignition - VIN Range: G00442->G45703.......................................................................................2974 Engine Ignition - VIN Range: G45704->G99999.......................................................................................2996 Removal and Installation..............................................................................................................3011 Ignition Coil-On-Plug LH..........................................................................................................3011 Ignition Coil-On-Plug RH..........................................................................................................3012 303-07B : Engine Ignition - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L NA V8................................................................3013 Description and Operation.............................................................................................................3014 Diagnosis and Testing.................................................................................................................3015 Engine Ignition - VIN Range: G00442->G45703.......................................................................................3015 Engine Ignition - VIN Range: G45704->G99999.......................................................................................3037 Removal and Installation..............................................................................................................3053 Ignition Coil-On-Plug.............................................................................................................3053 303-07C : Glow Plug System................................................................................................................3055 Description and Operation.............................................................................................................3056 Diagnosis and Testing.................................................................................................................3058 Removal and Installation..............................................................................................................3070 Glow Plugs........................................................................................................................3070 303-08A : Engine Emission Control - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L..............................................................3074 Description and Operation.............................................................................................................3076 Engine Emission Control - VIN Range: G00442->G45703...............................................................................3076 Engine Emission Control - VIN Range: G45704->G99999...............................................................................3078 Diagnosis and Testing.................................................................................................................3086 Engine Emission Control - VIN Range: G00442->G45703...............................................................................3086 Engine Emission Control - VIN Range: G45704->G99999...............................................................................3096 Removal and Installation..............................................................................................................3112 Exhaust Gas Recirculation (EGR) Valve.............................................................................................3112 Exhaust Manifold to Exhaust Gas Recirculation (EGR) Valve Tube....................................................................3121 Secondary Air Injection (AIR) Control Valve - 3.0L NA V6 - AJ27...................................................................3123 Secondary Air Injection (AIR) Control Valve - 4.2L NA V8 - AJV8/3.5L NA V8- AJV8..................................................3126 Secondary Air Injection (AIR) Control Valve - 4.2L SC V8 - AJV8...................................................................3129 Secondary Air Injection (AIR) Control Valve to Exhaust Manifold Tube LH -3.0L NA V6 - AJ27........................................3134 Secondary Air Injection (AIR) Control Valve to Exhaust Manifold Tube RH -3.0L NA V6 - AJ27........................................3136 Secondary Air Injection (AIR) Control Valve to Exhaust Manifold Tube -4.2L NA V8 - AJV8/3.5L NA V8 - AJV8, 4.2L...................3139 Secondary Air Injection (AIR) Control Valve to Exhaust Manifold Tube -4.2L SC V8 - AJV8, 4.2L.....................................3145 Secondary Air Injection (AIR) Pump................................................................................................3148 303-08B : Engine Emission Control - 2.7L V6 - TdV6........................................................................................3150 Description and Operation.............................................................................................................3151 Diagnosis and Testing.................................................................................................................3155 Removal and Installation..............................................................................................................3193 Crankcase Vent Oil Separator......................................................................................................3193 Exhaust Gas Recirculation (EGR) Valve LH..........................................................................................3199 Exhaust Gas Recirculation (EGR) Valve Outlet Tube.................................................................................3207 Exhaust Gas Recirculation (EGR) Valve RH..........................................................................................3213 303-12A : Intake Air Distribution and Filtering - 3.0L NA V6 - AJ27.......................................................................3221 Description and Operation.............................................................................................................3222 Diagnosis and Testing.................................................................................................................3223 Intake Air Distribution and Filtering - VIN Range: G00442->G45703.................................................................3223 Intake Air Distribution and Filtering - VIN Range: G45704->G99999.................................................................3224 Removal and Installation..............................................................................................................3229 Air Cleaner.......................................................................................................................3229 Air Cleaner Element...............................................................................................................3231 Air Cleaner Outlet Pipe...........................................................................................................3233 303-12B : Intake Air Distribution and Filtering - 4.2L NA V8 - AJV8/4.2L SC V8............................................................3234 Description and Operation.............................................................................................................3235 Diagnosis and Testing.................................................................................................................3239 Intake Air Distribution and Filtering - VIN Range: G00442->G45703.................................................................3239 Intake Air Distribution and Filtering - VIN Range: G45704->G99999.................................................................3240 Removal and Installation..............................................................................................................3246 Air Cleaner.......................................................................................................................3246 Air Cleaner Element...............................................................................................................3248 Air Cleaner Outlet Pipe...........................................................................................................3249 Charge Air Cooler.................................................................................................................3251 Supercharger - VIN Range: G00442->G45703..........................................................................................3252 Supercharger - VIN Range: G45704->G99999..........................................................................................3261 Supercharger Outlet Pipe..........................................................................................................3270 303-12C : Intake Air Distribution and Filtering - 2.7L V6 - TdV6..........................................................................3273 Description and Operation.............................................................................................................3274 Diagnosis and Testing.................................................................................................................3276 Removal and Installation..............................................................................................................3287 Air Cleaner.......................................................................................................................3287 Air Cleaner Element...............................................................................................................3290 Charge Air Cooler.................................................................................................................3291 303-13 : Evaporative Emissions............................................................................................................3292 Description and Operation.............................................................................................................3293 Evaporative Emissions - VIN Range: G00442->G45703.................................................................................3293 Evaporative Emissions - VIN Range: G45704->G99999.................................................................................3296 Diagnosis and Testing.................................................................................................................3298 Evaporative Emissions - VIN Range: G00442->G45703.................................................................................3298 Evaporative Emissions - VIN Range: G45704->G99999.................................................................................3318 Removal and Installation..............................................................................................................3331 Evaporative Emission Canister - VIN Range: G00442->G45703.........................................................................3331 Evaporative Emission Canister - VIN Range: G45704->G99999.........................................................................3348 Evaporative Emission Canister Purge Valve - VIN Range: G00442->G45703.............................................................3366 Evaporative Emission Canister Purge Valve - 3.0L NA V6 - AJ27, VIN Range:G45704->G99999...........................................3368 Evaporative Emission Canister Purge Valve - 4.2L SC V8 - AJV8/3.5L NA V8- AJV8, VIN Range: G45171->G99999.........................3371 Evaporative Emission Canister Purge Valve - 4.2L NA V8 - AJV8/3.5L NA V8- AJV8, VIN Range: G45171->G99999.........................3373 Evaporative Emission Canister Vent Solenoid.......................................................................................3376 Fuel Tank Pressure Sensor.........................................................................................................3378 303-14A : Electronic Engine Controls - 3.0L NA V6 - AJ27..................................................................................3379 General Procedures....................................................................................................................3380 Brake Pedal Position (BPP) Switch Adjustment......................................................................................3380 Description and Operation.............................................................................................................3381 Diagnosis and Testing.................................................................................................................3387 Electronic Engine Controls - VIN Range: G00442->G45703............................................................................3387 Electronic Engine Controls - VIN Range: G45704->G99999............................................................................3388 Removal and Installation..............................................................................................................3516 Brake Pedal Position (BPP) Switch.................................................................................................3516 Camshaft Position (CMP) Sensor LH.................................................................................................3519 Camshaft Position (CMP) Sensor RH.................................................................................................3521 Catalyst Monitor Sensor...........................................................................................................3522 Crankshaft Position (CKP) Sensor..................................................................................................3524 Engine Control Module (ECM).......................................................................................................3526 Engine Coolant Temperature (ECT) Sensor - VIN Range: G00442->G45703...............................................................3530 Engine Coolant Temperature (ECT) Sensor - VIN Range: G45704->G99999...............................................................3532 Fuel Rail Pressure (FRP) Sensor...................................................................................................3534 Fuel Temperature Sensor...........................................................................................................3537 Heated Oxygen Sensor..............................................................................................................3538 Intake Manifold Tuning (IMT) Valve LH.............................................................................................3540 Knock Sensor (KS) LH..............................................................................................................3541 Knock Sensor (KS) RH..............................................................................................................3542 Manifold Absolute Pressure (MAP) Sensor...........................................................................................3544 Mass Air Flow (MAF) Sensor........................................................................................................3545 Oil Temperature Sensor............................................................................................................3546 Variable Camshaft Timing (VCT) Oil Control Solenoid...............................................................................3548 303-14B : Electronic Engine Controls - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L...........................................................3549 General Procedures....................................................................................................................3550 Brake Pedal Position (BPP) Switch Adjustment......................................................................................3550 Powertrain Control Module (PCM) Long Drive Cycle Self-Test........................................................................3551 Powertrain Control Module (PCM) Short Drive Cycle Self-Test.......................................................................3553 Description and Operation.............................................................................................................3554 Vehicles with supercharger........................................................................................................3554 Vehicles without supercharger.....................................................................................................3556 Armoured XJ.......................................................................................................................3561 Diagnosis and Testing.................................................................................................................3562 Electronic Engine Controls - VIN Range: G00442->G45703............................................................................3562 Electronic Engine Controls - VIN Range: G45704->G99999............................................................................3689 Removal and Installation..............................................................................................................3822 Brake Pedal Position (BPP) Switch.................................................................................................3822 Camshaft Position (CMP) Sensor LH.................................................................................................3825 Camshaft Position (CMP) Sensor RH.................................................................................................3834 Catalyst Monitor Sensor...........................................................................................................3843 Crankshaft Position (CKP) Sensor..................................................................................................3845 Engine Control Module (ECM).......................................................................................................3847 Engine Coolant Temperature (ECT) Sensor - 4.2L SC V8 - AJV8.......................................................................3851 Engine Coolant Temperature (ECT) Sensor - 4.2L NA V8 - AJV8.......................................................................3853 Fuel Rail Pressure (FRP) Sensor...................................................................................................3855 Fuel Temperature Sensor...........................................................................................................3858 Heated Oxygen Sensor (HO2S).......................................................................................................3860 Intake Air Temperature (IAT) Sensor - 4.2L SC V8 - AJV8...........................................................................3862 Knock Sensor (KS) LH..............................................................................................................3864 Manifold Absolute Pressure (MAP) Sensor - 4.2L SC V8 - AJV8.......................................................................3866 Manifold Absolute Pressure (MAP) Sensor - 4.2L NA V8 - AJV8.......................................................................3874 Mass Air Flow (MAF) Sensor........................................................................................................3875 Oil Temperature Sensor............................................................................................................3876 Variable Camshaft Timing (VCT) Oil Control Solenoid...............................................................................3878 303-14C : Electronic Engine Controls - 2.7L V6 - TdV6.....................................................................................3879 General Procedures....................................................................................................................3880 Brake Pedal Position (BPP) Switch Adjustment...................................................................................... 30 Description and Operation.............................................................................................................3881 Diagnosis and Testing.................................................................................................................3885 Removal and Installation..............................................................................................................4094 Brake Pedal Position (BPP) Switch.................................................................................................4094 Camshaft Position (CMP) Sensor....................................................................................................4097 Crankshaft Position (CKP) Sensor..................................................................................................4100 Crankshaft Position (CKP) Sensor Ring.............................................................................................4104 Engine Control Module (ECM).......................................................................................................4108 Engine Coolant Temperature (ECT) Sensor...........................................................................................4112 Exhaust Gas Temperature Sensor....................................................................................................4114 Engine Oil Pressure (EOP) Sensor..................................................................................................4117 Fuel Rail Pressure (FRP) Sensor...................................................................................................4119 Fuel Temperature Sensor...........................................................................................................4120 Intake Air Temperature (IAT) Sensor...............................................................................................4124 Knock Sensor (KS) LH..............................................................................................................4126 Knock Sensor (KS) RH..............................................................................................................4129 Manifold Absolute Pressure (MAP) Sensor...........................................................................................4133 Mass Air Flow (MAF) Sensor........................................................................................................4135 Oil Temperature Sensor............................................................................................................4136 307 : Automatic Transmission/Transaxle........................................................................................................4139 307-01 : Automatic Transmission/Transaxle.................................................................................................4139 General Procedures....................................................................................................................4141 Transmission Fluid Drain and Refill...............................................................................................4141 Transmission Fluid Level Check....................................................................................................4144 Description and Operation.............................................................................................................4148 Diagnosis and Testing.................................................................................................................4176 Removal...............................................................................................................................4177 Transmission - 3.0L NA V6 - AJ27..................................................................................................4177 Transmission - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L NA V8 - AJV8..............................................................4185 Transmission - 2.7L V6 - TdV6.....................................................................................................4192 Installation..........................................................................................................................4202 Transmission - 3.0L NA V6 - AJ27..................................................................................................4202 Transmission - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L NA V8 - AJV8..............................................................4211 Transmission - 2.7L V6 - TdV6.....................................................................................................4219 In Vehicle Repair.....................................................................................................................4230 Extension Housing Seal............................................................................................................4230 Transmission Fluid Pan, Gasket and Filter.........................................................................................4239 Transmission Control Module (TCM) and Main Control Valve Body.....................................................................4242 Disassembly/Assembly of subassemblies.................................................................................................4248 Input Shaft Seal..................................................................................................................4248 307-02 : Transmission/Transaxle Cooling...................................................................................................4252 Description and Operation.............................................................................................................4253 Diagnosis and Testing.................................................................................................................4256 Removal and Installation..............................................................................................................4258 Transmission Fluid Cooler - 2.7L V6 - TdV6........................................................................................4258 Transmission Fluid Cooler Tubes - 4.2L NA V8 - AJV8/4.2L SC V8 -AJV8/3.0L NA V6 - AJ27/3.5L NA V8 - AJV8..........................4263 Transmission Fluid Cooler Tubes - 2.7L V6 - TdV6..................................................................................4270 307-05 : Automatic Transmission/Transaxle External Controls...............................................................................4277 General Procedures....................................................................................................................4278 Selector Lever Cable Adjustment ..................................................................................................4278 Description and Operation.............................................................................................................4281 Diagnosis and Testing.................................................................................................................4284 Removal and Installation..............................................................................................................4287 Selector Lever Cable and Bracket..................................................................................................4287 Selector Lever Assembly...........................................................................................................4293 309 : Exhaust System..........................................................................................................................4300 309-00 : Exhaust System...................................................................................................................4300 Description and Operation.............................................................................................................4301 Diagnosis and Testing.................................................................................................................4303 Removal and Installation..............................................................................................................4329 Catalytic Converter - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -AJ27/3.5L NA V8 - AJV8......................................4329 Catalytic Converter - 2.7L V6 - TdV6..............................................................................................4335 Diesel Particulate Filter (DPF)...................................................................................................4341 Diesel Particulate Filter (DPF) Differential Pressure Sensor......................................................................4345 Exhaust System - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -AJ27/3.5L NA V8 - AJV8...........................................4347 Exhaust System - 2.7L V6 - TdV6...................................................................................................4350 Front Muffler - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -AJ27/3.5L NA V8 - AJV8............................................4355 Front Muffler - 2.7L V6 - TdV6....................................................................................................4357 Muffler and Tailpipe..............................................................................................................4360 310 : Fuel System.............................................................................................................................4363 310-00 : Fuel System - General Information................................................................................................4363 General Procedures....................................................................................................................4364 Fuel System Pressure Check........................................................................................................4364 Fuel System Pressure Release - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0LNA V6 - AJ27/3.5L NA V8 - AJV8.............................4368 Fuel System Pressure Release - 2.7L V6 - TdV6.....................................................................................4372 Fuel Tank Draining - VIN Range: G00442->G45703....................................................................................4374 Fuel Tank Draining - VIN Range: G45704->G99999....................................................................................4389 High-Pressure Fuel System Bleeding - 2.7L V6 - TdV6...............................................................................4398 Low-Pressure Fuel System Bleeding - 2.7L V6 - TdV6................................................................................4404 Quick Release Coupling............................................................................................................4407 Quick Release Coupling - Push Connect.............................................................................................4409 Spring Lock Couplings.............................................................................................................4411 Description and Operation.............................................................................................................4416 Fuel System - VIN Range: G00442->G45703...........................................................................................4416 Fuel System - VIN Range: G45704->G99999...........................................................................................4420 310-01 : Fuel Tank and Lines..............................................................................................................4425 Description and Operation.............................................................................................................4426 Fuel Tank and Lines - VIN Range: G00442->G45703...................................................................................4426 Fuel Tank and Lines - VIN Range: G45704->G99999...................................................................................4429 Diagnosis and Testing.................................................................................................................4433 Fuel Tank and Lines - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -AJ27/3.5L NA V8 - AJV8, VIN Range: G00442->G45703...........4426 Fuel Tank and Lines - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -AJ27/3.5L NA V8 - AJV8, VIN Range: G45704->G99999...........4429 Fuel Tank and Lines - 2.7L V6 - TdV6..............................................................................................4433 Removal and Installation..............................................................................................................4516 Fuel Filter - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 - AJ27/3.5LNA V8 - AJV8..............................................4516 Fuel Filter - 2.7L V6 - TdV6......................................................................................................4520 Fuel Level Sender LH - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -AJ27/3.5L NA V8 - AJV8, VIN Range: G00442->G45703..........4525 Fuel Level Sender LH - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 AJ27/3.5L NA V8 - AJV8, VIN Range: G45704->G99999...........4527 Fuel Level Sender LH - 2.7L V6 - TdV6.............................................................................................4529 Fuel Level Sender RH - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -AJ27/3.5L NA V8 - AJV8, VIN Range: G00442->G45703..........4537 Fuel Level Sender RH - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -AJ27/3.5L NA V8 - AJV8, VIN Range: G45704->G99999..........4539 Fuel Level Sender RH - 2.7L V6 - TdV6.............................................................................................4542 Fuel Pump Module - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -AJ27/3.5L NA V8 - AJV8, VIN Range: G00442->G45703..............4546 Fuel Pump Module - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -AJ27/3.5L NA V8 - AJV8, VIN Range: G45704->G99999..............4564 Fuel Pump Module - 2.7L V6 - TdV6.................................................................................................4575 Fuel Tank - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 - AJ27/3.5L NAV8 - AJV8................................................4586 Fuel Tank - 2.7L V6 - TdV6........................................................................................................4594 Fuel Tank Filler Pipe.............................................................................................................4605 Fuel Transfer Pump - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -AJ27/3.5L NA V8 - AJV8, VIN Range: G00442->G45703............4612 Fuel Transfer Unit - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -AJ27/3.5L NA V8 - AJV8, VIN Range: G45704->G99999............4618 Fuel Transfer Unit - 2.7L V6 - TdV6...............................................................................................4634 Inertia Fuel Shutoff (IFS) Switch.................................................................................................4650 310-02 : Acceleration Control.............................................................................................................4651 Description and Operation.............................................................................................................4652 Diagnosis and Testing.................................................................................................................4654 Removal and Installation..............................................................................................................4664 Accelerator Pedal (19.20.01)......................................................................................................4664 310-03 : Speed Control....................................................................................................................4667 General Procedures....................................................................................................................4668 Speed Control Module Alignment - VIN Range: G00442->H18679........................................................................4668 Speed Control Module Alignment - VIN Range: H18680->H99999........................................................................4670 Description and Operation.............................................................................................................4672 Speed Control - VIN Range: G00442->G45703.........................................................................................4672 Speed Control - VIN Range: G45704->G99999.........................................................................................4676 Diagnosis and Testing.................................................................................................................4685 Speed Control - VIN Range: G00442->G45703.........................................................................................4685 Speed Control - VIN Range: G45704->G99999.........................................................................................4709 Removal and Installation..............................................................................................................4732 Speed Control Deactivator Switch..................................................................................................4732 Speed Control Module..............................................................................................................4734 Speed Control Sensor..............................................................................................................4737 Speed Control Switch..............................................................................................................4741 4. ELECTRICAL.....................................................................................................................................4743 412 : Climate Control System..................................................................................................................4743 412-00 : Climate Control System - General Information.....................................................................................4743 General Procedures....................................................................................................................4745 Air Conditioning (A/C) System Flushing............................................................................................4745 Air Conditioning (A/C) System Recovery, Evacuation and Charging (82.30.30)........................................................4747 Contaminated Refrigerant Handling.................................................................................................4749 Electronic Leak Detection.........................................................................................................4750 Fluorescent Dye Leak Detection....................................................................................................4751 Inspection and Assembly Requirements..............................................................................................4752 Manifold Gauge Set Connection.....................................................................................................4753 Refrigerant Oil Adding............................................................................................................4754 Refrigerant System Tests..........................................................................................................4755 Description and Operation.............................................................................................................4756 Climate Control System............................................................................................................4756 Diagnosis and Testing.................................................................................................................4759 Climate Control System............................................................................................................4759 412-01 : Air Distribution and Filtering...................................................................................................4765 Description and Operation.............................................................................................................4766 Diagnosis and Testing.................................................................................................................4768 Removal and Installation..............................................................................................................4769 Cabin Air Filter (76.10.09).......................................................................................................4769 Center Registers (82.20.38).......................................................................................................4771 Driver Side Register (82.20.39)...................................................................................................4774 Floor Console Register Duct (82.20.37)............................................................................................4776 Front Footwell Duct LH (82.20.91).................................................................................................4777 Front Footwell Duct RH (82.20.92).................................................................................................4779 Passenger Side Register (82.20.40)................................................................................................4781 Rear Footwell Duct (82.20.96).....................................................................................................4783 412-02A : Heating and Ventilation.........................................................................................................4785 Description and Operation.............................................................................................................4786 Diagnosis and Testing.................................................................................................................4789 Removal and Installation..............................................................................................................4790 Auxiliary Coolant Flow Pump - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5LNA V8 - AJV8 (82.25.59).....................................4790 Auxiliary Coolant Flow Pump - 2.7L V6 - TdV6 (82.25.59)...........................................................................4793 Blower Motor (82.25.66)...........................................................................................................4798 Heater Core (80.20.29)............................................................................................................4799 Heater Core and Evaporator Core Housing (82.25.21)................................................................................4805 Heater Hose (80.25.01)............................................................................................................4815 412-02B : Auxiliary Heating...............................................................................................................4823 Description and Operation.............................................................................................................4824 Fuel Fired Booster Heater.........................................................................................................4824 Diagnosis and Testing.................................................................................................................4826 Fuel Fired Booster Heater.........................................................................................................4826 Removal and Installation..............................................................................................................4832 Fuel Fired Booster Heater.........................................................................................................4832 412-03A : Air Conditioning................................................................................................................4836 Description and Operation.............................................................................................................4837 Diagnosis and Testing.................................................................................................................4843 Removal and Installation..............................................................................................................4844 Air Conditioning (A/C) Compressor - 3.0L NA V6 - AJ27, VIN Range:G00442->G45703 (82.10.20)........................................4844 Air Conditioning (A/C) Compressor - 3.0L NA V6 - AJ27, VIN Range:G45704->G99999 (82.10.20)........................................4851 Air Conditioning (A/C) Compressor - 4.2L NA V8 - AJV8/4.2L SC V8 -AJV8/3.5L NA V8 - AJV8, VIN Range: G00442->G45703 (82.10.20)....4859 Air Conditioning (A/C) Compressor - 4.2L NA V8 - AJV8/4.2L SC V8 -AJV8/3.5L NA V8 - AJV8, VIN Range: G45704->G99999 (82.10.20)....4872 Air Conditioning (A/C) Compressor - 2.7L V6 - TdV6 (82.10.20).....................................................................4886 Condenser Core - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -AJ27/3.5L NA V8 - AJV8 (82.15.07)................................4893 Condenser Core - 2.7L V6 - TdV6 (82.15.07)........................................................................................4898 Desiccant Bag - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -AJ27/3.5L NA V8 - AJV8 (82.17.03).................................4902 Desiccant Bag - 2.7L V6 - TdV6 (82.17.03).........................................................................................4904 Pressure Cutoff Switch - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -AJ27/3.5L NA V8 - AJV8 (82.10.32)........................4908 Pressure Cutoff Switch - 2.7L V6 - TdV6 (82.10.32)................................................................................4910 412-03B : Auxiliary Climate Control.......................................................................................................4913 Description and Operation.............................................................................................................4914 Auxiliary Climate Control.............................................................................................................4914 Auxiliary Climate Control – Armoured Vehicles.........................................................................................4917 Diagnosis and Testing.................................................................................................................4919 Removal and Installation..............................................................................................................4942 Auxiliary Climate Control Assembly................................................................................................4942 Auxiliary Evaporator Outlet and Inlet Line........................................................................................4944 Auxiliary Footwell Vent/Duct Blend Door Actuator..................................................................................4949 Auxiliary Heater Core and Evaporator Core Housing.................................................................................4951 Auxiliary Temperature Blend Door Actuator.........................................................................................4955 Auxiliary Blower Motor............................................................................................................4957 Auxiliary Blower Motor Resistor...................................................................................................4961 Evaporator Core...................................................................................................................4962 Heater Core.......................................................................................................................4964 Register..........................................................................................................................4970 412-04 : Control Components...............................................................................................................4972 Description and Operation.............................................................................................................4973 Control Components................................................................................................................4973 Control Components - VIN Range: H18680->H99999....................................................................................4977 Diagnosis and Testing.................................................................................................................4978 Removal and Installation..............................................................................................................4979 Air Discharge Temperature Sensor (82.20.64).......................................................................................4979 Ambient Air Temperature Sensor (82.20.02).........................................................................................4981 Climate Control Assembly (82.20.07)...............................................................................................4982 Cold Air Bypass Blend Door Actuator LH............................................................................................4984 Cold Air Bypass Blend Door Actuator RH............................................................................................4990 Defrost Vent/Register Blend Door Actuator LH......................................................................................4996 Defrost Vent/Register Blend Door Actuator RH......................................................................................4998 Footwell Vent/Duct Blend Door Actuator LH.........................................................................................5000 Footwell Vent/Duct Blend Door Actuator RH.........................................................................................5004 In-Vehicle Temperature Sensor (82.20.03)..........................................................................................5008 Recirculation Blend Door Actuator (82.20.67)......................................................................................5011 Sunload Sensor (82.20.70).........................................................................................................5015 413-00 : Instrument Cluster and Panel Illumination............................................................................................5016 Diagnosis and Testing.....................................................................................................................5016 Instrument Cluster and Panel Illumination.............................................................................................5016 413-01 : Instrument Cluster...................................................................................................................5017 Description and Operation.................................................................................................................5018 Instrument Cluster....................................................................................................................5018 Diagnosis and Testing.....................................................................................................................5020 Removal and Installation..................................................................................................................5032 Indicator Bulb (86.45.61).............................................................................................................5032 Instrument Cluster (88.20.01).........................................................................................................5033 Instrument Cluster Lens (88.20.28)....................................................................................................5035 413-06 : Horn.................................................................................................................................5036 Description and Operation.................................................................................................................5037 Diagnosis and Testing.....................................................................................................................5039 Removal and Installation..................................................................................................................5040 Horn (86.30.02).......................................................................................................................5040 Horn Switch (86.30.01)................................................................................................................5041 413-07 : Clock................................................................................................................................5043 Description and Operation.................................................................................................................5043 Diagnosis and Testing.....................................................................................................................5044 Removal and Installation..................................................................................................................5045 Clock (88.15.07)......................................................................................................................5045 413-08 : Information and Message Center.......................................................................................................5048 Description and Operation.................................................................................................................5048 Diagnosis and Testing.....................................................................................................................5051 Removal and Installation..................................................................................................................5052 Message Center Switch (86.66.11)......................................................................................................5052 413-09A : Warning Devices.....................................................................................................................5054 General Procedures........................................................................................................................5054 Oil Change Indicator Reset............................................................................................................5054 Description and Operation.................................................................................................................5055 Warning Devices.......................................................................................................................5055 Warning Devices – Armoured Vehicles ..................................................................................................5060 Engine Protection System - Armoured Vehicles..........................................................................................5060 Diagnosis and Testing.....................................................................................................................5063 Warning Devices.......................................................................................................................5063 413-13 : Parking Aid..........................................................................................................................5064 Description and Operation.................................................................................................................5064 Diagnosis and Testing.....................................................................................................................5066 Removal and Installation..................................................................................................................5073 Front Parking Aid Speaker (86.54.18)..................................................................................................5073 Parking Aid Module - VIN Range: G00442->G45703 (86.80.39).............................................................................5074 Parking Aid Module - VIN Range: G45704->G99999 (86.80.39).............................................................................5075 Parking Aid Sensor (86.62.01).........................................................................................................5077 Rear Parking Aid Speaker (86.54.19)...................................................................................................5078 414-00 : Charging System - General Information................................................................................................5079 General Procedures........................................................................................................................5079 Description and Operation.................................................................................................................5082 Diagnosis and Testing.....................................................................................................................5085 Charging System.......................................................................................................................5085 Charging System - 2.7L V6 - TdV6......................................................................................................5100 414-01 : Battery, Mounting and Cables.........................................................................................................5113 General Procedures........................................................................................................................5114 Battery Connect (86.15.15)............................................................................................................5114 Battery Disconnect and Connect........................................................................................................5117 Description and Operation.................................................................................................................5120 Battery and Cables....................................................................................................................5120 Diagnosis and Testing.....................................................................................................................5121 Battery...............................................................................................................................5121 Removal and Installation..................................................................................................................5122 Battery (86.15.01)....................................................................................................................5122 Battery Ground Cable (86.15.19).......................................................................................................5124 Battery Tray (86.15.11)...............................................................................................................5125 414-02 : Generator and Regulator..............................................................................................................5127 Specifications............................................................................................................................5127 Description and Operation.................................................................................................................5128 Diagnosis and Testing.....................................................................................................................5131 Removal and Installation..................................................................................................................5132 Generator - 3.0L NA V6 - AJ27 (86.10.02)..............................................................................................5132 Generator - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L NA V8 - AJV8(86.10.02)...........................................................5135 Generator - 2.7L V6 - TdV6 (86.10.02).................................................................................................5142 415-00 : Information and Entertainment System.................................................................................................5148 General Procedures........................................................................................................................5148 Cassette Player Cleaning..............................................................................................................5148 Diagnosis and Testing.....................................................................................................................5149 Audio System..........................................................................................................................5149 415-01 : Audio Unit...........................................................................................................................5164 Specifications............................................................................................................................5164 Description and Operation.................................................................................................................5165 Audio System..........................................................................................................................5165 Audio System......................................................................................................................5165 Audio System - VIN Range: H18680->H99999..........................................................................................5172 Audio System......................................................................................................................5185 Diagnosis and Testing.....................................................................................................................5186 Audio System..........................................................................................................................5186 Removal and Installation..................................................................................................................5187 Amplifier (86.50.10)..................................................................................................................5187 Audio Unit (86.50.03).................................................................................................................5190 Compact Disc (CD) Changer (86.50.06)..................................................................................................5192 Steering Wheel Audio Controls (86.50.42)..............................................................................................5195 415-02 : Antenna..............................................................................................................................5196 Description and Operation.................................................................................................................5196 Diagnosis and Testing.....................................................................................................................5198 Removal and Installation..................................................................................................................5199 Antenna Isolator Module (86.51.08)....................................................................................................5199 415-03 : Speakers.............................................................................................................................5200 Description and Operation.................................................................................................................5200 Diagnosis and Testing.....................................................................................................................5202 Removal and Installation..................................................................................................................5203 Front Door Speaker (86.50.13).........................................................................................................5203 Front Door Tweeter Speaker (86.50.63).................................................................................................5204 Instrument Panel Speaker..............................................................................................................5206 Rear Door Speaker (86.50.14)..........................................................................................................5207 Rear Door Tweeter Speaker (86.50.62)..................................................................................................5208 Subwoofer Speaker (86.51.05)..........................................................................................................5210 415-07 : Video System.........................................................................................................................5211 Specifications............................................................................................................................5211 Description and Operation.................................................................................................................5212 Diagnosis and Testing.....................................................................................................................5225 Removal and Installation..................................................................................................................5298 Digital Versatile Disc (DVD) Player...................................................................................................5298 Rear Passenger Entertainment Control Panel............................................................................................5301 Video Display.........................................................................................................................5302 Video System Module...................................................................................................................5304 417-01 : Exterior Lighting....................................................................................................................5306 Specifications............................................................................................................................5306 General Procedures........................................................................................................................5307 Headlamp Adjustment (86.40.18)........................................................................................................5307 Description and Operation.................................................................................................................5308 Exterior Lighting.....................................................................................................................5308 Exterior Lighting - VIN Range: H18680->H99999.........................................................................................5309 Exterior Lighting – Armoured Vehicles.................................................................................................5313 Diagnosis and Testing.....................................................................................................................5314 Headlamps.............................................................................................................................5314 Removal and Installation..................................................................................................................5315 Approach Lamp - VIN Range: G00442->H18679.............................................................................................5315 Approach Lamp - VIN Range: H18680->H99999.............................................................................................5316 Ballast - Vehicles With: High Intensity Discharge Headlamps (86.41.52)................................................................5317 Front Fog Lamp - VIN Range: G00442->H18679 (86.40.96).................................................................................5318 Fog Lamp - VIN Range: H18680->H99999..................................................................................................5319 Headlamp Assembly (86.41.33)..........................................................................................................5321 Headlamp Bulb - Vehicles With: High Intensity Discharge Headlamps(86.42.14)...........................................................5322 Headlamp Leveling Motor (86.42.04)....................................................................................................5324 Headlamp Leveling Sensor (86.42.15)...................................................................................................5326 High Mounted Stoplamp (86.41.01)......................................................................................................5328 Stoplamp Switch.......................................................................................................................5329 Rear Lamp Assembly (86.40.70).........................................................................................................5331 417-02 : Interior Lighting....................................................................................................................5333 Description and Operation.................................................................................................................5333 Diagnosis and Testing.....................................................................................................................5334 417-04 : Daytime Running Lamps................................................................................................................5335 Description and Operation.................................................................................................................5335 Diagnosis and Testing.....................................................................................................................5337 418-00 : Module Communications Network........................................................................................................5338 Description and Operation.................................................................................................................5338 Diagnosis and Testing.....................................................................................................................5342 418-01 : Module Configuration.................................................................................................................5423 Diagnosis and Testing....................................................................................................................5423 419-01A : Anti-Theft - Active.................................................................................................................5425 Description and Operation.................................................................................................................5425 Diagnosis and Testing.....................................................................................................................5436 Removal and Installation..................................................................................................................5437 Anti-Theft Alarm Horn (86.52.03)......................................................................................................5437 419-01B : Anti-Theft - Passive................................................................................................................5439 General Procedures........................................................................................................................5439 Anti-Theft Security Access............................................................................................................5439 Key Programming Using Diagnostic Equipment............................................................................................5440 Key Programming Using Two Programmed Keys.............................................................................................5441 Description and Operation.................................................................................................................5442 Diagnosis and Testing.....................................................................................................................5444 Removal and Installation..................................................................................................................5447 Passive Anti-Theft System (PATS) Transceiver (86.52.30)...............................................................................5447 419-02 : Remote Convenience...................................................................................................................5448 General Procedures........................................................................................................................5448 Universal Transmitter Programming.....................................................................................................5448 Description and Operation.................................................................................................................5451 Universal Transmitter.................................................................................................................5451 Diagnosis and Testing.....................................................................................................................5452 Universal Transmitter.................................................................................................................5452 419-07 : Navigation System....................................................................................................................5454 Description and Operation.................................................................................................................5454 Diagnosis and Testing.....................................................................................................................5456 Removal and Installation..................................................................................................................5462 Navigation System Antenna - VIN Range: G00442->H18679 (86.62.06)......................................................................5462 Navigation System Antenna - VIN Range: H18680->H99999 (86.62.06)......................................................................5463 Navigation System Display Module (86.62.07)...........................................................................................5468 Navigation System Module (86.62.05)...................................................................................................5469 419-08 : Cellular Phone.......................................................................................................................5472 Description and Operation.................................................................................................................5472 Cellular Phone - VIN Range: G00442->G45703............................................................................................5472 Cellular Phone - VIN Range: G45704->H18679............................................................................................5474 Cellular Phone - VIN Range: H18680->H99999............................................................................................5479 Diagnosis and Testing.....................................................................................................................5485 Cellular Phone........................................................................................................................5485 Cellular Phone - Vehicles With: Bluetooth.............................................................................................5488 Removal and Installation..................................................................................................................5540 Bluetooth Module......................................................................................................................5540 Cellular Phone Antenna - Vehicles With: Corded Cellular Phone, VINRange: G00442->H18679 (86.51.17)....................................5541 Cellular Phone Antenna - Vehicles With: Cordless Cellular Phone, VINRange: G00442->H18679 (86.51.17)..................................5544 Cellular Phone Antenna - VIN Range: H18680->H99999 (86.51.17).........................................................................5546 Front Handset Holder..................................................................................................................5551 Transceiver Module....................................................................................................................5552 419-10 : Multifunction Electronic Modules.....................................................................................................5556 Specifications............................................................................................................................5556 Description and Operation.................................................................................................................5557 Module Controlled Functions...........................................................................................................5557 Diagnosis and Testing.....................................................................................................................5560 Multifunction Electronic Module.......................................................................................................5560 Removal and Installation..................................................................................................................5587 Driver Door Module (DDM) (86.80.29)...................................................................................................5587 Driver Seat Module (DSM) (86.75.28)...................................................................................................5589 Front Electronic Module (FEM) (86.80.41)..............................................................................................5590 Multifunction Voice Activated Module (86.53.13).......................................................................................5592 Rear Electronic Module (REM) (86.80.37)...............................................................................................5596 Rear Seat Module (RSM) (86.75.40).....................................................................................................5598 5. BODY AND PAINT.................................................................................................................................5600 501-02 : Front End Body Panels................................................................................................................5600 Description and Operation.................................................................................................................5600 Removal and Installation..................................................................................................................5603 Air Deflector (76.11.41)..............................................................................................................5603 Cowl Vent Screen (76.10.01)...........................................................................................................5605 Fender Splash Shield (76.10.90).......................................................................................................5606 Radiator Grille Opening Panel (76.10.06)..............................................................................................5607 Radiator Splash Shield (76.22.90).....................................................................................................5608 Secondary Bulkhead Center Panel.......................................................................................................5609 501-03 : Body Closures........................................................................................................................5624 Specifications............................................................................................................................5624 General Procedures........................................................................................................................5625 Hood Alignment (76.16.02).............................................................................................................5625 Luggage Compartment Lid Alignment (76.19.03)..........................................................................................5629 Rear Door Alignment (76.28.08)........................................................................................................5634 Description and Operation.................................................................................................................5637 Removal and Installation..................................................................................................................5638 Front Door Opening Weatherstrip (76.40.01)............................................................................................5638 Hood (76.16.01).......................................................................................................................5640 Door Check Arm – Armoured Vehicle.....................................................................................................5642 501-05 : Interior Trim and Ornamentation......................................................................................................5647 Specifications............................................................................................................................5647 Description and Operation.................................................................................................................5648 Removal and Installation..................................................................................................................5650 A-Pillar Trim Panel (76.13.31)........................................................................................................5650 B-Pillar Lower Trim Panel (76.13.29)..................................................................................................5652 B-Pillar Upper Trim Panel (76.13.28)..................................................................................................5654 Cowl Side Trim Panel (76.13.30).......................................................................................................5657 C-Pillar Lower Trim Panel.............................................................................................................5659 C-Pillar Upper Trim Panel.............................................................................................................5661 Folding Tray (76.47.31)...............................................................................................................5664 Front Door Trim Panel (76.34.01)......................................................................................................5669 Front Door Trim Panel (76.34.01) – Armoured Vehicles .................................................................................5672 Headliner (76.64.01)..................................................................................................................5675 Parcel Shelf (76.67.06)...............................................................................................................5682 Rear Door Quarter Window Blind........................................................................................................5685 Rear Door Trim Panel (76.34.04).......................................................................................................5687 Rear Door Trim Panel (76.34.04) – Armoured Vehicles ..................................................................................5691 Rear Door Window Blind................................................................................................................5694 Rear Window Blind (76.14.04)..........................................................................................................5696 Rear Window Blind Arm.................................................................................................................5698 Rear Window Blind Motor...............................................................................................................5702 Scuff Plate Trim Panel (76.13.81).....................................................................................................5706 Sun Visor (76.10.48)..................................................................................................................5707 501-08 : Exterior Trim and Ornamentation......................................................................................................5709 Description and Operation.................................................................................................................5709 Removal and Installation..................................................................................................................5710 Door Moulding (76.43.72)..............................................................................................................5710 Luggage Compartment Lid Moulding - VIN Range: G00442->H18679(76.43.79)................................................................5712 Luggage Compartment Lid Moulding - VIN Range: H18680->H99999(76.43.79)................................................................5714 Radiator Grille (76.55.03)............................................................................................................5718 Rocker Panel Moulding (76.11.36)......................................................................................................5720 Window Moulding (76.43.20)............................................................................................................5724 501-09 : Rear View Mirrors....................................................................................................................5726 Specifications............................................................................................................................5726 Description and Operation.................................................................................................................5727 Rear View Mirrors.....................................................................................................................5727 Rear View Mirrors - VIN Range: H18680->H99999.........................................................................................5728 Diagnosis and Testing.....................................................................................................................5729 Rear View Mirrors.....................................................................................................................5729 Removal and Installation..................................................................................................................5730 Auto-Dimming Interior Mirror (76.10.56)...............................................................................................5730 Exterior Mirror (76.10.52)............................................................................................................5731 Exterior Mirror Cover (76.10.55)......................................................................................................5733 Exterior Mirror Glass (76.10.53)......................................................................................................5734 Exterior Mirror Motor - VIN Range: G00442->H18679 (76.10.57)..........................................................................5735 Exterior Mirror Motor - VIN Range: H18680->H99999 (76.10.57)..........................................................................5737 501-10 : Seating..............................................................................................................................5739 Specifications............................................................................................................................5739 Description and Operation.................................................................................................................5740 Seats - VIN Range: G00442->H18679.....................................................................................................5740 Seats - VIN Range: H18680->H99999.....................................................................................................5746 Diagnosis and Testing.....................................................................................................................5762 Seats - VIN Range: G00442->H18679.....................................................................................................5762 Seats - VIN Range: H18680->H99999.....................................................................................................5778 Removal and Installation..................................................................................................................5808 Front Seat (76.70.01).................................................................................................................5808 Front Seat Backrest - VIN Range: G00442->H18679 (76.70.06)............................................................................5812 Front Seat Backrest - VIN Range: H18680->H99999 (76.70.06)............................................................................5819 Front Seat Backrest Cover - VIN Range: G00442->H18679 (76.70.15)......................................................................5827 Front Seat Backrest Cover - VIN Range: H18680->H99999 (76.70.15)......................................................................5832 Front Seat Backrest Heater and Blower Assembly........................................................................................5838 Front Seat Backrest Rear Cover - VIN Range: G00442->H18679 (76.70.03).................................................................5840 Front Seat Backrest Rear Cover - VIN Range: H18680->H99999 (76.70.03).................................................................5846 Front Seat Control Switch (86.75.46)..................................................................................................5848 Front Seat Cushion Cover - VIN Range: G00442->H18679 (76.70.33).......................................................................5849 Front Seat Cushion Cover - VIN Range: H18680->H99999 (76.70.33).......................................................................5853 Front Seat Cushion Heater and Blower Assembly.........................................................................................5856 Front Seat Head Restraint - Vehicles With: Head Restraint Video Display,VIN Range: G00442->H18679 (76.70.14)..........................5859 Front Seat Head Restraint - Vehicles With: Head Restraint Video Display,VIN Range: H18680->H99999 (76.70.14)..........................5863 Front Seat Head Restraint Motor - VIN Range: G00442->H18679(86.75.17).................................................................5865 Front Seat Head Restraint Motor - VIN Range: H18680->H99999(86.75.17).................................................................5868 Front Seat Height Adjustment Motor (86.75.29).........................................................................................5870 Front Seat Lumbar Motor (86.75.44)....................................................................................................5872 Front Seat Rear Height Adjustment Motor (86.75.32)....................................................................................5877 Front Seat Recliner Motor - VIN Range: G00442->H18679 (86.75.04)......................................................................5880 Front Seat Recliner Motor - VIN Range: H18680->H99999 (86.75.04)......................................................................5883 Front Seat Track Motor (86.75.33).....................................................................................................5885 Lumbar Assembly (86.75.12)............................................................................................................5889 Memory Seat Position Switch...........................................................................................................5891 Rear Outer Seat Backrest (76.70.76)...................................................................................................5892 Rear Outer Seat Backrest Cover (76.70.51).............................................................................................5894 Rear Outer Seat Cushion (76.70.44)....................................................................................................5897 Rear Seat Armrest (76.70.39)..........................................................................................................5898 Rear Seat Backrest (76.70.38).........................................................................................................5899 Rear Seat Backrest Cover (76.70.48)...................................................................................................5901 Rear Seat Control Switch (86.75.42)...................................................................................................5904 Rear Seat Cushion (76.70.37)..........................................................................................................5905 Rear Seat Cushion Cover (76.70.47)....................................................................................................5907 Rear Seat Head Restraint Motor (86.75.41).............................................................................................5909 Rear Seat Lumbar Motor (86.75.43).....................................................................................................5911 Seat Armrest (76.70.97)...............................................................................................................5914 Seat Base (76.70.08)..................................................................................................................5915 Assembly & Disassembly....................................................................................................................5921 Rear Seat Backrest - Vehicles With: 40/20/40 Split Seat (76.70.48)....................................................................5921 501-11 : Glass, Frames and Mechanisms.........................................................................................................5925 Specifications............................................................................................................................5925 General Procedures........................................................................................................................5926 Door Window Motor Initialization......................................................................................................5926 Description and Operation.................................................................................................................5927 Glass, Frames and Mechanisms..........................................................................................................5927 Glass, Frames and Mechanisms – Armoured Vehicles......................................................................................5928 Diagnosis and Testing.....................................................................................................................5929 Removal and Installation..................................................................................................................5929 Front Door Window Glass (76.31.01)....................................................................................................5929 Front Door Window Glass (76.31.01) – Armoured Vehicles ...............................................................................5933 Front Door Window Regulator and Motor (86.25.04)......................................................................................5941 Front Door Window Regulator and Motor (86.25.04) – Armoured Vehicles ................................................................5943 Rear Door Fixed Window Glass..........................................................................................................5953 Rear Door Window Glass (76.31.02).....................................................................................................5960 Rear Door Window Glass (76.31.02) – Armoured Vehicles ................................................................................5962 Rear Door Window Regulator and Motor (86.25.09).......................................................................................5972 Rear Window Glass (76.81.11)..........................................................................................................5976 Rear Window Glass (76.81.11) – Armoured Vehicles .....................................................................................5986 Window Control Switch (86.25.08)......................................................................................................6001 Windshield Glass (76.81.40)...........................................................................................................6002 Windshield Glass (76.81.40) – Armoured Vehicles ......................................................................................6014 501-12 : Instrument Panel and Console.........................................................................................................6024 Specifications............................................................................................................................6024 Description and Operation.................................................................................................................6025 Removal and Installation..................................................................................................................6026 Floor Console - Vehicles With: Auxiliary Climate Control (76.25.01)...................................................................6026 Floor Console - Vehicles Without: Auxiliary Climate Control (76.25.01)................................................................6032 Glove Compartment (76.52.03)..........................................................................................................6041 Instrument Panel (76.46.01)...........................................................................................................6044 Instrument Panel Console (88.20.34)...................................................................................................6057 Overhead Console (76.13.69)...........................................................................................................6059 501-14 : Handles, Locks, Latches and Entry Systems............................................................................................6062 Specifications............................................................................................................................6062 General Procedures........................................................................................................................6063 Remote Transmitter Programming........................................................................................................6063 Description and Operation.................................................................................................................6065 Handles, Locks, Latches and Entry Systems.............................................................................................6065 Diagnosis and Testing.....................................................................................................................6071 Locks, Latches and Entry Systems......................................................................................................6071 Removal and Installation..................................................................................................................6072 Exterior Door Handle (76.58.07).......................................................................................................6072 Front Door Lock Actuator (76.37.74)...................................................................................................6075 Front Door Lock Cylinder (76.37.71)...................................................................................................6079 Interior Door Handle (76.37.31).......................................................................................................6084 Luggage Compartment Lid Latch Actuator - VIN Range: G00442->H18679(76.19.25)..........................................................6085 Luggage Compartment Lid Latch Actuator - VIN Range: H18680->H99999(76.19.25)..........................................................6089 Luggage Compartment Lid Lock Cylinder - VIN Range: G00442->H18679(76.19.19)...........................................................6093 Luggage Compartment Lid Lock Cylinder - VIN Range: H18680->H99999(76.19.19)...........................................................6097 Rear Door Lock Actuator (76.37.09)....................................................................................................6101 501-16 : Wipers and Washers...................................................................................................................6104 Specifications............................................................................................................................6104 Description and Operation.................................................................................................................6106 Wipers and Washers - VIN Range: G00442->G45703........................................................................................6106 Wipers and Washers - VIN Range: G45704->G99999........................................................................................6108 Diagnosis and Testing.....................................................................................................................6110 Removal and Installation..................................................................................................................6111 Headlamp Washer Jet (84.20.08)........................................................................................................6111 Headlamp Washer Pump - VIN Range: G00442->G45703 (84.20.21)...........................................................................6112 Headlamp Washer Pump - VIN Range: G45704->G99999 (84.20.21)...........................................................................6114 Rain Sensor (84.12.10)................................................................................................................6118 Windshield Washer Pump - VIN Range: G00442->G45703 (84.10.21).........................................................................6119 Windshield Washer Pump - VIN Range: G45704->G99999 (84.10.21).........................................................................6120 Windshield Washer Reservoir - VIN Range: G00442->G45703 (84.10.01)....................................................................6124 Windshield Washer Reservoir - VIN Range: G45704->G99999 (84.10.01)....................................................................6127 Windshield Wiper Motor (84.15.13).....................................................................................................6131 Wiper Mounting Arm and Pivot Shaft (84.15.24).........................................................................................6132 Wiper Pivot Arm (84.15.03)............................................................................................................6138 501-17 : Roof Opening Panel...................................................................................................................6142 Specifications............................................................................................................................6142 General Procedures........................................................................................................................6143 Motor Synchronization (76.82.48)......................................................................................................6143 Roof Opening Panel Alignment..........................................................................................................6145 Description and Operation.................................................................................................................6148 Diagnosis and Testing.....................................................................................................................6151 Removal and Installation..................................................................................................................6160 Air Deflector (76.82.07)..............................................................................................................6160 Roof Opening Panel Frame (76.82.01)...................................................................................................6161 Roof Opening Panel Front Drain Hose (76.82.21)........................................................................................6175 Roof Opening Panel Glass (76.82.05)...................................................................................................6180 Roof Opening Panel Motor (86.76.01)...................................................................................................6184 Roof Opening Panel Weatherstrip (76.82.15)............................................................................................6186 Trough Assembly (76.82.58)............................................................................................................6188 501-19 : Bumpers..............................................................................................................................6190 Specifications............................................................................................................................6190 Description and Operation.................................................................................................................6191 Removal and Installation..................................................................................................................6192 Front Bumper (76.22.08)...............................................................................................................6192 Front Bumper Cover - VIN Range: G00442->H18679 (76.22.78).............................................................................6193 Front Bumper Cover - VIN Range: H18680->H99999 (76.22.78).............................................................................6200 Front Bumper Cover Insert (76.22.73)..................................................................................................6207 Rear Bumper (76.22.27)................................................................................................................6209 Rear Bumper Cover - VIN Range: G00442->H18679 (76.22.74)..............................................................................6211 Rear Bumper Cover - VIN Range: H18680->H99999 (76.22.74)..............................................................................6215 Rear Bumper Cover Insert (76.22.75)...................................................................................................6220 501-20A : Safety Belt System..................................................................................................................6221 Specifications............................................................................................................................6221 Description and Operation.................................................................................................................6222 Diagnosis and Testing.....................................................................................................................6225 Removal and Installation..................................................................................................................6229 Front Safety Belt Buckle (76.73.49)...................................................................................................6229 Front Safety Belt Retractor (76.73.10)................................................................................................6231 Front Safety Belt Shoulder Height Adjuster (76.73.12).................................................................................6234 Rear Center Safety Belt Retractor (76.73.20)..........................................................................................6236 Rear Safety Belt Buckle (76.73.50)....................................................................................................6239 Rear Safety Belt Retractor (76.73.18).................................................................................................6241 501-20B : Supplemental Restraint System.......................................................................................................6243 Specifications............................................................................................................................6243 General Procedures........................................................................................................................6244 Air Bag Disposal......................................................................................................................6244 Description and Operation.................................................................................................................6250 Air Bag Supplemental Restraint System (SRS)...........................................................................................6250 Diagnosis and Testing.....................................................................................................................6260 Air Bag Supplemental Restraint System (SRS)...........................................................................................6260 Removal and Installation..................................................................................................................6334 B-Pillar Side Impact Sensor (76.73.68)................................................................................................6334 Clockspring (86.65.92)................................................................................................................6337 C-Pillar Side Impact Sensor (76.73.69)................................................................................................6341 Crash Sensor (76.73.55)...............................................................................................................6343 Driver Air Bag Module (76.73.39)......................................................................................................6345 Front Passenger Seat Occupant Classification Sensor (76.73.60)........................................................................6349 Passenger Air Bag Deactivation (PAD) Indicator (76.73.58).............................................................................6353 Passenger Air Bag Module (76.73.37)...................................................................................................6355 Restraints Control Module (RCM) (76.73.48)............................................................................................6360 Seat Position Sensor (76.73.62).......................................................................................................6365 Side Air Bag Module (76.73.47)........................................................................................................6367 Side Air Curtain Module (76.73.64)....................................................................................................6373 502-00 : Uni-Body, Subframe and Mounting System...............................................................................................6382 Specifications............................................................................................................................6382 Description and Operation.................................................................................................................6383 Frame Assembly........................................................................................................................6383 Removal and Installation..................................................................................................................6385 Front Subframe - 3.0L NA V6 - AJ27 (76.10.05).........................................................................................6385 Front Subframe - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L NA V8 - AJV8 (76.10.05).....................................................6408 Front Subframe - 2.7L V6 - TdV6 (76.10.05)............................................................................................6427 Front Subframe Front Bushing (60.35.51)...............................................................................................6449 Front Subframe Rear Bushing (60.35.26)................................................................................................6452 Rear Subframe (64.25.01)..............................................................................................................6455 Rear Subframe Front Bushing (64.25.34)................................................................................................6466 Rear Subframe Rear Bushing (64.25.36).................................................................................................6469
2003-09 JAGUAR XJ WORKSHOP MANUAL – PDF DOWNLOAD:
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