Jaguar X-Type 2.0 L 2.5 L & 3.0 L Gasoline 2.0 L & 2.2 L Diesel Workshop Manual PDF

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Jaguar X-Type Sedan and Estate (Wagon) 2.0 L 2.5 L & 3.0 L Gasoline 2.0 L & 2.2 L Diesel Workshop Manual – PDF DOWNLOAD

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Jaguar X-Type Sedan and Estate (Wagon) 2.0 L 2.5 L & 3.0 L Gasoline 2.0 L & 2.2 L Diesel Workshop Manual – PDF DOWNLOAD

Language : English
Pages : 2810
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Jaguar X-Type Sedan and Estate (Wagon) 2.0 L 2.5 L & 3.0 L Gasoline 2.0 L & 2.2 L Diesel Workshop Manual – PDF DOWNLOAD

Front Page 1
TABLE OF CONTENTS 2
1: General Information 46
100: Service Information 48
100-00: General Information 48
Description and Operation 48
About This Manual 46
Application and Use of Specifications 47
General Service Information 48
Health and Safety Precautions 56
How To Use This Manual 66
Important Safety Instructions 67
Road/Roller Testing 68
Solvents, Sealants and Adhesives 70
Standard Workshop Practices 71
100-01: Identification Codes 72
Description and Operation 72
Identification Codes 72
100-02: Jacking and Lifting 78
Description and Operation 78
Jacking 78
Lifting 79
100-04: Noise, Vibration and Harshness 82
Description and Operation 82
Noise, Vibration and Harshness (NVH) 82
Diagnosis and Testing 83
Noise, Vibration and Harshness (NVH) 83
General Procedures 88
Exhaust System Neutralizing 88
2: Chassis 89
204: Suspension 89
204-00: Suspension System – General Information 89
Specification 89
Description and Operation 90
Wheel Alignment Angles 90
Diagnosis and Testing 93
Suspension System 93
General Procedures 95
Front Toe Adjustment (576501) 95
Rear Toe Adjustment (576508) 97
Wheel Bearing Inspection 99
204-01: Front Suspension 100
Specification 100
Description and Operation 101
Front Suspension 101
Diagnosis and Testing 103
Front Suspension 103
Removal and Installation 104
Lower Arm (603502) 104
Shock Absorber and Spring Assembly (603002) 113
Front Stabilizer Bar (601001) 122
Front Stabilizer Bar Bushing (601004) 124
Front Wheel Bearing and Wheel Hub (602503) 130
Wheel Knuckle (602523) 133
Disassembly and Assembly 139
Shock Absorber and Spring Assembly (603021) 139
204-02: Rear Suspension 141
Specification 141
Description and Operation 142
Rear Suspension 142
Diagnosis and Testing 144
Rear Suspension 144
Removal and Installation 145
Damper 145
Front Lower Arm (643551) – 4-Door 147
Front Lower Arm (643551) – Wagon 149
Rear Lower Arm (643552) 154
Spring (642001) 157
Rear Stabilizer Bar (643508) 160
Rear Stabilizer Bar Link (643524) 161
Upper Arm (642531) 162
Wheel Hub (641514) 164
Wheel Knuckle (641522) 167
Wheel Knuckle Front Bushing (641528) 173
Wheel Knuckle Rear Bushing (641530) 174
204-04: Wheels and Tires 177
Specification 177
Description and Operation 178
Safety Precautions 178
Wheels and Tires 178
Diagnosis and Testing 184
Wheels and Tires 184
Removal and Installation 187
Tire Low Pressure Sensor – VIN Range: J28493->V99999 187
Tire Pressure Monitoring System (TPMS) Front Antenna – VIN Range: J28493->V99999 189
Tire Pressure Monitoring System (TPMS) Main Antenna – VIN Range: J28493->V99999 190
Tire Pressure Monitoring System (TPMS) Module – VIN Range: J28493->V99999 192
Tire Pressure Monitoring System (TPMS) Rear Antenna – VIN Range: J28493->V99999 194
Wheel and Tire (742005) 195
205: Driveline 196
205-00: Driveline System – General Information 196
Description and Operation 196
Driveline System 196
Diagnosis and Testing 197
Driveline System 197
205-01: Driveshaft 199
Specification 199
Description and Operation 200
Driveshaft 200
Diagnosis and Testing 201
Driveshaft 201
General Procedures 202
Driveshaft Runout and Balancing 202
Removal and Installation 203
Driveshaft (471501) 203
205-02: Rear Drive Axle/Differential 205
Specification 205
Description and Operation 206
Rear Drive Axle and Differential 206
Diagnosis and Testing 207
Rear Drive Axle and Differential 207
In-Vehicle Repair 208
Axle Shaft Seal (512004) (512036) 208
Drive Pinion Flange 209
Drive Pinion Seal (512001) 214
Removal and Installation 219
Axle Assembly (512513) 219
205-04: Front Drive Halfshafts 224
Specification 224
Description and Operation 225
Front Drive Halfshafts 225
Diagnosis and Testing 226
Front Drive Halfshafts 226
Removal and Installation 227
Front Halfshaft LH (471015) 227
Front Halfshaft RH (471016) – 20L NA V6 – AJV6/25L NA V6 – AJV6/30L NAV6 – AJ27 233
Front Halfshaft RH (471016) – 20L Duratorq-TDCi/22L Duratorq-TDCi(110kW/150PS) – Puma 241
Inner Constant Velocity (CV) Joint Boot (471018) 246
Intermediate Shaft 249
Outer Constant Velocity (CV) Joint Boot (471019) 251
205-05: Rear Drive Halfshafts 253
Specification 253
Description and Operation 254
Rear Drive Halfshafts 254
Diagnosis and Testing 255
Rear Drive Halfshafts 255
Removal and Installation 256
Rear Halfshaft (471013) 256
Outer Constant Velocity (CV) Joint Boot (471032) 258
206: Brake System 260
206-00: Brake System – General Information 260
Specification 260
Description and Operation 261
Brake System 261
Diagnosis and Testing 262
Brake System 262
General Procedures 270
Brake Disc Runout Check 270
Brake System Bleeding (702503) 271
206-03: Front Disc Brake 273
Specification 273
Description and Operation 274
Front Disc Brake 274
Diagnosis and Testing 275
Front Disc Brake 275
Removal and Installation 276
Brake Caliper (705502) 276
Brake Disc (701010) 278
Brake Pads (704002) 279
206-04: Rear Disc Brake 281
Specification 281
Description and Operation 282
Rear Disc Brake 282
Diagnosis and Testing 283
Rear Disc Brake 283
Removal and Installation 284
Brake Caliper (705503) (705525) 284
Brake Disc (701011) 287
Brake Disc Shield (701019) 288
Brake Pads (704003) 289
206-05: Parking Brake and Actuation 292
Specification 292
Description and Operation 293
Parking Brake 293
Diagnosis and Testing 294
Parking Brake 294
Removal and Installation 296
Parking Brake Cable (703529) – Vehicles With: Manually Adjusted Parking Brake 296
Parking Brake Cable (703529) – Vehicles With: Self-Adjusting Parking Brake 298
Parking Brake Control (703508) – Vehicles With: Manually Adjusted ParkingBrake 300
Parking Brake Control (703508) – Vehicles With: Self-Adjusting Parking Brake 302
206-06: Hydraulic Brake Actuation 305
Specification 305
Description and Operation 306
Hydraulic Brake Actuation 306
Diagnosis and Testing 307
Hydraulic Brake Actuation 307
Removal and Installation 308
Brake Fluid Reservoir (703016) 308
Brake Master Cylinder (703008) 311
Brake Pedal and Bracket (703503) 316
Brake Pedal Cross-Shaft 326
206-07: Power Brake Actuation 347
Specification 347
Description and Operation 348
Brake Booster 348
Diagnosis and Testing 349
Power Brake System 349
Removal and Installation 350
Brake Booster (705017) – LHD AWD/LHD FWD 350
Brake Booster (705017) – RHD AWD/RHD FWD 360
Brake Vacuum Pump – 20L NA V6 – AJV6 371
Brake Vacuum Pump – 20L Duratorq-TDCi/22L Duratorq-TDCi (110kW/150PS)– Puma 372
206-09: Anti-Lock Control – Stability Assist 375
Specification 375
Description and Operation 376
Anti-Lock Control – Stability Assist 376
Diagnosis and Testing 378
Anti-Lock Control – Stability Assist – VIN Range: C00344->J12991 378
Anti-Lock Control – Stability Assist – VIN Range: J12992->V99999 387
Removal and Installation 396
Anti-Lock Brake System (ABS) Module (706002) – VIN Range: C00001->J12991 396
Front Wheel Speed Sensor (706003) 397
Hydraulic Control Unit (HCU) (706018) (706019) – VIN Range: C00001->J12991 398
Hydraulic Control Unit (HCU) (706018) (706019) – VIN Range: J12992->V99999 400
Rear Wheel Speed Sensor (706004) 402
Stability Assist Module 404
Steering Wheel Rotation Sensor (865658) 405
Yaw Rate Sensor (865657) – 20L Duratorq-TDCi/20L NA V6 – AJV6/25L NA V6 –AJV6/30L NA V6 – AJ27 406
Yaw Rate Sensor (865657) – 22L Duratorq-TDCi (110kW/150PS) – Puma 407
211: Steering System 409
211-00: Steering System – General Information 409
Specification 409
Description and Operation 410
Steering System 410
Diagnosis and Testing 411
Steering System 411
General Procedures 423
Power Steering System Filling 423
Power Steering System Flushing (571508) 424
211-02: Power Steering 427
Specification 427
Description and Operation 428
Power Steering 428
Diagnosis and Testing 429
Power Steering 429
General Procedures 430
Start Up Procedure After Power Steering Pump/Gear Overhaul 430
Removal and Installation 431
Power Steering Control Valve Actuator (571032) – 25L NA V6 – AJV6/30L NAV6 – AJ27 431
Power Steering Fluid Cooler (571511) – 20L Duratorq-TDCi 433
Power Steering Fluid Cooler (571511) – 22L Duratorq-TDCi (110kW/150PS) –Puma 434
Power Steering Fluid Reservoir (571508) 436
Power Steering Pump (572014) – 20L NA V6 – AJV6/25L NA V6 – AJV6/30L NAV6 – AJ27 437
Power Steering Pump (572014) – 20L Duratorq-TDCi/22L Duratorq-TDCi(110kW/150PS) – Puma 439
Steering Gear (571001) – 20L Duratorq-TDCi/22L Duratorq-TDCi(110kW/150PS) – Puma 446
Steering Gear (571001) – 20L NA V6 – AJV6/25L NA V6 – AJV6/30L NA V6 –AJ27 451
211-03: Steering Linkage 463
Specification 463
Description and Operation 464
Steering Linkage 464
Diagnosis and Testing 465
Steering Linkage 465
Removal and Installation 466
Steering Gear Boot (571029) 466
Tie Rod End (575502) 467
211-04: Steering Column 469
Specification 469
Description and Operation 470
Steering Column 470
Diagnosis and Testing 471
Steering Column 471
Removal and Installation 472
Ignition Switch Lock Cylinder (574029) 472
Steering Column (574001) 473
Steering Column Coupling 476
Steering Wheel (576001) 477
211-05: Steering Column Switches 478
Description and Operation 478
Steering Column Switches 478
Diagnosis and Testing 479
Steering Column Switches 479
Removal and Installation 480
Steering Column Multifunction Switch LH (866578) 480
Steering Column Multifunction Switch RH (866541) 482
3: Powertrain 483
303: Engine 483
303-00: Engine System – General Information 483
Specification 483
Description and Operation 486
Engine 486
Diagnosis and Testing 487
Engine 487
General Procedures 492
Bearing Inspection 492
Camshaft Bearing Journal Clearance 493
Camshaft Bearing Journal Diameter 494
Camshaft End Play 495
Camshaft Lobe Lift 496
Camshaft Surface Inspection 497
Connecting Rod Cleaning 498
Connecting Rod Large End Bore 499
Crankshaft End Play 500
Crankshaft Main Bearing Journal Clearance 501
Crankshaft Main Bearing Journal Diameter 503
Cylinder Block Distortion 504
Cylinder Bore Out-of-Round 505
Cylinder Head Distortion 506
Exhaust Manifold Cleaning and Inspection 507
Flywheel Inspection 508
Piston Diameter 509
Piston Inspection 510
Piston Pin Diameter 511
Piston Pin to Bore Diameter 512
Piston Ring End Gap 513
Piston Ring-to-Groove Clearance 514
Valve Seat Inspection 515
Valve Spring Free Length 516
Valve Stem Diameter 517
Leakage Test Using Smoke Test Equipment 518
303-01A: Engine – 20L NA V6 – AJV6/25L NA V6 – AJV6/30L NA V6 – AJ27 520
Specification 520
Description and Operation 522
Engine 522
Diagnosis and Testing 525
Engine 525
General Procedures 526
Valve Clearance Adjustment (122948) 526
Valve Clearance Check (122947) 527
In-Vehicle Repair 528
Camshafts LH (121319) 528
Crankshaft Front Seal (122114) 529
Crankshaft Pulley (122109) 530
Crankshaft Rear Seal (122120) 534
Cylinder Head LH (122902) 536
Engine Front Cover (126501) 542
Engine Front Mount (124501) 564
Exhaust Manifold LH (301555) 568
Flexplate (125313) 575
Exhaust Manifold RH (301556) 576
Flywheel (125307) 578
Intake Manifold (301501) 579
Lower Intake Manifold (301561) 591
Oil Cooler (126068) 595
Oil Pan (126044) 596
Oil Pressure Sender 602
Oil Pump (126026) 603
Timing Drive Components (126513) 605
Valve Cover LH (122943) 614
Valve Cover RH (122944) 617
Removal 619
Engine (124101) – Vehicles With: 5-Speed Manual Transmission – MT75/6-Speed Manual Transaxle – MMT6 619
Engine (124101) – Vehicles With: 5-Speed Automatic Transaxle – JATCO/6-SpeedAutomatic Transaxle – AWF21 643
Disassembly 668
Engine 668
Disassembly and Assembly of Subassemblies 688
Cylinder Head (122922) 688
Piston (121702) 691
Assembly 694
Engine 694
Installation 720
Vehicles With: 5-Speed Manual Transmission – MT75/6-Speed Manual Transaxle – MMT6 720
EngineVehiclesWith: 5-Speed Automatic Transaxle – JATCO/6-Speed Automatic Transaxle – AWF21 743
303-01B: Engine – 20L Duratorq-TDCi/22L Duratorq-TDCi (110kW/150PS) – Puma 766
Specification 766
Description and Operation 767
Engine 767
In-Vehicle Repair 773
Crankshaft Front Seal (122114) 773
Crankshaft Rear Seal (122120) 776
Engine Front Cover (126501) 778
Engine Front Mount (124501) 787
Flexplate (125313) 794
Flywheel (125307) 795
Intake Manifold (301501) 796
Oil Pan (126044) 798
Timing Chain 800
Valve Cover 806
Removal 817
Engine (124101) – 20L Duratorq-TDCi 817
Engine (124101) – 22L Duratorq-TDCi (110kW/150PS) – Puma 838
Disassembly 860
Engine 860
Assembly 888
Engine 888
Installation 928
Engine (124101) – 20L Duratorq-TDCi 928
Engine (124101) – 22L Duratorq-TDCi (110kW/150PS) – Puma 947
303-03A: Engine Cooling – 20L NA V6 – AJV6/25L NA V6 – AJV6/30L NA V6 – AJ27 968
Specification 968
Description and Operation 969
Engine Cooling 969
Diagnosis and Testing 973
Engine Cooling 973
General Procedures 979
Cooling System Backflushing 979
Cooling System Draining, Filling and Bleeding 980
Cooling System Flushing 983
Removal and Installation 984
Block Heater (866218) 984
Coolant Expansion Tank (261501) 985
Cooling Fan Module (262538) 987
Cooling Fan Motor (262524) 989
Cooling Fan Motor and Shroud (262525) 990
Cooling Module (264016) 993
Radiator (264001)1004
Thermostat (264507)1005
Water Pump (265001)1006
Water Pump Housing (265007)1007
303-03B: Engine Cooling – 20L Duratorq-TDCi/22L Duratorq-TDCi (110kW/150PS) –Puma1010
Specification1010
Description and Operation1011
Engine Cooling1011
General Procedures1014
Cooling System Draining, Filling and Bleeding1014
Cooling System Draining and Vacuum Filling1017
Removal and Installation1021
Cooling Fan Motor and Shroud (262525)1021
Cooling Module (264016)1022
Radiator (264001)1026
Water Pump (265001)1027
303-04A: Fuel Charging and Controls – 20L NA V6 – AJV6/25L NA V6 – AJV6/30L NAV6 – AJ271034
Specification1034
Description and Operation1035
Fuel Charging and Controls1035
Diagnosis and Testing1037
Fuel Charging and Controls – 20L NA V6 – AJV61037
Fuel Charging and Controls – 25L NA V6 – AJV6/30L NA V6 – AJ27, VIN Range:E96603->J284921038
Fuel Charging and Controls – 25L NA V6 – AJV6/30L NA V6 – AJ27, VIN Range:J28493->V999991045
Removal and Installation1052
Fuel Charging Wiring Harness (867022)1052
Fuel Injection Supply Manifold (196013)1055
Fuel Injectors (181002)1058
Fuel Pulse Damper (183098) – 25L NA V6 – AJV6/30L NA V6 – AJ271060
Throttle Body (197004)1061
303-04B: Fuel Charging and Controls – 20L Duratorq-TDCi/22L Duratorq-TDCi(110kW/150PS) – Puma1065
Specification1065
Description and Operation1066
Fuel Charging and Controls1066
Diagnosis and Testing1069
Fuel Charging and Controls1069
General Procedures1073
Fuel Injection Component Cleaning1073
Removal and Installation1074
Fuel Injection Pump1074
Fuel Injection Supply Manifold (196013)1099
Fuel Injector (181001)1110
Fuel Metering Valve1119
Fuel Return Line Venturi1122
303-04C: Fuel Charging and Controls – Turbocharger1126
Specification1126
Description and Operation1127
Turbocharger1127
Diagnosis and Testing1131
Turbocharger1131
Removal and Installation1137
Turbocharger1137
303-05: Accessory Drive1150
Specification1150
Description and Operation1151
Accessory Drive1151
Diagnosis and Testing1154
Accessory Drive1154
Removal and Installation1155
Accessory Drive Belt (121040) – 20L Duratorq-TDCi/22L Duratorq-TDCi(110kW/150PS) – Puma1155
Accessory Drive Belt (121040) – 20L NA V6 – AJV6/25L NA V6 – AJV6/30L NAV6 – AJ271159
Accessory Drive Belt Tensioner (121041) – 20L Duratorq-TDCi/22L Duratorq-TDCi (110kW/150PS) – Puma1161
Accessory Drive Belt Tensioner (121041) – 20L NA V6 – AJV6/25L NA V6 –AJV6/30L NA V6 – AJ271166
Power Steering Pump Belt – 20L Duratorq-TDCi/22L Duratorq-TDCi(110kW/150PS) – Puma1167
Power Steering Pump Belt Tensioner – 20L Duratorq-TDCi/22L Duratorq-TDCi(110kW/150PS) – Puma1171
Water Pump Belt (121044) – 20L NA V6 – AJV6/25L NA V6 – AJV6/30L NA V6 –AJ271173
Water Pump Belt Tensioner (121045) – 20L NA V6 – AJV6/25L NA V6 –AJV6/30L NA V6 – AJ271174
303-06: Starting System1175
Specification1175
Description and Operation1176
Starting System1176
Diagnosis and Testing1179
Starting System – 20L NA V6 – AJV61179
Starting System – 25L NA V6 – AJV6/30L NA V6 – AJ271180
Removal and Installation1184
Starter Motor (866001) – 20L Duratorq-TDCi1184
Starter Motor (866001) – 22L Duratorq-TDCi (110kW/150PS) – Puma1188
Starter Motor (866001) – 20L NA V6 – AJV6/25L NA V6 – AJV6/30L NA V6 –AJ271192
303-07A: Engine Ignition – 20L NA V6 – AJV6/25L NA V6 – AJV6/30L NA V6 – AJ271197
Specification1197
Description and Operation1198
Engine Ignition1198
Diagnosis and Testing1199
Engine Ignition – 20L NA V6 – AJV61199
Engine Ignition – 25L NA V6 – AJV6/30L NA V6 – AJ271200
Removal and Installation1204
Ignition Coil-On-Plug LH (182044)1204
Ignition Coil-On-Plug RH (182043)1205
303-07B: Glow Plug System1206
Specification1206
Description and Operation1207
Glow Plug System1207
Diagnosis and Testing1209
Glow Plug System1209
Removal and Installation1213
Glow Plugs1213
303-08: Engine Emission Control – 20L Duratorq-TDCi/22L Duratorq-TDCi(110kW/150PS) – Puma1215
Specification1215
Description and Operation1216
Engine Emission Control1216
Diagnosis and Testing1217
Engine Emission Control1217
Removal and Installation1218
Exhaust Gas Recirculation (EGR) Cooler1218
Exhaust Gas Recirculation (EGR) Cooler to EGR Valve Tube1222
Exhaust Gas Recirculation (EGR) Valve (174501)1226
303-12A: Intake Air Distribution and Filtering – 20L NA V6 – AJV6/25L NA V6 –AJV6/30L NA V6 – AJ271230
Description and Operation1230
Intake Air Distribution and Filtering1230
Diagnosis and Testing1231
Intake Air Distribution and Filtering1231
Removal and Installation1232
Air Cleaner (191005)1232
Air Cleaner Element (191008)1233
Air Cleaner Outlet Pipe (191031)1235
303-12B: Intake Air Distribution and Filtering – 20L Duratorq-TDCi/22L Duratorq-TDCi (110kW/150PS) – Puma1236
Specification1236
Description and Operation1237
Intake Air Distribution and Filtering1237
Diagnosis and Testing1239
Intake Air Distribution and Filtering1239
Removal and Installation1240
Air Cleaner (191005)1240
Air Cleaner Element (191008)1243
Air Cleaner Outlet Pipe (191031)1245
Charge Air Cooler – 20L Duratorq-TDCi1248
Charge Air Cooler – 22L Duratorq-TDCi (110kW/150PS) – Puma1251
303-13: Evaporative Emissions1253
Specification1253
Description and Operation1254
Evaporative Emissions1254
Diagnosis and Testing1255
Evaporative Emissions – 20L NA V6 – AJV61255
Evaporative Emissions – 25L NA V6 – AJV6/30L NA V6 – AJ271256
Removal and Installation1263
Evaporative Emission Canister (171513) – 20L NA V6 – AJV61263
Evaporative Emission Canister (171513) – 25L NA V6 – AJV6/30L NA V6 – AJ271265
Evaporative Emission Canister Purge Valve (171530)1273
303-14A: Electronic Engine Controls – 20L NA V6 – AJV6/25L NA V6 – AJV6/30L NAV6 – AJ271275
Specification1275
Description and Operation1276
Electronic Engine Controls1276
Diagnosis and Testing1282
Electronic Engine Controls – 20L NA V6 – AJV61282
Electronic Engine Controls – 25L NA V6 – AJV6/30L NA V6 – AJ27, VIN Range:E96603->J284921286
Electronic Engine Controls – 25L NA V6 – AJV6/30L NA V6 – AJ27, VIN Range:J28493->V999991316
General Procedures1347
Powertrain Control Module (PCM) Long Drive Cycle Self-Test1347
Powertrain Control Module (PCM) Short Drive Cycle Self-Test1348
Removal and Installation1349
Camshaft Position (CMP) Sensor (183063)1349
Catalyst Monitor Sensor LH (183081)1350
Catalyst Monitor Sensor RH (183080)1352
Crankshaft Position (CKP) Sensor (183012)1354
Engine Control Module (ECM) (183001)1355
Fuel Temperature Sensor (183099) – 25L NA V6 – AJV6/30L NA V6 – AJ271357
Heated Oxygen Sensor (HO2S) LH (183079)1359
Heated Oxygen Sensor (HO2S) RH (183078)1360
Knock Sensor (KS) (183069)1361
Mass Air Flow (MAF) Sensor (183015)1365
Oil Temperature Sensor (183101)1366
Throttle Position (TP) Sensor (183017)1367
Variable Camshaft Timing (VCT) Oil Control Solenoid (183090)1369
303-14B: Electronic Engine Controls – 20L Duratorq-TDCi/22L Duratorq-TDCi(110kW/150PS) – Puma1370
Specification1370
Description and Operation1371
Electronic Engine Controls1371
Diagnosis and Testing1373
Electronic Engine Controls1373
Removal and Installation1386
Camshaft Position (CMP) Sensor (183063)1386
Catalytic Converter Temperature Sensor1387
Crankshaft Position (CKP) Sensor (183012)1391
Cylinder Head Temperature (CHT) Sensor (183097)1393
Diesel Particulate Filter (DPF) Temperature Sensor1396
Engine Control Module (ECM) (183001)1397
Engine Oil Pressure (EOP) Sensor1399
Fuel Temperature Sensor (183099)1400
Knock Sensor (KS) (183069)1402
Manifold Absolute Pressure and Temperature (MAPT) Sensor1404
Manifold Absolute Pressure (MAP) Sensor (183086)1408
Mass Air Flow (MAF) Sensor (183015)1410
307: Automatic Transmission/Transaxle1412
307-01A: Automatic Transmission/Transaxle – Vehicles With: 5-Speed AutomaticTransaxle – JATCO1412
Specification1412
Description and Operation1413
Transmission Description – Vehicles With: 5-Speed Automatic Transaxle – JATCO1413
Diagnosis and Testing1428
Diagnostic Strategy – Vehicles With: 5-Speed Automatic Transaxle – JATCO1428
General Procedures1441
Transmission Fluid Drain and Refill (442402)1441
Transmission Fluid Level Check1442
Transmission Range (TR) Sensor Adjustment (441537)1444
In-Vehicle Repair1445
Halfshaft Seal LH (372310)1445
Halfshaft Seal RH1446
Main Control Valve Body (444001)1447
Shift Solenoids (SS) (441550)1451
Transaxle Support Insulator (371642)1452
Transmission Control Module (TCM) (441532)1456
Transmission Range (TR) Sensor1459
Removal1460
Transaxle (442001)1460
Disassembly and Assembly of Subassemblies1471
Input Shaft Seal (443207)1471
Installation1473
Transaxle (442001)1473
307-01B: Automatic Transmission/Transaxle – Vehicles With: 6-Speed AutomaticTransaxle – AWF211484
Specification1484
Description and Operation1485
Transmission Description – Vehicles With: 6-Speed Automatic Transaxle – AWF211485
Transmission Electronic Control System – Vehicles With: 6-Speed Automatic1497
Diagnosis and Testing1501
Diagnostic Strategy – Vehicles With: 6-Speed Automatic Transaxle – AWF211501
General Procedures1513
Transmission Fluid Drain and Refill (442402)1513
Transmission Fluid Level Check1516
In-Vehicle Repair1518
Main Control Valve Body (444001)1518
Selector Shaft Seal1522
Transmission Control Module (TCM) (441532)1523
Transmission Internal Wiring Harness (441535)1525
Transmission Fluid Pan (442404)1527
Removal and Installation1529
Torque Converter1529
Torque Converter Seal1530
Turbine Shaft Speed (TSS) Sensor1531
Removal1532
Transmission (442001)1532
Installation1539
Transmission (442001)1539
307-02A: Transmission/Transaxle Cooling – Vehicles With: 5-Speed AutomaticTransaxle – JATCO1546
Specification1546
Description and Operation1547
Transmission Cooling – Vehicles With: 5-Speed Automatic Transaxle – JATCO1547
Diagnosis and Testing1548
Transmission Cooling1548
Removal and Installation1549
Transmission Fluid Cooler (442410)1549
Transmission Fluid Cooler Tubes (442419)1551
307-02B: Transmission/Transaxle Cooling – Vehicles With: 6-Speed AutomaticTransaxle – AWF211552
Specification1552
Description and Operation1553
Transmission Cooling – Vehicles With: 6-Speed Automatic Transaxle – AWF211553
Diagnosis and Testing1554
Transmission Cooling1554
Removal and Installation1555
Transmission Fluid Cooler (442410)1555
Transmission Fluid Cooler Return Tube (442413) (442429)1556
Transmission Fluid Cooler Supply Tube (442414) (442428)1558
307-05A: Automatic Transmission/Transaxle External Controls1560
Specification1560
Description and Operation1561
External Controls – Vehicles With: 5-Speed Automatic Transaxle – JATCO1561
Diagnosis and Testing1563
External Controls1563
General Procedures1566
Selector Lever Cable Adjustment (441507)1566
Removal and Installation1568
Selector Lever Cable and Bracket (441508)1568
Selector Lever Assembly (441504)1572
307-05B: Automatic Transmission/Transaxle External Controls – Vehicles With:6-Speed Automatic Transaxle – AWF211577
Specification1577
Description and Operation1578
External Controls – Vehicles With: 6-Speed Automatic Transaxle – AWF211578
Diagnosis and Testing1582
External Controls1582
General Procedures1585
Selector Lever Cable Adjustment (441507)1585
Removal and Installation1587
Selector Lever Assembly (441504)1587
Selector Lever Knob (441506)1590
308: Manual Transmission/Transaxle, Clutch and Transfer Case1591
308-00: Manual Transmission/Transaxle and Clutch – General Information1591
Specification1591
Description and Operation1592
Manual Transmission and Clutch1592
Diagnosis and Testing1593
Manual Transmission and Clutch1593
General Procedures1598
Clutch System Bleeding (331501) – Vehicles With: 5-Speed ManualTransmission – MT751598
Clutch System Bleeding (331501) – Vehicles With: 6-Speed Manual Transaxle –MMT61599
Gearshift Cable Adjustment (371647)1600
Release Hub and Bearing Check1603
308-01: Clutch1604
Specification1604
Description and Operation1605
Clutch1605
Diagnosis and Testing1606
Clutch1606
Removal and Installation1607
Clutch Disc and Pressure Plate (125313) (331001)1607
308-02: Clutch Controls1609
Specification1609
Description and Operation1610
Clutch Controls1610
Diagnosis and Testing1613
Clutch Controls1613
Removal and Installation1614
Clutch Master Cylinder (332001)1614
Clutch Slave Cylinder (333501) – Vehicles With: 5-Speed Manual Transmission –MT751619
Clutch Slave Cylinder (333501) – Vehicles With: 6-Speed Manual Transaxle –MMT61620
308-03: Manual Transmission/Transaxle1622
Specification1622
Description and Operation1623
Manual Transaxle – Vehicles With: 5-Speed Manual Transmission – MT751623
Manual Transaxle – Vehicles With: 6-Speed Manual Transaxle – MMT61624
Diagnosis and Testing1634
Manual Transaxle1634
General Procedures1635
Transaxle Draining and Filling (442402) – Vehicles With: 5-Speed ManualTransmission – MT751635
Transaxle Draining and Filling (442402) – Vehicles With: 6-Speed ManualTransaxle – MMT61636
In-Vehicle Repair1637
Halfshaft Seal LH1637
Halfshaft Seal RH1638
Input Shaft Seal (372309)1639
Selector Mechanism – Vehicles With: 5-Speed Manual Transmission – MT751640
Selector Mechanism – Vehicles With: 6-Speed Manual Transaxle – MMT61657
Support Insulator (371642)1661
Removal1666
Transaxle (372001) – 20L Duratorq-TDCi1666
Transaxle (372001) – 22L Duratorq-TDCi (110kW/150PS) – Puma1675
Transaxle (372001) – 20L NA V6 – AJV6/25L NA V6 – AJV6/30L NA V6 – AJ271682
Installation1692
Transaxle (372001) – 20L Duratorq-TDCi1692
Transaxle (372001) – 22L Duratorq-TDCi (110kW/150PS) – Puma1700
Transaxle (372001) – 20L NA V6 – AJV6/25L NA V6 – AJV6/30L NA V6 – AJ271707
308-06: Manual Transmission/Transaxle External Controls1717
Specification1717
Description and Operation1718
External Controls1718
Diagnosis and Testing1720
External Controls1720
Removal and Installation1721
Gearshift Cables (371645) – Vehicles With: 5-Speed Manual Transmission –MT751721
Gearshift Cables (371645) – Vehicles With: 6-Speed Manual Transaxle – MMT61725
Gearshift Lever (371604) – Vehicles With: 5-Speed Manual Transmission – MT751728
Gearshift Lever (371604) – Vehicles With: 6-Speed Manual Transaxle – MMT61730
308-07: Transfer Case1732
Specification1732
Description and Operation1733
Transfer Case1733
General Procedures1734
Transfer Case Draining and Filling1734
In-Vehicle Repair1742
Halfshaft Seal RH (461003)1742
Transfer Case Rear Output Shaft Seal (461004)1743
Removal1751
Transfer Case (461001)1751
Installation1761
Transfer Case (461001)1761
309: Exhaust System1772
309-00: Exhaust System1772
Specification1772
Description and Operation1773
Exhaust System1773
Diagnosis and Testing1780
Exhaust System1780
Removal and Installation1782
Catalytic Converter (175005) – 20L Duratorq-TDCi/22L Duratorq-TDCi(110kW/150PS) – Puma1782
Catalytic Converter LH (175015) – 20L NA V6 – AJV6/25L NA V6 – AJV6/30L NAV6 – AJ271787
Catalytic Converter RH (175016) – 20L NA V6 – AJV6/25L NA V6 – AJV6/30L NAV6 – AJ271793
Diesel Particulate Filter (DPF)1796
Diesel Particulate Filter (DPF) Differential Pressure Sensor1799
Exhaust Flexible Pipe (301057) – 20L Duratorq-TDCi/22L Duratorq-TDCi(110kW/150PS) – Puma1801
Front Muffler (301018) – 20L Duratorq-TDCi/22L Duratorq-TDCi(110kW/150PS) – Puma1803
Front Muffler (301018) – 20L NA V6 – AJV6/25L NA V6 – AJV6/30L NA V6 – AJ271805
Muffler and Tailpipe (301052) – 20L Duratorq-TDCi/22L Duratorq-TDCi(110kW/150PS) – Puma, 20L1808
Muffler and Tailpipe (301052) – 25L NA V6 – AJV6/30L NA V6 – AJ271809
Muffler Inlet Pipe (301006) – 20L NA V6 – AJV6/25L NA V6 – AJV6/30L NA V6 –AJ271810
Muffler Inlet Pipe (301006) – Vehicles With: Diesel Particulate Filter (DPF)1814
310: Fuel System1816
310-00: Fuel System – General Information1816
Specification1816
Description and Operation1817
Fuel System1817
Diagnosis and Testing1821
Fuel System1821
General Procedures1825
Fuel System Pressure Check1825
Fuel System Pressure Release (195002)1827
Fuel Tank Draining – 20L Duratorq-TDCi/22L Duratorq-TDCi (110kW/150PS) –Puma1828
Fuel Tank Draining – 20L NA V6 – AJV6/25L NA V6 – AJV6/30L NA V6 – AJ271829
Quick Release Coupling – Push Connect1833
Spring Lock Couplings1838
310-01: Fuel Tank and Lines1841
Specification1841
Description and Operation1842
Fuel Tank and Lines1842
Diagnosis and Testing1846
Fuel Tank and Lines1846
Removal and Installation1855
Fuel Filter (192502) – 20L Duratorq-TDCi/22L Duratorq-TDCi (110kW/150PS) –Puma1855
Fuel Filter (192502) – 20L NA V6 – AJV6/25L NA V6 – AJV6/30L NA V6 – AJ271858
Fuel Level Sender – 20L NA V6 – AJV61860
Fuel Level Sender – 20L Duratorq-TDCi/22L Duratorq-TDCi (110kW/150PS) –Puma1862
Fuel Level Sender LH – 25L NA V6 – AJV6/30L NA V6 – AJ271864
Fuel Level Sender RH – 25L NA V6 – AJV6/30L NA V6 – AJ271866
Fuel Level Sensor (882532) – 20L Duratorq-TDCi/22L Duratorq-TDCi(110kW/150PS) – Puma1867
Fuel Pump Module (194508) – 20L NA V6 – AJV61869
Fuel Pump Module (194508) – 25L NA V6 – AJV6/30L NA V6 – AJ271871
Fuel Tank (195501) – 20L NA V6 – AJV61877
Fuel Tank (195501) – 20L Duratorq-TDCi/22L Duratorq-TDCi (110kW/150PS) –Puma1882
Fuel Tank (195501) – 25L NA V6 – AJV6/30L NA V6 – AJ271886
Fuel Tank Filler Pipe (195533)1899
Gas Fuel Tank Pressure Sensor (195531)1901
Fuel Transfer Pump (194521)1902
Inertia Fuel Shutoff (IFS) Switch (183035)1906
Fuel Tank Filler Pipe Hose1907
310-02: Acceleration Control1909
Specification1909
Description and Operation1910
Acceleration Control1910
Diagnosis and Testing1911
Acceleration Control1911
General Procedures1916
Accelerator Cable Adjustment (122005) – 20L NA V6 – AJV61916
Removal and Installation1917
Accelerator Cable (192006) – 20L NA V6 – AJV61917
Accelerator Pedal (192001)1919
310-03: Speed Control1921
Specification1921
Description and Operation1922
Speed Control1922
Diagnosis and Testing1925
Speed Control – 20L NA V6 – AJV61925
Speed Control – 25L NA V6 – AJV6/30L NA V6 – AJ271926
Removal and Installation1932
Speed Control Deactivator Switch (197520)1932
Speed Control Module (197526)1933
Speed Control Switch (197525)1936
4: Electrical1937
412: Climate Control System1937
412-00: Climate Control System – General Information1937
Specification1937
Description and Operation1938
Climate Control System1938
Diagnosis and Testing1939
Climate Control System1939
General Procedures1943
Air Conditioning (A/C) Compressor Leak Detection1943
Air Conditioning (A/C) System Flushing1944
Air Conditioning (A/C) System Recovery, Evacuation and Charging (823030)1946
Contaminated Refrigerant Handling1947
Discharging and Recovery (823030)1948
Electronic Leak Detection1949
Inspection and Assembly Requirements1950
Leak Detection1951
Refrigerant Oil Adding1952
Refrigerant System Tests1953
412-01: Air Distribution and Filtering1954
Description and Operation1954
Air Distribution and Filtering1954
Diagnosis and Testing1955
Air Distribution and Filtering1955
Removal and Installation1956
Center Registers (822038)1956
Driver Side Register (822039)1957
Front Footwell Duct LH (822091)1958
Front Footwell Duct RH (822092)1959
Passenger Side Register (822040)1960
Pollen Filter (761009)1961
412-02A: Heating and Ventilation1962
Specification1962
Description and Operation1963
Heating and Ventilation1963
Diagnosis and Testing1964
Heating and Ventilation1964
Removal and Installation1965
Blower Motor (822566)1965
Evaporator Core Housing (802001)1966
Heater Core (802029)1972
Disassembly and Assembly1975
Evaporator Core Housing1975
412-02B: Auxiliary Heating1980
Specification1980
Description and Operation1981
Electric Booster Heater1981
Fuel Fired Booster Heater1983
Diagnosis and Testing1986
Auxiliary Heater1986
Fuel Fired Booster Heater1996
Removal and Installation2000
Electric Booster Heater2000
Fuel Fired Booster Heater2002
412-03: Air Conditioning2006
Specification2006
Description and Operation2007
Air Conditioning2007
Diagnosis and Testing2009
Air Conditioning2009
Removal and Installation2010
Air Conditioning (A/C) Compressor (821020) – 20L NA V6 – AJV6/25L NA V6 –AJV6/30L NA V6 – AJ272010
Air Conditioning (A/C) Compressor (821020) – 20L Duratorq-TDCi/22LDuratorq-TDCi (110kW/150PS) – Puma2012
Air Conditioning (A/C) Pressure Transducer (821047)2016
Clutch and Clutch Field Coil (821025) – 20L NA V6 – AJV6/25L NA V6 –AJV6/30L NA V6 – AJ272017
Condenser Core (821507)2022
Evaporator Core (822520)2024
Evaporator Core Orifice (822567)2026
Suction Accumulator (821702)2027
412-04: Control Components2029
Description and Operation2029
Control Components2029
Diagnosis and Testing2032
Control Components2032
Removal and Installation2033
Air Discharge Temperature Sensor (822064)2033
Ambient Air Temperature Sensor (822002)2034
Climate Control Assembly (822007)2035
Defrost Vent/Register Blend Door Actuator (822084)2038
Footwell Vent/Duct Blend Door Actuator (802020 or 822085)2039
Sunload Sensor (822070)2040
Temperature Blend Door Actuator (822086)2042
413: Instrumentation and Warning Systems2043
413-00: Instrument Cluster and Panel Illumination2043
Diagnosis and Testing2043
Instrument Cluster and Panel Illumination2043
413-01: Instrument Cluster2044
Description and Operation2044
Instrument Cluster2044
Diagnosis and Testing2047
Instrument Cluster2047
Removal and Installation2048
Instrument Cluster (882001)2048
413-06: Horn2049
Description and Operation2049
Diagnosis and Testing2051
Removal and Installation2052
Horn (863002) (863010)2052
Horn Switch (863001)2053
413-08: Information and Message Center2054
Description and Operation2054
Information and Message Center2054
Diagnosis and Testing2055
Information and Message Center2055
Removal and Installation2056
Message Center2056
Message Center Switch (866611)2057
413-09: Warning Devices2058
Description and Operation2058
Warning Devices2058
Diagnosis and Testing2061
Warning Devices2061
General Procedures2062
Oil Change Indicator Reset2062
Removal and Installation2063
Low Washer Fluid Warning Indicator Switch (841017)2063
413-13: Parking Aid2064
Description and Operation2064
Parking Aid2064
Diagnosis and Testing2066
Parking Aid2066
Removal and Installation2068
Front Parking Aid Sensor (866233)2068
Front Parking Aid Speaker (865418) (866234)2069
Parking Aid Module (868039) – 4-Door2072
Parking Aid Module (868039) – Wagon2073
Rear Parking Aid Sensor (865414) (866201)2075
Rear Parking Aid Speaker (865419) (866202) – 4-Door2076
Rear Parking Aid Speaker (865419) (866202) – Wagon, VIN Range: D86655->E434192077
Rear Parking Aid Speaker (865419) (866202) – Wagon, VIN Range: E43420->V999992079
414: Battery and Charging System2081
414-00: Battery and Charging System – General Information2081
Description and Operation2081
Charging System2081
Battery Care2082
Quiescent Drain2091
Diagnosis and Testing2092
Charging System – 20L NA V6 – AJV6/25L NA V6 – AJV6/30L NA V6 – AJ272092
Charging System – 20L Duratorq-TDCi/22L Duratorq-TDCi (110kW/150PS) –Puma2099
General Procedures2104
Battery Charging2104
414-01: Battery, Mounting and Cables2105
Specification2105
Description and Operation2106
Battery and Cables2106
Diagnosis and Testing2108
Battery2108
General Procedures2109
Battery Connect (861515)2109
Battery Disconnect and Connect2110
Removal and Installation2111
Battery (861501)2111
Battery Cables (861532) – 20L NA V6 – AJV6/25L NA V6 – AJV6/30L NA V6 –AJ272113
Battery Cables (861532) – 20L Duratorq-TDCi/22L Duratorq-TDCi(110kW/150PS) – Puma2117
Battery Tray (861511)2122
414-02: Generator and Regulator2123
Specification2123
Description and Operation2124
Generator2124
Diagnosis and Testing2126
Generator2126
Removal and Installation2127
Generator (861002) – 20L NA V6 – AJV6/25L NA V6 – AJV6/30L NA V6 – AJ272127
Generator (861002) – 20L Duratorq-TDCi/22L Duratorq-TDCi (110kW/150PS) –Puma2129
415: Information and Entertainment Systems2135
415-00: Information and Entertainment System – General Information2135
Diagnosis and Testing2135
Audio System2135
415-01: Audio Unit2139
Description and Operation2139
Audio System2139
Diagnosis and Testing2143
Audio System2143
Removal and Installation2144
Audio Unit (865003)2144
Audio Unit Amplifier (865010) (865036) – 4-Door2145
Audio Unit Amplifier (865010) (865036) – Wagon2147
Compact Disc (CD) Changer (865006) – 4-Door2150
Compact Disc (CD) Changer (865006) – Wagon2153
Steering Wheel Audio Controls (865042)2158
415-02: Antenna2159
Specification2159
Description and Operation2160
Antenna2160
Diagnosis and Testing2163
Antenna2163
Removal and Installation2164
Antenna (86511760) – Wagon2164
Module2168
415-03: Speakers2169
Description and Operation2169
Speakers2169
Diagnosis and Testing2170
Speakers2170
Removal and Installation2171
Front Door Speaker (865013)2171
Front Door Tweeter Speaker (865063)2172
Parcel Shelf Speaker (865106)2173
Rear Door Speaker (865014)2174
Rear Door Tweeter Speaker (865062)2175
417: Lighting2176
417-01: Exterior Lighting2176
Specification2176
Description and Operation2177
Exterior Lighting2177
Diagnosis and Testing2178
Headlamps2178
General Procedures2180
Headlamp Adjustment (864018)2180
Removal and Installation2181
Ballast (864152)2181
Front Fog Lamp (864096)2182
Headlamp Assembly (864133)2183
Headlamp Bulb (864214) – Vehicles With: High Intensity Discharge Headlamps2185
Headlamp Leveling Module2186
Headlamp Leveling Sensor (864215)2187
Headlamp Switch (866526)2189
High Mounted Stoplamp (864101) (864132) – 4-Door2190
High Mounted Stoplamp (864101) (864132) – Wagon2191
Rear Lamp Assembly (864070) – 4-Door2192
Rear Lamp Assembly (864070) – Wagon2193
417-02: Interior Lighting2194
Description and Operation2194
Interior Lighting2194
Diagnosis and Testing2195
Interior Lighting2195
Removal and Installation2196
Front Interior Lamp (864512)2196
Rear Interior Lamp (864603)2197
417-04: Daytime Running Lamps (DRL)2198
Description and Operation2198
Daytime Running Lamps (DRL)2198
Diagnosis and Testing2199
Daytime Running Lamps (DRL)2199
418: Electrical Distribution2200
418-00: Module Communications Network2200
Description and Operation2200
Communications Network2200
Diagnosis and Testing2201
Communications Network – VIN Range: E96603->J284922201
Communications Network – VIN Range: J28493->V999992239
418-01: Module Configuration2280
Diagnosis and Testing2280
Module Configuration2280
General Procedures2281
Module Configuration2281
418-02: Wiring Harnesses2282
Description and Operation2282
Wiring Harness2282
General Procedures2293
Wiring Harness Repair2293
419: Electronic Feature Group2294
419-01A: Anti-Theft – Active2294
Description and Operation2294
Anti-Theft – Active2294
Diagnosis and Testing2296
Anti-Theft – Active2296
Removal and Installation2297
Anti-Theft Alarm Horn (865203)2297
419-01B: Anti-Theft – Passive2298
Description and Operation2298
Anti-Theft – Passive2298
Diagnosis and Testing2299
Anti-Theft – Passive2299
General Procedures2300
Anti-Theft Security Access2300
Key Programming Using Diagnostic Equipment2301
Removal and Installation2302
Passive Anti-Theft System (PATS) Transceiver (865230)2302
419-02: Remote Convenience2303
Description and Operation2303
Universal Transmitter2303
Diagnosis and Testing2304
Universal Transmitter2304
General Procedures2305
Universal Transmitter Programming2305
419-07: Navigation System2307
Description and Operation2307
Navigation System2307
Diagnosis and Testing2309
Navigation System2309
Removal and Installation2311
Navigation System Antenna (866206) – 4-Door, VIN Range: E96603->J399052311
Navigation System Antenna (866206) – 4-Door, VIN Range: J39906->V999992313
Navigation System Antenna (866206) – Wagon2315
Navigation System Display Module (866207)2316
Navigation System Module (866205) – 4-Door2319
Navigation System Module (866205) – Wagon2322
419-08: Cellular Phone2327
Specification2327
Description and Operation2328
Cellular Phone2328
Diagnosis and Testing2331
Cellular Phone2331
Cellular Phone – Vehicles With: Bluetooth2333
Removal and Installation2350
Bluetooth Module2350
Handset Holder (865112)2351
Module – 4-Door2355
Module – Wagon2356
419-10: Multifunction Electronic Modules2357
Specification2357
Description and Operation2358
Module Controlled Functions2358
Diagnosis and Testing2360
Multifunction Electronic Module2360
Removal and Installation2363
Generic Electronic Module (GEM) (865575) (868038)2363
Multifunction Voice Activated Module (865313) (868040) – 4-Door2364
Multifunction Voice Activated Module (865313) (868040) – Wagon2366
5: Body and Paint2367
501: Body and Paint2367
501-02: Front End Body Panels2367
Description and Operation2367
Front End Body Panels2367
Removal and Installation2368
Air Deflector (761141) – 20L Duratorq-TDCi/22L Duratorq-TDCi (110kW/150PS)- Puma2368
Cowl Vent Screen (761001)2369
Fender Splash Shield (761090)2370
Radiator Splash Shield (762290)2371
501-03: Body Closures2372
Specification2372
Description and Operation2373
Body Closures2373
General Procedures2374
Door Alignment2374
Hood Alignment (761602)2376
Liftgate Alignment (76195460)2378
Luggage Compartment Lid Alignment (761903)2382
Removal and Installation2385
Weatherstrip2385
501-05: Interior Trim and Ornamentation2388
Specification2388
Description and Operation2389
Interior Trim2389
Removal and Installation2390
A-Pillar Trim Panel (761331)2390
B-Pillar Lower Trim Panel (761329)2391
B-Pillar Upper Trim Panel (761328)2392
Cowl Side Trim Panel (761330)2394
C-Pillar Trim Panel (761373) – 4-Door2395
C-Pillar Trim Panel (761373) – Wagon2396
D-Pillar Trim Panel (76137360)2398
Front Door Trim Panel (763401)2400
Front Scuff Plate Trim Panel (761381)2402
Headliner (766401) – 4-Door2403
Headliner (766401) – Wagon2406
Liftgate Trim Panel (76196560)2411
Loadspace Scuff Plate Trim Panel (76199060)2413
Loadspace Trim Panel (76137360)2415
Parcel Shelf (766706)2418
Rear Door Trim Panel (763404)2420
Rear Scuff Plate Trim Panel (761382)2422
Rear Window Blind (761404)2423
Sun Visor (761048)2425
501-08: Exterior Trim and Ornamentation2426
Specification2426
Description and Operation2427
Exterior Trim2427
Removal and Installation2429
Door Moulding (764372)2429
Liftgate Moulding (764379)2430
Radiator Grille (765503)2432
Rear Spoiler (76198660) – Wagon2433
Rocker Panel Moulding (761136)2435
Roof Rail (76438660)2436
Window Moulding (764320)2438
501-09: Rear View Mirrors2439
Specification2439
Description and Operation2440
Rear View Mirrors2440
Diagnosis and Testing2441
Rear View Mirrors2441
Removal and Installation2442
Auto-Dimming Interior Mirror (761056)2442
Exterior Mirror (761052)2443
Exterior Mirror Control Switch (866575)2445
Exterior Mirror Cover (761055)2446
Exterior Mirror Glass (761053)2447
Exterior Mirror Motor (761057) (761109)2448
Interior Mirror (761051)2449
501-10: Seating2450
Specification2450
Description and Operation2451
Seats2451
Diagnosis and Testing2459
Seats2459
Removal and Installation2468
Front Seat (767001)2468
Front Seat Backrest (767006)2471
Front Seat Cushion (767011)2475
Front Seat Front Height Adjustment Motor (867531)2476
Front Seat Rear Height Adjustment Motor (867532)2478
Front Seat Recliner Motor (867504)2480
Front Seat Track Motor (867533)2482
Lumbar Assembly (867512)2484
Rear Seat Backrest (767038) – 4-Door2487
Rear Seat Backrest (767038) – 4-Door, Vehicles With: 70/30 Split Seat2488
Rear Seat Backrest (767038) – Wagon, Vehicles With: 70/30 Split Seat2489
Rear Seat Backrest Latch (76706260) – Wagon2491
Rear Seat Bolster (767067) – 4-Door2492
Rear Seat Bolster (767067) – Wagon2493
Rear Seat Cushion (767037)2494
Seat Base (767008)2495
Seat Control Switch (867523)2497
Disassembly and Assembly2499
Front Seat Backrest (767023)2499
Front Seat Cushion (767034)2502
Rear Seat Backrest (767048) – 4-Door, Vehicles With: 70/30 Split Seat2503
Rear Seat Backrest (767048) – Wagon, Vehicles With: 70/30 Split Seat2505
Rear Seat Backrest (767048)2509
Rear Seat Bolster2511
Rear Seat Cushion (767047)2512
501-11: Glass, Frames and Mechanisms2514
Specification2514
Description and Operation2515
Glass, Frames and Mechanisms2515
Diagnosis and Testing2516
Glass, Frames and Mechanisms2516
General Procedures2517
Door Window Motor Initialization2517
Liftgate Window Glass Adjustment2518
Removal and Installation2520
Front Door Window Glass (763101)2520
Front Door Window Regulator and Motor (763145)2522
Liftgate Window Glass (763122) (76811160)2523
Rear Door Fixed Window Glass2529
Rear Door Window Glass (763102)2532
Rear Door Window Regulator (763146)2534
Rear Door Window Regulator and Motor (862509)2537
Rear Quarter Window Glass (763131)2538
Rear Window Glass Using Cheese Wire (768141)2543
Rear Window Glass Using Cutting Tool2551
Window Control Switch (862508)2559
Windshield Glass Using Cheese Wire (768140)2560
Windshield Glass Using Cutting Tool (768101)2565
501-12: Instrument Panel and Console2572
Description and Operation2572
Instrument Panel2572
Removal and Installation2573
Floor Console (762501)2573
Instrument Panel (764601)2577
Overhead Console (761369)2582
Overhead Console Switch Moulding2583
501-14: Handles, Locks, Latches and Entry Systems2587
Specification2587
Description and Operation2588
Handles, Locks, Latches and Entry Systems2588
Diagnosis and Testing2591
Locks, Latches and Entry Systems2591
General Procedures2594
Remote Transmitter Programming2594
Removal and Installation2595
Exterior Front Door Handle (765801)2595
Front Door Lock Actuator (763774)2597
Front Door Lock Cylinder (763771)2599
Fuel Filler Door Release Handle and Cable (761139) – 4-Door2600
Fuel Filler Door Release Handle and Cable (761139) – Wagon2604
Liftgate Latch Actuator (86256560)2608
Liftgate Window Glass Release Switch (76195960)2609
Luggage Compartment Lid Latch Actuator (761925)2614
Rear Door Lock Actuator (763709)2615
501-16: Wipers and Washers2617
Specification2617
Description and Operation2618
Wipers and Washers2618
Diagnosis and Testing2620
Wipers and Washers2620
Removal and Installation2621
Headlamp Washer Pump (842021)2621
Rain Sensor (841210) (865662)2622
Rain Sensor Module (865660)2623
Rear Window Wiper Motor (84154860) (843512)2624
Windshield and Rear Window Washer Pump (84102160)2627
Windshield Washer Pump (841021)2628
Windshield Washer Reservoir (841001) (841003)2629
Windshield Wiper Motor (841513)2631
Wiper Mounting Arm and Pivot Shaft (841524)2632
Wiper Pivot Arm (841503)2633
501-17: Roof Opening Panel2635
Specification2635
Description and Operation2636
Roof Opening Panel2636
Diagnosis and Testing2638
Roof Opening Panel2638
General Procedures2641
Motor Synchronization (768248)2641
Roof Opening Panel Alignment2642
Removal and Installation2643
Air Deflector (768207)2643
Lifter Arms (768257)2644
Roof Opening Panel Control Switch (867605)2645
Roof Opening Panel Drain Hose (768226)2646
Roof Opening Panel Frame (768201)2648
Roof Opening Panel Glass (768205)2653
Roof Opening Panel Motor (867601)2654
Roof Opening Panel Shield (768206)2655
Roof Opening Panel Weatherstrip (768215)2656
501-19: Bumpers2657
Specification2657
Description and Operation2658
Bumpers2658
Removal and Installation2659
Front Bumper Cover (762278)2659
Front Bumper Cover Insert (762273)2662
Rear Bumper (762227) (762252) – 4-Door2663
Rear Bumper (762227) (762252) – Wagon2664
Rear Bumper Cover (762274) (762277) – 4-Door2665
Rear Bumper Cover (762274) (762277) – Wagon2669
Rear Bumper Cover Insert (762275) – 4-Door2676
Rear Bumper Cover Insert (762275) – Wagon2677
501-20A: Safety Belt System2678
Specification2678
Description and Operation2679
Safety Belt System2679
Diagnosis and Testing2681
Safety Belt System2681
Removal and Installation2691
Front Safety Belt Retractor (767310)2691
Front Safety Belt Shoulder Height Adjuster (767312)2693
Rear Center Safety Belt Retractor (767320) – 4-Door2694
Rear Center Safety Belt Retractor (767320) – Wagon2696
Rear Safety Belt Buckle (767350)2697
Rear Safety Belt Retractor (767318) – 4-Door2698
Rear Safety Belt Retractor (767318) – Wagon2700
Safety Belt Buckle and Pretensioner (767349)2702
501-20B: Supplemental Restraint System2704
Specification2704
Description and Operation2705
Air Bag Supplemental Restraint System (SRS)2705
Diagnosis and Testing2708
Air Bag Supplemental Restraint System (SRS)2708
General Procedures2722
Air Bag Disposal2722
Removal and Installation2725
Clockspring (866592)2725
Crash Sensor (767355)2728
Driver Air Bag Module (767339)2730
Driver Lower Air Bag Module (767375)2733
Occupant Classification Sensor (767360)2736
Passenger Air Bag Deactivation (PAD) Indicator (767358)2739
Passenger Air Bag Module (767337)2741
Restraints Control Module (RCM) (767348)2745
Seat Position Sensor (767362)2746
Side Air Curtain Module (767364) – 4-Door2748
Side Air Curtain Module (767364) – Wagon2752
Side Impact Sensor (767353)2758
502: Frame and Mounting2759
502-00: Uni-Body, Subframe and Mounting System2759
Specification2759
Description and Operation2760
Frame Assembly2760
General Procedures2761
Underbody Misalignment Check (576520)2761
Removal and Installation2766
Front Subframe (761005) – 20L NA V6 – AJV6/25L NA V6 – AJV6/30L NA V6 –AJ272766
Front Subframe (761005) – 20L Duratorq-TDCi/22L Duratorq-TDCi(110kW/150PS) – Puma2781
Front Subframe Front Bushing (603551)2793
Front Subframe Rear Bushing (603526)2796
Rear Axle Crossmember Bushing (642502)2799
Rear Subframe (642501)2802
Rear Subframe Bushing (642504)2808

DESCRIPTION:

Jaguar X-Type Sedan and Estate (Wagon) 2.0 L 2.5 L & 3.0 L Gasoline 2.0 L & 2.2 L Diesel Workshop Manual – PDF DOWNLOAD

General Information: – General Service Information Description and Operation

• 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.

G.B 25/01/25