Jaguar XJ Workshop Repair & Service Manual 1979-2016
Complete digital official shop manual contains service, maintenance, and troubleshooting information for the 1979-2016 Jaguar XJ, XJ6, XJ6 L, XJ6 Majestic, XJ6 Sovereign, XJ6 Vanden Plas, XJ6 Vanden Plas Majestic, XJ8, XJ8 L, XJ8 Super V8, XJ8 Super V8 Portfolio, XJ8 Vanden Plas, XJ12, XJ40, XJ L, XJ L Portfolio, XJ L Supercharged, XJ L Supersport, XJ L Ultimate, XJR, XJR 100, XJR L, XJR-S, XJS, XJ-S, XJ-S Collection Rouge, XJ-SC, XJ Sport, XJ Super, XJ Supercharged, XJ Supersport, X300, X308, X350, X358. 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 Jaguar XJ 1979-2016 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.
Jaguar X350 - XJ Workshop Service Manual/US001 - Table of contents.pdf
Jaguar X350 - XJ Workshop Service Manual/US002 - 1. General information.pdf
Jaguar X350 - XJ Workshop Service Manual/US003 - 2. Chassis.pdf
Jaguar X350 - XJ Workshop Service Manual/US004 - 3. Powertrain.pdf
Jaguar X350 - XJ Workshop Service Manual/US005 - 4. Electrical.pdf
Jaguar X350 - XJ Workshop Service Manual/US006 - 5. Body and Paint.pdf
Jaguar XJ6 & Sovereign (D to M registration) Service & Repair Manual '86-'94.pdf
TABLE OF CONTENTS
1 : General Information
100 : Service Information
100-00 : General Information [page 1]
Description and Operation
About This Manual
Application and Use of Specifications
General Service Information
Health and Safety Precautions
How To Use This Manual
Important Safety Instructions
Road/Roller Testing
Solvents, Sealants and Adhesives
Standard Workshop Practices
100-01 : Identification Codes [page 59]
Description and Operation
Identification Codes - VIN Range: G00442->G45703
Identification Codes - VIN Range: G45704->G99999
100-02 : Jacking and Lifting [page 79]
Description and Operation
Jacking
Lifting100-04 : Noise, Vibration and Harshness [page 84]
General Procedures
Exhaust System Neutralizing
Description and Operation
Noise, Vibration and Harshness (NVH)
Diagnosis and Testing
Noise, Vibration and Harshness (NVH)2 : Chassis
204 : Suspension
204-00 : Suspension System - General Information [page 1]
Specifications
Specifications
General Procedures
Camber and Caster Adjustment
Front Toe Adjustment (57.65.01)
Rear Toe Adjustment (57.65.08)
Wheel Bearing Inspection
Description and Operation
Wheel Alignment Angles
Diagnosis and Testing
Suspension System
204-01 : Front Suspension [page 24]
Specifications
Specifications
Description and Operation
Front Suspension
Diagnosis and Testing
Front Suspension
Removal and Installation
Front Lower Arm (60.35.53)
Rear Lower Arm (60.35.54)
Rear Lower Arm Bushing (60.35.56)
Shock Absorber Bushing (60.30.16)
Front Stabilizer Bar - 3.0L NA V6 - AJ27 (60.10.01)
Front Stabilizer Bar - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L NA V8 -
AJV8 (60.10.01)
Front Stabilizer Bar - 2.7L V6 - TdV6 (60.10.01)Front Stabilizer Bar Link (60.10.02)
Stabilizer Bar Link Bushing (60.10.03)
Upper Arm LH (60.35.41)
Upper Arm RH (60.35.42)
Front Wheel Bearing and Wheel Hub (60.25.03)
Wheel Knuckle (60.25.23)
204-02 : Rear Suspension [page 117]
Specifications
Specifications
Description and Operation
Rear Suspension
Diagnosis and Testing
Rear Suspension
Removal and Installation
Lower Arm (64.35.43)
Rear Stabilizer Bar (64.35.08)
Rear Stabilizer Bar Link (64.35.24)
Upper Arm (64.25.31)
Rear Wheel Bearing (64.15.14)
204-04 : Wheels and Tires [page 157]
Specifications
Specifications
Specifications
Specifications
Description and Operation
Wheels and Tires - VIN Range: G00442->G45703
Wheels and Tires - VIN Range: G45704->H18679
Wheels and Tires - VIN Range: H18680->H99999
Diagnosis and Testing
Wheels and Tires - VIN Range: G00442->G45703
Wheels and Tires - VIN Range: G45704->G99999
Removal and Installation
Tire Low Pressure SensorTire Pressure Monitoring System (TPMS) Front Antenna
Tire Pressure Monitoring System (TPMS) Module
Tire Pressure Monitoring System (TPMS) Rear Antenna
Wheel and Tire (74.20.05)
204-05 : Vehicle Dynamic Suspension [page 252]
Specifications
Specifications
General Procedures
Air Leaks
Ride Height Adjustments
Description and Operation
Vehicle Dynamic Suspension
Diagnosis and Testing
Vehicle Dynamic Suspension
Removal and Installation
Air Suspension Compressor
Air Suspension Control Module (60.32.03)
Air Suspension Reservoir
Air Suspension Solenoid Valve Block
Front Air Spring (60.32.08)
Front Vertical Accelerometer (86.56.53)
Rear Air Spring - VIN Range: G00442->G45703 (60.32.10)
Rear Air Spring - VIN Range: G45704->G99999 (60.32.10)
Rear Air Spring Lower Bushing (64.32.03)
Rear Vertical Accelerometer (86.56.55)
Suspension Height Sensor (60.32.05)
205 : Driveline
205-00 : Driveline System - General Information [page 363]
General Procedures
Driveline Angle Inspection
Description and OperationDriveline System
Diagnosis and Testing
Driveline System
205-01 : Driveshaft [page 378]
Specifications
Specifications
General Procedures
Driveshaft Runout and Balancing
Description and Operation
Driveshaft
Diagnosis and Testing
Driveshaft
Removal and Installation
Driveshaft (47.15.01)
205-02 : Rear Drive Axle/Differential [page 389]
Specifications
Specifications
Description and Operation
Rear Drive Axle and Differential
Diagnosis and Testing
Rear Drive Axle and Differential
Removal and Installation
Axle Assembly - Vehicles Without: Differential Drain Plug (51.25.13)
Axle Assembly - Vehicles With: Differential Drain Plug (51.25.13)
Axle Housing Bushing (64.25.30)
In Vehicle Repair
Drive Pinion Seal (51.20.01)
205-05 : Rear Drive Halfshafts [page 408]
SpecificationsSpecifications
Description and Operation
Rear Drive Halfshafts
Diagnosis and Testing
Rear Drive Halfshafts
Removal and Installation
Rear Halfshaft (47.10.13)
Inner Constant Velocity (CV) Joint Boot (47.10.33)
Outer Constant Velocity (CV) Joint Boot (47.10.32)
206 : Brake System
206-00 : Brake System - General Information [page 433]
Specifications
Specifications
Specifications
General Procedures
Brake Disc Runout Check
Brake System Bleeding - VIN Range: G00442->G45703 (70.25.03)
Brake System Bleeding - VIN Range: G45704->H99999 (70.25.03)
Description and Operation
Brake System - VIN Range: G00442->G45703
Brake System - VIN Range: G45704->G99999
Diagnosis and Testing
Brake System
206-03 : Front Disc Brake [page 479]
Specifications
Specifications
Specifications
Description and Operation
Front Disc Brake - VIN Range: G00442->G45703
Front Disc Brake - VIN Range: G45704->G99999
Front Disc BrakeDiagnosis and Testing
Front Disc Brake
Removal and Installation
Brake Caliper - Vehicles With: Standard Brakes, VIN Range: G00442-
>G45703 (70.55.02)
Brake Caliper - Vehicles With: Standard Brakes, VIN Range: G45704-
>G99999 (70.55.02)
Brake Caliper - Vehicles With: High Performance Brakes, VIN Range:
G00442->G45704 (70.55.02)
Brake Caliper - Vehicles With: High Performance Brakes, VIN Range:
G45704->G99999 (70.55.02)
Brake Disc - Vehicles With: Standard Brakes, VIN Range: G00442->G45703
(70.10.10)
Brake Disc - Vehicles With: Standard Brakes, VIN Range: G45704->G99999
(70.10.10)
Brake Disc - Vehicles With: High Performance Brakes, VIN Range: G00442-
>G45703 (70.10.10)
Brake Disc - Vehicles With: High Performance Brakes, VIN Range: G45704-
>G99999 (70.10.10)
Brake Disc Shield - Vehicles With: Standard Brakes (70.10.18)
Brake Disc Shield - Vehicles With: High Performance Brakes (70.10.18)
Brake Pads - Vehicles With: Standard Brakes, VIN Range: G00442->G45703
(70.40.02)
Brake Pads - Vehicles With: Standard Brakes, VIN Range: G45704->G99999
(70.40.02)
Brake Pads - Vehicles With: High Performance Brakes, VIN Range: G00442-
>G45703 (70.40.02)
Brake Pads - Vehicles With: High Performance Brakes, VIN Range: G45704-
>G99999 (70.40.02)
206-04 : Rear Disc Brake [page 540]
Specifications
Specifications
Specifications
Description and Operation
Rear Disc Brake - VIN Range: G00442->G45703
Rear Disc Brake - VIN Range: G45704->G99999
Rear Disc BrakeDiagnosis and Testing
Rear Disc Brake
Removal and Installation
Brake Caliper - Vehicles With: Standard Brakes, VIN Range: G00442-
>G45703 (70.55.03)
Brake Caliper - Vehicles With: High Performance Brakes, VIN Range:
G00442->G45703 (70.55.03)
Brake Caliper - VIN Range: G45704->G99999 (70.55.03)
Brake Disc - Vehicles With: Standard Brakes, VIN Range: G00442->G45703
(70.10.11)
Brake Disc - Vehicles With: High Performance Brakes, VIN Range: G00442-
>G45703 (70.10.11)
Brake Disc - VIN Range: G45704->G99999 (70.10.11)
Brake Disc Shield (70.10.19)
Brake Pads - Vehicles With: Standard Brakes, VIN Range: G00442->G45703
(70.40.03)
Brake Pads - Vehicles With: High Performance Brakes, VIN Range: G00442-
>G45703 (70.40.03)
Brake Pads - VIN Range: G45704->G99999 (70.40.03)
206-05 : Parking Brake and Actuation [page 594]
Specifications
Specifications
Specifications
General Procedures
Parking Brake Cable Tension Release - VIN Range: G00442->G45703
Parking Brake Cable Tension Release - VIN Range: G45704->G99999
Description and Operation
Parking Brake - VIN Range: G00442->G45703
Parking Brake - VIN Range: G45704->G99999
Diagnosis and Testing
Parking Brake - VIN Range: G00442->G45170
Parking Brake - VIN Range: G45171->G99999
Removal and Installation
Parking Brake Module - VIN Range: G00442->G45703 (70.35.47)
Parking Brake Module - VIN Range: G45704->G99999 (70.35.47)
Parking Brake Pads - Vehicles With: High Performance Brakes (70.40.04)
Parking Brake Rear CablesParking Brake Release Actuator - VIN Range: G00001->G03445 (70.35.45)
Parking Brake Release Actuator - VIN Range: G03446->H99999 (70.35.45)
Parking Brake Switch (70.35.46)
206-06 : Hydraulic Brake Actuation [page 716]
Specifications
Specifications
Description and Operation
Hydraulic Brake Actuation
Hydraulic Brake Actuation
Diagnosis and Testing
Hydraulic Brake Actuation
Removal and Installation
Brake Fluid Reservoir (70.30.16)
Brake Master Cylinder - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
AJ27/3.5L NA V8 - AJV8 (70.30.08)
Brake Master Cylinder - 2.7L V6 - TdV6 (70.30.08)
206-07 : Power Brake Actuation [page 730]
Specifications
Specifications
Description and Operation
Brake Booster
Brake Booster
Diagnosis and Testing
Power Brake System
Removal and Installation
Brake Booster (70.50.17)
Brake Vacuum Pump
206-09 : Anti-Lock Control - Stability Assist [page 748]
SpecificationsSpecifications
Description and Operation
Anti-Lock Control - Stability Assist - VIN Range: G00442->G45703
Anti-Lock Control - Stability Assist - VIN Range: G45704->G99999
Anti-Lock Control - Stability Assist
Diagnosis and Testing
Anti-Lock Control - Stability Assist - VIN Range: G00442->G45703
Anti-Lock Control - Stability Assist - VIN Range: G45704->G99999
Removal and Installation
Anti-Lock Brake System (ABS) Module (70.60.02)
Brake Master Cylinder Pressure Transducer
Brake Pedal Travel Sensor - VIN Range: G00442->G49700
Front Wheel Speed Sensor (70.60.03)
Hydraulic Control Unit (HCU) - VIN Range: G00442->G45703 (70.60.18)
Hydraulic Control Unit (HCU) - VIN Range: G45704->G99999 (70.60.18)
Rear Wheel Speed Sensor (70.60.04)
Steering Wheel Rotation Sensor (86.56.58)
Yaw Rate Sensor and Accelerometer (86.56.64)
211 : Steering System
211-00 : Steering System - General Information [page 881]
Specifications
Specifications
General Procedures
Power Steering System Bleeding (57.15.02 )
Steering Column Lower Shaft Setting
Power Steering System Flushing (57.15.08)
Description and Operation
Steering System
Diagnosis and Testing
Steering System
211-02 : Power Steering [page 916]Specifications
Specifications
Description and Operation
Power Steering
Diagnosis and Testing
Power Steering
Removal and Installation
Power Steering Control Valve Actuator (57.10.32)
Power Steering Fluid Cooler (57.15.11)
Power Steering Fluid Reservoir - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L
NA V6 - AJ27/3.5L NA V8 - AJV8 (57.15.08)
Power Steering Fluid Reservoir - 2.7L V6 - TdV6 (57.15.08)
Power Steering Pump - 3.0L NA V6 - AJ27 (57.20.14)
Power Steering Pump - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L NA V8 -
AJV8 (57.20.14)
Power Steering Pump - 2.7L V6 - TdV6 (57.20.14)
Steering Gear (57.10.01)
Steering Gear Bushing (57.10.30)
211-03 : Steering Linkage [page 948]
Specifications
Specifications
Description and Operation
Steering Linkage
Diagnosis and Testing
Steering Linkage
Removal and Installation
Steering Gear Boot (57.10.29)
Tie Rod End (57.55.02)
211-04 : Steering Column [page 957]
Specifications
Specifications
Description and Operation
Steering ColumnDiagnosis and Testing
Steering Column
Removal and Installation
Ignition Switch Lock Cylinder (57.40.29)
Steering Column (57.40.01)
Steering Column Lower Shaft (57.40.05)
Steering Wheel (57.60.01)
Assembly & Disassembly
Steering Column
211-05 : Steering Column Switches [page 985]
Description and Operation
Steering Column Switches
Diagnosis and Testing
Steering Column Switches
Removal and Installation
Steering Column Lock Actuator (57.40.41)
Steering Column Multifunction Switch LH (86.65.78)
Steering Column Multifunction Switch RH (86.65.41)3 : Powertrain
303 : Engine
303-00 : Engine System - General Information [page 1]
Specifications
Specifications
General Procedures
Bearing Inspection
Camshaft Bearing Journal Clearance
Camshaft Bearing Journal Diameter
Camshaft End Play
Camshaft Lobe Lift
Camshaft Surface Inspection
Connecting Rod Cleaning
Connecting Rod Large End Bore
Crankshaft End Play
Crankshaft Main Bearing Journal Clearance - 3.0L NA V6 - AJ27
Crankshaft Main Bearing Journal Clearance - 4.2L NA V8 - AJV8/4.2L SC V8
- AJV8/3.5L NA V8 - AJV8
Cylinder Bore Out-of-Round
Cylinder Head Distortion
Exhaust Manifold Cleaning and Inspection
Piston Inspection
Piston Pin Diameter
Piston Pin to Bore Diameter
Piston Ring End Gap
Piston Ring-to-Groove Clearance
Valve Spring Free Length
Valve Stem Diameter
Description and Operation
Engine
Diagnosis and Testing
Engine - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 - AJ27/3.5L NA
V8 - AJV8
Engine - 2.7L V6 - TdV6303-01A : Engine - 3.0L NA V6 - AJ27 [page 52]
Specifications
Specifications
General Procedures
Valve Clearance Adjustment (12.29.48)
Valve Clearance Check (12.29.47)
Description and Operation
Engine
Diagnosis and Testing
Engine
Removal
Engine (12.41.01)
Installation
Engine (12.41.01)
In Vehicle Repair
Camshafts LH (12.13.19)
Crankshaft Front Seal (12.21.14)
Crankshaft Pulley (12.21.09)
Crankshaft Rear Seal (12.21.20)
Cylinder Head (12.29.01)
Engine Front Cover (12.65.01)
Engine Mount (12.45.13)
Exhaust Manifold LH - VIN Range: G004442->G45703 (30.15.55)
Exhaust Manifold LH - VIN Range: G45704->G99999 (30.15.55)
Flexplate (12.53.13)
Intake Manifold (30.15.01)
Lower Intake Manifold (30.15.61)
Oil Cooler (12.60.68)
Oil Pan (12.60.44)
Oil Pump (12.60.26)
Timing Drive Components (12.65.13)
Valve Cover LH (12.29.43)
Valve Cover RH (12.29.44)
Disassembly
Engine
Disassembly/Assembly of subassemblies
Cylinder Head (12.29.22)Piston (12.17.02)
Assembly
Engine
303-01B : Engine - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L NA V8 - AJV8 [page
279]
Specifications
Specifications
General Procedures
Valve Clearance Adjustment (12.29.48)
Valve Clearance Check (12.29.47)
Description and Operation
Engine
Diagnosis and Testing
Engine
Removal and Installation
Crankshaft Main Bearing Carrier
Removal
Engine (12.41.01)
Installation
Engine (12.41.01)
In Vehicle Repair
Camshafts RH - VIN Range: G00442->G45703 (12.13.18)
Camshafts RH - VIN Range: G45704->G99999 (12.13.18)
Crankshaft Front Seal - VIN Range: G00442->G45703 (12.21.14)
Crankshaft Front Seal - VIN Range: G45704->G99999 (12.21.14)
Crankshaft Pulley (12.21.09)
Crankshaft Rear Seal (12.21.20)
Cylinder Head LH - VIN Range: G00442->G45703 (12.29.02)
Cylinder Head LH - VIN Range: G45704->G99999 (12.29.02)
Engine Front Cover - VIN Range: G00442->G45703 (12.65.01)
Engine Front Cover - VIN Range: G45704->G99999 (12.65.01)
Engine Mount LH (12.45.01)
Engine Mount RH (12.45.03)
Exhaust Manifold RH - VIN Range: G00442->G45703 (30.15.56)
Exhaust Manifold RH - VIN Range: G45704->G99999 (30.15.56)
Flexplate (12.53.13)
Intake Manifold - VIN Range: G00442->G45703 (30.15.01)
Intake Manifold - VIN Range: G45704->G99999 (30.15.01)Oil Cooler - Vehicles With: Supercharger (12.60.68)
Oil Cooler - Vehicles Without: Supercharger (12.60.68)
Oil Pan (12.60.44)
Oil Pan Extension (12.60.48)
Oil Pump - VIN Range: G00442->G45703 (12.60.26)
Oil Pump - VIN Range: G45704->G99999 (12.60.26)
Secondary Timing Chain Tensioner
Timing Drive Components - VIN Range: G00442->G45703 (12.65.13)
Timing Drive Components - VIN Range: G45704->G99999 (12.65.13)
Valve Cover LH - VIN Range: G00442->G45703 (12.29.43)
Valve Cover LH - VIN Range: G45704->G99999 (12.29.43)
Valve Cover RH - VIN Range: G00442->G45703 (12.29.44)
Valve Cover RH - VIN Range: G45704->G99999 (12.29.44)
Disassembly
Engine
Disassembly/Assembly of subassemblies
Cylinder Head (12.29.22)
Assembly
Engine
303-01C : Engine - 2.7L V6 - TdV6 [page 876]
Specifications
Specifications
Description and Operation
Engine
Diagnosis and Testing
Engine
Removal
Engine (12.41.01)
Installation
Engine (12.41.01)
In Vehicle Repair
Camshaft Front Seal
Camshaft Rear Seal
Camshafts LH (12.13.19)
Crankshaft Front Seal (12.21.14)
Crankshaft Rear Seal (12.21.20)
Crankshaft Vibration Damper (12.21.09)Cylinder Head LH (12.29.02)
Engine Mount LH (12.45.01)
Engine Mount RH (12.45.03)
Exhaust Manifold LH (30.15.55)
Exhaust Manifold RH (30.15.56)
Flexplate (12.53.13)
Oil Filter Element (12.60.02)
Oil Pan (12.60.44)
Oil Pan Extension (12.60.48)
Oil Pump (12.60.26)
Timing Belt
Timing Belt Cover
Valve Cover LH (12.29.43)
Valve Cover RH (12.29.44)
303-03A : Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
AJ27/3.5L NA V8 - AJV8 [page 1155]
Specifications
Specifications
General Procedures
Cooling System Backflushing
Cooling System Draining, Filling and Bleeding
Cooling System Draining and Vacuum Filling
Cooling System Flushing
Description and Operation
Engine Cooling
Diagnosis and Testing
Engine Cooling
Removal and Installation
Coolant Expansion Tank (26.15.01)
Cooling Fan Motor and Shroud (26.25.25)
Radiator (26.40.01)
Thermostat - 3.0L NA V6 - AJ27 (26.45.07)
Thermostat - 4.2L NA V8 - AJV8/3.5L NA V8 - AJV8 (26.45.07)
Thermostat - 4.2L SC V8 - AJV8 (26.45.07)
Water Pump - 3.0L NA V6 - AJ27, VIN Range: G00442->G45703 (26.50.01)
Water Pump - 3.0L NA V6 - AJ27, VIN Range: G45704->G99999 (26.50.01)
Water Pump - 4.2L NA V8 - AJV8/3.5L NA V8 - AJV8 (26.50.01)
Water Pump - 4.2L SC V8 - AJV8 (26.50.01)303-03B : Supercharger Cooling [page 1238]
Specifications
Specifications
General Procedures
Supercharger Cooling System Draining, Filling and Bleeding
Description and Operation
Supercharger Cooling
Diagnosis and Testing
Supercharger Cooling
Removal and Installation
Radiator
Water Pump
303-03C : Engine Cooling - 2.7L V6 - TdV6 [page 1253]
Specifications
Specifications
General Procedures
Cooling System Draining, Filling and Bleeding
Cooling System Draining and Vacuum Filling
Description and Operation
Engine Cooling
Diagnosis and Testing
Engine Cooling
Removal and Installation
Coolant Expansion Tank (26.15.01)
Cooling Fan Motor and Shroud (26.25.25)
Radiator (26.40.01)
Thermostat (26.45.07)
Water Pump (26.50.01)
303-04A : Fuel Charging and Controls - 3.0L NA V6 - AJ27 [page 1298]Specifications
Specifications
Description and Operation
Fuel Charging and Controls
Diagnosis and Testing
Fuel Charging and Controls - VIN Range: G00442->G45703
Fuel Charging and Controls - VIN Range: G45704->G99999
Removal and Installation
Fuel Charging Wiring Harness (86.70.22)
Fuel Injectors (18.10.02)
Fuel Injection Supply Manifold (19.60.13)
Throttle Body - VIN Range: G00442->G45703 (19.70.04)
Throttle Body - VIN Range: G45704->G99999 (19.70.04)
303-04B : Fuel Charging and Controls - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L
NA V8 - AJV8 [page 1357]
Specifications
Specifications
Description and Operation
Fuel Charging and Controls
Diagnosis and Testing
Fuel Charging and Controls - VIN Range: G00442->G45703
Fuel Charging and Controls - VIN Range: G45704->G99999
Removal and Installation
Fuel Injection Supply Manifold (19.60.13)
Fuel Injectors (18.10.02)
Throttle Body - 4.2L SC V8 - AJV8, VIN Range: G00442->G45703 (19.70.04)
Throttle Body - 4.2L SC V8 - AJV8, VIN Range: G45704->G99999 (19.70.04)
Throttle Body - 4.2L NA V8 - AJV8/3.5L NA V8 - AJV8, VIN Range: G00442-
>G45703 (19.70.04)
Throttle Body - 4.2L NA V8 - AJV8/3.5L NA V8 - AJV8, VIN Range: G45704-
>G99999 (19.70.04)
303-04C : Fuel Charging and Controls - 2.7L V6 - TdV6 [page 1434]
Specifications
SpecificationsGeneral Procedures
Fuel Injection Component Cleaning
Description and Operation
Fuel Charging and Controls
Diagnosis and Testing
Fuel Charging and Controls
Removal and Installation
Fuel Diverter Rail
Fuel Injection Pump
Fuel Injector (18.10.01)
Fuel Rail
Intake Air Shutoff Throttle
Swirl Plate Actuator Diaphragm
303-04D : Fuel Charging and Controls - Turbocharger - 2.7L V6 - TdV6 [page
1670]
Specifications
Specifications
Description and Operation
Turbocharger
Diagnosis and Testing
Turbocharger
Removal and Installation
Turbocharger LH
Turbocharger RH
303-05 : Accessory Drive [page 1721]
Specifications
Specifications
Description and Operation
Accessory Drive
Diagnosis and Testing
Accessory Drive - 3.0L/3.5L/4.2L
Accessory Drive - 2.7L Diesel
Removal and Installation
Accessory Drive Belt - 3.0L NA V6 - AJ27, VIN Range: G00442->G45703(12.10.40)
Accessory Drive Belt - 3.0L NA V6 - AJ27, VIN Range: G45704->G99999
(12.10.40)
Accessory Drive Belt - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L NA V8 -
AJV8 (12.10.40)
Accessory Drive Belt - 2.7L V6 - TdV6 (12.10.40)
Accessory Drive Belt Idler Pulley - 3.0L NA V6 - AJ27, VIN Range: G00442-
>G45703 (12.10.43)
Accessory Drive Belt Idler Pulley - 3.0L NA V6 - AJ27, VIN Range: G45704-
>G99999 (12.10.43)
Accessory Drive Belt Idler Pulley - 4.2L NA V8 - AJV8/4.2L SC V8 -
AJV8/3.5L NA V8 - AJV8, VIN Range: G00442->G45703 (12.10.43)
Accessory Drive Belt Idler Pulley - 4.2L NA V8 - AJV8/4.2L SC V8 -
AJV8/3.5L NA V8 - AJV8, VIN Range: G45704->G99999 (12.10.43)
Accessory Drive Belt Idler Pulley - 2.7L V6 - TdV6 (12.10.43)
Accessory Drive Belt Tensioner - 3.0L NA V6 - AJ27, VIN Range: G00442-
>G45703 (12.10.41)
Accessory Drive Belt Tensioner - 3.0L NA V6 - AJ27, VIN Range: G45704-
>G99999 (12.10.41)
Accessory Drive Belt Tensioner - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L
NA V8 - AJV8 (12.10.41)
Accessory Drive Belt Tensioner - 2.7L V6 - TdV6 (12.10.41)
Fuel Injection Pump Belt
Fuel Injection Pump Pulley
Supercharger Belt - VIN Range: G00442->G45703 (18.50.08)
Supercharger Belt - VIN Range: G45704->G99999 (18.50.08)
Supercharger Belt Idler Pulley - VIN Range: G04422->G45703 (18.50.09)
Supercharger Belt Idler Pulley - VIN Range: G45704->G99999 (18.50.09)
Supercharger Belt Tensioner - VIN Range: G00442->G45703 (18.50.24)
Supercharger Belt Tensioner - VIN Range: G45704->G99999 (18.50.24)
303-06 : Starting System [page 1780]
Specifications
Specifications
Description and Operation
Starting System
Diagnosis and Testing
Starting SystemRemoval and Installation
Starter Motor - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
AJ27/3.5L NA V8 - AJV8 (86.60.01)
Starter Motor - 2.7L V6 - TdV6 (86.60.01)
303-07A : Engine Ignition - 3.0L NA V6 - AJ27 [page 1805]
Specifications
Specifications
Description and Operation
Engine Ignition
Diagnosis and Testing
Engine Ignition - VIN Range: G00442->G45703
Engine Ignition - VIN Range: G45704->G99999
Removal and Installation
Ignition Coil-On-Plug LH (18.20.44)
Ignition Coil-On-Plug RH (18.20.43)
303-07B : Engine Ignition - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L NA V8 -
AJV8 [page 1846]
Specifications
Specifications
Description and Operation
Engine Ignition
Diagnosis and Testing
Engine Ignition - VIN Range: G00442->G45703
Engine Ignition - VIN Range: G45704->G99999
Removal and Installation
Ignition Coil-On-Plug (18.20.40)
303-07C : Glow Plug System [page 1888]
Specifications
Specifications
Description and OperationGlow Plug System
Diagnosis and Testing
Glow Plug System
Removal and Installation
Glow Plugs
303-08A : Engine Emission Control - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L
NA V6 - AJ27/3.5L NA V8 - AJV8 [page 1907]
Specifications
Specifications
Specifications
Description and Operation
Engine Emission Control - VIN Range: G00442->G45703
Engine Emission Control - VIN Range: G45704->G99999
Diagnosis and Testing
Engine Emission Control - VIN Range: G00442->G45703
Engine Emission Control - VIN Range: G45704->G99999
Removal and Installation
Exhaust Gas Recirculation (EGR) Valve (17.45.01)
Exhaust Manifold to Exhaust Gas Recirculation (EGR) Valve Tube
(17.45.11)
Secondary Air Injection (AIR) Control Valve - 3.0L NA V6 - AJ27
Secondary Air Injection (AIR) Control Valve - 4.2L NA V8 - AJV8/3.5L NA V8
- AJV8
Secondary Air Injection (AIR) Control Valve - 4.2L SC V8 - AJV8
Secondary Air Injection (AIR) Control Valve to Exhaust Manifold Tube LH -
3.0L NA V6 - AJ27
Secondary Air Injection (AIR) Control Valve to Exhaust Manifold Tube RH -
3.0L NA V6 - AJ27
Secondary Air Injection (AIR) Control Valve to Exhaust Manifold Tube -
4.2L NA V8 - AJV8/3.5L NA V8 - AJV8, 4.2L
Secondary Air Injection (AIR) Control Valve to Exhaust Manifold Tube -
4.2L SC V8 - AJV8, 4.2L
Secondary Air Injection (AIR) Pump
303-08B : Engine Emission Control - 2.7L V6 - TdV6 [page 1983]Specifications
Specifications
Description and Operation
Engine Emission Control
Diagnosis and Testing
Engine Emission Control
Removal and Installation
Crankcase Vent Oil Separator
Exhaust Gas Recirculation (EGR) Valve LH
Exhaust Gas Recirculation (EGR) Valve Outlet Tube (17.45.11)
Exhaust Gas Recirculation (EGR) Valve RH
303-12A : Intake Air Distribution and Filtering - 3.0L NA V6 - AJ27 [page 2054]
Specifications
Specifications
Description and Operation
Intake Air Distribution and Filtering
Diagnosis and Testing
Intake Air Distribution and Filtering - VIN Range: G00442->G45703
Intake Air Distribution and Filtering - VIN Range: G45704->G99999
Removal and Installation
Air Cleaner (19.10.05)
Air Cleaner Element (19.10.08)
Air Cleaner Outlet Pipe (19.10.31)
303-12B : Intake Air Distribution and Filtering - 4.2L NA V8 - AJV8/4.2L SC V8 -
AJV8/3.5L NA V8 - AJV8 [page 2067]
Specifications
Specifications
Description and Operation
Intake Air Distribution and Filtering
Diagnosis and Testing
Intake Air Distribution and Filtering - VIN Range: G00442->G45703
Intake Air Distribution and Filtering - VIN Range: G45704->G99999
Removal and Installation
Air Cleaner (19.10.05)Air Cleaner Element (19.10.08)
Air Cleaner Outlet Pipe (19.10.31)
Charge Air Cooler
Supercharger - VIN Range: G00442->G45703 (18.50.15)
Supercharger - VIN Range: G45704->G99999 (18.50.15)
Supercharger Outlet Pipe (18.50.16)
303-12C : Intake Air Distribution and Filtering - 2.7L V6 - TdV6 [page 2110]
Specifications
Specifications
Description and Operation
Intake Air Distribution and Filtering
Diagnosis and Testing
Intake Air Distribution and Filtering
Removal and Installation
Air Cleaner (19.10.05)
Air Cleaner Element (19.10.08)
Charge Air Cooler
303-13 : Evaporative Emissions [page 2129]
Specifications
Specifications
Description and Operation
Evaporative Emissions - VIN Range: G00442->G45703
Evaporative Emissions - VIN Range: G45704->G99999
Diagnosis and Testing
Evaporative Emissions - VIN Range: G00442->G45703
Evaporative Emissions - VIN Range: G45704->G99999
Removal and Installation
Evaporative Emission Canister - VIN Range: G00442->G45703 (17.15.13)
Evaporative Emission Canister - VIN Range: G45704->G99999 (17.15.13)
Evaporative Emission Canister Purge Valve - VIN Range: G00442->G45703
(17.15.30)
Evaporative Emission Canister Purge Valve - 3.0L NA V6 - AJ27, VIN Range:
G45704->G99999 (17.15.30)Evaporative Emission Canister Purge Valve - 4.2L SC V8 - AJV8/3.5L NA V8
- AJV8, VIN Range: G45171->G99999 (17.15.30)
Evaporative Emission Canister Purge Valve - 4.2L NA V8 - AJV8/3.5L NA V8
- AJV8, VIN Range: G45171->G99999 (17.15.30)
Evaporative Emission Canister Vent Solenoid (17.15.45)
Fuel Tank Pressure Sensor (19.55.31)
303-14A : Electronic Engine Controls - 3.0L NA V6 - AJ27 [page 2216]
Specifications
Specifications
General Procedures
Brake Pedal Position (BPP) Switch Adjustment
Description and Operation
Electronic Engine Controls
Diagnosis and Testing
Electronic Engine Controls - VIN Range: G00442->G45703
Electronic Engine Controls - VIN Range: G45704->G99999
Removal and Installation
Brake Pedal Position (BPP) Switch
Camshaft Position (CMP) Sensor LH (18.31.12)
Camshaft Position (CMP) Sensor RH (18.31.11)
Catalyst Monitor Sensor (18.30.66)
Crankshaft Position (CKP) Sensor (18.30.12)
Engine Control Module (ECM) (18.30.01)
Engine Coolant Temperature (ECT) Sensor - VIN Range: G00442->G45703
(18.30.10)
Engine Coolant Temperature (ECT) Sensor - VIN Range: G45704->G99999
(18.30.10)
Fuel Rail Pressure (FRP) Sensor (18.30.98)
Fuel Temperature Sensor (18.30.99)
Heated Oxygen Sensor (HO2S)
Intake Manifold Tuning (IMT) Valve LH (19.70.30)
Knock Sensor (KS) LH (18.30.92)
Knock Sensor (KS) RH (18.30.93)
Manifold Absolute Pressure (MAP) Sensor (18.30.86)
Mass Air Flow (MAF) Sensor (18.30.15)
Oil Temperature Sensor (18.31.01)
Variable Camshaft Timing (VCT) Oil Control Solenoid (18.30.90)303-14B : Electronic Engine Controls - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L
NA V8 - AJV8 [page 2389]
Specifications
Specifications
General Procedures
Brake Pedal Position (BPP) Switch Adjustment
Powertrain Control Module (PCM) Long Drive Cycle Self-Test
Powertrain Control Module (PCM) Short Drive Cycle Self-Test
Description and Operation
Electronic Engine Controls
Diagnosis and Testing
Electronic Engine Controls - VIN Range: G00442->G45703
Electronic Engine Controls - VIN Range: G45704->G99999
Removal and Installation
Brake Pedal Position (BPP) Switch
Camshaft Position (CMP) Sensor LH (18.31.12)
Camshaft Position (CMP) Sensor RH (18.31.11)
Catalyst Monitor Sensor (18.30.66)
Crankshaft Position (CKP) Sensor (18.30.12)
Engine Control Module (ECM) (18.30.01)
Engine Coolant Temperature (ECT) Sensor - 4.2L SC V8 - AJV8 (18.30.10)
Engine Coolant Temperature (ECT) Sensor - 4.2L NA V8 - AJV8 (18.30.10)
Fuel Rail Pressure (FRP) Sensor (18.30.98)
Fuel Temperature Sensor (18.30.99)
Heated Oxygen Sensor (HO2S)
Intake Air Temperature (IAT) Sensor - 4.2L SC V8 - AJV8 (18.30.52)
Knock Sensor (KS) LH (18.30.92)
Manifold Absolute Pressure (MAP) Sensor - 4.2L SC V8 - AJV8 (18.30.86)
Manifold Absolute Pressure (MAP) Sensor - 4.2L NA V8 - AJV8 (18.30.86)
Mass Air Flow (MAF) Sensor (18.30.15)
Oil Temperature Sensor (18.31.01)
Variable Camshaft Timing (VCT) Oil Control Solenoid (18.30.90)
303-14C : Electronic Engine Controls - 2.7L V6 - TdV6 [page 2724]
SpecificationsSpecifications
General Procedures
Brake Pedal Position (BPP) Switch Adjustment
Description and Operation
Electronic Engine Controls
Diagnosis and Testing
Electronic Engine Controls
Removal and Installation
Brake Pedal Position (BPP) Switch
Camshaft Position (CMP) Sensor (18.30.63)
Crankshaft Position (CKP) Sensor (18.30.12)
Crankshaft Position (CKP) Sensor Ring
Engine Control Module (ECM) (18.30.01)
Engine Coolant Temperature (ECT) Sensor (18.30.10)
Exhaust Gas Temperature Sensor
Engine Oil Pressure (EOP) Sensor
Fuel Rail Pressure (FRP) Sensor (18.30.98)
Fuel Temperature Sensor (18.30.99)
Intake Air Temperature (IAT) Sensor (18.30.52)
Knock Sensor (KS) LH (18.30.92)
Knock Sensor (KS) RH (18.30.93)
Manifold Absolute Pressure (MAP) Sensor (18.30.86)
Mass Air Flow (MAF) Sensor (18.30.15)
Oil Temperature Sensor (18.31.01)
307 : Automatic Transmission/Transaxle
307-01 : Automatic Transmission/Transaxle [page 2984]
Specifications
Specifications
General Procedures
Transmission Fluid Drain and Refill (44.24.02)
Transmission Fluid Level Check
Description and Operation
Transmission Description
Diagnosis and Testing
Diagnostic StrategyRemoval
Transmission - 3.0L NA V6 - AJ27 (44.20.01)
Transmission - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L NA V8 - AJV8
(44.20.01)
Transmission - 2.7L V6 - TdV6 (44.20.01)
Installation
Transmission - 3.0L NA V6 - AJ27 (44.20.01)
Transmission - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L NA V8 - AJV8
(44.20.01)
Transmission - 2.7L V6 - TdV6 (44.20.01)
In Vehicle Repair
Extension Housing Seal (44.20.18)
Transmission Fluid Pan, Gasket and Filter (44.24.07)
Transmission Control Module (TCM) and Main Control Valve Body
Disassembly/Assembly of subassemblies
Input Shaft Seal (44.32.07)
307-02 : Transmission/Transaxle Cooling [page 3097]
Specifications
Specifications
Description and Operation
Transmission Cooling
Diagnosis and Testing
Transmission Cooling
Removal and Installation
Transmission Fluid Cooler - 2.7L V6 - TdV6 (44.24.10)
Transmission Fluid Cooler Tubes - 4.2L NA V8 - AJV8/4.2L SC V8 -
AJV8/3.0L NA V6 - AJ27/3.5L NA V8 - AJV8 (44.24.19)
Transmission Fluid Cooler Tubes - 2.7L V6 - TdV6 (44.24.19)
307-05 : Automatic Transmission/Transaxle External Controls [page 3122]
Specifications
Specifications
General Procedures
Selector Lever Cable Adjustment (44.15.07)Description and Operation
External Controls
Diagnosis and Testing
External Controls
Removal and Installation
Selector Lever Cable and Bracket (44.15.08)
Selector Lever Assembly (44.15.04)
309 : Exhaust System
309-00 : Exhaust System [page 3145]
Specifications
Specifications
Description and Operation
Exhaust System
Diagnosis and Testing
Exhaust System
Removal and Installation
Catalytic Converter - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
AJ27/3.5L NA V8 - AJV8 (17.50.05)
Catalytic Converter - 2.7L V6 - TdV6 (17.50.05)
Diesel Particulate Filter (DPF)
Diesel Particulate Filter (DPF) Differential Pressure Sensor
Exhaust System - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
AJ27/3.5L NA V8 - AJV8
Exhaust System - 2.7L V6 - TdV6
Front Muffler - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
AJ27/3.5L NA V8 - AJV8 (30.10.18)
Front Muffler - 2.7L V6 - TdV6 (30.10.18)
Muffler and Tailpipe (30.10.52)
310 : Fuel System
310-00 : Fuel System - General Information [page 3208]Specifications
Specifications
General Procedures
Fuel System Pressure Check
Fuel System Pressure Release - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L
NA V6 - AJ27/3.5L NA V8 - AJV8 (19.50.02)
Fuel System Pressure Release - 2.7L V6 - TdV6 (19.50.02)
Fuel Tank Draining - VIN Range: G00442->G45703
Fuel Tank Draining - VIN Range: G45704->G99999
High-Pressure Fuel System Bleeding - 2.7L V6 - TdV6
Low-Pressure Fuel System Bleeding - 2.7L V6 - TdV6
Quick Release Coupling
Quick Release Coupling - Push Connect
Spring Lock Couplings
Description and Operation
Fuel System - VIN Range: G00442->G45703
Fuel System - VIN Range: G45704->G99999
310-01 : Fuel Tank and Lines [page 3271]
Specifications
Specifications
Description and Operation
Fuel Tank and Lines - VIN Range: G00442->G45703
Fuel Tank and Lines - VIN Range: G45704->G99999
Diagnosis and Testing
Fuel Tank and Lines - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
AJ27/3.5L NA V8 - AJV8, VIN Range: G00442->G45703
Fuel Tank and Lines - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
AJ27/3.5L NA V8 - AJV8, VIN Range: G45704->G99999
Fuel Tank and Lines - 2.7L V6 - TdV6
Removal and Installation
Fuel Filter - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 - AJ27/3.5L
NA V8 - AJV8 (19.25.02)
Fuel Filter - 2.7L V6 - TdV6 (19.25.02)
Fuel Level Sender LH - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
AJ27/3.5L NA V8 - AJV8, VIN Range: G00442->G45703
Fuel Level Sender LH - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -AJ27/3.5L NA V8 - AJV8, VIN Range: G45704->G99999
Fuel Level Sender LH - 2.7L V6 - TdV6
Fuel Level Sender RH - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
AJ27/3.5L NA V8 - AJV8, VIN Range: G00442->G45703
Fuel Level Sender RH - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
AJ27/3.5L NA V8 - AJV8, VIN Range: G45704->G99999
Fuel Level Sender RH - 2.7L V6 - TdV6
Fuel Pump Module - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
AJ27/3.5L NA V8 - AJV8, VIN Range: G00442->G45703 (19.45.08)
Fuel Pump Module - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
AJ27/3.5L NA V8 - AJV8, VIN Range: G45704->G99999 (19.45.08)
Fuel Pump Module - 2.7L V6 - TdV6 (19.45.08)
Fuel Tank - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 - AJ27/3.5L NA
V8 - AJV8 (19.55.01)
Fuel Tank - 2.7L V6 - TdV6 (19.55.01)
Fuel Tank Filler Pipe (19.55.33)
Fuel Transfer Pump - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
AJ27/3.5L NA V8 - AJV8, VIN Range: G00442->G45703 (19.45.21)
Fuel Transfer Unit - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
AJ27/3.5L NA V8 - AJV8, VIN Range: G45704->G99999
Fuel Transfer Unit - 2.7L V6 - TdV6
Inertia Fuel Shutoff (IFS) Switch (18.30.35)
310-02 : Acceleration Control [page 3500]
Specifications
Specifications
Description and Operation
Acceleration Control
Diagnosis and Testing
Acceleration Control
Removal and Installation
Accelerator Pedal (19.20.01)
310-03 : Speed Control [page 3517]
SpecificationsSpecifications
General Procedures
Speed Control Module Alignment - VIN Range: G00442->H18679
Speed Control Module Alignment - VIN Range: H18680->H99999
Description and Operation
Speed Control - VIN Range: G00442->G45703
Speed Control - VIN Range: G45704->G99999
Diagnosis and Testing
Speed Control - VIN Range: G00442->G45703
Speed Control - VIN Range: G45704->G99999
Removal and Installation
Speed Control Deactivator Switch (19.75.20)
Speed Control Module (19.75.26)
Speed Control Sensor
Speed Control Switch (19.75.25)4 : Electrical
412 : Climate Control System
412-00 : Climate Control System - General Information [page 1]
Specifications
Specifications
General Procedures
Air Conditioning (A/C) System Flushing
Air Conditioning (A/C) System Recovery, Evacuation and Charging
(82.30.30)
Contaminated Refrigerant Handling
Electronic Leak Detection
Fluorescent Dye Leak Detection
Inspection and Assembly Requirements
Manifold Gauge Set Connection
Refrigerant Oil Adding
Refrigerant System Tests
Description and Operation
Climate Control System
Diagnosis and Testing
Climate Control System
412-01 : Air Distribution and Filtering [page 21]
Specifications
Specifications
Description and Operation
Air Distribution and Filtering
Diagnosis and Testing
Air Distribution and Filtering
Removal and Installation
Cabin Air Filter (76.10.09)
Center Registers (82.20.38)Driver Side Register (82.20.39)
Floor Console Register Duct (82.20.37)
Front Footwell Duct LH (82.20.91)
Front Footwell Duct RH (82.20.92)
Passenger Side Register (82.20.40)
Rear Footwell Duct (82.20.96)
412-02A : Heating and Ventilation [page 43]
Specifications
Specifications
Description and Operation
Heating and Ventilation
Diagnosis and Testing
Heating and Ventilation
Removal and Installation
Auxiliary Coolant Flow Pump - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L
NA V8 - AJV8 (82.25.59)
Auxiliary Coolant Flow Pump - 2.7L V6 - TdV6 (82.25.59)
Blower Motor (82.25.66)
Heater Core (80.20.29)
Heater Core and Evaporator Core Housing (82.25.21)
Heater Hose (80.25.01)
412-02B : Auxiliary Heating [page 81]
Specifications
Specifications
Description and Operation
Fuel Fired Booster Heater
Diagnosis and Testing
Fuel Fired Booster Heater
Removal and Installation
Fuel Fired Booster Heater
412-03A : Air Conditioning [page 94]Specifications
Specifications
Description and Operation
Air Conditioning
Diagnosis and Testing
Air Conditioning
Removal and Installation
Air Conditioning (A/C) Compressor - 3.0L NA V6 - AJ27, VIN Range:
G00442->G45703 (82.10.20)
Air Conditioning (A/C) Compressor - 3.0L NA V6 - AJ27, VIN Range:
G45704->G99999 (82.10.20)
Air Conditioning (A/C) Compressor - 4.2L NA V8 - AJV8/4.2L SC V8 -
AJV8/3.5L NA V8 - AJV8, VIN Range: G00442->G45703 (82.10.20)
Air Conditioning (A/C) Compressor - 4.2L NA V8 - AJV8/4.2L SC V8 -
AJV8/3.5L NA V8 - AJV8, VIN Range: G45704->G99999 (82.10.20)
Air Conditioning (A/C) Compressor - 2.7L V6 - TdV6 (82.10.20)
Condenser Core - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
AJ27/3.5L NA V8 - AJV8 (82.15.07)
Condenser Core - 2.7L V6 - TdV6 (82.15.07)
Desiccant Bag - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
AJ27/3.5L NA V8 - AJV8 (82.17.03)
Desiccant Bag - 2.7L V6 - TdV6 (82.17.03)
Pressure Cutoff Switch - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
AJ27/3.5L NA V8 - AJV8 (82.10.32)
Pressure Cutoff Switch - 2.7L V6 - TdV6 (82.10.32)
412-03B : Auxiliary Climate Control [page 171]
Specifications
Specifications
Description and Operation
Auxiliary Climate Control
Diagnosis and Testing
Auxiliary Climate Control
Removal and Installation
Auxiliary Climate Control Assembly
Auxiliary Evaporator Outlet and Inlet Line
Auxiliary Footwell Vent/Duct Blend Door ActuatorAuxiliary Heater Core and Evaporator Core Housing
Auxiliary Temperature Blend Door Actuator
Auxiliary Blower Motor
Auxiliary Blower Motor Resistor
Evaporator Core
Heater Core
Register
412-04 : Control Components [page 228]
Specifications
Specifications
Description and Operation
Control Components
Control Components - VIN Range: H18680->H99999
Diagnosis and Testing
Control Components
Removal and Installation
Air Discharge Temperature Sensor (82.20.64)
Ambient Air Temperature Sensor (82.20.02)
Climate Control Assembly (82.20.07)
Cold Air Bypass Blend Door Actuator LH
Cold Air Bypass Blend Door Actuator RH
Defrost Vent/Register Blend Door Actuator LH
Defrost Vent/Register Blend Door Actuator RH
Footwell Vent/Duct Blend Door Actuator LH
Footwell Vent/Duct Blend Door Actuator RH
In-Vehicle Temperature Sensor (82.20.03)
Recirculation Blend Door Actuator (82.20.67)
Sunload Sensor (82.20.70)
413 : Instrumentation and Warning Systems
413-00 : Instrument Cluster and Panel Illumination [page 272]Diagnosis and Testing
Instrument Cluster and Panel Illumination
413-01 : Instrument Cluster [page 273]
Specifications
Specifications
Description and Operation
Instrument Cluster
Diagnosis and Testing
Instrument Cluster
Removal and Installation
Indicator Bulb (86.45.61)
Instrument Cluster (88.20.01)
Instrument Cluster Lens (88.20.28)
413-06 : Horn [page 292]
Specifications
Specifications
Description and Operation
Horn
Diagnosis and Testing
Horn
Removal and Installation
Horn (86.30.02)
Horn Switch (86.30.01)
413-07 : Clock [page 299]
Description and Operation
Clock
Diagnosis and Testing
Clock
Removal and InstallationClock (88.15.07)
413-08 : Information and Message Center [page 304]
Description and Operation
Information and Message Center
Diagnosis and Testing
Information and Message Center
Removal and Installation
Message Center Switch (86.66.11)
413-09A : Warning Devices [page 310]
General Procedures
Oil Change Indicator Reset
Description and Operation
Warning Devices
Diagnosis and Testing
Warning Devices
413-13 : Parking Aid [page 318]
Description and Operation
Parking Aid
Diagnosis and Testing
Parking Aid
Removal and Installation
Front Parking Aid Speaker (86.54.18)
Parking Aid Module - VIN Range: G00442->G45703 (86.80.39)
Parking Aid Module - VIN Range: G45704->G99999 (86.80.39)
Parking Aid Sensor (86.62.01)
Rear Parking Aid Speaker (86.54.19)
414 : Battery and Charging System414-00 : Charging System - General Information [page 334]
General Procedures
Battery Charging
Description and Operation
Charging System
Diagnosis and Testing
Charging System
Charging System - 2.7L V6 - TdV6
414-01 : Battery, Mounting and Cables [page 368]
Specifications
Specifications
General Procedures
Battery Connect (86.15.15)
Battery Disconnect and Connect
Description and Operation
Battery and Cables
Diagnosis and Testing
Battery
Removal and Installation
Battery (86.15.01)
Battery Ground Cable (86.15.19)
Battery Tray (86.15.11)
414-02 : Generator and Regulator [page 382]
Specifications
Specifications
Description and Operation
Generator
Diagnosis and Testing
GeneratorRemoval and Installation
Generator - 3.0L NA V6 - AJ27 (86.10.02)
Generator - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L NA V8 - AJV8
(86.10.02)
Generator - 2.7L V6 - TdV6 (86.10.02)
415 : Information and Entertainment Systems
415-00 : Information and Entertainment System - General Information [page
403]
General Procedures
Cassette Player Cleaning
Diagnosis and Testing
Audio System
415-01 : Audio Unit [page 419]
Specifications
Specifications
Description and Operation
Audio System
Audio System - VIN Range: H18680->H99999
Audio System
Diagnosis and Testing
Audio System
Removal and Installation
Amplifier (86.50.10)
Audio Unit (86.50.03)
Compact Disc (CD) Changer (86.50.06)
Steering Wheel Audio Controls (86.50.42)
415-02 : Antenna [page 451]
Description and OperationAntenna
Diagnosis and Testing
Antenna
Removal and Installation
Antenna Isolator Module (86.51.08)
415-03 : Speakers [page 456]
Description and Operation
Speakers
Speakers
Diagnosis and Testing
Speakers
Removal and Installation
Front Door Speaker (86.50.13)
Front Door Tweeter Speaker (86.50.63)
Instrument Panel Speaker
Rear Door Speaker (86.50.14)
Rear Door Tweeter Speaker (86.50.62)
Subwoofer Speaker (86.51.05)
415-07 : Video System [page 467]
Specifications
Specifications
Description and Operation
Video System
Diagnosis and Testing
Video System
Removal and Installation
Digital Versatile Disc (DVD) Player
Rear Passenger Entertainment Control Panel
Video Display
Video System Module
417 : Lighting417-01 : Exterior Lighting [page 561]
Specifications
Specifications
General Procedures
Headlamp Adjustment (86.40.18)
Description and Operation
Exterior Lighting
Exterior Lighting - VIN Range: H18680->H99999
Diagnosis and Testing
Headlamps
Removal and Installation
Approach Lamp - VIN Range: G00442->H18679
Approach Lamp - VIN Range: H18680->H99999
Ballast - Vehicles With: High Intensity Discharge Headlamps (86.41.52)
Front Fog Lamp - VIN Range: G00442->H18679 (86.40.96)
Fog Lamp - VIN Range: H18680->H99999
Headlamp Assembly (86.41.33)
Headlamp Bulb - Vehicles With: High Intensity Discharge Headlamps
(86.42.14)
Headlamp Leveling Motor (86.42.04)
Headlamp Leveling Sensor (86.42.15)
High Mounted Stoplamp (86.41.01)
Stoplamp Switch
Rear Lamp Assembly (86.40.70)
417-02 : Interior Lighting [page 592]
Description and Operation
Interior Lighting
Diagnosis and Testing
Interior Lighting
417-04 : Daytime Running Lamps (DRL) [page 595]Description and Operation
Daytime Running Lamps (DRL)
Diagnosis and Testing
Daytime Running Lamps (DRL)
418 : Electrical Distribution
418-00 : Module Communications Network [page 598]
Description and Operation
Communications Network
Diagnosis and Testing
Communications Network
418-01 : Module Configuration [page 683]
Diagnosis and Testing
Module Configuration
419 : Electronic Feature Group
419-01A : Anti-Theft - Active [page 685]
Description and Operation
Anti-Theft - Active
Diagnosis and Testing
Anti-Theft - Active
Removal and Installation
Anti-Theft Alarm Horn (86.52.03)419-01B : Anti-Theft - Passive [page 699]
General Procedures
Anti-Theft Security Access
Key Programming Using Diagnostic Equipment
Key Programming Using Two Programmed Keys
Description and Operation
Anti-Theft - Passive
Diagnosis and Testing
Anti-Theft - Passive
Removal and Installation
Passive Anti-Theft System (PATS) Transceiver (86.52.30)
419-02 : Remote Convenience [page 709]
General Procedures
Universal Transmitter Programming
Description and Operation
Universal Transmitter
Diagnosis and Testing
Universal Transmitter
419-07 : Navigation System [page 715]
Description and Operation
Navigation System
Diagnosis and Testing
Navigation System
Removal and Installation
Navigation System Antenna - VIN Range: G00442->H18679 (86.62.06)
Navigation System Antenna - VIN Range: H18680->H99999 (86.62.06)
Navigation System Display Module (86.62.07)
Navigation System Module (86.62.05)
419-08 : Cellular Phone [page 733]Description and Operation
Cellular Phone - VIN Range: G00442->G45703
Cellular Phone - VIN Range: G45704->H18679
Cellular Phone - VIN Range: H18680->H99999
Diagnosis and Testing
Cellular Phone
Cellular Phone - Vehicles With: Bluetooth
Removal and Installation
Bluetooth Module
Cellular Phone Antenna - Vehicles With: Corded Cellular Phone, VIN
Range: G00442->H18679 (86.51.17)
Cellular Phone Antenna - Vehicles With: Cordless Cellular Phone, VIN
Range: G00442->H18679 (86.51.17)
Cellular Phone Antenna - VIN Range: H18680->H99999 (86.51.17)
Front Handset Holder
Transceiver Module
419-10 : Multifunction Electronic Modules [page 817]
Specifications
Specifications
Description and Operation
Module Controlled Functions
Diagnosis and Testing
Multifunction Electronic Module
Removal and Installation
Driver Door Module (DDM) (86.80.29)
Driver Seat Module (DSM) (86.75.28)
Front Electronic Module (FEM) (86.80.41)
Multifunction Voice Activated Module (86.53.13)
Rear Electronic Module (REM) (86.80.37)
Rear Seat Module (RSM) (86.75.40)5 : Body and Paint
501 : Body and Paint
501-02 : Front End Body Panels [page 1]
Description and Operation
Front End Body Panels
Removal and Installation
Air Deflector (76.11.41)
Cowl Vent Screen (76.10.01)
Fender Splash Shield (76.10.90)
Radiator Grille Opening Panel (76.10.06)
Radiator Splash Shield (76.22.90)
Secondary Bulkhead Center Panel
501-03 : Body Closures [page 26]
Specifications
Specifications
General Procedures
Hood Alignment (76.16.02)
Luggage Compartment Lid Alignment (76.19.03)
Rear Door Alignment (76.28.08)
Description and Operation
Body Closures
Removal and Installation
Front Door Opening Weatherstrip (76.40.01)
Hood (76.16.01)
501-05 : Interior Trim and Ornamentation [page 36]
SpecificationsSpecifications
Description and Operation
Interior Trim
Removal and Installation
A-Pillar Trim Panel (76.13.31)
B-Pillar Lower Trim Panel (76.13.29)
B-Pillar Upper Trim Panel (76.13.28)
Cowl Side Trim Panel (76.13.30)
C-Pillar Lower Trim Panel
C-Pillar Upper Trim Panel
Folding Tray (76.47.31)
Front Door Trim Panel (76.34.01)
Headliner (76.64.01)
Parcel Shelf (76.67.06)
Rear Door Quarter Window Blind
Rear Door Trim Panel (76.34.04)
Rear Door Window Blind
Rear Window Blind (76.14.04)
Rear Window Blind Arm
Rear Window Blind Motor
Scuff Plate Trim Panel (76.13.81)
Sun Visor (76.10.48)
501-08 : Exterior Trim and Ornamentation [page 102]
Description and Operation
Exterior Trim
Removal and Installation
Door Moulding (76.43.72)
Luggage Compartment Lid Moulding - VIN Range: G00442->H18679
(76.43.79)
Luggage Compartment Lid Moulding - VIN Range: H18680->H99999
(76.43.79)
Radiator Grille (76.55.03)
Rocker Panel Moulding (76.11.36)
Window Moulding (76.43.20)
501-09 : Rear View Mirrors [page 119]Specifications
Specifications
Description and Operation
Rear View Mirrors
Rear View Mirrors - VIN Range: H18680->H99999
Diagnosis and Testing
Rear View Mirrors
Removal and Installation
Auto-Dimming Interior Mirror (76.10.56)
Exterior Mirror (76.10.52)
Exterior Mirror Cover (76.10.55)
Exterior Mirror Glass (76.10.53)
Exterior Mirror Motor - VIN Range: G00442->H18679 (76.10.57)
Exterior Mirror Motor - VIN Range: H18680->H99999 (76.10.57)
501-10 : Seating [page 133]
Specifications
Specifications
Description and Operation
Seats - VIN Range: G00442->H18679
Seats - VIN Range: H18680->H99999
Diagnosis and Testing
Seats - VIN Range: G00442->H18679
Seats - VIN Range: H18680->H99999
Removal and Installation
Front Seat (76.70.01)
Front Seat Backrest - VIN Range: G00442->H18679 (76.70.06)
Front Seat Backrest - VIN Range: H18680->H99999 (76.70.06)
Front Seat Backrest Cover - VIN Range: G00442->H18679 (76.70.15)
Front Seat Backrest Cover - VIN Range: H18680->H99999 (76.70.15)
Front Seat Backrest Heater and Blower Assembly
Front Seat Backrest Rear Cover - VIN Range: G00442->H18679 (76.70.03)
Front Seat Backrest Rear Cover - VIN Range: H18680->H99999 (76.70.03)
Front Seat Control Switch (86.75.46)
Front Seat Cushion Cover - VIN Range: G00442->H18679 (76.70.33)
Front Seat Cushion Cover - VIN Range: H18680->H99999 (76.70.33)
Front Seat Cushion Heater and Blower AssemblyFront Seat Head Restraint - Vehicles With: Head Restraint Video Display,
VIN Range: G00442->H18679 (76.70.14)
Front Seat Head Restraint - Vehicles With: Head Restraint Video Display,
VIN Range: H18680->H99999 (76.70.14)
Front Seat Head Restraint Motor - VIN Range: G00442->H18679
(86.75.17)
Front Seat Head Restraint Motor - VIN Range: H18680->H99999
(86.75.17)
Front Seat Height Adjustment Motor (86.75.29)
Front Seat Lumbar Motor (86.75.44)
Front Seat Rear Height Adjustment Motor (86.75.32)
Front Seat Recliner Motor - VIN Range: G00442->H18679 (86.75.04)
Front Seat Recliner Motor - VIN Range: H18680->H99999 (86.75.04)
Front Seat Track Motor (86.75.33)
Lumbar Assembly (86.75.12)
Memory Seat Position Switch
Rear Outer Seat Backrest (76.70.76)
Rear Outer Seat Backrest Cover (76.70.51)
Rear Outer Seat Cushion (76.70.44)
Rear Seat Armrest (76.70.39)
Rear Seat Backrest (76.70.38)
Rear Seat Backrest Cover (76.70.48)
Rear Seat Control Switch (86.75.42)
Rear Seat Cushion (76.70.37)
Rear Seat Cushion Cover (76.70.47)
Rear Seat Head Restraint Motor (86.75.41)
Rear Seat Lumbar Motor (86.75.43)
Seat Armrest (76.70.97)
Seat Base (76.70.08)
Assembly & Disassembly
Rear Seat Backrest - Vehicles With: 40/20/40 Split Seat (76.70.48)
501-11 : Glass, Frames and Mechanisms [page 321]
Specifications
Specifications
General Procedures
Door Window Motor Initialization
Description and OperationGlass, Frames and Mechanisms
Diagnosis and Testing
Glass, Frames and Mechanisms
Removal and Installation
Front Door Window Glass (76.31.01)
Front Door Window Regulator and Motor (86.25.04)
Rear Door Fixed Window Glass
Rear Door Window Glass (76.31.02)
Rear Door Window Regulator and Motor (86.25.09)
Rear Window Glass (76.81.11)
Window Control Switch (86.25.08)
Windshield Glass (76.81.40)
501-12 : Instrument Panel and Console [page 369]
Specifications
Specifications
Description and Operation
Instrument Panel
Removal and Installation
Floor Console - Vehicles With: Auxiliary Climate Control (76.25.01)
Floor Console - Vehicles Without: Auxiliary Climate Control (76.25.01)
Glove Compartment (76.52.03)
Instrument Panel (76.46.01)
Instrument Panel Console (88.20.34)
Overhead Console (76.13.69)
501-14 : Handles, Locks, Latches and Entry Systems [page 407]
Specifications
Specifications
General Procedures
Remote Transmitter Programming
Description and Operation
Handles, Locks, Latches and Entry Systems
Diagnosis and Testing
Locks, Latches and Entry SystemsRemoval and Installation
Exterior Door Handle (76.58.07)
Front Door Lock Actuator (76.37.74)
Front Door Lock Cylinder (76.37.71)
Interior Door Handle (76.37.31)
Luggage Compartment Lid Latch Actuator - VIN Range: G00442->H18679
(76.19.25)
Luggage Compartment Lid Latch Actuator - VIN Range: H18680->H99999
(76.19.25)
Luggage Compartment Lid Lock Cylinder - VIN Range: G00442->H18679
(76.19.19)
Luggage Compartment Lid Lock Cylinder - VIN Range: H18680->H99999
(76.19.19)
Rear Door Lock Actuator (76.37.09)
501-16 : Wipers and Washers [page 449]
Specifications
Specifications
Specifications
Description and Operation
Wipers and Washers - VIN Range: G00442->G45703
Wipers and Washers - VIN Range: G45704->G99999
Diagnosis and Testing
Wipers and Washers
Removal and Installation
Headlamp Washer Jet (84.20.08)
Headlamp Washer Pump - VIN Range: G00442->G45703 (84.20.21)
Headlamp Washer Pump - VIN Range: G45704->G99999 (84.20.21)
Rain Sensor (84.12.10)
Windshield Washer Pump - VIN Range: G00442->G45703 (84.10.21)
Windshield Washer Pump - VIN Range: G45704->G99999 (84.10.21)
Windshield Washer Reservoir - VIN Range: G00442->G45703 (84.10.01)
Windshield Washer Reservoir - VIN Range: G45704->G99999 (84.10.01)
Windshield Wiper Motor (84.15.13)
Wiper Mounting Arm and Pivot Shaft (84.15.24)
Wiper Pivot Arm (84.15.03)501-17 : Roof Opening Panel [page 488]
Specifications
Specifications
General Procedures
Motor Synchronization (76.82.48)
Roof Opening Panel Alignment
Description and Operation
Roof Opening Panel
Diagnosis and Testing
Roof Opening Panel
Removal and Installation
Air Deflector (76.82.07)
Roof Opening Panel Frame (76.82.01)
Roof Opening Panel Front Drain Hose (76.82.21)
Roof Opening Panel Glass (76.82.05)
Roof Opening Panel Motor (86.76.01)
Roof Opening Panel Weatherstrip (76.82.15)
Trough Assembly (76.82.58)
501-19 : Bumpers [page 536]
Specifications
Specifications
Description and Operation
Bumpers
Removal and Installation
Front Bumper (76.22.08)
Front Bumper Cover - VIN Range: G00442->H18679 (76.22.78)
Front Bumper Cover - VIN Range: H18680->H99999 (76.22.78)
Front Bumper Cover Insert (76.22.73)
Rear Bumper (76.22.27)
Rear Bumper Cover - VIN Range: G00442->H18679 (76.22.74)
Rear Bumper Cover - VIN Range: H18680->H99999 (76.22.74)
Rear Bumper Cover Insert (76.22.75)
501-20A : Safety Belt System [page 567]Specifications
Specifications
Description and Operation
Safety Belt System
Diagnosis and Testing
Safety Belt System
Removal and Installation
Front Safety Belt Buckle (76.73.49)
Front Safety Belt Retractor (76.73.10)
Front Safety Belt Shoulder Height Adjuster (76.73.12)
Rear Center Safety Belt Retractor (76.73.20)
Rear Safety Belt Buckle (76.73.50)
Rear Safety Belt Retractor (76.73.18)
501-20B : Supplemental Restraint System [page 589]
Specifications
Specifications
General Procedures
Air Bag Disposal
Description and Operation
Air Bag Supplemental Restraint System (SRS)
Diagnosis and Testing
Air Bag Supplemental Restraint System (SRS)
Removal and Installation
B-Pillar Side Impact Sensor (76.73.68)
Clockspring (86.65.92)
C-Pillar Side Impact Sensor (76.73.69)
Crash Sensor (76.73.55)
Driver Air Bag Module (76.73.39)
Front Passenger Seat Occupant Classification Sensor (76.73.60)
Passenger Air Bag Deactivation (PAD) Indicator (76.73.58)
Passenger Air Bag Module (76.73.37)
Restraints Control Module (RCM) (76.73.48)
Seat Position Sensor (76.73.62)
Side Air Bag Module (76.73.47)
Side Air Curtain Module (76.73.64)502 : Frame and Mounting
502-00 : Uni-Body, Subframe and Mounting System [page 728]
Specifications
Specifications
Description and Operation
Frame Assembly
Removal and Installation
Front Subframe - 3.0L NA V6 - AJ27 (76.10.05)
Front Subframe - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L NA V8 - AJV8
(76.10.05)
Front Subframe - 2.7L V6 - TdV6 (76.10.05)
Front Subframe Front Bushing (60.35.51)
Front Subframe Rear Bushing (60.35.26)
Rear Subframe (64.25.01)
Rear Subframe Front Bushing (64.25.34)
Rear Subframe Rear Bushing (64.25.36)
Jaguar XJ Workshop Repair & Service Manual 1979-2016
