Jaguar X-Type / X-Type Sport Workshop Repair Service Manual 2001-2009
Complete digital official shop manual contains service, maintenance, and troubleshooting information for the 2001-2009 Jaguar X-Type, X-Type Sport. Diagnostic and repair procedures are covered in great detail to repair, maintain, rebuild, refurbish or restore your vehicle like a professional mechanic in local service/repair workshop. This cost-effective quality manual is 100% complete and intact as should be without any missing pages. It is the same factory shop manual used by dealers that guaranteed to be fully functional to save your precious time.
This manual for 2001-2009 Jaguar X-Type, X-Type Sport is divided into different sections. Each section covers a specific component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. It is in the cross-platform PDF document format so that it works like a charm on all kinds of devices. You do not need to be skilled with a computer to use the manual.
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 (57.65.01)....95
Rear Toe Adjustment (57.65.08)....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 (60.35.02)....104
Shock Absorber and Spring Assembly (60.30.02)....113
Front Stabilizer Bar (60.10.01)....122
Front Stabilizer Bar Bushing (60.10.04)....124
Front Wheel Bearing and Wheel Hub (60.25.03)....130
Wheel Knuckle (60.25.23)....133
Disassembly and Assembly....139
Shock Absorber and Spring Assembly (60.30.21)....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 (64.35.51) - 4-Door....147
Front Lower Arm (64.35.51) - Wagon....149
Rear Lower Arm (64.35.52)....154
Spring (64.20.01)....157
Rear Stabilizer Bar (64.35.08)....160
Rear Stabilizer Bar Link (64.35.24)....161
Upper Arm (64.25.31)....162
Wheel Hub (64.15.14)....164
Wheel Knuckle (64.15.22)....167
Wheel Knuckle Front Bushing (64.15.28)....173
Wheel Knuckle Rear Bushing (64.15.30)....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 (74.20.05)....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 (47.15.01)....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 (51.20.04) (51.20.36)....208
Drive Pinion Flange....209
Drive Pinion Seal (51.20.01)....214
Removal and Installation....219
Axle Assembly (51.25.13)....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 (47.10.15)....227
Front Halfshaft RH (47.10.16) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NAV6 – AJ27....233
Front Halfshaft RH (47.10.16) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) - Puma....241
Inner Constant Velocity (CV) Joint Boot (47.10.18)....246
Intermediate Shaft....249
Outer Constant Velocity (CV) Joint Boot (47.10.19)....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 (47.10.13)....256
Outer Constant Velocity (CV) Joint Boot (47.10.32)....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 (70.25.03)....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 (70.55.02)....276
Brake Disc (70.10.10)....278
Brake Pads (70.40.02)....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 (70.55.03) (70.55.25)....284
Brake Disc (70.10.11)....287
Brake Disc Shield (70.10.19)....288
Brake Pads (70.40.03)....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 (70.35.29) - Vehicles With: Manually Adjusted Parking Brake....296
Parking Brake Cable (70.35.29) - Vehicles With: Self-Adjusting Parking Brake....298
Parking Brake Control (70.35.08) - Vehicles With: Manually Adjusted ParkingBrake....300
Parking Brake Control (70.35.08) - 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 (70.30.16)....308
Brake Master Cylinder (70.30.08)....311
Brake Pedal and Bracket (70.35.03)....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 (70.50.17) - LHD AWD/LHD FWD....350
Brake Booster (70.50.17) - RHD AWD/RHD FWD....360
Brake Vacuum Pump - 2.0L NA V6 - AJV6....371
Brake Vacuum Pump - 2.0L Duratorq-TDCi/2.2L 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 (70.60.02) - VIN Range: C00001->J12991....396
Front Wheel Speed Sensor (70.60.03)....397
Hydraulic Control Unit (HCU) (70.60.18) (70.60.19) - VIN Range: C00001->J12991....398
Hydraulic Control Unit (HCU) (70.60.18) (70.60.19) - VIN Range: J12992->V99999....400
Rear Wheel Speed Sensor (70.60.04)....402
Stability Assist Module....404
Steering Wheel Rotation Sensor (86.56.58)....405
Yaw Rate Sensor (86.56.57) - 2.0L Duratorq-TDCi/2.0L NA V6 - AJV6/2.5L NA V6 –AJV6/3.0L NA V6 - AJ27....406
Yaw Rate Sensor (86.56.57) - 2.2L 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 (57.15.08)....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 (57.10.32) - 2.5L NA V6 - AJV6/3.0L NAV6 - AJ27....431
Power Steering Fluid Cooler (57.15.11) - 2.0L Duratorq-TDCi....433
Power Steering Fluid Cooler (57.15.11) - 2.2L Duratorq-TDCi (110kW/150PS) –Puma....434
Power Steering Fluid Reservoir (57.15.08)....436
Power Steering Pump (57.20.14) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NAV6 - AJ27....437
Power Steering Pump (57.20.14) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) - Puma....439
Steering Gear (57.10.01) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) - Puma....446
Steering Gear (57.10.01) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L 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 (57.10.29)....466
Tie Rod End (57.55.02)....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 (57.40.29)....472
Steering Column (57.40.01)....473
Steering Column Coupling....476
Steering Wheel (57.60.01)....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 (86.65.78)....480
Steering Column Multifunction Switch RH (86.65.41)....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 - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27....520
Specification....520
Description and Operation....522
Engine....522
Diagnosis and Testing....525
Engine....525
General Procedures....526
Valve Clearance Adjustment (12.29.48)....526
Valve Clearance Check (12.29.47)....527
In-Vehicle Repair....528
Camshafts LH (12.13.19)....528
Crankshaft Front Seal (12.21.14)....529
Crankshaft Pulley (12.21.09)....530
Crankshaft Rear Seal (12.21.20)....534
Cylinder Head LH (12.29.02)....536
Engine Front Cover (12.65.01)....542
Engine Front Mount (12.45.01)....564
Exhaust Manifold LH (30.15.55)....568
Flexplate (12.53.13)....575
Exhaust Manifold RH (30.15.56)....576
Flywheel (12.53.07)....578
Intake Manifold (30.15.01)....579
Lower Intake Manifold (30.15.61)....591
Oil Cooler (12.60.68)....595
Oil Pan (12.60.44)....596
Oil Pressure Sender....602
Oil Pump (12.60.26)....603
Timing Drive Components (12.65.13)....605
Valve Cover LH (12.29.43)....614
Valve Cover RH (12.29.44)....617
Removal....619
Engine (12.41.01) - Vehicles With: 5-Speed Manual Transmission - MT75/6-Speed Manual Transaxle - MMT6....619
Engine (12.41.01) - Vehicles With: 5-Speed Automatic Transaxle - JATCO/6-SpeedAutomatic Transaxle - AWF21....643
Disassembly....668
Engine....668
Disassembly and Assembly of Subassemblies....688
Cylinder Head (12.29.22)....688
Piston (12.17.02)....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 - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma....766
Specification....766
Description and Operation....767
Engine....767
In-Vehicle Repair....773
Crankshaft Front Seal (12.21.14)....773
Crankshaft Rear Seal (12.21.20)....776
Engine Front Cover (12.65.01)....778
Engine Front Mount (12.45.01)....787
Flexplate (12.53.13)....794
Flywheel (12.53.07)....795
Intake Manifold (30.15.01)....796
Oil Pan (12.60.44)....798
Timing Chain....800
Valve Cover....806
Removal....817
Engine (12.41.01) - 2.0L Duratorq-TDCi....817
Engine (12.41.01) - 2.2L Duratorq-TDCi (110kW/150PS) - Puma....838
Disassembly....860
Engine....860
Assembly....888
Engine....888
Installation....928
Engine (12.41.01) - 2.0L Duratorq-TDCi....928
Engine (12.41.01) - 2.2L Duratorq-TDCi (110kW/150PS) – Puma....947
303-03A: Engine Cooling - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L 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 (86.62.18)....984
Coolant Expansion Tank (26.15.01)....985
Cooling Fan Module (26.25.38)....987
Cooling Fan Motor (26.25.24)....989
Cooling Fan Motor and Shroud (26.25.25)....990
Cooling Module (26.40.16)....993
Radiator (26.40.01)....1004
Thermostat (26.45.07)....1005
Water Pump (26.50.01)....1006
Water Pump Housing (26.50.07)....1007
303-03B: Engine Cooling - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) –Puma....1010
Specification....1010
Description and Operation....1011
Engine Cooling....1011
General Procedures....1014
Cooling System Draining, Filling and Bleeding....1014
Cooling System Draining and Vacuum Filling....1017
Removal and Installation....1021
Cooling Fan Motor and Shroud (26.25.25)....1021
Cooling Module (26.40.16)....1022
Radiator (26.40.01)....1026
Water Pump (26.50.01)....1027
303-04A: Fuel Charging and Controls - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NAV6 - AJ27....1034
Specification....1034
Description and Operation....1035
Fuel Charging and Controls....1035
Diagnosis and Testing....1037
Fuel Charging and Controls - 2.0L NA V6 - AJV6....1037
Fuel Charging and Controls - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, VIN Range:E96603->J28492....1038
Fuel Charging and Controls - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, VIN Range:J28493->V99999....1045
Removal and Installation....1052
Fuel Charging Wiring Harness (86.70.22)....1052
Fuel Injection Supply Manifold (19.60.13)....1055
Fuel Injectors (18.10.02)....1058
Fuel Pulse Damper (18.30.98) - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27....1060
Throttle Body (19.70.04)....1061
303-04B: Fuel Charging and Controls - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) - Puma....1065
Specification....1065
Description and Operation....1066
Fuel Charging and Controls....1066
Diagnosis and Testing....1069
Fuel Charging and Controls....1069
General Procedures....1073
Fuel Injection Component Cleaning....1073
Removal and Installation....1074
Fuel Injection Pump....1074
Fuel Injection Supply Manifold (19.60.13)....1099
Fuel Injector (18.10.01)....1110
Fuel Metering Valve....1119
Fuel Return Line Venturi....1122
303-04C: Fuel Charging and Controls - Turbocharger....1126
Specification....1126
Description and Operation....1127
Turbocharger....1127
Diagnosis and Testing....1131
Turbocharger....1131
Removal and Installation....1137
Turbocharger....1137
303-05: Accessory Drive....1150
Specification....1150
Description and Operation....1151
Accessory Drive....1151
Diagnosis and Testing....1154
Accessory Drive....1154
Removal and Installation....1155
Accessory Drive Belt (12.10.40) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) - Puma....1155
Accessory Drive Belt (12.10.40) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NAV6 - AJ27....1159
Accessory Drive Belt Tensioner (12.10.41) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma....1161
Accessory Drive Belt Tensioner (12.10.41) - 2.0L NA V6 - AJV6/2.5L NA V6 –AJV6/3.0L NA V6 - AJ27....1166
Power Steering Pump Belt - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) - Puma....1167
Power Steering Pump Belt Tensioner - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) - Puma....1171
Water Pump Belt (12.10.44) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 –AJ27....1173
Water Pump Belt Tensioner (12.10.45) - 2.0L NA V6 - AJV6/2.5L NA V6 –AJV6/3.0L NA V6 - AJ27....1174
303-06: Starting System....1175
Specification....1175
Description and Operation....1176
Starting System....1176
Diagnosis and Testing....1179
Starting System - 2.0L NA V6 - AJV6....1179
Starting System - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27....1180
Removal and Installation....1184
Starter Motor (86.60.01) - 2.0L Duratorq-TDCi....1184
Starter Motor (86.60.01) - 2.2L Duratorq-TDCi (110kW/150PS) - Puma....1188
Starter Motor (86.60.01) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 –AJ27....1192
303-07A: Engine Ignition - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27....1197
Specification....1197
Description and Operation....1198
Engine Ignition....1198
Diagnosis and Testing....1199
Engine Ignition - 2.0L NA V6 - AJV6....1199
Engine Ignition - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27....1200
Removal and Installation....1204
Ignition Coil-On-Plug LH (18.20.44)....1204
Ignition Coil-On-Plug RH (18.20.43)....1205
303-07B: Glow Plug System....1206
Specification....1206
Description and Operation....1207
Glow Plug System....1207
Diagnosis and Testing....1209
Glow Plug System....1209
Removal and Installation....1213
Glow Plugs....1213
303-08: Engine Emission Control - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) - Puma....1215
Specification....1215
Description and Operation....1216
Engine Emission Control....1216
Diagnosis and Testing....1217
Engine Emission Control....1217
Removal and Installation....1218
Exhaust Gas Recirculation (EGR) Cooler....1218
Exhaust Gas Recirculation (EGR) Cooler to EGR Valve Tube....1222
Exhaust Gas Recirculation (EGR) Valve (17.45.01)....1226
303-12A: Intake Air Distribution and Filtering - 2.0L NA V6 - AJV6/2.5L NA V6 –AJV6/3.0L NA V6 - AJ27....1230
Description and Operation....1230
Intake Air Distribution and Filtering....1230
Diagnosis and Testing....1231
Intake Air Distribution and Filtering....1231
Removal and Installation....1232
Air Cleaner (19.10.05)....1232
Air Cleaner Element (19.10.08)....1233
Air Cleaner Outlet Pipe (19.10.31)....1235
303-12B: Intake Air Distribution and Filtering - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma....1236
Specification....1236
Description and Operation....1237
Intake Air Distribution and Filtering....1237
Diagnosis and Testing....1239
Intake Air Distribution and Filtering....1239
Removal and Installation....1240
Air Cleaner (19.10.05)....1240
Air Cleaner Element (19.10.08)....1243
Air Cleaner Outlet Pipe (19.10.31)....1245
Charge Air Cooler - 2.0L Duratorq-TDCi....1248
Charge Air Cooler - 2.2L Duratorq-TDCi (110kW/150PS) – Puma....1251
303-13: Evaporative Emissions....1253
Specification....1253
Description and Operation....1254
Evaporative Emissions....1254
Diagnosis and Testing....1255
Evaporative Emissions - 2.0L NA V6 - AJV6....1255
Evaporative Emissions - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27....1256
Removal and Installation....1263
Evaporative Emission Canister (17.15.13) - 2.0L NA V6 - AJV6....1263
Evaporative Emission Canister (17.15.13) - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27....1265
Evaporative Emission Canister Purge Valve (17.15.30)....1273
303-14A: Electronic Engine Controls - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NAV6 - AJ27....1275
Specification....1275
Description and Operation....1276
Electronic Engine Controls....1276
Diagnosis and Testing....1282
Electronic Engine Controls - 2.0L NA V6 - AJV6....1282
Electronic Engine Controls - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, VIN Range:E96603->J28492....1286
Electronic Engine Controls - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, VIN Range:J28493->V99999....1316
General Procedures....1347
Powertrain Control Module (PCM) Long Drive Cycle Self-Test....1347
Powertrain Control Module (PCM) Short Drive Cycle Self-Test....1348
Removal and Installation....1349
Camshaft Position (CMP) Sensor (18.30.63)....1349
Catalyst Monitor Sensor LH (18.30.81)....1350
Catalyst Monitor Sensor RH (18.30.80)....1352
Crankshaft Position (CKP) Sensor (18.30.12)....1354
Engine Control Module (ECM) (18.30.01)....1355
Fuel Temperature Sensor (18.30.99) - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27....1357
Heated Oxygen Sensor (HO2S) LH (18.30.79)....1359
Heated Oxygen Sensor (HO2S) RH (18.30.78)....1360
Knock Sensor (KS) (18.30.69)....1361
Mass Air Flow (MAF) Sensor (18.30.15)....1365
Oil Temperature Sensor (18.31.01)....1366
Throttle Position (TP) Sensor (18.30.17)....1367
Variable Camshaft Timing (VCT) Oil Control Solenoid (18.30.90)....1369
303-14B: Electronic Engine Controls - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) - Puma....1370
Specification....1370
Description and Operation....1371
Electronic Engine Controls....1371
Diagnosis and Testing....1373
Electronic Engine Controls....1373
Removal and Installation....1386
Camshaft Position (CMP) Sensor (18.30.63)....1386
Catalytic Converter Temperature Sensor....1387
Crankshaft Position (CKP) Sensor (18.30.12)....1391
Cylinder Head Temperature (CHT) Sensor (18.30.97)....1393
Diesel Particulate Filter (DPF) Temperature Sensor....1396
Engine Control Module (ECM) (18.30.01)....1397
Engine Oil Pressure (EOP) Sensor....1399
Fuel Temperature Sensor (18.30.99)....1400
Knock Sensor (KS) (18.30.69)....1402
Manifold Absolute Pressure and Temperature (MAPT) Sensor....1404
Manifold Absolute Pressure (MAP) Sensor (18.30.86)....1408
Mass Air Flow (MAF) Sensor (18.30.15)....1410
307: Automatic Transmission/Transaxle....1412
307-01A: Automatic Transmission/Transaxle - Vehicles With: 5-Speed AutomaticTransaxle - JATCO....1412
Specification....1412
Description and Operation....1413
Transmission Description - Vehicles With: 5-Speed Automatic Transaxle - JATCO....1413
Diagnosis and Testing....1428
Diagnostic Strategy - Vehicles With: 5-Speed Automatic Transaxle - JATCO....1428
General Procedures....1441
Transmission Fluid Drain and Refill (44.24.02)....1441
Transmission Fluid Level Check....1442
Transmission Range (TR) Sensor Adjustment (44.15.37)....1444
In-Vehicle Repair....1445
Halfshaft Seal LH (37.23.10)....1445
Halfshaft Seal RH....1446
Main Control Valve Body (44.40.01)....1447
Shift Solenoids (SS) (44.15.50)....1451
Transaxle Support Insulator (37.16.42)....1452
Transmission Control Module (TCM) (44.15.32)....1456
Transmission Range (TR) Sensor....1459
Removal....1460
Transaxle (44.20.01)....1460
Disassembly and Assembly of Subassemblies....1471
Input Shaft Seal (44.32.07)....1471
Installation....1473
Transaxle (44.20.01)....1473
307-01B: Automatic Transmission/Transaxle - Vehicles With: 6-Speed AutomaticTransaxle - AWF21....1484
Specification....1484
Description and Operation....1485
Transmission Description - Vehicles With: 6-Speed Automatic Transaxle - AWF21....1485
Transmission Electronic Control System - Vehicles With: 6-Speed Automatic....1497
Diagnosis and Testing....1501
Diagnostic Strategy - Vehicles With: 6-Speed Automatic Transaxle - AWF21....1501
General Procedures....1513
Transmission Fluid Drain and Refill (44.24.02)....1513
Transmission Fluid Level Check....1516
In-Vehicle Repair....1518
Main Control Valve Body (44.40.01)....1518
Selector Shaft Seal....1522
Transmission Control Module (TCM) (44.15.32)....1523
Transmission Internal Wiring Harness (44.15.35)....1525
Transmission Fluid Pan (44.24.04)....1527
Removal and Installation....1529
Torque Converter....1529
Torque Converter Seal....1530
Turbine Shaft Speed (TSS) Sensor....1531
Removal....1532
Transmission (44.20.01)....1532
Installation....1539
Transmission (44.20.01)....1539
307-02A: Transmission/Transaxle Cooling - Vehicles With: 5-Speed AutomaticTransaxle - JATCO....1546
Specification....1546
Description and Operation....1547
Transmission Cooling - Vehicles With: 5-Speed Automatic Transaxle - JATCO....1547
Diagnosis and Testing....1548
Transmission Cooling....1548
Removal and Installation....1549
Transmission Fluid Cooler (44.24.10)....1549
Transmission Fluid Cooler Tubes (44.24.19)....1551
307-02B: Transmission/Transaxle Cooling - Vehicles With: 6-Speed AutomaticTransaxle - AWF21....1552
Specification....1552
Description and Operation....1553
Transmission Cooling - Vehicles With: 6-Speed Automatic Transaxle - AWF21....1553
Diagnosis and Testing....1554
Transmission Cooling....1554
Removal and Installation....1555
Transmission Fluid Cooler (44.24.10)....1555
Transmission Fluid Cooler Return Tube (44.24.13) (44.24.29)....1556
Transmission Fluid Cooler Supply Tube (44.24.14) (44.24.28)....1558
307-05A: Automatic Transmission/Transaxle External Controls....1560
Specification....1560
Description and Operation....1561
External Controls - Vehicles With: 5-Speed Automatic Transaxle - JATCO....1561
Diagnosis and Testing....1563
External Controls....1563
General Procedures....1566
Selector Lever Cable Adjustment (44.15.07)....1566
Removal and Installation....1568
Selector Lever Cable and Bracket (44.15.08)....1568
Selector Lever Assembly (44.15.04)....1572
307-05B: Automatic Transmission/Transaxle External Controls - Vehicles With:6-Speed Automatic Transaxle - AWF21....1577
Specification....1577
Description and Operation....1578
External Controls - Vehicles With: 6-Speed Automatic Transaxle - AWF21....1578
Diagnosis and Testing....1582
External Controls....1582
General Procedures....1585
Selector Lever Cable Adjustment (44.15.07)....1585
Removal and Installation....1587
Selector Lever Assembly (44.15.04)....1587
Selector Lever Knob (44.15.06)....1590
308: Manual Transmission/Transaxle, Clutch and Transfer Case....1591
308-00: Manual Transmission/Transaxle and Clutch - General Information....1591
Specification....1591
Description and Operation....1592
Manual Transmission and Clutch....1592
Diagnosis and Testing....1593
Manual Transmission and Clutch....1593
General Procedures....1598
Clutch System Bleeding (33.15.01) - Vehicles With: 5-Speed ManualTransmission - MT75....1598
Clutch System Bleeding (33.15.01) - Vehicles With: 6-Speed Manual Transaxle –MMT6....1599
Gearshift Cable Adjustment (37.16.47)....1600
Release Hub and Bearing Check....1603
308-01: Clutch....1604
Specification....1604
Description and Operation....1605
Clutch....1605
Diagnosis and Testing....1606
Clutch....1606
Removal and Installation....1607
Clutch Disc and Pressure Plate (12.53.13) (33.10.01)....1607
308-02: Clutch Controls....1609
Specification....1609
Description and Operation....1610
Clutch Controls....1610
Diagnosis and Testing....1613
Clutch Controls....1613
Removal and Installation....1614
Clutch Master Cylinder (33.20.01)....1614
Clutch Slave Cylinder (33.35.01) - Vehicles With: 5-Speed Manual Transmission –MT75....1619
Clutch Slave Cylinder (33.35.01) - Vehicles With: 6-Speed Manual Transaxle –MMT6....1620
308-03: Manual Transmission/Transaxle....1622
Specification....1622
Description and Operation....1623
Manual Transaxle - Vehicles With: 5-Speed Manual Transmission - MT75....1623
Manual Transaxle - Vehicles With: 6-Speed Manual Transaxle - MMT6....1624
Diagnosis and Testing....1634
Manual Transaxle....1634
General Procedures....1635
Transaxle Draining and Filling (44.24.02) - Vehicles With: 5-Speed ManualTransmission - MT75....1635
Transaxle Draining and Filling (44.24.02) - Vehicles With: 6-Speed ManualTransaxle - MMT6....1636
In-Vehicle Repair....1637
Halfshaft Seal LH....1637
Halfshaft Seal RH....1638
Input Shaft Seal (37.23.09)....1639
Selector Mechanism - Vehicles With: 5-Speed Manual Transmission - MT75....1640
Selector Mechanism - Vehicles With: 6-Speed Manual Transaxle - MMT6....1657
Support Insulator (37.16.42)....1661
Removal....1666
Transaxle (37.20.01) - 2.0L Duratorq-TDCi....1666
Transaxle (37.20.01) - 2.2L Duratorq-TDCi (110kW/150PS) - Puma....1675
Transaxle (37.20.01) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27....1682
Installation....1692
Transaxle (37.20.01) - 2.0L Duratorq-TDCi....1692
Transaxle (37.20.01) - 2.2L Duratorq-TDCi (110kW/150PS) - Puma....1700
Transaxle (37.20.01) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27....1707
308-06: Manual Transmission/Transaxle External Controls....1717
Specification....1717
Description and Operation....1718
External Controls....1718
Diagnosis and Testing....1720
External Controls....1720
Removal and Installation....1721
Gearshift Cables (37.16.45) - Vehicles With: 5-Speed Manual Transmission –MT75....1721
Gearshift Cables (37.16.45) - Vehicles With: 6-Speed Manual Transaxle - MMT6....1725
Gearshift Lever (37.16.04) - Vehicles With: 5-Speed Manual Transmission - MT75....1728
Gearshift Lever (37.16.04) - Vehicles With: 6-Speed Manual Transaxle - MMT6....1730
308-07: Transfer Case....1732
Specification....1732
Description and Operation....1733
Transfer Case....1733
General Procedures....1734
Transfer Case Draining and Filling....1734
In-Vehicle Repair....1742
Halfshaft Seal RH (46.10.03)....1742
Transfer Case Rear Output Shaft Seal (46.10.04)....1743
Removal....1751
Transfer Case (46.10.01)....1751
Installation....1761
Transfer Case (46.10.01)....1761
309: Exhaust System....1772
309-00: Exhaust System....1772
Specification....1772
Description and Operation....1773
Exhaust System....1773
Diagnosis and Testing....1780
Exhaust System....1780
Removal and Installation....1782
Catalytic Converter (17.50.05) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) - Puma....1782
Catalytic Converter LH (17.50.15) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NAV6 - AJ27....1787
Catalytic Converter RH (17.50.16) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NAV6 - AJ27....1793
Diesel Particulate Filter (DPF)....1796
Diesel Particulate Filter (DPF) Differential Pressure Sensor....1799
Exhaust Flexible Pipe (30.10.57) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) - Puma....1801
Front Muffler (30.10.18) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) - Puma....1803
Front Muffler (30.10.18) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27....1805
Muffler and Tailpipe (30.10.52) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) - Puma, 2.0L....1808
Muffler and Tailpipe (30.10.52) - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27....1809
Muffler Inlet Pipe (30.10.06) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 –AJ27....1810
Muffler Inlet Pipe (30.10.06) - Vehicles With: Diesel Particulate Filter (DPF)....1814
310: Fuel System....1816
310-00: Fuel System - General Information....1816
Specification....1816
Description and Operation....1817
Fuel System....1817
Diagnosis and Testing....1821
Fuel System....1821
General Procedures....1825
Fuel System Pressure Check....1825
Fuel System Pressure Release (19.50.02)....1827
Fuel Tank Draining - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) –Puma....1828
Fuel Tank Draining - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27....1829
Quick Release Coupling - Push Connect....1833
Spring Lock Couplings....1838
310-01: Fuel Tank and Lines....1841
Specification....1841
Description and Operation....1842
Fuel Tank and Lines....1842
Diagnosis and Testing....1846
Fuel Tank and Lines....1846
Removal and Installation....1855
Fuel Filter (19.25.02) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) –Puma....1855
Fuel Filter (19.25.02) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27....1858
Fuel Level Sender - 2.0L NA V6 - AJV6....1860
Fuel Level Sender - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) –Puma....1862
Fuel Level Sender LH - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27....1864
Fuel Level Sender RH - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27....1866
Fuel Level Sensor (88.25.32) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) - Puma....1867
Fuel Pump Module (19.45.08) - 2.0L NA V6 - AJV6....1869
Fuel Pump Module (19.45.08) - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27....1871
Fuel Tank (19.55.01) - 2.0L NA V6 - AJV6....1877
Fuel Tank (19.55.01) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) –Puma....1882
Fuel Tank (19.55.01) - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27....1886
Fuel Tank Filler Pipe (19.55.33)....1899
Gas Fuel Tank Pressure Sensor (19.55.31)....1901
Fuel Transfer Pump (19.45.21)....1902
Inertia Fuel Shutoff (IFS) Switch (18.30.35)....1906
Fuel Tank Filler Pipe Hose....1907
310-02: Acceleration Control....1909
Specification....1909
Description and Operation....1910
Acceleration Control....1910
Diagnosis and Testing....1911
Acceleration Control....1911
General Procedures....1916
Accelerator Cable Adjustment (12.20.05) - 2.0L NA V6 - AJV6....1916
Removal and Installation....1917
Accelerator Cable (19.20.06) - 2.0L NA V6 - AJV6....1917
Accelerator Pedal (19.20.01)....1919
310-03: Speed Control....1921
Specification....1921
Description and Operation....1922
Speed Control....1922
Diagnosis and Testing....1925
Speed Control - 2.0L NA V6 - AJV6....1925
Speed Control - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27....1926
Removal and Installation....1932
Speed Control Deactivator Switch (19.75.20)....1932
Speed Control Module (19.75.26)....1933
Speed Control Switch (19.75.25)....1936
4: Electrical....1937
412: Climate Control System....1937
412-00: Climate Control System - General Information....1937
Specification....1937
Description and Operation....1938
Climate Control System....1938
Diagnosis and Testing....1939
Climate Control System....1939
General Procedures....1943
Air Conditioning (A/C) Compressor Leak Detection....1943
Air Conditioning (A/C) System Flushing....1944
Air Conditioning (A/C) System Recovery, Evacuation and Charging (82.30.30)....1946
Contaminated Refrigerant Handling....1947
Discharging and Recovery (82.30.30)....1948
Electronic Leak Detection....1949
Inspection and Assembly Requirements....1950
Leak Detection....1951
Refrigerant Oil Adding....1952
Refrigerant System Tests....1953
412-01: Air Distribution and Filtering....1954
Description and Operation....1954
Air Distribution and Filtering....1954
Diagnosis and Testing....1955
Air Distribution and Filtering....1955
Removal and Installation....1956
Center Registers (82.20.38)....1956
Driver Side Register (82.20.39)....1957
Front Footwell Duct LH (82.20.91)....1958
Front Footwell Duct RH (82.20.92)....1959
Passenger Side Register (82.20.40)....1960
Pollen Filter (76.10.09)....1961
412-02A: Heating and Ventilation....1962
Specification....1962
Description and Operation....1963
Heating and Ventilation....1963
Diagnosis and Testing....1964
Heating and Ventilation....1964
Removal and Installation....1965
Blower Motor (82.25.66)....1965
Evaporator Core Housing (80.20.01)....1966
Heater Core (80.20.29)....1972
Disassembly and Assembly....1975
Evaporator Core Housing....1975
412-02B: Auxiliary Heating....1980
Specification....1980
Description and Operation....1981
Electric Booster Heater....1981
Fuel Fired Booster Heater....1983
Diagnosis and Testing....1986
Auxiliary Heater....1986
Fuel Fired Booster Heater....1996
Removal and Installation....2000
Electric Booster Heater....2000
Fuel Fired Booster Heater....2002
412-03: Air Conditioning....2006
Specification....2006
Description and Operation....2007
Air Conditioning....2007
Diagnosis and Testing....2009
Air Conditioning....2009
Removal and Installation....2010
Air Conditioning (A/C) Compressor (82.10.20) - 2.0L NA V6 - AJV6/2.5L NA V6 –AJV6/3.0L NA V6 - AJ27....2010
Air Conditioning (A/C) Compressor (82.10.20) - 2.0L Duratorq-TDCi/2.2LDuratorq-TDCi (110kW/150PS) - Puma....2012
Air Conditioning (A/C) Pressure Transducer (82.10.47)....2016
Clutch and Clutch Field Coil (82.10.25) - 2.0L NA V6 - AJV6/2.5L NA V6 –AJV6/3.0L NA V6 - AJ27....2017
Condenser Core (82.15.07)....2022
Evaporator Core (82.25.20)....2024
Evaporator Core Orifice (82.25.67)....2026
Suction Accumulator (82.17.02)....2027
412-04: Control Components....2029
Description and Operation....2029
Control Components....2029
Diagnosis and Testing....2032
Control Components....2032
Removal and Installation....2033
Air Discharge Temperature Sensor (82.20.64)....2033
Ambient Air Temperature Sensor (82.20.02)....2034
Climate Control Assembly (82.20.07)....2035
Defrost Vent/Register Blend Door Actuator (82.20.84)....2038
Footwell Vent/Duct Blend Door Actuator (80.20.20 or 82.20.85)....2039
Sunload Sensor (82.20.70)....2040
Temperature Blend Door Actuator (82.20.86)....2042
413: Instrumentation and Warning Systems....2043
413-00: Instrument Cluster and Panel Illumination....2043
Diagnosis and Testing....2043
Instrument Cluster and Panel Illumination....2043
413-01: Instrument Cluster....2044
Description and Operation....2044
Instrument Cluster....2044
Diagnosis and Testing....2047
Instrument Cluster....2047
Removal and Installation....2048
Instrument Cluster (88.20.01)....2048
413-06: Horn....2049
Description and Operation....2049
Diagnosis and Testing....2051
Removal and Installation....2052
Horn (86.30.02) (86.30.10)....2052
Horn Switch (86.30.01)....2053
413-08: Information and Message Center....2054
Description and Operation....2054
Information and Message Center....2054
Diagnosis and Testing....2055
Information and Message Center....2055
Removal and Installation....2056
Message Center....2056
Message Center Switch (86.66.11)....2057
413-09: Warning Devices....2058
Description and Operation....2058
Warning Devices....2058
Diagnosis and Testing....2061
Warning Devices....2061
General Procedures....2062
Oil Change Indicator Reset....2062
Removal and Installation....2063
Low Washer Fluid Warning Indicator Switch (84.10.17)....2063
413-13: Parking Aid....2064
Description and Operation....2064
Parking Aid....2064
Diagnosis and Testing....2066
Parking Aid....2066
Removal and Installation....2068
Front Parking Aid Sensor (86.62.33)....2068
Front Parking Aid Speaker (86.54.18) (86.62.34)....2069
Parking Aid Module (86.80.39) - 4-Door....2072
Parking Aid Module (86.80.39) - Wagon....2073
Rear Parking Aid Sensor (86.54.14) (86.62.01)....2075
Rear Parking Aid Speaker (86.54.19) (86.62.02) - 4-Door....2076
Rear Parking Aid Speaker (86.54.19) (86.62.02) - Wagon, VIN Range: D86655->E43419....2077
Rear Parking Aid Speaker (86.54.19) (86.62.02) - Wagon, VIN Range: E43420->V99999....2079
414: Battery and Charging System....2081
414-00: Battery and Charging System - General Information....2081
Description and Operation....2081
Charging System....2081
Battery Care....2082
Quiescent Drain....2091
Diagnosis and Testing....2092
Charging System - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27....2092
Charging System - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) –Puma....2099
General Procedures....2104
Battery Charging....2104
414-01: Battery, Mounting and Cables....2105
Specification....2105
Description and Operation....2106
Battery and Cables....2106
Diagnosis and Testing....2108
Battery....2108
General Procedures....2109
Battery Connect (86.15.15)....2109
Battery Disconnect and Connect....2110
Removal and Installation....2111
Battery (86.15.01)....2111
Battery Cables (86.15.32) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 –AJ27....2113
Battery Cables (86.15.32) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) - Puma....2117
Battery Tray (86.15.11)....2122
414-02: Generator and Regulator....2123
Specification....2123
Description and Operation....2124
Generator....2124
Diagnosis and Testing....2126
Generator....2126
Removal and Installation....2127
Generator (86.10.02) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27....2127
Generator (86.10.02) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) –Puma....2129
415: Information and Entertainment Systems....2135
415-00: Information and Entertainment System - General Information....2135
Diagnosis and Testing....2135
Audio System....2135
415-01: Audio Unit....2139
Description and Operation....2139
Audio System....2139
Diagnosis and Testing....2143
Audio System....2143
Removal and Installation....2144
Audio Unit (86.50.03)....2144
Audio Unit Amplifier (86.50.10) (86.50.36) - 4-Door....2145
Audio Unit Amplifier (86.50.10) (86.50.36) - Wagon....2147
Compact Disc (CD) Changer (86.50.06) - 4-Door....2150
Compact Disc (CD) Changer (86.50.06) - Wagon....2153
Steering Wheel Audio Controls (86.50.42)....2158
415-02: Antenna....2159
Specification....2159
Description and Operation....2160
Antenna....2160
Diagnosis and Testing....2163
Antenna....2163
Removal and Installation....2164
Antenna (86.51.17.60) - Wagon....2164
Module....2168
415-03: Speakers....2169
Description and Operation....2169
Speakers....2169
Diagnosis and Testing....2170
Speakers....2170
Removal and Installation....2171
Front Door Speaker (86.50.13)....2171
Front Door Tweeter Speaker (86.50.63)....2172
Parcel Shelf Speaker (86.51.06)....2173
Rear Door Speaker (86.50.14)....2174
Rear Door Tweeter Speaker (86.50.62)....2175
417: Lighting....2176
417-01: Exterior Lighting....2176
Specification....2176
Description and Operation....2177
Exterior Lighting....2177
Diagnosis and Testing....2178
Headlamps....2178
General Procedures....2180
Headlamp Adjustment (86.40.18)....2180
Removal and Installation....2181
Ballast (86.41.52)....2181
Front Fog Lamp (86.40.96)....2182
Headlamp Assembly (86.41.33)....2183
Headlamp Bulb (86.42.14) - Vehicles With: High Intensity Discharge Headlamps....2185
Headlamp Leveling Module....2186
Headlamp Leveling Sensor (86.42.15)....2187
Headlamp Switch (86.65.26)....2189
High Mounted Stoplamp (86.41.01) (86.41.32) - 4-Door....2190
High Mounted Stoplamp (86.41.01) (86.41.32) - Wagon....2191
Rear Lamp Assembly (86.40.70) - 4-Door....2192
Rear Lamp Assembly (86.40.70) – Wagon....2193
417-02: Interior Lighting....2194
Description and Operation....2194
Interior Lighting....2194
Diagnosis and Testing....2195
Interior Lighting....2195
Removal and Installation....2196
Front Interior Lamp (86.45.12)....2196
Rear Interior Lamp (86.46.03)....2197
417-04: Daytime Running Lamps (DRL)....2198
Description and Operation....2198
Daytime Running Lamps (DRL)....2198
Diagnosis and Testing....2199
Daytime Running Lamps (DRL)....2199
418: Electrical Distribution....2200
418-00: Module Communications Network....2200
Description and Operation....2200
Communications Network....2200
Diagnosis and Testing....2201
Communications Network - VIN Range: E96603->J28492....2201
Communications Network - VIN Range: J28493->V99999....2239
418-01: Module Configuration....2280
Diagnosis and Testing....2280
Module Configuration....2280
General Procedures....2281
Module Configuration....2281
418-02: Wiring Harnesses....2282
Description and Operation....2282
Wiring Harness....2282
General Procedures....2293
Wiring Harness Repair....2293
419: Electronic Feature Group....2294
419-01A: Anti-Theft - Active....2294
Description and Operation....2294
Anti-Theft - Active....2294
Diagnosis and Testing....2296
Anti-Theft - Active....2296
Removal and Installation....2297
Anti-Theft Alarm Horn (86.52.03)....2297
419-01B: Anti-Theft - Passive....2298
Description and Operation....2298
Anti-Theft - Passive....2298
Diagnosis and Testing....2299
Anti-Theft - Passive....2299
General Procedures....2300
Anti-Theft Security Access....2300
Key Programming Using Diagnostic Equipment....2301
Removal and Installation....2302
Passive Anti-Theft System (PATS) Transceiver (86.52.30)....2302
419-02: Remote Convenience....2303
Description and Operation....2303
Universal Transmitter....2303
Diagnosis and Testing....2304
Universal Transmitter....2304
General Procedures....2305
Universal Transmitter Programming....2305
419-07: Navigation System....2307
Description and Operation....2307
Navigation System....2307
Diagnosis and Testing....2309
Navigation System....2309
Removal and Installation....2311
Navigation System Antenna (86.62.06) - 4-Door, VIN Range: E96603->J39905....2311
Navigation System Antenna (86.62.06) - 4-Door, VIN Range: J39906->V99999....2313
Navigation System Antenna (86.62.06) - Wagon....2315
Navigation System Display Module (86.62.07)....2316
Navigation System Module (86.62.05) - 4-Door....2319
Navigation System Module (86.62.05) – Wagon....2322
419-08: Cellular Phone....2327
Specification....2327
Description and Operation....2328
Cellular Phone....2328
Diagnosis and Testing....2331
Cellular Phone....2331
Cellular Phone - Vehicles With: Bluetooth....2333
Removal and Installation....2350
Bluetooth Module....2350
Handset Holder (86.51.12)....2351
Module - 4-Door....2355
Module – Wagon....2356
419-10: Multifunction Electronic Modules....2357
Specification....2357
Description and Operation....2358
Module Controlled Functions....2358
Diagnosis and Testing....2360
Multifunction Electronic Module....2360
Removal and Installation....2363
Generic Electronic Module (GEM) (86.55.75) (86.80.38)....2363
Multifunction Voice Activated Module (86.53.13) (86.80.40) - 4-Door....2364
Multifunction Voice Activated Module (86.53.13) (86.80.40) – Wagon....2366
5: Body and Paint....2367
501: Body and Paint....2367
501-02: Front End Body Panels....2367
Description and Operation....2367
Front End Body Panels....2367
Removal and Installation....2368
Air Deflector (76.11.41) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS)- Puma....2368
Cowl Vent Screen (76.10.01)....2369
Fender Splash Shield (76.10.90)....2370
Radiator Splash Shield (76.22.90)....2371
501-03: Body Closures....2372
Specification....2372
Description and Operation....2373
Body Closures....2373
General Procedures....2374
Door Alignment....2374
Hood Alignment (76.16.02)....2376
Liftgate Alignment (76.19.54.60)....2378
Luggage Compartment Lid Alignment (76.19.03)....2382
Removal and Installation....2385
Weatherstrip....2385
501-05: Interior Trim and Ornamentation....2388
Specification....2388
Description and Operation....2389
Interior Trim....2389
Removal and Installation....2390
A-Pillar Trim Panel (76.13.31)....2390
B-Pillar Lower Trim Panel (76.13.29)....2391
B-Pillar Upper Trim Panel (76.13.28)....2392
Cowl Side Trim Panel (76.13.30)....2394
C-Pillar Trim Panel (76.13.73) - 4-Door....2395
C-Pillar Trim Panel (76.13.73) - Wagon....2396
D-Pillar Trim Panel (76.13.73.60)....2398
Front Door Trim Panel (76.34.01)....2400
Front Scuff Plate Trim Panel (76.13.81)....2402
Headliner (76.64.01) - 4-Door....2403
Headliner (76.64.01) - Wagon....2406
Liftgate Trim Panel (76.19.65.60)....2411
Loadspace Scuff Plate Trim Panel (76.19.90.60)....2413
Loadspace Trim Panel (76.13.73.60)....2415
Parcel Shelf (76.67.06)....2418
Rear Door Trim Panel (76.34.04)....2420
Rear Scuff Plate Trim Panel (76.13.82)....2422
Rear Window Blind (76.14.04)....2423
Sun Visor (76.10.48)....2425
501-08: Exterior Trim and Ornamentation....2426
Specification....2426
Description and Operation....2427
Exterior Trim....2427
Removal and Installation....2429
Door Moulding (76.43.72)....2429
Liftgate Moulding (76.43.79)....2430
Radiator Grille (76.55.03)....2432
Rear Spoiler (76.19.86.60) - Wagon....2433
Rocker Panel Moulding (76.11.36)....2435
Roof Rail (76.43.86.60)....2436
Window Moulding (76.43.20)....2438
501-09: Rear View Mirrors....2439
Specification....2439
Description and Operation....2440
Rear View Mirrors....2440
Diagnosis and Testing....2441
Rear View Mirrors....2441
Removal and Installation....2442
Auto-Dimming Interior Mirror (76.10.56)....2442
Exterior Mirror (76.10.52)....2443
Exterior Mirror Control Switch (86.65.75)....2445
Exterior Mirror Cover (76.10.55)....2446
Exterior Mirror Glass (76.10.53)....2447
Exterior Mirror Motor (76.10.57) (76.11.09)....2448
Interior Mirror (76.10.51)....2449
501-10: Seating....2450
Specification....2450
Description and Operation....2451
Seats....2451
Diagnosis and Testing....2459
Seats....2459
Removal and Installation....2468
Front Seat (76.70.01)....2468
Front Seat Backrest (76.70.06)....2471
Front Seat Cushion (76.70.11)....2475
Front Seat Front Height Adjustment Motor (86.75.31)....2476
Front Seat Rear Height Adjustment Motor (86.75.32)....2478
Front Seat Recliner Motor (86.75.04)....2480
Front Seat Track Motor (86.75.33)....2482
Lumbar Assembly (86.75.12)....2484
Rear Seat Backrest (76.70.38) - 4-Door....2487
Rear Seat Backrest (76.70.38) - 4-Door, Vehicles With: 70/30 Split Seat....2488
Rear Seat Backrest (76.70.38) - Wagon, Vehicles With: 70/30 Split Seat....2489
Rear Seat Backrest Latch (76.70.62.60) - Wagon....2491
Rear Seat Bolster (76.70.67) - 4-Door....2492
Rear Seat Bolster (76.70.67) - Wagon....2493
Rear Seat Cushion (76.70.37)....2494
Seat Base (76.70.08)....2495
Seat Control Switch (86.75.23)....2497
Disassembly and Assembly....2499
Front Seat Backrest (76.70.23)....2499
Front Seat Cushion (76.70.34)....2502
Rear Seat Backrest (76.70.48) - 4-Door, Vehicles With: 70/30 Split Seat....2503
Rear Seat Backrest (76.70.48) - Wagon, Vehicles With: 70/30 Split Seat....2505
Rear Seat Backrest (76.70.48)....2509
Rear Seat Bolster....2511
Rear Seat Cushion (76.70.47)....2512
501-11: Glass, Frames and Mechanisms....2514
Specification....2514
Description and Operation....2515
Glass, Frames and Mechanisms....2515
Diagnosis and Testing....2516
Glass, Frames and Mechanisms....2516
General Procedures....2517
Door Window Motor Initialization....2517
Liftgate Window Glass Adjustment....2518
Removal and Installation....2520
Front Door Window Glass (76.31.01)....2520
Front Door Window Regulator and Motor (76.31.45)....2522
Liftgate Window Glass (76.31.22) (76.81.11.60)....2523
Rear Door Fixed Window Glass....2529
Rear Door Window Glass (76.31.02)....2532
Rear Door Window Regulator (76.31.46)....2534
Rear Door Window Regulator and Motor (86.25.09)....2537
Rear Quarter Window Glass (76.31.31)....2538
Rear Window Glass Using Cheese Wire (76.81.41)....2543
Rear Window Glass Using Cutting Tool....2551
Window Control Switch (86.25.08)....2559
Windshield Glass Using Cheese Wire (76.81.40)....2560
Windshield Glass Using Cutting Tool (76.81.01)....2565
501-12: Instrument Panel and Console....2572
Description and Operation....2572
Instrument Panel....2572
Removal and Installation....2573
Floor Console (76.25.01)....2573
Instrument Panel (76.46.01)....2577
Overhead Console (76.13.69)....2582
Overhead Console Switch Moulding....2583
501-14: Handles, Locks, Latches and Entry Systems....2587
Specification....2587
Description and Operation....2588
Handles, Locks, Latches and Entry Systems....2588
Diagnosis and Testing....2591
Locks, Latches and Entry Systems....2591
General Procedures....2594
Remote Transmitter Programming....2594
Removal and Installation....2595
Exterior Front Door Handle (76.58.01)....2595
Front Door Lock Actuator (76.37.74)....2597
Front Door Lock Cylinder (76.37.71)....2599
Fuel Filler Door Release Handle and Cable (76.11.39) - 4-Door....2600
Fuel Filler Door Release Handle and Cable (76.11.39) - Wagon....2604
Liftgate Latch Actuator (86.25.65.60)....2608
Liftgate Window Glass Release Switch (76.19.59.60)....2609
Luggage Compartment Lid Latch Actuator (76.19.25)....2614
Rear Door Lock Actuator (76.37.09)....2615
501-16: Wipers and Washers....2617
Specification....2617
Description and Operation....2618
Wipers and Washers....2618
Diagnosis and Testing....2620
Wipers and Washers....2620
Removal and Installation....2621
Headlamp Washer Pump (84.20.21)....2621
Rain Sensor (84.12.10) (86.56.62)....2622
Rain Sensor Module (86.56.60)....2623
Rear Window Wiper Motor (84.15.48.60) (84.35.12)....2624
Windshield and Rear Window Washer Pump (84.10.21.60)....2627
Windshield Washer Pump (84.10.21)....2628
Windshield Washer Reservoir (84.10.01) (84.10.03)....2629
Windshield Wiper Motor (84.15.13)....2631
Wiper Mounting Arm and Pivot Shaft (84.15.24)....2632
Wiper Pivot Arm (84.15.03)....2633
501-17: Roof Opening Panel....2635
Specification....2635
Description and Operation....2636
Roof Opening Panel....2636
Diagnosis and Testing....2638
Roof Opening Panel....2638
General Procedures....2641
Motor Synchronization (76.82.48)....2641
Roof Opening Panel Alignment....2642
Removal and Installation....2643
Air Deflector (76.82.07)....2643
Lifter Arms (76.82.57)....2644
Roof Opening Panel Control Switch (86.76.05)....2645
Roof Opening Panel Drain Hose (76.82.26)....2646
Roof Opening Panel Frame (76.82.01)....2648
Roof Opening Panel Glass (76.82.05)....2653
Roof Opening Panel Motor (86.76.01)....2654
Roof Opening Panel Shield (76.82.06)....2655
Roof Opening Panel Weatherstrip (76.82.15)....2656
501-19: Bumpers....2657
Specification....2657
Description and Operation....2658
Bumpers....2658
Removal and Installation....2659
Front Bumper Cover (76.22.78)....2659
Front Bumper Cover Insert (76.22.73)....2662
Rear Bumper (76.22.27) (76.22.52) - 4-Door....2663
Rear Bumper (76.22.27) (76.22.52) - Wagon....2664
Rear Bumper Cover (76.22.74) (76.22.77) - 4-Door....2665
Rear Bumper Cover (76.22.74) (76.22.77) - Wagon....2669
Rear Bumper Cover Insert (76.22.75) - 4-Door....2676
Rear Bumper Cover Insert (76.22.75) – Wagon....2677
501-20A: Safety Belt System....2678
Specification....2678
Description and Operation....2679
Safety Belt System....2679
Diagnosis and Testing....2681
Safety Belt System....2681
Removal and Installation....2691
Front Safety Belt Retractor (76.73.10)....2691
Front Safety Belt Shoulder Height Adjuster (76.73.12)....2693
Rear Center Safety Belt Retractor (76.73.20) - 4-Door....2694
Rear Center Safety Belt Retractor (76.73.20) - Wagon....2696
Rear Safety Belt Buckle (76.73.50)....2697
Rear Safety Belt Retractor (76.73.18) - 4-Door....2698
Rear Safety Belt Retractor (76.73.18) - Wagon....2700
Safety Belt Buckle and Pretensioner (76.73.49)....2702
501-20B: Supplemental Restraint System....2704
Specification....2704
Description and Operation....2705
Air Bag Supplemental Restraint System (SRS)....2705
Diagnosis and Testing....2708
Air Bag Supplemental Restraint System (SRS)....2708
General Procedures....2722
Air Bag Disposal....2722
Removal and Installation....2725
Clockspring (86.65.92)....2725
Crash Sensor (76.73.55)....2728
Driver Air Bag Module (76.73.39)....2730
Driver Lower Air Bag Module (76.73.75)....2733
Occupant Classification Sensor (76.73.60)....2736
Passenger Air Bag Deactivation (PAD) Indicator (76.73.58)....2739
Passenger Air Bag Module (76.73.37)....2741
Restraints Control Module (RCM) (76.73.48)....2745
Seat Position Sensor (76.73.62)....2746
Side Air Curtain Module (76.73.64) - 4-Door....2748
Side Air Curtain Module (76.73.64) - Wagon....2752
Side Impact Sensor (76.73.53)....2758
502: Frame and Mounting....2759
502-00: Uni-Body, Subframe and Mounting System....2759
Specification....2759
Description and Operation....2760
Frame Assembly....2760
General Procedures....2761
Underbody Misalignment Check (57.65.20)....2761
Removal and Installation....2766
Front Subframe (76.10.05) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 –AJ27....2766
Front Subframe (76.10.05) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) - Puma....2781
Front Subframe Front Bushing (60.35.51)....2793
Front Subframe Rear Bushing (60.35.26)....2796
Rear Axle Crossmember Bushing (64.25.02)....2799
Rear Subframe (64.25.01)....2802
Rear Subframe Bushing (64.25.04)....2808
Jaguar X-Type / X-Type Sport Workshop Repair Service Manual 2001-2009
